Auxiliary Joining Element for One-Sided Multi-Material Assembly
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Solution Overview
Problem
Joining components made of different materials, such as aluminum and steel, is challenging due to their disparate properties, and existing methods like resistance spot welding require accessibility from both sides and do not consistently achieve sufficient strength.
Innovation Solution
A composite assembly is created by pressing a retaining portion of an auxiliary joining element into a through-hole in one component, which engages with a fastening receptacle portion in the other component, allowing for form- and force-fitting connections that can be coordinated independently of the materials, enabling flexibility and high strength even with reduced component thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resistance spot welding is used to join aluminum and steel components, then the joint strength is improved, but accessibility from both sides is required which limits applicability
Solution Approach 1:
An auxiliary joining element serves as an intermediary between the aluminum and steel components. This auxiliary element can be welded to one component (e.g., steel) while providing a mechanical fastening interface (e.g., threaded hole or receptacle) for the other component (e.g., aluminum), thereby eliminating the need for bidirectional welding access and enabling unidirectional welding operations
Solution Approach 2:
The joining function is segmented into two distinct parts: a welding interface for joining to one component and a mechanical fastening interface for joining to the other component. The auxiliary joining element separates these two functions, allowing each interface to be optimized independently for its specific joining method
2Ease of manufacture
If force- or form-fitting connections are used to join components, then the joining process is simplified, but the connection strength is insufficient for many material combinations
Solution Approach 1:
The solution merges two joining methods into a single auxiliary joining element: a welding portion for material-bonded joining to provide high strength, and a fastening portion for force- or form-fitting connection to simplify the joining process. This combination allows the element to achieve both high connection strength and ease of manufacture
3Reliability
If auxiliary joining elements are pressed into through-holes with indentations, then material consolidation and reduced hydrogen embrittlement are achieved, but the component thickness is reduced
Solution Approach 1:
The indentation is applied locally at the through-hole periphery rather than uniformly across the entire component thickness. This localized material consolidation improves reliability at the critical joining zone (hole periphery) where stress concentration occurs, while minimizing the overall impact on component thickness and maintaining sufficient material in other regions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for strong, flexible connections between various materials with accessibility from one side, reducing hydrogen embrittlement and edge cracking risks, and achieving high strength through material consolidation and indentation processes.
Implementation Method 1
the process of indentation, whereby material consolidation in the peripheral region of the indentation is achieved, which, in combination with the subsequent pressing in of the retaining element, is increased even further
Data Source
AI summary
A component combination of at least two components, which are joined at at least one joint, is provided. The component combination includes a first component, wherein a first joining element having a supporting section is pressed into a passage hole in the first component at the joint, and includes a second component, in which a fastening receiving section is formed at the joint, wherein the first joining element also has a fastening section, which engages in the fastening receiving section of the second component in a form-fitting and/or force-fitting manner. A method for producing the component combination is also provided.