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In recent years, Advanced High Strength Steels have been widely used for the manufacture of both traditional fuel vehicles and new energy vehicles to improve the fuel efficiency, reduce the emission of CO2, achieve the safety requirements in car crash measurements, and expand the range of the distance. With excellent strength and good formability, hot-stamping steels—a kind of AHSS—have been applied to the fabrication of car body components, such as B-pillars, reinforcements, bumpers, roof rails, rocker rails, and tunnels.1–3) Resistance projection welding (RPW), which localizes current flow and heat input by a predetermined projection on one of the parts, is a variation of resistance spot welding. The RPW of nuts to steels is widely used for the assembly of the front axles, rear axles, the seatbelt, and steering columns to reduce loose automobile components and improve the assembly quality. However, the Al–Si coating, which is uneven, discontinuous, and porous after hot stamping, causes unstable welding quality when welding nuts to hot-stamping steels using traditional spot welding processes and equipment.4,5) Though the RPW of nuts is widely applied in vehicle manufacturing, home appliances, electronic equipment, and Microstructure and Failure Analysis of Resistance Projection Welding of Nuts to AHSS with Capacitor Discharge Welding