Setting Flow-Form Welding Rivets

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

Fig 1: Checking Aluminium Component Material Thickness Measurement

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Projection

-A- : Standard projection

5X00IN11 STUD WELDING

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

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

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

IMPORTANT: 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.

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.

Set up stud welder and prepare components for welding.

5X00IN11 STUD WELDING

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Preparing stud welder

2.1 Fit stud holder -1- > VAS 852 001/5 - Rivet holder for flow-form welding rivets.
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-flow time [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

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

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Positioning and securing aluminium component
Push flow-form welding rivets -1- onto stud holder -2- > VAS 852 001/5 - Rivet holder .

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

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Welding
After welding all flow-form welding rivets, remove aluminium spare part from the steel component.
Prepare steel and aluminium components for bonding and riveting and coat with adhesive.
5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00
Position and secure aluminium spare part on steel component.
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