The Effect of Thread Throat Diameter of Welding Bolt on Weld Defect Formation and its Optimization in Projection Welding

Hilal Kır; Mustafa Yazar; Şükrü Talaş

doi:10.64808/engineeringperspective.1753998

The Effect of Thread Throat Diameter of Welding Bolt on Weld Defect Formation and its Optimization in Projection Welding

Abstract

The welding process plays a critical role in the joining of sheet metal parts in the automotive industry, as in other manufacturing sectors. In this study, a welding defect observed in M6x21 weld bolts joined by projection welding—utilizing the protrusion geometry on the fasteners was investigated. The joining was carried out using 3 mm thick WSS-M1A365-A22 sheet steel and 8.8 grade M6x21 weld bolts; however, insufficient weld strength and low rupture loads were detected. Analytical evaluations revealed that the root cause of the defect was the contact between the bolt geometry and the sheet sur-face, which caused the welding current to dissipate over a wide area. To eliminate this issue, an M6x26 weld bolt with a smaller thread root diameter and longer thread length was used in the welding process. In order to ensure adequate rupture strength in projection welding with the M6x26 bolt, welding process parameters were investigated. The Taguchi L9 orthogonal array was used to evaluate three different welding currents (26, 28, 30 kA) and three different welding forces (400, 500, 600 daN), with the cycle time kept constant. The rupture load results were analyzed using the “larger-the-better” crite-rion, and the optimum welding parameters were determined as 600 daN welding force and 30 kA welding current. However, considering energy efficiency in the production environment, it was concluded that a current of 28 kA and a force of 600 daN also provided sufficient weld strength. Scanning Electron Microscope (SEM) analyses enabled microstructural evaluation of weld region defects.

Keywords

Supporting Institution

Şahinkul Machine and Spare Parts Manufacturing Co. Ltd.

Project Number

ARGE-2023-036 2300790000

Ethical Statement

The authors must declare that there is no conflict of interest in the study.

Thanks

This study was supported by Şahinkul Makine in frame of the project code of ARGE-2023-036 2300790000 as researchers, Scholarship in this study was supported by TÜBİTAK BİDEB (Turkish Scientific and Technological Research Council, Scien-tist Support Department) (Project No: 119C053).

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Details

Primary Language

English

Subjects

Welding Engineering and Extractive Metallurgy (Other), Optimization in Manufacturing

Journal Section

Research Article

Authors

Hilal Kır ^*
0000-0002-9623-4738
Türkiye

Mustafa Yazar
Türkiye

Şükrü Talaş
Türkiye

Publication Date

September 30, 2025

Submission Date

July 30, 2025

Acceptance Date

September 29, 2025

Published in Issue

Year 2025 Volume: 5 Number: 3

DOI

https://doi.org/10.64808/engineeringperspective.1753998

IZ

https://izlik.org/JA97SE25JS

Cite

RIS / Bibtex

APA

Kır, H., Yazar, M., & Talaş, Ş. (2025). The Effect of Thread Throat Diameter of Welding Bolt on Weld Defect Formation and its Optimization in Projection Welding. Engineering Perspective, 5(3), 123-128. https://doi.org/10.64808/engineeringperspective.1753998

AMA

1.Kır H, Yazar M, Talaş Ş. The Effect of Thread Throat Diameter of Welding Bolt on Weld Defect Formation and its Optimization in Projection Welding. engineeringperspective. 2025;5(3):123-128. doi:10.64808/engineeringperspective.1753998

Chicago

Kır, Hilal, Mustafa Yazar, and Şükrü Talaş. 2025. “The Effect of Thread Throat Diameter of Welding Bolt on Weld Defect Formation and Its Optimization in Projection Welding”. Engineering Perspective 5 (3): 123-28. https://doi.org/10.64808/engineeringperspective.1753998.

EndNote

Kır H, Yazar M, Talaş Ş (September 1, 2025) The Effect of Thread Throat Diameter of Welding Bolt on Weld Defect Formation and its Optimization in Projection Welding. Engineering Perspective 5 3 123–128.

IEEE

[1]H. Kır, M. Yazar, and Ş. Talaş, “The Effect of Thread Throat Diameter of Welding Bolt on Weld Defect Formation and its Optimization in Projection Welding”, engineeringperspective, vol. 5, no. 3, pp. 123–128, Sept. 2025, doi: 10.64808/engineeringperspective.1753998.

ISNAD

Kır, Hilal - Yazar, Mustafa - Talaş, Şükrü. “The Effect of Thread Throat Diameter of Welding Bolt on Weld Defect Formation and Its Optimization in Projection Welding”. Engineering Perspective 5/3 (September 1, 2025): 123-128. https://doi.org/10.64808/engineeringperspective.1753998.

JAMA

1.Kır H, Yazar M, Talaş Ş. The Effect of Thread Throat Diameter of Welding Bolt on Weld Defect Formation and its Optimization in Projection Welding. engineeringperspective. 2025;5:123–128.

MLA

Kır, Hilal, et al. “The Effect of Thread Throat Diameter of Welding Bolt on Weld Defect Formation and Its Optimization in Projection Welding”. Engineering Perspective, vol. 5, no. 3, Sept. 2025, pp. 123-8, doi:10.64808/engineeringperspective.1753998.

Vancouver

1.Hilal Kır, Mustafa Yazar, Şükrü Talaş. The Effect of Thread Throat Diameter of Welding Bolt on Weld Defect Formation and its Optimization in Projection Welding. engineeringperspective. 2025 Sep. 1;5(3):123-8. doi:10.64808/engineeringperspective.1753998

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