Bonding and Riveting

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Bonding and Riveting
By Peter Coffey Bodyshop Solutions Ltd
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Bonding and Riveting

• Designers
• 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.

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Bonding and Riveting

• Repairers
• 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

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Blind Riveting
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Bonding and Riveting
Powerbird Up to 1.2 tons
Used by BMW
Taurus 4 Up to 1.8 Tons
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

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BMW Rivets used on front repair with Gesipa
Powerbird rivet gun Recommended 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.
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Bonding and Riveting
Self Piercing Rivets. Punch Rivets

• Used by
• Audi
• BMW
• Mercedes Benz
• Jaguar / Land Rover
• Ferrari etc.
• Mainly in production but eventually in repair

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Bonding and Riveting
Self Piercing Rivets. Punch Rivets

• Why were these chosen
• No pre-drilling needed
• Very neat, once fitted.

New Tools were needed, new training procedures
Böllhoff

• Can be used
• For hybrid joining
• On galvanised and coated steels
• On High Strength Steels
• On Aluminium,
• Or combinations of these different materials

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Bonding and Riveting

• Rivets 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

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Bonding and Riveting
Self piercing rivets being fitted.
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Bonding and Riveting
Basic repair method
1. Cut the panels and prepare the special
reinforcement plate
2. Apply the glue to the reinforcement plate
and fit into position
3. Clamp the panels in place and remove any
excess glue.
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Self piercing rivets here
Blind rivets are fitted here
Maximum of three repairs on same section
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.
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Bonding and Riveting
Flow Form Rivets. From Mercedes Benz
In sizes for Aluminium / Steel A1 / S1 Overall
thickness 2.30 and 3.15mm A2 / S2 Overall
thickness 3.35 and 3.95mm A3 / 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.

• The repair process is as follows
• Remove any existing rivets and remove the damaged
  panel
• Punch hole through all panels including new panel
• Fit new panel, glue, place rivet insert and press
  together.

Proved to be very safe in all crash tests
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Bonding and Riveting
Repair 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
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Bonding and Riveting
Repair process with Flow Form Riveting
Step 2 Punch hole through all panels
including the new panel
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Bonding and Riveting
Repair process with Flow Form Riveting
Step 3 Fit new panel, glue, place rivet insert
and press together trying to avoid
damage to the panels
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Bonding and Riveting
So why do we do it?

• To avoid as much welding as possible
• This will prevent corrosion after welding
• To obtain a very rigid connection
• 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 Panels
• Quarter panels
• inner wing reinforcement
• Front inner wing
• Chassis leg repairs
• Roof replacement
• Boot floor replacement

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Bonding and Riveting
What 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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1
4
2
5
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Bonding and Riveting
What is the future?

The future is Cold Joining

• 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!
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Bonding and Riveting
What is the future?

• 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.

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Bonding and Riveting
What is the future?
Modular System
Blind Rivet nut adaptor
Blind Rivet adaptor
Just one complete system to do all the new
joining techniques.. With Power Control
Handy and Lightweight to use
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Bonding and Riveting
What is the future?

• Accessible
• Small blind rivet adapter in
• narrow areas

• Versatile
• Fitting Rivnuts
• Fitting blind rivets
• Blind rivet nuts in specific areas

• Modular System
• User Friendly!

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Bonding and Riveting
This is the future?

• Self Piercing Rivets
• Larger C Clamp
• Easy to operate

• Flow Form Rivets
• Small C Clamp
• Easy to operate

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Bonding and Riveting
This is the future?
In many cases a big C -arm is indispensable!
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Bonding and Riveting