Abstract: A method of rivet bonding a workpiece stack-up that includes one or more polymer composite workpieces, such as carbon fiber composite workpieces, involves several steps. In one step, adhesive is applied to a surface of the workpiece stack-up. In another step, workpieces—including the polymer composite workpiece(s)—are brought together. In yet another step the adhesive is partially or more cured. A rivet is installed through the workpiece stack-up and through the adhesive in another step. The method strengthens the resulting rivet-bonded joint by minimizing or altogether precluding fracture, cracking, and/or delamination thereat.

Abstract: A method for joining a plurality of workpieces includes providing a rotating drive tool. A fastener is secured to the drive tool. The drive tool is then rotatably driven such that a distal end of the fastener rotates against a surface of the plurality of workpieces. A heated material zone is then generated on the plurality of workpieces as caused by friction from the rotation of the fastener against the surface of the plurality of workpieces. The distal end of the fastener is rotatably and axially driven through the heated material zone. Finally, the drive tool is removed from the fastener, such that when the heated material zone cools, a portion of the heated material zone is fused to the fastener.

Abstract: A two-part mechanical fastener comprising an elongated body with a bore slidably carrying a mandrel adapted to interferingly engage the body is described. The fastener body has one or more protuberances on its exterior surface. In an aspect, the protuberances form a thread. The fastener is adapted to form an opening in, and penetrate, a stack of two or more workpieces. To secure the workpieces in the workpiece stack and form a robust joint, the fastener body is deformed by the mandrel, expanding the body, so that a body end engages a surface of the workpiece stack and the one or more protuberances are brought into engagement with the walls of the opening. Methods of using such a fastener to secure non-ferrous or polymer-based sheet-like workpieces to one another are disclosed.

Abstract: A riveting system, for use in mechanically linking adjacent workpieces, including a rivet having a height greater than a sum of thicknesses, measured along a line of riveting, of the workpieces being linked, so that the rivet can pass fully through the workpieces. The system also includes a riveting die, which may be a separate product. The die includes a protrusion extending from a peak toward a transition point; and a trough having a trough surface. The trough surface includes a trough inner wall, extending from the transition point to a trough bottom, and a trough outer wall, extending from the trough bottom to a trough outer edge. The technology also includes computerized systems for comparing a load-displacement profile of riveting to a pre-set profile to determine whether the riveting was performed properly.

Abstract: A fastening assembly includes a panel, a fastener and a primary anode insert. The panel defines an aperture and the fastener includes a shaft portion disposed within the aperture. The primary anode insert may be disposed adjacent to a reaction region of the fastener. Alternatively, the fastening assembly may include a fastener and a primary anode insert. The fastener includes a shaft portion which is configured to be disposed within at least two aligned component apertures. The primary anode insert may be also be disposed adjacent to a reaction region of the fastener.

Abstract: An adhesive composition includes an epoxy component and an additive component reactive with the epoxy component. The additive component includes an imidazole present in an amount of less than or equal to 10 parts by weight based on 100 parts by weight of the adhesive composition, and an amine present in an amount of less than or equal to 5 parts by weight based on 100 parts by weight of the adhesive composition. The epoxy component and the additive component are present in the adhesive composition in a ratio of from 1:1 to 15:1. A method of forming a component includes curing the adhesive composition at a temperature of less than or equal to 150° C. for less than or equal to 30 minutes to thereby join the first substrate and the second substrate.

Abstract: A rivet nut (“rivnut”) installation method and a rivnut structural configuration are disclosed that can be implemented separately in conjunction with one another to serve as an anchor in and/or a workpiece at an installation location. The rivnut installation method involves inserting a rivnut onto an externally threaded mandrel, rotating the mandrel while a free end of the mandrel is in contact with the workpiece, and driving the free end of the mandrel and the rivnut through the workpiece while continuing to rotate the mandrel. The method is particularly useful when the workpiece includes one or more substrate layers composed of a low ductility material such as a polymer composite. The rivnut structural configuration includes the incorporation of an external threading onto at least a portion of a hollow shaft of the rivnut.

Abstract: A riveting system, for use in mechanically linking adjacent workpieces, including a rivet having a height greater than a sum of thicknesses, measured along a line of riveting, of the workpieces being linked, so that the rivet can pass fully through the workpieces. The system also includes a riveting die, which may be a separate product. The die includes a protrusion extending from a peak toward a transition point; and a trough having a trough surface. The trough surface includes a trough inner wall, extending from the transition point to a trough bottom, and a trough outer wall, extending from the trough bottom to a trough outer edge. The technology also includes computerized systems for comparing a load-displacement profile of riveting to a pre-set profile to determine whether the riveting was performed properly.

Abstract: A method of manufacturing a resistance weld in at least three overlying sheet metal layers includes the steps of: (1) providing a first sheet metal layer having a first thickness; (2) providing a second sheet metal layer having a second thickness; (3) providing a filler material on the second sheet metal layer; (4) providing a third sheet metal layer having a third thickness onto the filler material and the second sheet metal layer wherein the third thickness is less than each of the first and the second thicknesses; (5) pressing a pair of welding electrodes against a pair of opposing outer surfaces with the filler material disposed therebetween; and (6) passing an electric current between the pair of electrodes through the filler material and the first, second, and third sheet metal layers to form a weld nugget which penetrates into at least the first and second sheet metal layers.

