A dimpled substrate for use in an assembly having joined substrates is provided that defines at least one preformed interior cavity, at least one preformed exterior profile adjacent the interior cavity and defining a wall therebetween, and at least one locating feature configured to identify a location of the at least one preformed exterior profile. In one form, the locating feature is disposed in the preformed exterior profile or adjacent to the preformed exterior profile. Alternatively, the locating feature is a notch formed into the dimpled substrate away from the preformed exterior profile.

A method of bonding a connector to a first object includes providing the connector, the connector being separate from the first object and including a thermoplastic material; arranging the first object and the connector relative to one another so that the connector reaches from a proximal side of the object through a first opening in the object; generating and applying vibrations and mechanical pressure to the connector until a flow portion of the thermoplastic material is liquefied and caused to flow sideways radially into an open space; and removing the source of the vibrations and causing the liquefied thermoplastic material to re-solidify, resulting in the connector with a foot portion, a head portion, and a shaft portion between the foot portion and the head portion. The shaft portion extends along an axis through the first opening, and secures the connector to the first object.

A method for coupling a first structure to a second structure is disclosed. The method includes providing a rivet having a shaft with a first end and a second end, a head positioned at the first end, and a cavity formed in the second end and extending along an axis of the shaft. The method also includes positioning the first structure and the second structure against each other and inserting the second end through the first structure and the second structure until the head contacts the first structure and the second end extends past the second structure. The method further includes positioning a first flat tool and a second flat tool against the head and the second end, respectively, and moving the first flat tool and the second flat tool toward each other until the second end expands radially against the second structure.

A method of rivet bonding a workpiece stack-up that includes one or more polymer composite workpieces, such as carbon fiber composite workpieces, involves several steps. In one step, adhesive is applied to a surface of the workpiece stack-up. In another step, workpiecesincluding the polymer composite workpiece(s)are brought together. In yet another step the adhesive is partially or more cured. A rivet is installed through the workpiece stack-up and through the adhesive in another step. The method strengthens the resulting rivet-bonded joint by minimizing or altogether precluding fracture, cracking, and/or delamination thereat.

An assembly includes an upper substrate, a lower substrate, and a self-piercing rivet. The lower substrate defines a preformed interior cavity and a preformed exterior profile adjacent the interior cavity to define a variable thickness wall. The self-piercing rivet extends through the upper substrate and into the preformed interior cavity of the lower substrate.

A method for connecting two aircraft components composed of thermoplastic composite material by a rivet. The two aircraft components are arranged, in sections, areally on one another, before bores in the two aircraft components are expanded by a mandrel element such that the bores, after the expansion, form one continuous bore for receiving the rivet. Here, the two aircraft components are locally warmed by the mandrel element such that, during the expansion of the bores, the components are thermoplastically deformed. The mandrel element is inserted through the first bore into the second bore. The rivet is introduced into the continuous bore. A system for carrying out the method is also disclosed.

A component assembly having a stacked arrangement comprising an upper and lower sheet part, of which at least one is formed as an organic sheet composite part, with an auxiliary joining part and with at least one apertured metal washer, wherein the auxiliary joining part has a functional section having an undercut at one end and also has a piercing section at the other end having a lateral shaft surface and a shaft recess formed therein, wherein the metal washer contacts a surface of the organic sheet composite part, with the functional section or the piercing section extending through an aperture of the metal washer and wherein washer material has been driven into the undercut or into the at least one shaft recess.

A method of connecting a first component and a second component with the aid of an auxiliary joining part, wherein the auxiliary joining part is formed from a pin and a plate. A position of intended fracture is present between the plate and the pin. The first component, the second component and the auxiliary joining part are brought into a stacked arrangement such that the plate contacts the first component and the pin projects away from the side of the plate remote from the first component. A force is exerted on the pin of the auxiliary joining part in the direction towards the stacked components which leads to a fracture at a position of intended fracture and the pin is used in order to pierce slugs from the stacked components. The end of the pin which is pressed through the second component, and/or a washer which is optionally provided there, is deformed in order to provide a form-locked connection to the second component or to a washer which is provided there. Furthermore, an auxiliary joining part is claimed.

A method of riveting a first substrate and a second substrate with a rivet includes delivering a first ultrasonic pulse to a respective exterior surface of the first substrate at a predefined target area, via an ultrasonic device. The first ultrasonic pulse is configured to soften the first substrate at a first softening temperature. The method includes attaching a crust layer on a rivet head of the rivet. A second ultrasonic pulse is delivered to the predefined target area to soften the crust layer at a second softening temperature, via the ultrasonic device. A surface profile of the crust layer is fashioned via compression of a horn inner cavity of the ultrasonic device over the crust layer. The crust layer is cooled to harden into a seal configured to prevent entry of moisture between the rivet and the respective exterior surface of the first substrate, thereby reducing galvanic corrosion.

A different-material joining structure includes a plurality of different types of plate materials stacked on one other and secured by means of a rivet. The plate materials include a first member and a second member of which end surfaces at one end of each overlap each other, and a third member arranged overlapping the surface of the first member on the opposite side to the second member. The rivet has a shank part penetrating through the first member and the third member and joined to the second member at a tip end thereof, and a head part not inserted into the third member and remaining on the surface of the third member. A joining part for joining the first member and the third member together is formed in at least a part of an overlapping region of the first member and the third member, on the side toward the other end of the second member relative to the position at which the rivet penetrates.