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The effects of the process parameters on the joint quality of TO-Can using resistance projection welding were investigated. A capacitor discharge stored energy welding machine was used for joining caps and headers both coated with nickel SPCC steel. The electrode materials used in this study were brass and W- Cu alloy. Experimental results indicated that the peak current of the W-Cu electrode was higher than that of the brass electrode, irrespective of the operating pressure variation. Increased operating pressure influenced the interfacial heat generation and nugget formation. The nugget area increased rapidly with increasing charging voltage, resulting in expulsions and electrodes getting stuck. An acceptable welding zone was found in the relationship between the charging voltage and the operating pressure. Representative test specimens of the acceptable welding zone satisfactorily passed the helium leak test. The microscopic morphology of the nugget showed a recrystallized fine grain structure resulting in the nugget being harder than with the HAZ.