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 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 system for assembling vehicle components includes a die assembly securing first and second vehicle components having first and second apertures, respectively. The die assembly positions the first and second vehicle components with the first and second apertures overlapping, and at least one of the first and second vehicle components including a polymeric material. The system further includes a joining component extending through the first and second apertures. The die assembly supports the joining component, and the joining component including a support shank and a moldable body at least partially encasing the support shank. The system also includes a punch member selectively engaging and deforming the moldable body of the joining component. The die assembly guides the moldable body into engagement with the first and second vehicle components, and the die assembly locates the support shank within at least one of the first and second apertures.

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 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: Systems and methods for locally softening high strength steel are disclosed. One method may include heat treating one or more local regions of a steel component having a hardness of at least 450 HV to soften the local region(s) to a hardness of at most 250 HV. The heat treating may include heating only the local region(s) to a target temperature above an AC1 temperature of the component and below an AC3 temperature of the component. In another method, the heat treating may include heating only the local region(s) to a first target temperature above an AC3 temperature of the component, cooling the local region(s) to below an AC1 temperature of the component, and isothermally holding the local region(s) at a second target temperature below the AC1 temperature. The locally softened region(s) may allow for improved joining and/or trimming of the component.

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 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: A joined sheet stack and a method and system for forming the stack are disclosed. The stack may include a steel sheet and a second sheet. The steel sheet may include a bulk portion having a first tensile strength and one or more fastener regions having a second tensile strength that is lower than the first tensile strength and a microstructure that includes tempered martensite. A fastener may extend through each fastener region joining the steel sheet to the second sheet. The method may include heat treating one or more regions of a steel sheet to form one or more fastener regions having a tensile strength that is lower than a bulk tensile strength of the steel sheet and a microstructure that includes tempered martensite. A fastener may then be inserted into the one or more fastener regions to join the steel sheet to a second sheet.

Abstract: An assembly of vehicle components includes first and second components abutting each other. At least one of the first and second components includes a non-metallic material. The first and second components respectively include overlapping first and second apertures. The assembly further includes a joining component extending through the first and second apertures. The joining component has a support body and an outer body at least partially encasing the support body. The outer body includes a polymeric material. The joining component clamps the first and second components between first and second flanges of the outer body, and the support body extends into at least one of the first and second apertures.

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 vehicle includes a body panel assembly including first and second panels. Each panel defines different materials, and the first and second panels are fastened at a joint using a fastener. A compression limiter is disposed at the joint and configured to reduce stress on the first and second panels due to the fastener. The compression limiter has a first ring to contact the first panel and a second ring to contact the second panel. The first ring defines a drain extending through the first ring to the second ring on an outer periphery of the first ring, and is oriented such that moisture between the first and second panels is wicked through the drain and removed from the panel assembly.

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: 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: 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 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.