Ford Global Technolgoies, LLC

Atlas Copco Ias Gmbh

Semblex Corporation

Amanda Kay Freis

Garret Sankey Huff

Aindrea McKelvey Campbell

Thomas Norton

S George Luckey, Jr

Peter A Friedman

Nia R Harrison

Vladimir Vladimirovich Bogachuk

Andrey M Ilinich

Nicholas Dornik

Anthony J Grima

Shawn Michael Morgans

James Maurice Boileau

Jason Scott Balzer

David John Hill

Daniel Quinn Houston

Joy Hines Forsmark

Jason Douglas Scott

David Edward Paul

Rosa Lynda Nuno

Jina Kim

Kim Lazarz

Darrin Neil Wagner

Laurent Bernard Chappuis

Srinath Vijayakumar

Brandt J Ruszkiewicz

Stephen J Crockett

David John Coldwell

Vlad Bogachuk

Ronald David Ketelhut

A method of joining substrates includes positioning the substrates on a die and pressing a self-piercing rivet until it penetrates into the bottom substrate and deforms the bottom substrate into a relief of the die defined by at least: a raised central portion, an outer portion disposed about a central axis of the die, a side surface disposed about the central axis, and an annular channel disposed about the central axis and disposed, in a radial direction, between the raised central portion and the outer portion. The side surface connects the outer portion to the top surface. The annular channel is recessed axially from the raised central portion and at least a part of the outer portion that is adjacent to the annular channel. The annular channel is radially inward of a toe of the self-piercing rivet after the deforming the bottom substrate into the relief.

Self-piercing rivet die, assembly, and method of joining materials with a self-piercing rivet

A method includes operating an automatic tool at a first setting to drive a flow drill screw (FDS) into a substrate. The first setting is configured to rotate the FDS at a first rotational speed and apply a first axial feed force. The first setting is configured to cause flow of the substrate to permit the FDS to penetrate the substrate. The method includes detecting a predetermined first trigger condition including at least one of a depth gradient and a depth and switching the tool from the first setting to a second setting in response to a predetermined second trigger condition including at least one of a predetermined axial feed distance after detecting the first trigger condition and a predetermined time delay after detecting the first trigger condition. The second setting is configured to rotate the FDS at a lower rotational speed and apply a lower axial feed force.

Flow drill screw installation method to reduce installation torque and permit installation into thick materials

A method of installing a flow drill screw (FDS) into a substrate includes engaging the FDS with an automatic tool, operating the tool at a first setting to drive the FDS into the substrate by causing flow of the substrate to permit the FDS to penetrate the substrate, and switching the automatic tool from the first setting to a second setting in response to a controller analyzing axial acceleration data of the FDS. The first setting is configured to rotate the FDS at a first rotational speed and to apply a first axial feed force. The first setting is further configured to cause flow of the substrate to permit the FDS to penetrate the substrate. The second setting is configured to rotate the FDS at a second rotational speed and to apply a second axial feed force. The second rotational speed is less than the first rotational speed.

Method and system with acceleration based flow drill screw control

A screw includes a head portion, an externally threaded shank extending from the head portion, the externally threaded shank having an external surface, and a flow-hole-forming tip disposed at a distal end portion of the externally threaded shank. The flow-hole-forming tip includes a radiused lower zone having an external surface tangent to the external surface of the externally threaded shank, a conical middle zone having an external surface tangent to the external surface of the radiused lower zone, the conical middle zone defining a vertex angle, and a radiused distal end zone having an external surface tangent to the external surface of the conical middle zone. The flow-hole-forming tip includes a width of the flow-hole-forming tip is greater than a length of the flow-hole-forming tip and/or the vertex angle is greater than or equal to 90 degrees.

Flow drill screw and tip configuration

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.

Clearance hole for self-piercing rivet

A welded structural assembly and method, in one form, includes an upper substrate, a lower substrate adjacent the upper substrate, a fastener, and a sealing member. The fastener includes a shank portion, a first head portion, and a second head portion. The shank portion extends through the upper substrate and into the lower substrate. The shank is welded to the lower substrate. The first head portion has an outer periphery and an underside. The second head portion is frangibly coupled to the first head portion. The sealing member is disposed under the first head portion between the upper substrate and the first head portion. The sealing member contacts the underside and extends beyond the outer periphery such that the sealing member extends radially outward beyond all points of the first head portion.

Friction element weld element modification to increase corrosion resistance of thermal mechanical joint

An incremental forming machine and a process are disclosed that comprise selecting a blank and selecting a stylus tool that has a tip at one end. The stylus tool may be heated to a desired temperature before contacting the blank with the stylus tool to change a characteristic of the blank or part. The stylus tool apparatus may include a tip on an end of a shaft and a resistance heating element disposed inside the tip. Alternatively, the stylus tool apparatus may include an induction heating coil disposed around the tip. The tip of the stylus tool may have a rotatable ball that engages the blank or part.

Method and apparatus for incrementally forming prototype parts with a heated stylus tool

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.

Net shaped substrate material for substrate joint

A method includes identifying a location of a locating feature disposed on an exterior profile of a lower substrate, the locating feature configured to identify a specified location of the exterior profile, positioning a self-piercing rivet along an upper substrate according to the identified location of the locating feature, and installing the self-piercing rivet through the upper substrate and into the lower substrate.

Surface features for locating net substrate buttons to enable self-piercing riveting (SPR) on brittle and low toughness materials

A vehicle assembly includes a first component having a stand-off that provides a cavity. The stand-off protrudes from an insertion side of the first component. The stand-off includes at least one side wall that extends from a floor of the cavity to at least one outer surface of the stand-off. The assembly further includes a second component that contacts the first component at an interface. The cavity is configured to receive a mechanical fastener that joins the first component to the second component. A distance between the floor of the cavity and the interface is greater in some areas than in other areas such that a cross-sectional thickness at a bottom of the cavity is varied.

Vehicle component joining assembly

A dimpled substrate for use in an assembly having joined substrates is provided that defines at least one preformed interior cavity, at least one preformed exterior profile adjacent the interior cavity and defining a wall therebetween, and at least one locating feature configured to identify a location of the at least one preformed exterior profile. In one form, the locating feature is disposed in the preformed exterior profile or adjacent to the preformed exterior profile. Alternatively, the locating feature is a notch formed into the dimpled substrate away from the preformed exterior profile.

A system is provided for attaching a layer of a metal to other layers in a material stack-up using a metal mechanical fastener that does not allow for direct contact between the fastener and the metal layer, thereby neutralizing any galvanic reaction between the metal sheet and the fastener and avoiding corrosion. The metal layer may be any of several metals, including magnesium. The fastener is a rivet, a screw or a bolt. The disclosed inventive concept uses an insulating layer to insulate the magnesium layer. In one embodiment, a layer of a thin metal is formed over the insulating layer. Where the fastener is a rivet and the metal is magnesium, the insulating layer and thin metal provide a barrier between the magnesium layer and the rivet prongs following rivet insertion, thus isolating the rivet. The system enables a greater application of fastener joining, particularly with magnesium and mixed material joining.

Mechanical joining top sheet isolation

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.

Method and apparatus for incrementally forming prototype parts with a heated stylus

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.

Growing community of inventors

Ann Arbor, MI, United States of America

Amanda Kay Freis