1. Bonding and Riveting By Peter Coffey Bodyshop Solutions Ltd

2. 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.

3. 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 ? Blind Riveting

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

5. 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.

6. 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

7. Bonding and Riveting Self Piercing Rivets. “Punch Rivets” Böllhoff Can be used: For hybrid joining On galvanised and coated steels On High Strength Steels On Aluminium, Or combinations of these different materials New Tools were needed, new training procedures Why were these chosen No pre-drilling needed Very neat, once fitted.

8. 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

9. Bonding and Riveting Self piercing rivets being fitted.

10. 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.

11. Blind rivets are fitted here Self piercing rivets here 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. Maximum of three repairs on same section

12. Bonding and Riveting Flow Form Rivets. From Mercedes Benz The repair process is as follows 1)Remove any existing rivets and remove the damaged panel 2)Punch hole through all panels including new panel 3)Fit new panel, glue, place rivet insert and press together. 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. Proved to be very safe in all crash tests

13. 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

14. Bonding and Riveting Repair process with Flow Form Riveting Step 2: Punch hole through all panels including the new panel

15. 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

16. Bonding and Riveting So why do we do it? 1To avoid as much welding as possible 1This will prevent corrosion after welding 1To obtain a very rigid connection 1Repair 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 Repair methods vary from manufacturer to manufacturer Bonding and riveting is here to stay

17. 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) 1 2 3 4 5

18. Bonding and Riveting The future is: Cold Joining What is the future? 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!

19. 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. What is the future? Bonding and Riveting

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

21. What is the future? Bonding and Riveting Accessible Small blind rivet adapter in narrow areas Versatile Fitting Rivnuts Fitting blind rivets Blind rivet nuts in specific areas Modular System User Friendly!

22. Bonding and Riveting Self Piercing Rivets Larger C Clamp Easy to operate Flow Form Rivets Small C Clamp Easy to operate This is the future?

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

24. Bonding and Riveting