Adhesive Manufacturing Processes

Chapter 8: Hybrid Joining

Univ.-Prof. Dr.-Ing. Prof. h.c. Stefan Böhm

Department for Cutting and Joining Manufacturing Processes (tff)
University of Kassel, Germany

Source: Wikipedia
Agenda

 Introduction

 Relevant Joining Methods

 Possible Combinations

 Fields of Application and Examples

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

Source: DVS – Ausschuss für Technik 3

Properties of Adhesively Joined Bonds
 Negative Properties of Bonds
● low beginning strength
● low peel strength
● tendency to creep
● dependent on time, temperature and environment

 Positive Properties of Bonds

● transmission of force onto a bigger surface
● high potential for leight weight constructions
● increased stiffness of construction elements

Source: Uni Siegen 4

Reasons for Hybrid Joining
 Interpretation: load adhesive bonding
(brittle-hard epoxy resin)
● application of easy bonding
methods achieves the best bond
forces hybrid joint

● lower bonding forces of hybrid

bonds through damage of the
adhesive layer during mechanial riveted bond
joining processes
● but: purely adhesively joined bonds
last less longer path

 Goal: increase of durability and

therefore a better usage of the Pic. 1: Relative bonding strength:
adhesive bonding – hybrid bonding – riveted bonds
material characteristics
Source: EAA, Matter at University of Liverpool 5
Why is a spot-joined structure also joined adhesively?

 Increase of energy absorption under impact stress

 More equal distribution of tension
 Increase in vibration strength
 Improvement of vibration damping
 Increase of connection stiffness
 Sealing of the bonding seem against gases and fluids
 Improvement of corrosion resistance

Source: Uni Siegen 6

Why is an adhesively bonded structure also spot joined?

 Fixation of joint elements until the adhesive is cured

 Relief of peel stress
 Partly compensation of loss in hardness due to ageing
 Increase of procedural temperature range
 Reliefl of adhesive bond when under high static load

Stress: Uni Siegen 7

Agenda

 Introduction

 Relevant Joining Methods

 Possible Combinations

 Fields of Application and Examples

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):

● Spot Welding – Bonding

● Riveting/Studding – Bonding
● Punch Riveting – Bonding
● Clinching – Bonding
● Folding – Bonding

Pic. 2: Hybrid-joint of CFK-aluminiumprofile with

adhesive through setting bolts

Source: Habenicht, S.608 10

Classification of Relevant Joining Methods According to
DIN 8593
Gruppe 4.3. Pressing in
Screwing
and on

Punch Riveting

Riveting

Gruppe 4.5. Reforming

Main Group 4 Joining
Clinching
DIN 8593 Teil 0

Folding

resistance spot
4.6. Welding
welding

4.8. Adhesive bonding

11
Strengths and Weaknesses of the Joining Method - Overview
(1)
good
Material Hardness on Flat force Damage of the
moderate
variety sm. area Initiation joint element
bad
Adhesive
Bonding
Spot Welsing
Riveting
Punch Riveting
Screwing
Clinching
Folding
Table 1: Analysis of the strengths and weaknesses (1) 12
Strengths and Weaknesses of the Joining Method -
Overview (2)
good
Temperature Dist- Inconspicuou
moderate Density Damping
Resistance ortion sness/Design
bad
Adhesive
Bondig
Spot Welding
Riveting
Punch Riveting
Screwing
Clinching
Folding
Table2: Analysis of the strengths and weaknesses (2) 13
Strengths and Weaknesses of the Joining Method -
Overview (3)
good
Proce-
Forecast of
moderate Fixation dural Removability
duration
bad length

Adhesive
Bonding
Spot Welding
Riveting
Punch Riveting
Screwing
Clinching
Folding
Table 3: Analysis of the strengths and weaknesses (3) 14
Agenda

 Introduction

 Relevant Joining Methods

 Possible Combinations

 Fields of Application and Examples

15
 Hybrid Joining Methods:

Resistance Spot Welding - Bonding

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

● additional resistance through work pieces

 Consequence:
● electrode heats up work piece
workpiece
● material is partly melted

Electrode

Pic. 3: Functional principle of resistance

spot welding
Source: Zinn 18
Procedural Description - (Resistance) Spot Welding (3)
 Implementation:
(A) Positioning of workpiece (A) (B)

(B) Pressing of electrodes on workpiece

(C) Current flows between the electrodes;
material is partly melted
(D) The materials are welded
(C) (D)

Pic. 4: Spot Welding – Procedure

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: 2nd Step: 3rd Step:

4th Step: 5th Step:
Preparation of joint Application of Positioning of joint
Joining Completed
element adhesive elements
Abb. 5: Fixiermethode Source: EAA, Matter at University of Liverpool 20
Hybrid Joining Methods: Spot Welding – Bonding (2)
 Injection Method
● Joint elements are spot welded
● Adhesive is injected into the gap between the spot wekded elements
● 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

Pic. 7: Sequential Method Source: EAA, Matter at University of Liverpool 22

Advantages: Resistance Spot Welding - Bonding

Resitance Spot Welding Bonding

Thermal resistance Possible material combinations

Mechanical hardness Influence of heat on joint elements
Behaviour under static load Apearance of joint area/seam
Beginning hardness Behaviour under dynamic load
Experience

