GALM PRESENTATIONREVIEWING THE COMPLEXITY OF HENROB SELF-PIERCE

RIVETING (HSPR) APPLICATIONS IN BIW / CIW TO

UNDERSTAND ITS FULL CAPACITY

April 14, 2015

HENROB – WHAT WE DO

Our sole focus is Self-piercing Rivets (SPR) and Self-piercing

Riveting Systems

Innovative Joining Solutions

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HENROB – IN BIW / CIW TRENDS

Complexity of Henrob Self-Pierce Riveting (HSPR)

AL Sheet

AL Casting

AL Extrusion

AL Sheet

AL Casting

AL Extrusion

HSS Steel

PHS Steel

AL Sheet

AL Casting

AL Extrusion

HSS Steel

PHS Steel

Mg Casting

Composites

15-years ago 5-years ago 5-years from now

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2T Joint

Steel to steel

Aluminum to aluminum

Multiple Joint

Aluminum alloys

Up to 10 mm

Mild Steel alloys

Up to 6 mm

Dissimilar

Metals

Aluminum to steel

to aluminum

Dissimilar

Materials

Plastic / aluminum

3mm extrusion

+ gasket

+ 2mm HS steel

HENROB – IN BIW / CIW

Complexity of Henrob Self-Pierce Riveting (HSPR)

Quiet Steel

1mm + steel laminate

+ 3mm with Adhesive

reduces NVH

3mm + 3mm + 2.7mm

3T Aluminum with

Adhesive

Self Piercing Stud

M6 SPS in 2.3 mm

.9mm + 1.2mm

+ 2mm Aluminum

to Aluminum to

Mild Steel

.9mm +2mm + 2.7mm

3T Aluminum with Adhesive

.9mm + 3mm + 3.2mm

3T Aluminum with

Adhesive

T-Rivet geometry increases

bore depth allowing for a longer

rivet and increased interlock

FAQS

Rivet weight per AIV BIW

SPR Cycle time vs. RSW Aluminum

SPR Fatigue strength and properties

Surface prep requirements

Galvanic reaction with Steel/Aluminum

Non-Destructive-Testing (NDT)

Energy consumption

Aftermarket sustainability

WHAT IS HENROB SPR

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Innovative Joining Solution for aluminum and mixed

material applications

The Process

Rivet pierces upper sheet

material

Rivet flares into lower material but

does not break through

Rivet head clamps down tightly onto

top material

WHAT IS HENROB SPR

WHAT'S CRITICAL TO AN SPR JOINT

Early Engagement – Is Key

Preferred - Thin to Thick

Bottom sheet is >33% of the TOTAL stack

Better strength consistency

Easier rivet rationalization

Less chance of rivet tail breakthrough

Non-Preferred - Thick to Thin

Bottom sheet is <33% of the TOTAL stack

Lower strength consistency

Difficult rivet rationalization

Increased chance of rivet tail breakthrough

Basic Design Rule

WHAT'S CRITICAL TO AN SPR JOINT

Resources to support CAE &

Modeling

Early Engagement – Is Key for Joint Development testing

Riveted “coupons” are made using the application materials to test joint strength and integrity.

WHAT'S CRITICAL TO AN SPR JOINT

WHAT'S CRITICAL TO AN SPR JOINT

Required Process Inputs – Tooling

• What product parts will be present in cell

• Identify spots each tool will be riveting

• Correlate the spot numbers to the Joint

Identification (JID) numbers

• Section the parts though the rivet

centerline and stack all the joints together

to define the total access requirements

• Develop part holding/locating

requirements to assess gun access

Rivet Setter

Rivet Spool

Die PostFeedSystem

C-Frame

Robot Mount

Early Engagement – Is Key

LESSONS

Early engagement with vendors is critical with AIV development

Manufacturing strategy aligned with product development

Reduce learning curve utilizing vendors with previous experience

Early testing and validation is key to success

Eliminate changes or organize and manage the change process

Quality and operational issues can be negated with early adoption

of new technology standards and procedures

Utilize vendor resources at every level of product design cycle

through launch