Bonding and Riveting By Peter Coffey Bodyshop Solutions Ltd.

Bonding and RivetingBy

Peter CoffeyBodyshop Solutions Ltd

Bonding and RivetingDesigners:

•The designers of new cars always choose the materials that best suit the job. •Lightweight, strong, and is able to be re-cycled.•This can be a combination of several different types of steel together with aluminium, plastics, carbon fibre etc. •Not everything can be welded, so other joining methods are needed.

Bonding and RivetingRepairers:

•No repairer is ever forced to repair any car, whether it is steel or aluminium or Carbon Fibre or Plastic.•Once they decide to do so, the onus is clearly on the repairer to always have the correct equipment and the training in place to repair the cars.

• Firstly: The correct equipment• Secondly: The correct training

?Blind Riveting

Bonding and Riveting

PowerbirdUp to 1.2 tons

Taurus 4Up to 1.8 Tons

Used by BMW

Used By Mercedes Benz

• Pre-drilling is required• Each rivet has a specifically designed “breaking point”• If the wrong tool is used, the rivet may not be securely

fitted

BMW: Rivets used on front repair with Gesipa Powerbird rivet gunRecommended repair method for 5 series

Note: With all types of riveting, there will always be glue and adhesives involved. Glue such as Betamate 2096 is widely used.

Bonding and RivetingSelf Piercing Rivets. “Punch Rivets”

Used by: •Audi •BMW •Mercedes Benz •Jaguar / Land Rover•Ferrari etc.

•Mainly in production but eventually in repair

Bonding and RivetingSelf Piercing Rivets. “Punch Rivets”

Böllhoff

•Can be used:•For hybrid joining•On galvanised and coated steels•On High Strength Steels•On Aluminium, •Or combinations of these different materials

New Tools were needed, new training procedures

Why were these chosen

•No pre-drilling needed•Very neat, once fitted.

Bonding and RivetingRivets must be matched to the job

•What is the required strength of the joint•How robust must the joint be•What access to the joint is available•How thick is the material ( the total stack)•How hard is the material

• ( L ) The length is decided by the stack thickness• ( D ) Two main sizes, 3mm and 5mm in diameter but there are many other sizes

The tools must be matched to the rivet

• Do they have enough clamping force• Do they distort the work-piece• Are they accessible

Bonding and Riveting

Self piercing rivets being fitted.

Bonding and RivetingBasic repair method

1. Cut the panels and prepare the special reinforcementplate

2. Apply the glue to the reinforcement plate andfit into position

3. Clamp the panels in place and remove any excess glue.

Blind rivets are fitted here

Self piercing rivets here

Gluing

• Use the correct glue as supplied• Use correct cartridge applicator• Must be battery power• Do not use air powered• Do not hand operated

Note: It is important to have the correct mix with no risk of air getting into the mix. This may make the glue weaker.

Maximum of three repairs on same section

Bonding and RivetingFlow Form Rivets. From Mercedes Benz

The repair process is as follows1)Remove any existing rivets and remove the damaged panel2)Punch hole through all panels including new panel3)Fit new panel, glue, place rivet insert and press together.

In sizes for Aluminium / SteelA1 / S1 Overall thickness 2.30 and 3.15mmA2 / S2 Overall thickness 3.35 and 3.95mmA3 / S3 Overall thickness 4.20 and 5.15mm

Advantages of Flow Form over Self Piercing

•Can be used with any material•With any combination of materials•Steel, Aluminium, Plastic, Carbon Fibre etc.•Can do repeat repairs in same holes.

Proved to be very safe in all crash tests

Bonding and RivetingRepair process with Flow Form Riveting

Step 1: Punch out any existing rivets and remove the damaged panel.

Use safety glasses in case the rivet flies out

Bonding and RivetingRepair process with Flow Form Riveting

Step 2: Punch hole through all panels including the new panel

Bonding and RivetingRepair process with Flow Form Riveting

Step 3: Fit new panel, glue, place rivet insert and press together trying to avoid damage to the panels

Bonding and RivetingSo why do we do it?

1 To avoid as much welding as possible

1 This will prevent corrosion after welding

1 To obtain a very rigid connection

1 Repair times are drastically reduced Less time spent removing and re-assembling panels Repairs are approximately 30% quicker

Repairs can be carried out to:Rear PanelsQuarter panelsinner wing reinforcementFront inner wingChassis leg repairsRoof replacementBoot floor replacement

Repair methods vary from manufacturer to manufacturer

Bonding and riveting is here to stay

Bonding and RivetingWhat is the future?

•The future is: Material mix •It is a fact that the new generation of electro-powered vehicles are still far too heavy. Definitely they have to become lighter•More Carbon + Aluminium+ Plastics, etc.•Lighter steels (much harder steels)

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Bonding and Riveting

•The future is: Cold JoiningWhat is the future?

• Flow form rivets• Self piercing rivets• Pop rivets• Blind rivets, • Blind rivet studs• Rivet nut studs • Rivet nuts• Clinching• Punching• Screws• More jobs to come…..

There are many different rivets and many different tools or machines that are required to be able to fit them.

There must be a way to fix the different rivets using just one modular system!

Any new system has to better and it has to be different from the existing ones. Old rivets systems always have a problem with accessibility. But their biggest problem is:

•Either they are too soft – rivet not set to full strength! •Either they are too strong – material surface already damaged or flattened!

The goal is “Power Control”•The correct strength for the job with no distortion to the work-piece.

What is the future?Bonding and Riveting

Modular System

What is the future?

Just one complete system to do all the new joining techniques..

…With Power Control

Bonding and Riveting

Blind Rivet nut adaptor

Blind Rivet adaptor

Handy and Lightweight to use

What is the future?Bonding and Riveting

• Accessible• Small blind rivet adapter in narrow areas

• Versatile• Fitting Rivnuts• Fitting blind rivets• Blind rivet nuts in specific areas

• Modular System• User Friendly!

Bonding and Riveting

• Self Piercing Rivets• Larger C Clamp• Easy to operate

• Flow Form Rivets• Small C Clamp• Easy to operate

This is the future?

Bonding and RivetingThis is the future?

In many cases a big C -arm is indispensable!

Bonding and Riveting