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Source: Wikipedia
Agenda
Introduction
Possible Combinations
2
Hybrid Joining in General
Hybrid joining is a combination of two or more elemental joining methods
The joining processes
● are in the same areas of the workpiece
● parallel or after each other
Goal:
● compensate negative charateristics of the bonding methods
● combine positive characteristics of the bonding methods with each other
Introduction
Possible Combinations
8
Classification of Joining Methods According to DIN 8593
Group 4.1
Composition
Group 4.2
Filling
Group 4.3
Pressing in and on
Group 4.4
Joining through casting
Main Group 4 Joining Group 4.5
DIN 8593 Teil 0 Joining through forming
Group 4.6
Joining through Welding
Group 4.7
Joining through Soldering
Group 4.8
Adhesive Bonding
Group 4.9
Textile Joining
9
Hybrid Joining Methods that Are Relevant for Adhesive
Bonding
Industrial applications of these hybrid joining methods (selected):
Punch Riveting
Riveting
Folding
resistance spot
4.6. Welding
welding
Adhesive
Bonding
Spot Welding
Riveting
Punch Riveting
Screwing
Clinching
Folding
Table 3: Analysis of the strengths and weaknesses (3) 14
Agenda
Introduction
Possible Combinations
15
Hybrid Joining Methods:
16
Procedural Description - (Resistance) Spot Welding (1)
Classification according to DIN 8593: Group 4.6 Welding
Welding Procedure of sheets and profiles
Definition
„By applying two electrodes, the elements that are to be welded are integrated into an
electrical circuit.
The bonding area heats up, due to electrical resistance and a welding spot is formed.“
Source: Waldmann 17
Procedural Description - (Resistance-)Spot Welding (2)
Functional Principle:
● welding charge is started Force
Electrode
● narrowed cross-section provides Energy:
alternating
resistance current impuls
Consequence:
● electrode heats up work piece
workpiece
● material is partly melted
Electrode
Source: Rime 19
Hybrid Joining Methods: Spot Welding – Bonding (1)
Method of Fixation:
● Adhesive is applied to the joint elements
● A welding spot is set
● Curing of adhesive layer
1st Step:
Preparation of joint
element
2nd Step:
3rd Step: 4th Step: 5th : 6th Step:
Positioning of joint
Joining Injection of adhesive Curing of adhesive Completed
element
Pic. 6: Injection Method Source: EAA, Matter at University of Liverpool 21
Hybrid Joining Methods: Spot Welding – Bonding (3)
Sequential Method
● Adhesive is applied to joint elements
● Joint elements are pressed together
● Spot welding after curing of adhesive
1st Step:
Preparation of Joint
Element
3rd Step:
2nd Step: 4th Step: 5th Step: 6th Step:
Positioning of joint
Application of Adhesive Adhesive Cures Joining Completed
elements
Source: Uni
Siegen 23
Advantages: Hybrid Joining Methods – Spot Welding and
Bonding
Advantages through the combination of both joining methods:
● Increase of energy intake under impact load
● Even distribution of stress in joint area
● Increase of dynamic strength
● Sealing of the joint seam against gases and fluids
● Improvement of corrosion resitance
● Fixation of joint element until adhesive is cured
● Increase in procedural temperature range
Source: Uni
Siegen 24
Hybrid Joining Methods:
Riveting - Bonding
Procedural Description - Riveting
Classification according to DIN 8593: Group 4.5 Casting
Joint elements need to be pre-punched Closing
head
Joint is unseparable as the rivet in form of
a bolt is compressed
Principle:
● The cold casted (compressed) rivet fills out
the punched hole entirely Setting
Head
Pic. 8: Principle of riveted joints
Procedure is the same as the fixation method for resistance spot welding:
1. Thourough cleaning of the surface/preparation
2. Drilling of rivet holes, deburring of drilled holes
3. Surface pretreatment
4. Application of adhesive
5. Riveting of the joint elements
6. Curing of the adhesive
Source: Senkel 27
Advantages: Riveting - Bonding
Riveting Bonding
Source: Uni
Siegen 28
