arconic rsr™ overview - lbcg€¦ · arconic rsr™ overview galm joining, forming &...
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Arconic RSR™ Overview GALM Joining, Forming & Manufacturing Technologies Conference Graham Musgrove, P.E., Project Engineer – Automotive November 30, 2016
Arconic Company Profile
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EPS Engineered Products and Solutions
GRP Global Rolled Products
TCS Transportation and Construction Solutions
APP AFSR AFE ATEP AAP BCI MPS AWTP BCS LAE
Arconic Fastening Systems and Rings
2015: $2.2B Revenue
8,200 Employees
Aerospace and Automotive Products
2015: $2.8B Revenue
4,200 Employees
AFSR: Where We Are
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Facili&esSuppor&ngAutomo&ve• Waco,Texas BlindFasteners• Telford,UK BlindFasteners• Suzhou,China BlindFasteners• Melbourne,Australia Inserts• Kelkheim,Germany Latches• St.Cosme,France SpecialtyNuts• Kingston,NewYork InstallaJonTools• Carmel,Indiana DistribuJon• Tracy,California DistribuJon• MexicoCity,Mexico SalesOffice• SaoPaulo,Brazil SalesOffice• Kolkata,India SalesOffice• Tokyo,Japan SalesOffice
RSR™ Commercialization Team Developing the Next Generation Multi-Material Automotive Joining Technology
Arconic Technical Center (ATC) with ~400 employees is the world’s largest
light metals research and development center with extensive expertise in aluminum welding,
alloy development, surface coatings and corrosion for the automotive industry.
Arconic Fastening Systems & Rings (AFSR) with over 8,000 employees in 13
countries and revenue of $2.2B, AFSR is a global supplier of engineered fastening
solutions to aerospace, automotive, heavy truck, rail, green energy and other industries.
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RSR™ Uniquely Differentiated to Meet Emerging Auto Trends Automotive is moving to a combination of conventional / high strength aluminum and ultra high strength steels which
cannot be joined with resistance spot welding and self pierce riveting
Steel & Aluminum High strength Al to St./UHSS
Limited Joining Options
Aluminum Intensive Conventional Al to Al High strength Al to Al
Aluminum Closures Conventional Al to Al Conventional Al to St
RSR™ can join a variety of dissimilar materials with minor
modifications to the capital infrastructure in place today
Steel / UHSS
Aluminum
High Strength Al
Mg & Composites not shown
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Arconic RSR™ (Resistance Spot Riveting) A new technology being commercialized by the Arconic Fastening Systems and Rings group leveraging
existing RSW infrastructure for high performance joining in current and future material combinations
R1009JointCrossSec&on
2mmAl
HighPerformanceMul&-materialJoints
Aluminum&SteelFastenerFamilies+Installa&onEquipment
Conven&onalRSWInfrastructure
RSR AL
UHSS
Arconic Fastening Systems and Rings
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RSR™ Process Pilot and Self-Piloting Technology Developed to Meet Customer Demands
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4
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2mm 6022-T4 to 1.2mm 590MPa
2mm 7075-T6 to 1.2mm 590MPa
2mm 7075-T6 to 1.2mm 980MPa
Aver
age
Join
t Ten
sile
She
ar S
tren
gth,
kN
SPR
590MPa RSW Min Current Materials
980MPa RSW Min Future Materials
Current Materials 5xxx Al, 6xxx Al and
Advanced High Strength St
Future Auto OEM Material Direction High Strength Al and Ultra High Strength St
Outside SPR
Limits
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Arconic RSR™ Performance: Current versus Future Automotive Materials RSR™ Exceeds Strengths of Competing Technologies for Current and Future Automotive Materials
7xxx/7xxxRSWAvgMin
6xxx/6xxxRSWAvgMin
Join steel to aluminum (bare or coated), magnesium and composites Zinc electroplated for enhanced corrosion protection
RSR™ Family
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Family of fasters developed for a variety of sheet combinations including both piloted and self-piloted applications
RSR-R4-2
RSR-R4-4 (LPH)
RSR-R4-4 RSR-R4-6
Low Profile Head
22% ↓ Head Diameter 33% ↓ Head Height
Steel Fastener Family Aluminum Fastener Family
Join aluminum to aluminum, painted metal (steel or magnesium) and composites Lower weld currents required than traditional aluminum spot welding
Steel RSR™ Family – Grip Range for Various Applications
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0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
RSR-R4-2
RSR-R4-4
RSR-R4-6
GripLength,mm
GripLengthforSteelRSR™Applications
Piloted
Self-Piloted
Small Number of Fastener Sizes Handle Wide Grip Range
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Innovative Strengths & Adaptability Leverage Existing Joining Technology to Expand Beyond Steel Sheet Combinations
STEEL RSR™
ALUM. RSR™
SttoStSpotWeld
AltoStRSR™
AltoAlSpotWeld
SttoStSpotWeld
SttoAlRSR™
Seamlessly transition between conventional spot welding to RSR™ on the same welding equipment
AltoAlRSR™
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RSR™ Joint Examples Applications being developed for variety of materials and product forms for both piloted and self-piloted
*Self-Pilotnotpossiblethroughcompositematerialsornon-conducJvecoaJngs
Steel Fastener Family Aluminum Fastener Family
2Thickness 3Thickness SheettoTube 2Thickness 3Thickness
Top Sheet (Rivet Feed Side)
Al, painted Al Mg, painted Mg
Composites
Al, painted Al Mg, painted Mg
Composites, St to UHSS, painted St
Bottom Sheet (Weld Side) St to UHSS Al
Self Pilot Available? Yes No
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RSR™ Pilot Line Now Available
Arconic Developing Fastener and Installation Equipment for OEMs Pilot and Production Cells
Rivet Delivered to Electrode Gun Delivers Rivet to Workpiece
100kVA C-Gun Pilot Station
Feed System Pulls Out During Heating and Welding
4 3 2 1
Commercializing fastener family and joining equipment
Developing applications and design guidelines with OEMs
Equipment available in 2018
Multiple material combinations - same joining
cell - no changeover
Reduced manufacturing footprint by consolidating
joining technologies
Current material optimized, future material capable -
including ultra high strength aluminum, steels,
magnesium, composites
Leverage existing RSW capital and logistics
Significant capital cost avoidance while reducing
development costs
RSR™ Technology
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Further Information
Graham Musgrove Project Engineer – Automotive Arconic Fastening Systems and Rings, USA +1 254 751 5225 [email protected] Jay Sahadew Marketing Manager Arconic Fastening Systems and Rings Limited, UK +44 (0) 1952 204 607 [email protected] Stop by our booth in the Exhibition Hall
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