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 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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2
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5
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?