Abstract: A self-penetrating thread forming and flow drilling fastener for thick materials with a generally cylindrical partially threaded shank, a drive system at the first end of the shank and a flow drilling tip at the second end of the shank. The flow drilling tip is sized larger than the minor diameter of the threaded shank but less than the major diameter to control installation torque enabling installation into thick materials with greatly reduced risk of torsional failure resultant from a decrease in torque. The flow drilling tip and threads may be a variety of shapes or thread types based on the substrate material the fastener is installed into.

Abstract: A fastener has a generally cylindrical shank and a driver at a first end of the shank. The shank has a thread having a first side and a second side opposed to the first side. The first and second sides form a compound angle between the shank and an apex where the first and second sides meet. The compound angle is formed by a body portion extending along the first and second sides from the shank to an intersection, and a crest portion extending along the first and second sides from the intersection to the apex. The first and second sides in the body portion form a body angle with respect to each other, and the first and second sides in the crest portion form a crest angle with respect to each other. The crest angle is greater than the body angle.

Abstract: A fastener has a generally cylindrical shank and a driver at a first end of the shank. The shank has a thread having a first side and a second side opposed to the first side. The first and second sides form a compound angle between the shank and an apex where the first and second sides meet. The compound angle is formed by a body portion extending along the first and second sides from the shank to an intersection, and a crest portion extending along the first and second sides from the intersection to the apex. The first and second sides in the body portion form a body angle with respect to each other, and the first and second sides in the crest portion form a crest angle with respect to each other. The crest angle is greater than the body angle.

Abstract: Electrically assisted flow drill screwdriving processes (EAFDS) and devices are described. The methods can augment traditional FDS and allow for softening of metals of a stack-up, which can enable FDS joining of thicker and stronger materials such as boron steel. EAFDS methods can reduce cycle time and can be used to join thicker cross-sections with reduced installation torque. Also disclosed are fixtures for attachment to existing devices that can provide for the electrical augmentation of existing FDS processes.

Abstract: Electrically assisted flow drill screwdriving processes (EAFDS) and devices are described. The methods can augment traditional FDS and allow for softening of metals of a stack-up, which can enable FDS joining of thicker and stronger materials such as boron steel. EAFDS methods can reduce cycle time and can be used to join thicker cross-sections with reduced installation torque. Also disclosed are fixtures for attachment to existing devices that can provide for the electrical augmentation of existing FDS processes.