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 joint and related method. The joint includes bottom and top layers contacted to form first and second contacting portions. The bottom layer is a fiber composite material that is non-ductile at room temperature. A joint member joins the bottom and top layers such that the joint and the top layer are unexposed through the bottom layer.

Abstract: An assembly including a plurality of parts fastened together with a flow drill screw. An indentation is formed on one side of a first part and a second part is assembled into engagement with the side of the first part with the indentation facing the second part. The flow drill screw is inserted through the indentation and material is displaced from the part into the indentation. Two or more panels or parts may be joined by aligning a flow drill screw with the indentations that are formed by embossing one or more panels.

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: An assembly comprising a first composite fiber reinforced part that is joined to a second part by a clinch joint. The first part includes a first layer of resin that is reinforced with fibers and a second layer of resin that is devoid of fibers and applied to one side of the first layer of fiber reinforced resin. The second part contacts the first layer of the first part. The first part and second part are joined by a clinch joint including a pressed out portion that is pressed into a clinching portion. The second layer of resin contains the fibers in the first part. An alternative assembly has fiber-free intended clinch joint forming areas that extend through the first part. A method is provided in which a first part including a first layer of resin reinforced with fibers is molded with a second layer of resin on one side of the first layer is joined by a clinch joint to a second part.

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.

Abstract: A clinch joint punch includes an elastomeric tip on a distal end of an engagement section. The elastomeric tip may include a partially spherical surface or may be a cylindrical member having a planar circular engagement surface. A method of joining a clinch joint and a plurality of panels by driving a punch having an elastomeric tip into the panels. The elastomeric tip is compressed within a recess formed in the panels to mechanically interlock the panels.

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: 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: An assembly including a plurality of parts fastened together with a flow drill screw. An indentation is formed on one side of a first part and a second part is assembled into engagement with the side of the first part with the indentation facing the second part. The flow drill screw is inserted through the indentation and material is displaced from the part into the indentation. Two or more panels or parts may be joined by aligning a flow drill screw with the indentations that are formed by embossing one or more panels.

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 method of fastening a plurality of parts together with a flow drill screw. An indentation is formed on one side of a first part and a second part is assembled into engagement with the side of the first part with the indentation facing the second part. The flow drill screw is inserted through the indentation and material is displaced from the part into a void defined by the indentation. Two or more panels or parts may be joined by aligning a flow drill screw with voids formed by indentations that are formed by embossing one or more panels.

Abstract: A method of joining parts together with a self-piercing rivet that is inserted through a part and partially through a second part. The second part includes a fiber-filled layer and a resin matrix layer that together form a composite part. A self-piercing rivet extends into the second part, but does not penetrate completely through the matrix layer. An assembly, including a first part and a second part that includes a reinforced layer and a resin layer in which a fastener is inserted, but does not extend through the second layer. A composite part including a first layer of resin matrix reinforces the filler and a second layer of resin matrix that does not include a filler and is more than 3 microns thick.

Abstract: A method of joining parts together with a self-piercing rivet that is inserted through a part and partially through a second part. The second part includes a fiber-filled layer and a resin matrix layer that together form a composite part. A self-piercing rivet extends into the second part, but does not penetrate completely through the matrix layer. An assembly, including a first part and a second part that includes a reinforced layer and a resin layer in which a fastener is inserted, but does not extend through the second layer. A composite part including a first layer of resin matrix reinforces the filler and a second layer of resin matrix that does not include a filler and is more than 3 microns thick.

Abstract: A method of joining parts together with a self-piercing rivet that is inserted through a part and partially through a second part. The second part includes a fiber-filled layer and a resin matrix layer that together form a composite part. A self-piercing rivet extends into the second part, but does not penetrate completely through the matrix layer. An assembly, including a first part and a second part that includes a reinforced layer and a resin layer in which a fastener is inserted, but does not extend through the second layer. A composite part including a first layer of resin matrix reinforces the filler and a second layer of resin matrix that does not include a filler and is more than 3 microns thick.

Abstract: A method of joining parts together with a flow drill screw or with a clinch joint. A first part formed of metal or a composite material is joined to a second part that includes a fiber-filled layer and a resin matrix layer. The flow drill screw extends through the first part and the second part into the second part. The resin matrix layer prevents fibers from the fiber filled layer from being forced through the back of the second panel. A clinch joint may be formed into the first part and the second part but does not penetrate completely through the resin matrix layer. When the clinch joint is formed, the resin matrix layer inhibits the fiber filled layer from pushing through the second layer of the second panel.

Abstract: A method of fastening a plurality of parts together with a flow drill screw. An indentation is formed on one side of a first part and a second part is assembled into engagement with the side of the first part with the indentation facing the second part. The flow drill screw is inserted through the indentation and material is displaced from the part into a void defined by the indentation. Two or more panels or parts may be joined by aligning a flow drill screw with voids formed by indentations that are formed by embossing one or more panels.