Setting Flow-Form Welding Rivets

Information 

Adjust projection of stud holder -1-  according to material thickness of the aluminium component using flow-form welding rivets:

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Projection

• -A-  : Standard projection

  > 5X00IN11 STUD WELDING 

• -B-  : Additional projection due to material thickness of aluminium spare part -2- 

Information 

Adjust pressure setting on > VAS 6790 - Compact Booster  to pressure stage 4.

Information 

Unless specified otherwise in the specific Workshop Service Information, the loosened friction element welded joints will be replaced with flow-form welding rivets. The components will also be bonded at the joint.

Information 

Check the following before welding:

• The coating on flow-form welding rivets must not be damaged. 
• Flow-form welding rivets must not touch aluminium spare parts because this can result in a shunt during welding. 

1. Drill through aluminium spare part at the position specified in the Workshop Service Information using a drill bit with a diameter of 7.0 mm.
2. Set up stud welder and prepare components for welding.

   > 5X00IN11 STUD WELDING 

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   Preparing stud welder

   1. 2.1  Fit stud holder -1-  > VAS 852 001/5 - Rivet holder  for flow-form welding rivets.
   2. 2.2  Fit open gas nozzle -2-  .

   Welding parameter guidelines for flow-form welding rivets 

   Bolt	Welding time [ms]	Amperage rating [A]	Lift [mm]	Gas pre-flowtime [ms]	Gas parameters [l/min]	Power terminal	Ground terminal	Polarity
   Flow-form welding rivets	7	910	1.0	1, 500	6-8	Gun	Component	Normal

3. Position and secure aluminium spare part -1-  on steel component.

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   Positioning and securing aluminium component

4. Push flow-form welding rivets -1-  onto stud holder -2-  > VAS 852 001/5 - Rivet holder  .

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   Flow-form welding rivet

5. Weld flow-form welding rivets onto the steel component through the drilled hole in the aluminium spare part.

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   Welding

6. After welding all flow-form welding rivets, remove aluminium spare part from the steel component.
7. Prepare steel and aluminium components for bonding and riveting and coat with adhesive.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00 

8. Position and secure aluminium spare part on steel component.
9. Set and press flow-form welding rivets using > VAS 6790 - compact booster  and punch and bottom die pair -1-  from > VAS 6790/70 - rivet inserts  .

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   Setting flow-form welding rivets