Advantages: Hybrid Joining Method: Riveting - Bonding
Advantages through the combination of both joining methods:
● Equal distribution of tension
● Joint seam is sealed against aggressive media
● Stiffness reaction when compressed
Screwing - Bonding
Procedural Description - Screwing
Classification according to DIN 8593: Group 4.3 Pressing In and On
External thread is applied to pin or bolt
Production of a form locked, separable bond
The tightening torque, that is created through the assembly, creates a preload
force
● Preload force defines the operational safety
Source: Rieg, Kaczmarek Pic. 10: Tightening torque MA and preload force FV 31
Securing of the Screw
To prevent loosening of the screws, they have to be secured:
● Settling lock: Increase of elacticity of the joint and balance of settling effect
● Retainer: prevents the falling apart of the joint
● Locking device: prevents the independent loosening caused by the decreased
preload force (i.e. through vibration)
– Adhesive fixation of bond through
– anaerobic curing adhesives
– mikro-encapsulating adhesive
● Separable and non-separable screwed connections can be realised with the help of balanced
hardness characteristics
● Principle:
– Adhesive is encapsulated into tiny capsules that contain hardeners
Adhesive
layer with
Capsule contained
shell is capsule
destroyed shells
through
shear stress
Pic. 12: Securing of the screws with micro-encapsulated adhesive Source: Rieg, Kaczmarek 34
Hybrid Joining Method: Screwing - Bonding
In combination with adhesives, screws also serve to
● fixate the joint during curing
● to ensure safety requirements
35
Advantages: Screwing - Bonding
Screwing Bonding
Little effort in surface pretreatment
Thermal resistance Constructional design possibilities
Non-destructive testing Apearance of joint area/ seam
Joint is separable Resistance to corrosion
Easy handling Behaviour under dynamic load
Source: Uni
Siegen 36
Advantages: Hybrid Joining Method Screwing - Bonding
Advantages through the combination of both joining methods:
● Similar to the hybrid joining method riveting – bonding
● Even distribution of stress
● Joint seam is sealed against aggressive media
● Stiffenss effect when compressed
Source: Habenicht 37
Hybrid Joining Method
Punch Riveting - Bonding
Procedural Description – Punch Riveting
Classififcation according to DIN 8593: Group 4.5 Casting
Connection through form and force lock
Principle: grouting through undercuts in the material
Joining without prepunched holes possible with cutting-punching-procedure
setting
headf
40
Punch Riveting- Procedural Description
Source: Titgemeyer 41
Hybrid Joining Method: Punch Riveting - Bonding
In combination with adhesion, the rivets serve as
● fixation of the sheets that are to be bounded until the adhesive is cured
● ensurance of safety measures
42
Advantages: Punch Riveting - Bonding
Source: Uni
Siegen 43
Hybrid Joining Method:
Clinching - Bonding
Procedural Description - Clinching
Classification according to DIN 8593: Group 4.5 Casting
Casting technique in which both overlapping joint elements are clinched
Quasi-form locking joint
Differentiation between:
a. Clinching with rigid matrice
b. Clinching with parted matrice
i. Clinching with cut-section
ii. Clinching without cut-section
45
Clinching with Rigid Matrice without Cut-Section (1)
down-
holder
stamp
joint
elements
ejector
matrice
2nd Step
4th Step
1st Step i.Stamp presses joint 3rd Step
i.Bringing back of stamp
i.Positioning of the joint elements against the i.First shrinkage of sheet
ii.Ejection of building
elements matrice thickness through
element
ii.Bringing down of stamp ii.Displacement of the impressure of the
iii.Fixation and pre-tensing neighbouring joint matrice
of the building elements elements against each ii.Formation of a joint
other
Source: DVS - Ausschuss für
Pic. 16: Clinching process (1) Technik 46
Clinching with Rigid Matrice without Cut-Section (2)
stamp joint
elem
ents
4th Step
1st Step 2nd Step
