Abstract: Methods and systems for joining multiple workpieces are provided. In one example, the method includes dispensing adhesive on a first workpiece. A second workpiece is contacted with the adhesive such that the adhesive is disposed between the first and second workpieces. Resistance heating is produced in the first and second workpieces at first processing conditions to partially cure the adhesive and affix the first and second workpieces together to form a partially cured, adhesive-joined workpiece assembly. The partially cured, adhesive-joined workpiece assembly is exposed to heat at second processing conditions to substantially fully cure the adhesive.

Abstract: Methods and systems for joining multiple workpieces are provided. In one example, the method includes dispensing adhesive on a first workpiece. A second workpiece is contacted with the adhesive such that the adhesive is disposed between the first and second workpieces. Resistance heating is produced in the first and second workpieces at first processing conditions to partially cure the adhesive and affix the first and second workpieces together to form a partially cured, adhesive-joined workpiece assembly. The partially cured, adhesive-joined workpiece assembly is exposed to heat at second processing conditions to substantially fully cure the adhesive.

Abstract: A method for tempering steel for riveting includes positioning a first component having a first composition over a second component having a second composition, and resistance spot welding the first component to the second component using a resistance spot weld gun to form a spot weld. The method includes tempering at least one of the first component, the second component and the spot weld with the resistance spot weld gun, and coupling a third component having a third composition to the first component and the second component with a rivet, and the third composition is different than the first composition and the second composition.

Abstract: A fastening assembly includes a panel defining an aperture, a fastener having a head, a shaft portion extending from the head, and a recess formed in the head, and a sacrificial primary anode insert disposed in the recess. The sacrificial primary anode insert is configured to corrode at a rate faster than a corrosion rate of the fastener.

Abstract: A method of joining a multiple member work-piece includes providing a first steel work-piece having a first thickness and a second steel work-piece having a second thickness. The first thickness is at least twice the second thickness. A third material is disposed in contact with the second steel work-piece. For example, the third material may be in the form of a rivet, a plurality of pins, or a coating material. The method includes resistance welding the first and second work-pieces together. A bonded assembly includes the first and second steel members and the third material being bonded together, where the thickness of the first member is at least twice the thickness of the second member.

Abstract: A fastening assembly includes: a panel defining an aperture; a fastener having a cap and a shaft extending from the cap, the shaft being disposed through the aperture, the fastener having a first corrosion rate, and the fastener including: a recess formed in the cap and extending at least partially around the shaft; face surfaces that are planar and that are to directly contact the panel; and recessed channels that are disposed between the face surfaces, respectively, that are recessed relative to the face surfaces, and that extend from a radially outer edge of the cap to the recess; and an anode insert disposed in the recess and having a second corrosion rate that is faster than the first corrosion rate.

Abstract: A method of joining a multiple member work-piece includes providing a first steel work-piece having a first electrical resistivity and a second steel work-piece having a second electrical resistivity that is lower than the first electrical resistivity. A third material is disposed in contact with the second steel work-piece. The third material has an electrical resistivity that is greater than the second electrical resistivity. The method includes resistance welding the first and second work-pieces together. The third material may be in the form of a rivet, a third work-piece, or a coating material disposed between the first and second work-pieces. A bonded assembly includes steel members and a third material being bonded together, wherein the electrical resistivity of the second member is lower than the electrical resistivity of the first member, and the third material has an electrical resistivity that is greater than the electrical resistivity of the second member.

Abstract: A fastening assembly includes a panel defining an aperture, a fastener having a head, a shaft portion extending from the head, and a recess formed in the head, and a sacrificial primary anode insert disposed in the recess. The sacrificial primary anode insert is configured to corrode at a rate faster than a corrosion rate of the fastener.

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: A method of joining a multiple member work-piece includes providing a first steel work-piece having a first thickness and a second steel work-piece having a second thickness. The first thickness is at least twice the second thickness. A third material is disposed in contact with the second steel work-piece. For example, the third material may be in the form of a rivet, a plurality of pins, or a coating material. The method includes resistance welding the first and second work-pieces together. A bonded assembly includes the first and second steel members and the third material being bonded together, where the thickness of the first member is at least twice the thickness of the second member.

Abstract: A method of joining a multiple member work-piece includes providing a first steel work-piece having a first electrical resistivity and a second steel work-piece having a second electrical resistivity that is lower than the first electrical resistivity. A third material is disposed in contact with the second steel work-piece. The third material has an electrical resistivity that is greater than the second electrical resistivity. The method includes resistance welding the first and second work-pieces together. The third material may be in the form of a rivet, a third work-piece, or a coating material disposed between the first and second work-pieces. A bonded assembly includes steel members and a third material being bonded together, wherein the electrical resistivity of the second member is lower than the electrical resistivity of the first member, and the third material has an electrical resistivity that is greater than the electrical resistivity of the second member.

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 weld rivet for use in a method of resistance element welding of dissimilar materials includes a shank portion, a cap portion, and a coating. The shank portion has a cylindrical shape, a first end, and a second end opposite the first end. The cap portion has a flat disc shape, a top surface, and a bottom surface. The bottom surface of the cap portion is disposed on the first end of the shank portion. The coating is disposed on the bottom surface of the cap portion. The coating electrically insulates the cap portion.

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 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 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: 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 spin fastening system includes a first member and an adhesive layer applied to the first member. A second member is positioned in contact with the adhesive layer. At least a portion of the adhesive layer is cured after the second member is positioned in contact with the adhesive layer to render at least the portion of the adhesive layer substantially rigid. At least one spin fastener is inserted successively through each of the second member, the cured portion of the adhesive layer, and the first member.