RB&W GLOBAL LIGHTWEIGHT MATERIAL PRESENTATION AUG 18, SPAC Applica,ons 1

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1 RB&W GLOBAL LIGHTWEIGHT MATERIAL PRESENTATION AUG 18, 2015 SPAC Applica,ons 1

2 Global Market Trend CO2 Emission Fuel Efficiency Vehicle Weight ReducIon INCREASED USAGE High Strength Steels Aluminum Magnesium Composites

3 IMPLEMENT DESIGN SOLUTIONS: PIERCE AND CLINCH FASTENING

4 PIERCE and CLINCH BENEFITS Mass Reduc,on in Joint Compact Packaging Property Class 10 Elimina,on of Secondary Opera,ons Nut Center to Center Tolerance 0.2mm

5 Pierce and Clinch Video

6 Packaging ReducIon SPAC Nut JOINT Flange Weld Nut JOINT Base Material Thickness Less Mass within the Joint Lighter Nut (SPAC Nut vs. Flange Weld Nut) Shorter MaIng Bolt in Joint with SPAC Nut s Base Material replaced by the SPAC Nut s Punch

7 LOWER MANUFACTURING COSTS

8 HIGH STRENGTH STEELS and HOT STAMPED MATERIALS SPAC Applica,ons 8

9 HIGH STRENGTH / HOT- STAMPED MPa MATERIAL TYPES : Ø Hot Stamped 1300 to 1600 Ø Cold Rolled 980 Mpa Ø J Ø J DL- 1300DL Ø Usibor 1500 Ø M 190 Ø MBW 1500 Ø MBW 1900 Ø DOCOL 1000/1200

GOAL: LIMIT MICRO CRACKING PROPOGATION IN WORKPIECE PIERCE METHOD: NO Pre- pierced or laser cut hole required for SPAC Nut installa,on 1,me use, single direc,on pierce is created thru SPAC RESULT:

10 GOAL: LIMIT MICRO CRACKING PROPOGATION IN WORKPIECE PIERCE METHOD: NO Pre- pierced or laser cut hole required for SPAC Nut installa,on 1,me use, single direc,on pierce is created thru SPAC RESULT: Tes,ng was conducted to inves,gate the pa]ern and magnitude of the Residual Stresses within Hot- Stamping Materials. Test results show the test coupons with an installed SPAC Nut were in a state of compression. A compressive state is desirable since cracks cannot be propagated.

11 July 2014 SPAC Applica,ons 11

12 July 2014 SPAC Applica,ons 12

13 July 2014 SPAC Applica,ons 13

14 Hot Stamped 1300 Mpa tensile strength material Fastener close to radius Issues with weld nuts cold welds & weld arcing at stamping radius Micro- crack poten,al with pre- pierced or laser cut holes

15 Hot Stamped Structural Beam - Usibor mm thick - 20 Ton sedng force

product posi,on achieved 950 C (1700 F) INSERT PIERCE Nut During

16 HOT STAMPING Insert SPAC in die - Eliminate secondary opera,on - No laser cudng - Material structural integrity unchanged - True product posi,on achieved 950 C (1700 F) INSERT PIERCE Nut During the forming and dwell time 150 C (300 F) 0 >>Dwell at BDC Seconds>> 10

17 ALUMINUM SPAC Applica,ons 17

Aluminum Self Pierce & Clinch Fasteners ü ü ü ü ü ü ü

55-61% Recyclable Compact design Can be used in

Can be auto- fed in die / robo,c cell / stand alone

18 Aluminum Self Pierce & Clinch Fasteners ü ü ü ü ü ü ü ü Fastener range M6 to M16 Property Class 10 pierce & clinch Material thickness range mm Weight saving when compared to steel version 55-61% Recyclable Compact design Can be used in aluminum & magnesium materials no hole required! Can be auto- fed in die / robo,c cell / stand alone press More Than Fasteners More Than Ever RB&W CorporaIon helping industries keep it together...

Lightweight Material Challenges Torque Relaxation Typical joint

19 Lightweight Material Challenges Torque Relaxation Typical joint compression zone Optimised bearing surface area for the joint (load, material). Material / component layers ü No additional washers required ü No loose components ü Low profile ü Light-weight ü Short bolt required ü Self pierce & clinch fasteners available with large bearing surface areas ü High clamp loads can be achieved ü Can be auto-fed in die / robotic cell Bolt & Washer

20 Side Impact ProtecIon Aluminum 7075 T6

21 Crush Can / Crash Tube Brackets

22 ALUMINUM CASTINGS SPAC Applica,ons 22

DESIGN OPTIONS RIVNUTS / INSERTS SPAC NUTS - - - - Costly

design and cost Low torque and high costs + No Embossment of

Excep,onal torque performance Extra material, machining is

23 DESIGN OPTIONS RIVNUTS / INSERTS SPAC NUTS Costly Machining Required Locally embossed higher wall Complex die design and cost Low torque and high costs + No Embossment of material + No pre hole Required + True posi,on accuracy + Excep,onal torque performance Extra material, machining is needed to use threaded inserts. SUMMARY Reduced cycle,mes and lower fastener and die costs

24 TYPICAL CURRENT APPLICATIONS Wiper Bracket Front End Bumper A]achment Cas,ng 2 x M10 (M14 Body) Swan neck cas,ng 3 x M12 for 2nd row seat a]achments. Transmission Bracket (3) M10 Shock Tower (2)M10, M8, (6) M6 24

25 FASTENING IN MAGNESIUM GALVANIC PROTECTION TRADITIONAL FASTENING DESIGN ALUMINUM PIERCE AND CLINCH NUT DESIGN ALUMINUM SELF PIERCE NUT MAGNESIUM DISSIMILAR METAL ALUMINUM HEX FLANGE BOLT 25

26 HIGH PERFORMANCE CRITICAL PIERCE NUT PRODUCT APPLICATIONS Cast Magnesium with Pierce Nuts JOINT CONSIDERATIONS Packaging constraints Costs and Time to machine holes CasIng die complexity and cost for pre hole InserIng without cracking material Corrosion Magnesium ConverIble 26

27 THANK YOU SPAC Applica,ons 27

Mechanical Attachment of Fasteners to UHSS Materials

Mechanical Attachment of Fasteners to UHSS Materials Rob Edwards PROFIL System Incorporated Agenda Mechanical Attachment of Fasteners to UHSS Materials 1. Mechanical Fastener Basics 2. Evolution: Market