3rd Step Bringing back of the
i.Positioning of joint i.Stamp presses joint
i.Further impressing of the stamp
elements elements against the
material against the i.Ejection of the builiding
ii.Bringing down of stamp matrice
matrice element
iii.Fixation and pre- ii.Displacement and
ii.Creation of a joint as the
tensing on building cutting of bars
materials flows in from the
element
side
Source: DVS - Ausschuss für
Pic. 17: Clinching Process (2) Technik 48
Hybrid Joining Method: Clinching – Bonding (1)
Adhesively joined and clinched joints
● Adhesive or sealant serves primariliy as sealant, protective against corrosion or as
damping material
● Usage
– of adhesives with high castability, i.e. polyurethanes
Source: Habenicht 49
Hybrid Joining Methods: Clinching – Bonding (2)
Production of clinched-bonded joints analog to spot welds
● Method of fixation
● Injection method
● Sequential Method
50
Problemes with the Hybrid Joining Method Punch riveting
- Bonding
Unwanted crack formation between the sheets
Consequence:
● surface contact tears
● adhesive cannot function any more
● crack formation prevents controlled adhesive bonding
3-5mm
1-2mm
1st Step
2nd Step 3rd Step
Premounti
Mounting Pressing
ng
together
Source: Fraunhofer 54
Hybrid Joining Method: Folding – Bonding (1)
Procedure:
● Application of adhesive to sheets
● Folding of the sheets adhesive spreads out
Source: 55
Fraunhofer
Hybrid Joining Method: Folding – Bonding (2)
Positive effects when formulating glass pearls into the adhesive:
● Minimal thickness of the adhesive layer is complied to
● The glass pearls dig into the metal surface, this gives additional handling strength
● Decreased spring back
Source: 56
Fraunhofer
Requirements for the Adhesive
Special requirements for the adhesive for folded bonds:
● Needs to hold on oiled surfaces
● Gap bridging of up to 5mm
● Insensitive to the following methods (degreasing, varnishing, phosphating)
● Possibility of automtic adhesive application
Usage of
● Plastisols
● Hard-curing 1C epoxy resin adhesives
● Rubber based adhesive
Introduction
Possible Combinations
59
Fields of Application and Examples for
Hybrid Joining Methods
Fields of Application
Fields of Application for hybrid joining methods are mainly:
● Aeroplane constructions:
– Leight weight constructions
● Vehicle Costructions:
– Leight weight construction: car body
– Repairs
61
Leight Weight Constructions in Aeroplanes – Rivet
Bonding
Goal: Decrease of weight to save fuel
Solution: Usage of leight weight metals and fibre material compounds
Quelle: Aluminium 62
Leight Weight Constructions in Vehicle Constructions –
Spot Welding
Spot Welding in Car Body Constructions
Advantages:
● Increase of stiffness in the car body
● Better crash behaviour
● Reduction of material thickness
● Primarily reinforced building elements are not necessary any more
● Additionally: increase in stiffness, sealing, noise absorbing
Source: Schütt 63
Leight Weight Constructions in Car Bodies – Lotus Elise
Leight weight sports car
Leight weight through: chassis out of aluminium, car body is made mearly
completely out of glass fibre reinforced plastics (GFK)
Additionally:
● Instead of welding: the chassis is completely bonded adhesively
● Some rivets for reinforcement „security rivets“
● Advantages:
– Thinner sheets through adhesion
Source: dp-media 65
Quality and Security Standards in Car Constructions –
Folding and Bonding
Folded bonds for interior-exterior-sheet bonds, for example in the production
of doors, hoods, boot lids
Goal:
● Increase of work intake in a crash
● Increased resistance to corrosion (separation of the potentials)
● Force initiation and vibration damping
Reason: rising demands for security, comfort and quality in the car industry
● Advantages:
– Undesired side effects can be avoided, i.e. welding sparks, flying sparks, deformation
through heat
– Resistance to corrosion
– Saving of time due to less set-up and installation effort much cheaper
Source: Ermisch 67