A projection weld element can include structure that prevents gases or other contaminants from passing through or around the weld element before, during or after attachment to a workpiece such as a vehicle body part. The projection weld element can include a barrel having a first axial end and a second axial end, a central axial bore being defined through the barrel from the first axial end towards the second axial end, and at least a portion of the central axial bore including an attachment structure, such as internal threads. A radial flange can extend from the second axial end of the barrel, with the flange including a distal axial face on a side of the flange facing away from the first axial end of the barrel and a proximal axial face on a side of the flange facing toward the first axial end of the barrel. The flange can include an annular projection weld ring formed along the proximal axial face of the flange on the same side of the flange as the barrel that extends from the flange. The weld ring can be configured to prevent transmission of contaminants, such as water, vapor, or other contaminants, from passing through the weld element to either side of a working piece to which the weld element is attached. A method for joining a working piece with a weld element can include joining a working piece with the above-described weld element and heating the structures to effect a projection welding between the working piece and the weld element. The resulting weld forming a continuous weld seal about the barrel portion of the weld element and between the weld element and the vehicle body part to prevent contaminants from transmitting through or around the weld element.