Abstract: An incremental forming machine and a process are disclosed that comprise selecting a blank and selecting a stylus tool that has a tip at one end. The stylus tool may be heated to a desired temperature before contacting the blank with the stylus tool to change a characteristic of the blank or part. The stylus tool apparatus may include a tip on an end of a shaft and a resistance heating element disposed inside the tip. Alternatively, the stylus tool apparatus may include an induction heating coil disposed around the tip. The tip of the stylus tool may have a rotatable ball that engages the blank or part.

Abstract: A welded structural assembly and method, in one form, includes an upper substrate, a lower substrate adjacent the upper substrate, a fastener, and a sealing member. The fastener includes a shank portion, a first head portion, and a second head portion. The shank portion extends through the upper substrate and into the lower substrate. The shank is welded to the lower substrate. The first head portion has an outer periphery and an underside. The second head portion is frangibly coupled to the first head portion. The sealing member is disposed under the first head portion between the upper substrate and the first head portion. The sealing member contacts the underside and extends beyond the outer periphery such that the sealing member extends radially outward beyond all points of the first head portion.

Abstract: An assembly includes an upper substrate, a lower substrate, and a self-piercing rivet. The lower substrate defines a preformed interior cavity and a preformed exterior profile adjacent the interior cavity to define a variable thickness wall. The self-piercing rivet extends through the upper substrate and into the preformed interior cavity of the lower substrate.

Abstract: A welded structural assembly and method, in one form, includes an upper substrate, a lower substrate adjacent the upper substrate, a fastener, and a sealing member. The fastener includes a shank portion, a first head portion, and a second head portion. The shank portion extends through the upper substrate and into the lower substrate. The shank is welded to the lower substrate. The first head portion has an outer periphery and an underside. The second head portion is frangibly coupled to the first head portion. The sealing member is disposed under the first head portion between the upper substrate and the first head portion. The sealing member contacts the underside and extends beyond the outer periphery such that the sealing member extends radially outward beyond all points of the first head portion.

Abstract: A vehicle assembly includes a first component having a stand-off that provides a cavity. The stand-off protrudes from an insertion side of the first component. The stand-off includes at least one side wall that extends from a floor of the cavity to at least one outer surface of the stand-off. The assembly further includes a second component that contacts the first component at an interface. The cavity is configured to receive a mechanical fastener that joins the first component to the second component. A distance between the floor of the cavity and the interface is greater in some areas than in other areas such that a cross-sectional thickness at a bottom of the cavity is varied.

Abstract: A method of installing a friction element includes driving the friction element through a top panel and friction welding the friction element to a bottom panel. At least one additional panel may or may not be between the top panel and the bottom panel. Also, at least one key friction element weld (FEW) parameter is controlled during installing of the friction element, at least one key FEW parameter is monitored during installing of the friction element, and the at least one key FEW controlled parameter is adjusted in real-time as a function of and in response to the at least one key FEW monitored parameter exhibiting completion of at least one key FEW process characteristic. Non-limiting examples of the at least one key FEW controlled parameter include RPM of the friction element and insertion force applied to the friction element.

Abstract: A vehicle assembly includes a first component having a stand-off that provides a cavity. The stand-off protrudes from an insertion side of the first component. The stand-off includes at least one side wall that extends from a floor of the cavity to at least one outer surface of the stand-off. The assembly further includes a second component that contacts the first component at an interface. The cavity is configured to receive a mechanical fastener that joins the first component to the second component. A distance between the floor of the cavity and the interface is greater in some areas than in other areas such that a cross-sectional thickness at a bottom of the cavity is varied.

Abstract: A self-piercing rivet (SPR) includes a head portion and a shaft extending from the head portion. The shaft defines a hollow bore and a sidewall surrounding the hollow bore. The sidewall has a reduced thickness towards a distal end portion of the shaft to define a cutting edge on a distal end tip of the shaft, and the SPR defines a circumferential groove disposed at least partially around the shaft and extending into the sidewall.

Abstract: An incremental forming machine and a process are disclosed that comprise selecting a blank and selecting a stylus tool that has a tip at one end. The stylus tool may be heated to a desired temperature before contacting the blank with the stylus tool to change a characteristic of the blank or part. The stylus tool apparatus may include a tip on an end of a shaft and a resistance heating element disposed inside the tip. Alternatively, the stylus tool apparatus may include an induction heating coil disposed around the tip. The tip of the stylus tool may have a rotatable ball that engages the blank or part.

Abstract: A system is provided for attaching a layer of a metal to other layers in a material stack-up using a metal mechanical fastener that does not allow for direct contact between the fastener and the metal layer, thereby neutralizing any galvanic reaction between the metal sheet and the fastener and avoiding corrosion. The metal layer may be any of several metals, including magnesium. The fastener is a rivet, a screw or a bolt. The disclosed inventive concept uses an insulating layer to insulate the magnesium layer. In one embodiment, a layer of a thin metal is formed over the insulating layer. Where the fastener is a rivet and the metal is magnesium, the insulating layer and thin metal provide a barrier between the magnesium layer and the rivet prongs following rivet insertion, thus isolating the rivet. The system enables a greater application of fastener joining, particularly with magnesium and mixed material joining.

