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 forming a threaded sleeve. The flow-drill screw is secured by the threads of the threaded sleeve to secure the top part to the bottom part.

Abstract: A screw for use in joining workpieces, for example automotive body parts, is provided that includes a head portion, an externally threaded shank extending from the head portion, a flow-hole-forming tip disposed at a distal end portion of the externally threaded shank, and a recessed spring washer disposed under the head portion. The recessed spring washer is configured to apply a clamping load to joined workpieces as they expand and contract.

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 self-piercing rivet includes a barrel having a cutting edge formed on an insertion tip and a head is formed on an opposite end of the barrel from the insertion tip. The head includes a concave inner surface, or a recess, that includes a peripheral edge radially aligned outboard of a cylindrical outer surface of the barrel adjacent the head. An assembly is disclosed that includes at least two panels that are joined by one or more self-piercing rivets that include a head provided having a concave inner surface. A peripheral edge is configured to form a contact ring that has continuous contact with the outer surface of the first panel to form a closed arcuate recess between the barrel and the periphery of the head.

Abstract: An assembly, for example an automotive assembly, is provided that includes an upper workpiece, a lower workpiece, and a rivet extending through the upper workpiece and into the lower workpiece. The rivet, which may be a self-piercing rivet (SPR) in one form, includes a head portion and a shaft portion extending from the head portion. A diameter of the head portion (Hd) is less than or equal to a diameter of the shaft portion (Sd), and an interface between the head portion of the rivet and the upper workpiece is flush.

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 a material that is difficult to pierce or can be damaged if pierced.

Abstract: Systems and methods for reducing or eliminating corrosion in joined materials are disclosed, for example, multi-material joints. The system may include a sealing device including a body and a tip. The tip may be configured to form a seal around a local region of a material having a fastener disposed therein. The sealing device may be configured to apply a sealant material from the tip to the local region and form a cap thereover. The tip of the sealing device may form a cavity between the material and the inner surface of the tip, which may be filled with the sealant material to form the cap. In one embodiment, the sealing device may be configured to couple to the joining device that inserted the fastener. This may allow for accurate and robust placement of the sealant material directly after the fastener is inserted.

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 welded structural assembly and method are provided, which in one form includes at least one upper substrate, at least one lower substrate disposed adjacent the upper substrate, and a fastener extending through the upper substrate and into the lower substrate. The fastener is welded to the lower substrate and defines a head portion having an outer periphery and an underside. A sealing member is disposed under the head portion and contacts the underside thereof, and further extends beyond the outer periphery of the head portion.

Abstract: A screw for use in joining workpieces, for example automotive body parts, is provided that includes a head portion, an externally threaded shank extending from the head portion, a flow-hole-forming tip disposed at a distal end portion of the externally threaded shank, and a recessed spring washer disposed under the head portion. The recessed spring washer is configured to apply a clamping load to joined workpieces as they expand and contract.

Abstract: A fastener for use in joining workpieces, for example automotive body parts such as a roof to a body frame member, is provided that includes a plastically deformable head portion, a platform disposed at a bottom of the head portion, and a distal end portion extending from the platform and defining at least one of elastically deformable locking member. The head portion is heat staked to one workpiece, and the elastically deformable locking member engages another workpiece to secure the workpieces together. The platform provides spacing, or a bond gap in one form, between the workpieces, and a material and geometry of the fastener are configured to compensate for a difference in thermal expansion of the workpieces.

Abstract: An automotive aluminum alloy component assembly includes a first vehicle component defining a first joint region and a first cutout. The assembly also includes a second vehicle component defining a second joint region. The assembly also includes a third vehicle component defining a third joint region. Portions of the first and third joint region sandwich the second joint region. A first self-piercing rivet is disposed within the second and third components and aligned with the first cutout.

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.

Abstract: A method is provided for assembling a stack-up including a first workpiece with a clearance hole and a second workpiece. The method comprises adhering an adhesive to a first face of the first workpiece so as to completely cover and close the clearance hole and securing the second workpiece to a second face of the first workpiece with an adhesive. A stack-up and the method of capturing adhesive squeeze-out during a stack-up assembly process are also disclosed.

Abstract: A method of joining a first panel and a second panel with an adhesive and flow drill screws is provided. The adhesive is applied in a continuous strip and the flow drill screws are inserted through the first panel, the continuous strip of adhesive, and through a second panel. Material displaced by the flow drill screw forms a collar. An intermediate portion of the collar defines a bond gap for the adhesive between the panels. An assembly is made according to the method includes the intermediate collar portion formed by the flow drill screw displacing material from the panels that sets a bond gap between the first and second panels for the adhesive.

Abstract: A die for use with a cold-formed joint tool such as a clinching tool or clinch punch or self-piercing rivet punch. A split die made of a plurality of partial cup-shaped segments is disposed within a collar that defines a recess. The recess includes a forming area in which the cold-formed joint is formed and a relieved area in which the partial cup-shaped segments are shifted radially outwardly after forming to permit removal of the cold-formed joint tool from the cold-formed joint.

Abstract: Joints and methods of forming the same are disclosed. The joint may include a first component including an indentation formed therein having a width, a second component, an adhesive layer disposed between the first and second components, and a fastener extending through the indentation. The fastener may join the first and second components and have a head with a width greater than a minimum width of the indentation. The method may include forming an indentation having a width in a first component, applying an adhesive to one of multiple components, and stacking the components. The indentation may form a bond gap between two components. A fastener may be inserted having a head with a width greater than the width of the indentation into the indentation to join the components. The indentation may space the components apart to provide a larger bond gap for the adhesive.

Abstract: A clinch punch including a core and an sleeve that includes a plurality of teeth for forming an enhanced clinch joint. The core includes a first cam surface that engages cam surfaces on the teeth that drive the teeth into the sides of the clinch joint. In an alternative embodiment, the core acts upon jaws that are driven into engagement with the sides of the clinch joint.

Abstract: In at least one embodiment, an assembly is provided comprising a first member including a 6xxx series aluminum alloy heat treated to have a yield strength of at least 200 MPa and an r/t (bendability) ratio of up to 0.4. One or more members may be secured to the first member with a rivet (e.g., a self-piercing rivet). The heat treated alloy may have a yield strength of at least 260 MPa and may have a bendability ratio of up to 0.3. A method of forming an assembly is also provided, including heat treating a 6xxx series aluminum alloy to produce an alloy having a yield strength of at least 200 MPa and an r/t (bendability) ratio of up to 0.4 and riveting a member including the heat treated alloy to one or more additional members.

Abstract: An assembly for a vehicle and a method of making an assembly including more than three panels stacked together and joined by self-piercing rivets or by clinch joints. A first panel and a second panel are joined together at a first attachment point. A third panel and the first panel are joined together at a second attachment point. A fourth panel and the third panel are joined together at a third attachment point. The first, second and third attachment points are spaced apart to avoid interference between the self-piercing rivets or the clinch joints.