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

Source: Risse, S. 24626

Hybrid Joining Methods: Riveting - Bonding
 In combination with a bond, the rivets serve to
● fixate during the curing process
● as safety rivets

 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

Little effort in surface pretreatment Constructional design possibilities

Thermal resistance Apearance of joint area/seam
Non-destructive testing Resistance to corrosion
Behaviour under dynamic load

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

Pic. 9: Stiffness effect in a bonded/riveted joint

Source: Habenicht 29
Hybrid Joining Method:

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

Source: Rieg, Kaczmarek 32

Securing of the Screws with Adhesion (1)
 Anaerobically curing adhesives (curing through contact with metal and exclusion
of oxygen)
● Adhesives: Methacrylates (one component, solvent-freel, curing)
● After curing: quasi-form lock within the thread
● Prevents tilting and relative movements within the thread under dynamic stress
● Needs to be applied to the thread before processing

Pic. 11: Application of anaerobically

Source: Rieg, Kaczmarek
curing adhesive 33
Securing of the Screw with Adhesion (2)
 Micro-encapsulated adhesives
● Coating of the thread with the micro-encapsulated adhesive in the screw production

● 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

– The capsules are destroyed when the screw is screwed in

– The adhesive is mixed with the hardener

Micro-encapsulated
adhesive

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

Pic. 13: Half hollow rivet

39
Differentiation of Solid and Half Rivet:

setting
headf

rivet entire thickness of

length
Solid Rivet: sheet

rivet diameter closing

undercutt
head
setting
head
entire thickness of
rivet sheet
length
closing
Half Hollow Rivet: rivet diameter undercut head

Pic. 14: Solid and Half Hollow

Rivet

40
Punch Riveting- Procedural Description

(A) Punch rivet is brought close

(B) Tool clamps materials tightly
(C) Rivet punches the upper
material and spreads out in the
lower material
(D) Form lock provides a high joint Pic. 15: Punch riveting process of a half
strength hollow

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

Punch Riveting Bonding

Little effort in surface pretreatment Constructional design possibilities

Thermal resistance Apearance of joint area/seam
Non-destructive testing Resistance to corrosion
Behaviour under dynamic load

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)

Source: DVS - Ausschuss für

Animation 1: Clinching Process Technik 47
Clinching with Parted Matrice with Cut-Section
down-
holder

stamp joint
elem
ents

matrice anvil matrice

lamellae

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

 Clinched Bonded Joints

● Clinching as fixation
● Relief of the adhesive layer under peel stress or static long-term stress
● Application
– of highly string adhesives, i.e. epoxy resins

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

Pic. 18: Crack Formation during punch riveting

Source: Henning, Moeller 51

Hybrid Joining Method:
Folding - Bonding
Procedural Description- Folding
 Classification according to DIN 8593: Group 4.3
Casting
 Separable joint
 Joining method for sheets
 Principle: the edges of the materials are formed so
that they form lock
standing fold lyingfold

standing double fold lying double fold

Pic. 19: Folding Types Quelle: König, S. 512 53

Production of a Folded Joint

3-5mm

1-2mm

1st Step
2nd Step 3rd Step
Premounti
Mounting Pressing
ng
together

Pic. 20: Folding Process

Source: Fraunhofer 54
Hybrid Joining Method: Folding – Bonding (1)
 Procedure:
● Application of adhesive to sheets
● Folding of the sheets  adhesive spreads out

1) Minimal filling degree Fill 2:

•Wetting of the surface under the inner sheet
•Folding radix is filled with adhesive

2) Maximum filling degree Fill 3:

•wetting of the surface under the inner sheet
•Folding radix is filled with adhesive
•Additionally: adhesive leaks from the folding root
up to the front edge of the fold flanch

Pic. 21: Cross-section representation of a folded

bond with sealed seam

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

Source: Habenicht S. 616ff 57

Advantages: Hybrid Joining Method Folding - Bonding
 Increased intake of work
 Improvement of the bending and torsion stiffness of the bonded joint
 Improvement of the corrosion resistance (separation of the potentials)
 Even initiation of force
 Vibration Damping

Problems when folding and bonding:

 No quality assurance of the fold as there is no access

Source: Uni Siegen 58

Agenda

 Introduction

 Relevant Joining Methods

 Possible Combinations

 Fields of Application and Examples

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

– Leight weight construction: Lotus Elise

– Quality and security standards: Interior and exterior sheet connections

– 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

 Joining of fibre compounds through riveting

 Problem: rivet holes disturb the force flow and decrease the resilience

 Solution: usage of hybrid techniques  rivet bonding

● only few rivet holes necessary,
● higher resilience,
● flat force initiation

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

– No weakening of the materials that surround the welding seam

 no reinforcement necessary, thinner wall thickness possible

Source: dp-media 64
Leight Weight Construction in Car Bodies– Lotus Elise
 In Comparison:
● Lotus Elise (chassis out of aluminium), chassis bonded and riveted: entire weight
750kg
● Renault Spider (chassis out of aluminium), chassis welded: entire weight 1000kg

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

Pic. 23: Folded bond on a car door Source: Fraunhofer 66

Field of Application - Repairs
 Hybrid joining technology often used on damaged car body parts in car
constructions
● Before: Repair through welding
● Now: Repair through rivet bonding

● 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

– Clean method: car parts do not need to be covered

Source: Ermisch 67