New Fastener Design for Lightweight Applications

Purpose and goal:

The main goal of the project was to develop and evaluate various fasteners w.r.t. joinability, joint properties and possibilities for large-scale manufacturing of the fastener. The results showed that the length of the screw and the ductility of the materials affected joinability the most. Cross tensile tests showed that the fasteners created joints that could take a lower maximum force than comparable FDF joints.

Another objective was to create a road map around the implementation of the technology. The roadmap has identified critical milestones and barriers to implementation. Expected results and effects:

The results of the project have developed and evaluated new fasteners that can contribute to new and better construction solutions for vehicle applications such as body and cab constructions or battery boxes. The improvements take place by enabling constructions with lower weight and easier disassembly and thus easier repair and/or recycling. If the technology is successfully implemented, these improvements can lead to a competitive advantage that makes the end product more sustainable, more attractive to the end consumer and more profitable.

Approach and implementation:

The project has been carried out through experimental trials and theoretical reasoning based on the experiences of the project partners. The trials were conducted with equipment already implemented in industry and in a semi-industrial lab environment. The evaluation of joinability and joint properties was based on relevant industrial criteria such as cracking and maximum loads.

The theoretical reasoning was used to evaluate potential for large-scale manufacturing of the fasteners and in the creation of a roadmap for industrial implementation.