Optimizing automated joining with flow drill fastening
Modern manufacturing increasingly involves the joining of new materials, more complex structures, and mixed compounds. An effective solution for these challenges is flow drill fastening, a method suitable for multiple layers of similar and mixed materials. This hybrid joining technique enables the combination of steel, aluminum, and adhesive layers. The fastener is positioned while the material is clamped. Frictional heat softens the material, allowing the fastener to penetrate, form a thread without cutting, and tighten to the required torque.
Tailored for automotive manufacturing:
This method is particularly beneficial in the assembly of electric and other lightweight vehicles, where joining of diverse materials is often required. It is tailored for joints that only have single-sided access and does not require a pre-hole due to its flexible and powerful joining capabilities.
The four main steps in the flow drill fastening process
With the extensive know-how of our joint analysts and process experts, we develop the ideal process parameters for your individual requirements and material combinations. Visit us in our Innovation Centers to solve your individual joining challenge.
1. Finding
The initial contact point is identified, the fastener is positioned and the components are pressed together.
2. Passage
With high rotation speed (up to 9000 rpm) and high process force, the material is heated and plasticized, forming an initial pass.
3. Thread forming
With reduced speed and process force, the fastener drives through the material and forms a thread without cutting.
4. Final tightening
The fastener is tightened with the required final torque.
Values for your manufacturing process
Multi-material joining
Flow drill fastening can join multiple layers of different materials. Varying material thicknesses do not impact the result and are taken into account during the joining process.
One-sided accessibility
A strong and reliable joint entered from one side in a one-shot process. In combination with the different tools, limited acess is no problem.
Reliable process
Best alignment of K-Flow system solution, fastener and materials by experts lead to a fast and reliable process.
Serviceability
Removable joints enable a quick and easy disassembly for maintenance and repair work. This is a particular benefit in battery assembly.
Hybrid joining
By combining flow drill fastening with adhesive bonding, the dynamic joint strength and corrosion resistance are increased.
Less damage to the fastener
By implementing our swivel module, we enable less wear on the hoses and less damage to the fastening elements as well as a cycle time improvement.
Dive into our K-Flow flow drill fastening technology
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