Abstract: A method of installing and sealing a friction fastener to at least an upper substrate and a lower substrate includes providing an expandable sealant to an underhead volume of the friction fastener, installing the friction fastener through the upper substrate and into the lower substrate using a joining device, and applying heat in-situ to the expandable sealant such that the friction fastener is sealed to at least the upper substrate. The heat in-situ is applied to the expandable sealant via installing the friction fastener and/or with an external heating source disposed downstream from the joining device.

Abstract: A system for attaching layers of material together comprised of a self-piercing rivet, a layer having a clearance hole through which the self-piercing rivet passes on assembly, and a layer free of a clearance hole and into which the self-piercing rivet is at least partially inserted. The system may include a third layer free of a clearance hole. The system may also include three layers wherein the clearance hole is formed in the middle layer. If the clearance hole is formed in the middle layer, the width of the hole may be greater than the diameter of the self-piercing rivet to avoid contact between the rivet and the middle layer. The layer having the clearance hole may be a hard material such as steel. One or more of the layers may be material that is difficult to pierce or can be damaged if pierced.

Abstract: An incremental forming machine and a process are disclosed that comprise selecting a blank and selecting a stylus that has a tip at one end. The stylus may be heated to a desired temperature before contacting the blank with the stylus to change a characteristic of the blank or part. The stylus apparatus may include a tip on an end of a shaft and a resistance heating element disposed inside the tip. Alternatively, the stylus apparatus may include an induction heating coil disposed around the tip. The tip of the stylus may have a rotatable ball that engages the blank or part.

Abstract: A system and method of verifying that a part is heat treated to strengthen the part. The part is marked with a thermo-chromatic composition before heat treating. The part is then heat treated to strengthen the part and change the color of the thermo-chromatic composition to indicate successful completion of the heat treating process. A detector may act to prevent the inclusion of a non-heat treated part in an assembly by disabling an assembly tool. A controller may also provide data related to the completion of the heat treating process to be recorded in a database.

Abstract: A system for attaching material stack-up layers of at least two layers together using mechanical fasteners is disclosed. The material stack-up comprises at least an upper layer and a lower layer. The lower layer has a relatively constant thickness equal to or greater than 4.0 mm or may have alternating thick and thin areas in which the thickness of the thick area is equal to or greater than 4.0 mm. A mechanical fastener attaches the upper layer and the lower layer and is inserted at least partially into the lower layer. The fastener is inserted into the thick area of the embodiment having alternating thick and thin areas. The lower layer may be any of a variety of materials, including magnesium or any other brittle material. The lower layer may also be a casting, such as a magnesium casting. The mechanical fastener may be any of fasteners, screws or bolts.

Abstract: An assembly includes an upper substrate, a lower substrate, and a self-piercing rivet. The lower substrate defines a preformed interior cavity and a preformed exterior profile adjacent the interior cavity to define a variable thickness wall. The self-piercing rivet extends through the upper substrate and into the preformed interior cavity of the lower substrate.

Abstract: A system for attaching layers of material together comprised of a self-piercing rivet, a layer having a clearance hole through which the self-piercing rivet passes on assembly, and a layer free of a clearance hole and into which the self-piercing rivet is at least partially inserted. The system may include a third layer free of a clearance hole. The system may also include three layers wherein the clearance hole is formed in the middle layer. If the clearance hole is formed in the middle layer, the width of the hole may be greater than the diameter of the self-piercing rivet to avoid contact between the rivet and the middle layer. The layer having the clearance hole may be a hard material such as steel. One or more of the layers may be material that is difficult to pierce or can be damaged if pierced.

Abstract: A vehicle component joining method includes, among other things, positioning a contact side of a first component adjacent a contact side of a second component, inserting a mechanical fastener into a cavity of the first component, and rotating the mechanical fastener to drive the mechanical fastener through an interface between the contact sides of the first and second components. The interface is disposed along an interface plane and the mechanical fastener is driven through the interface in a direction that is nonperpendicular to the interface plane.

Abstract: A method of reducing the cycle time required for flow-drill screw operations by providing a dimple on a part that is engaged by a flow-drill screw. A tip of the flow-drill screw engages a contact band at a location spaced from the tip of the distal end of the flow-drill screw and base portion of the dimple. Friction between the flow-drill screw tip and dimple creates a heat concentration area and results in displaced material fanning a threaded collar. The flow-drill screw is secured by the threads of the threaded collar.

Abstract: A process for joining fiber composite materials using self-piercing rivets. The process includes contacting first and second panels. The second panel is a fiber composite material. The process further includes elevating a temperature of only a fastening portion of the second panel. The process also includes placing the first and second panels on a die and joining the first and second panels with one or more rivets while the fastening portion is at an elevated temperature.