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GLOBAL SOLUTIONS

PROBLEM: PIERCE AND CLINCH

FASTENING

SOLUTION: � Welding complexity � Robust method of

attachment � Torque relaxation � Corrosion � Cost

Lightweight Material Challenges

Pierce and Clinch Video

PIERCE and CLINCH BENEFITS

Mass Reduction in Joint

Compact Packaging

Elimination of Secondary Operations

Nut Center to Center

Tolerance 0.2mm

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Shorter nut body = Shorter mating bolt + reduced weight + reduced cost

SPAC nut punch fills parent material

- Smaller Envelope - Shorter nut body - Shorter Bolt - Reduced Weight - Reduced Cost

Packaging Reduction

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SPAC nut punch fills parent material

- Smaller Envelope - Shorter nut body - Shorter Bolt - Reduced Weight - Reduced Cost

Adjacent Material

Packaging Reduction

LOWER MANUFACTURING COSTS

HIGH STRENGTH / HOT-STAMPED

MATERIAL TYPES : ¾ Hot Stamped 1300 to 1600 ¾ Cold Rolled 980 Mpa ¾ J 2340 1300-1500 ¾ J 2340 800DL-1300DL ¾ Usibor 1500 ¾ M 190 ¾ MBW 1500 ¾ MBW 1900 ¾ DOCOL 1000/1200

X-Ray Diffraction Residual Stress Summary

www.rbwmfg.com

• X-Ray Diffraction test was conducted to investigate the pattern and magnitude of the Residual Stresses within “Hot-Stamp Materials.

• Test results from X-Ray Diffraction show that the test coupons were in a state of compression. A compressive state is desirable since cracks cannot be propagated.

• Reference Standards: • ASTM E975-03(Reapproved

2008) • ASTM E915-10

Delayed Fracture Testing Summary

• Delayed Fracture testing was conducted to determine if stress corrosion cracking could initiate micro-cracks in the “Hot-Stamp” material under a fully loaded condition.

• Test results have demonstrated that micro-cracking was not evidenced for various installation methods as governed by referenced test methods and guidelines.

• Reference Standards: • ASTM G39-99( Reapproved 2011) • NACE Standard TM0177 – 2005 Item

No. 1212

Boron Steel Property Class 10 Joint

Hot Stamped

• 1300 Mpa tensile strength material • Fastener close to radius • Issues with weld nuts – cold welds &

weld arcing at stamping radius • Micro-crack potential with pre-pierced

or laser cut holes

More Than Fasteners More Than Ever

RB&W Corporation helping industries keep it together....

Welded solution Nut plate with weld nuts welded to the B Pillar

Self Pierce & Clinch Solution 1. 2 SPAC nuts installed post hot

stamping automatically & simultaneously through 2 layers of material

Usibor 1500 (1.5 & 1.4mm = 2.9mm total thickness)

High Strength Application Business Case

Boron Hot Stamped Beam

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Total Length = 1130mm - 1500 Mpa - Pierce and Clinch

ALUMINUM MATERIAL TYPES: ¾ 6061 - T6 ¾ 5000 Series 90 MPa ¾ 6000 Series 90- 115 MPa ¾ 6063 – T6 ¾ 6111 – T4 ¾ A5023 – H24 ¾ EN-AW 6082 ¾ BG- AlSi 12- 230

RIVNUTS / INSERTS SPAC® NUTS

Locally higher wall thickness is a big problem for die cast tooling

Consistent wall thickness throughout the casting Lower overall height

Extra material is needed to use

threaded inserts.

Cheaper tool design because of straight

walls.

Applications: - Cast Aluminum - Extruded Shapes - Stampings

Typical Cast Design

Helicoil in Castings VS. SPAC Nuts in casting

Operations: Casting an Embossment Drilling and tapping Insert Helicoil

Summary: difficult to cast an embossment, many operations needed

Operations: Pierce and clinch into casting up to 10 mm Aluminum

Summary: one operation needed. No added wall thickness necessary

M10 attachment points

M6 attachment points

M8 attachment points

Aluminum Cast Attachment Points

Remove embossments and material usage Simpler die design Remove machining and drilling/tapping Overcome material thickness variation

Resulting Enhancements

Lightweight Material Challenges “Torque Relaxation”

Additional washers / spacers need to be used to increase bearing surface area adding cost + weight + increased length of bolt.

Self pierce & clinch fastener provides a one piece light-weight low profile solution

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SPAC®PLUG Top Flush with Aluminum Stamping

Multi Material Joining Solution

SPAC ® PLUG INSERT

Aluminum Stamped Structure

High Strength Steel Stamped Structure Weld Tip

Weld Tip

Joining Aluminum to High Strength Steel

- Create Resistance Spot Weld Point - Utilize existing weld line

MAGNESIUM

MATERIAL TYPES: ¾ AZ91D ¾ AM 50 ¾ AM 60

Cast Magnesium with Pierce Nuts

HIGH PERFORMANCE CRITICAL PIERCE NUT PRODUCT APPLICATIONS

JOINT CONSIDERATIONS

• Packaging constraints • Costs and Time to machine

holes • Casting die complexity and

cost for pre hole • Inserting without cracking

material • Corrosion

FASTENING IN MAGNESIUM GALVANIC PROTECTION

TRADITIONAL FASTENING DESIGN

MAGNESIUM

DISSIMILAR METAL

ALUMINUM SELF PIERCE NUT

ALUMINUM HEX FLANGE BOLT

ALUMINUM PIERCE AND CLINCH NUT DESIGN

Magnesium Pierce and Clinch Joints

6000 / 7000 Series Aluminum SPAC Nut

Load Monitored Insertion Forces No pre hole Flush Surface

THANK YOU