Abstract: A method to mitigate liquid metal embrittlement cracking in resistance welding of galvanized steels includes modifying at least one face of a steel member to create a first workpiece by: applying a zinc containing material in a first layer to the at least one face of the steel member; and spraying a second layer of a copper containing material onto the first layer of the zinc containing material. The at least one face of the first workpiece is abutted to a second workpiece of a steel material. A resistance welding operation is performed to join the first workpiece to the second workpiece. A temperature of the resistance welding operation locally melts the zinc containing material and the copper containing material to create a brass alloy of the zinc containing material and the copper containing material.

Abstract: An adhesive-bonded component including a first workpiece having a first substrate and a first mating surface including a plurality of protrusions. The component also includes a second workpiece comprising a second substrate having a second mating surface contacting the first mating surface and adhesive positioned on the first mating surface. In various embodiments, the second mating surface comprises troughs receiving the protrusions of the first workpiece, and the plurality of protrusions of the first workpiece and the troughs of the second workpiece may be arranged in multiple mating patterns. The technology also includes processes of making the components.

Abstract: A method of resistance spot welding a workpiece stack-up that includes a first steel workpiece and a second steel workpiece. The method includes several steps. The first steel workpiece can have a first surface coating. One step involves applying a filler metal to a surface of the first steel workpiece. Another step involves bringing a surface of the second steel workpiece to adjoin the filler metal. Yet another step involves clamping a first welding electrode and a second welding electrode on the first and second steel workpieces. And another step involves passing electrical current between the first and second welding electrodes and hence through the filler metal. And yet another step involves terminating passage of the electrical current in order to establish a weld joint between the first and second steel workpieces.

Abstract: A method of resistance spot brazing a workpiece stack-up that includes a first thin-gauge steel workpiece and a second thin-gauge steel workpiece. The method includes several steps. A first step involves applying a filler material to a surface of the first thin-gauge steel workpiece. A second step involves bringing a surface of the second thin-gauge steel workpiece to adjoin the filler material. A third step involves clamping a first welding electrode and a second welding electrode on the first and second thin-gauge steel workpieces and over the filler material. A fourth step involves passing electrical current between the first and second welding electrodes and hence through the filler material. And a fifth step involves terminating passage of the electrical current in order to establish a brazed joint between the first and second thin-gauge steel workpieces.

Abstract: A fastener assembly for use with one or more workpieces. The fastener assembly can be a single-sided (i.e., blind) fastener assembly in which the fastener assembly is inaccessible from one side of the workpiece(s). In this regard, the workpiece(s) can make-up an enclosed component, for example. The fastener assembly can have a fastening end, such as a threaded stud, for securement with a distinct component that is otherwise detached from the fastener assembly. The workpiece(s) can be composed of a carbon fiber composite material, an aluminum material, or another type of material.

Abstract: A double ended dual attached fastener includes a first portion having a stud bolt, a second portion configured to anchor to a panel member, and a flange nut partitioning the first end and the second end. The flange nut includes a flat interior annular surface facing the second portion. The flange nut includes a plurality of radially spaced weld projections extending toward the second portion. The weld projection includes a material that amendable to form a weld joining the flange nut to a panel member through which the second portion is inserted. The second portion defines a fastener selected from a group consisting of a self-tapping friction screw, a self-piercing rivet, and a swage bolt.

Abstract: A method of joining top and bottom layers of material according to the principles of the present disclosure includes providing a rivet having a head and a headless end, wherein a rimmed edge extends downward from the head toward the headless end, applying a layer of adhesive between the top and bottom layers and allowing the adhesive layer to at least partially cure. The method further includes piercing the top layer with a headless end of a rivet after the adhesive layer is cured, deforming the top layer with the rimmed edge and bottom layer with the headless end of the rivet, and forcing the rimmed edge and the headless end of the rivet to bend radially outward during deformation of the top and bottom layers.

Abstract: A method of joining first and second layers of polymeric composite material includes disposing a portion of a molded insert having a bottom end into a top surface of a first layer of material and then applying a layer of adhesive between the top surface of the first layer and a bottom surface of a second layer of material to create a bond-line thickness. Next, a top surface of the second layer is pierced with a headless end of a fastener and interlocked into the molded insert. A layer of protective coating is then applied to the top surface of the second layer of material to cover the interlocked fastener.

Abstract: A method includes forming a first pocket in a first sheet of material and a second pocket in a second sheet of material, pressing the first pocket and the second pocket together at a nonlinear interface, and welding material of the first pocket and the second pocket at the interface.

Abstract: A method of rivet bonding a workpiece stack-up that includes one or more polymer composite workpieces, such as carbon fiber composite workpieces, involves several steps. In one step, adhesive is applied to a surface of the workpiece stack-up. In another step, workpieces—including the polymer composite workpiece(s)—are brought together. In yet another step the adhesive is partially or more cured. A rivet is installed through the workpiece stack-up and through the adhesive in another step. The method strengthens the resulting rivet-bonded joint by minimizing or altogether precluding fracture, cracking, and/or delamination thereat.

Abstract: One or more ductile metal inserts may be selectively incorporated into articles of limited ductility, including metal castings and molded polymers. The inserts are positioned at joint locations for joining of the article to other articles using self-piercing riveting (SPR). The inserts are of suitable ductility, thickness and strength to receive and retain self-piercing rivets and enable a strong riveted joint between the article and a second article. In an embodiment the articles are magnesium alloy castings formed by any of sand casting, die casting and semi-solid metal casting. The chemical composition of the insert may be informed by the anticipated corrosive environment of the joint and the casting temperature of the magnesium alloy. For magnesium alloy castings which may be exposed to corrosive environments, aluminum alloy inserts are preferred.