A method and device are provided for simplifying a flow-drill screwing process. Based on work performed during the process, a process variable E is formed. This variable is compared to analogously formed comparison values in order to be able to determine the proper or faulty running of the process.

A method and a device are provided for simplifying a flow-hole screw process, in which the difference between a process parameter and its smoothed value is employed as a criterion for changing said process parameter or another process parameter in order in particular to be able to determine the changeover point between hole forming and thread forming.

A self-penetrating thread forming and flow drilling fastener for thick materials with a generally cylindrical partially threaded shank, a drive system at the first end of the shank and a flow drilling tip at the second end of the shank. The flow drilling tip is sized larger than the minor diameter of the threaded shank but less than the major diameter to control installation torque enabling installation into thick materials with greatly reduced risk of torsional failure resultant from a decrease in torque. The flow drilling tip and threads may be a variety of shapes or thread types based on the substrate material the fastener is installed into.

A method produces a composite component from a first joining element and a second joining element by use of an adhesive and a flow drill screw. Before attaching the second joining element to the first joining element, a recess is made around the at least one screw position in which the respective flow drill screw penetrates the second joining element, in a joining surface of the second joining element.

A fastening structure includes: plural overlapping co-fastened members, a clearance hole being formed at at least one mating face of mutual mating faces of the plural co-fastened members, and a screw utilizing frictional heat to bore a hole and form a thread, passing through the clearance hole, and fastening the plural co-fastened members together.

A vehicle assembly includes a first component having a stand-off that provides a cavity. The stand-off protrudes from an insertion side of the first component. The stand-off includes at least one side wall that extends from a floor of the cavity to at least one outer surface of the stand-off. The assembly further includes a second component that contacts the first component at an interface. The cavity is configured to receive a mechanical fastener that joins the first component to the second component. A distance between the floor of the cavity and the interface is greater in some areas than in other areas such that a cross-sectional thickness at a bottom of the cavity is varied.

To eliminate galvanic corrosion, a housing includes a clad material. The clad material includes an interior metal disposed within an exterior metal. The exterior metal is different from the interior metal. The housing further includes a clad interface and a melt interface. The melt interface includes a layer of hardened flux disposed on a portion of the interior metal.

A method for joining dissimilar materials is provided. The method includes a solid-state joining process in which a rivet is plunged into a predrilled hole in a top workpiece. When the rivet contacts the bottom workpiece, ultrasonic vibration by oscillatory motion of a sonotrode, such as horizontal, vertical, or rotational motion, creates frictional heat at the interface between the rivet and the lower workpiece. With the aid of frictional heat and axial compression, metallurgical bonding is achieved at the interface between the rivet and the bottom sheet, while being below the melting temperature of the bottom workpiece. The sonotrode is retracted while the rivet remains.

A method of providing an electrical grounding point on an aluminum structural member of a motor vehicle. The member is hydro-formed to produce a closed cross-section, after which a hole surrounded by a flange is formed in a wall of the member. The flange is generally the shape of a truncated cone and extends toward an interior of the member. A self-tapping fastener having a grounding lead attached thereto is driven into the hole to cut threads into the flange and secure the grounding lead to the member. The self-tapping fastener allows the grounding connection to be achieved without any access to the hollow interior of the member as would otherwise be required.

A method is provided for producing a steel component assembly, wherein a steel component having a predetermined breaking point is provided and the predetermined breaking point of the steel component is punched through by way of a press-fit element in order to form an opening. Subsequently, the press-fit element is pressed into the opening of the steel component, and, at least in overlap with the press-fit element, a component is adhesively bonded to the steel component by an adhesive applied over an area. A friction-drilling hole is melted through the press-fit element, the steel component and the component by way of a friction-drilling element.