Hybrid Joining

Hybrid joining is the joining process with a combination of two or more joining techniques. The commonly used hybrid joining processes are below:

Resistance Weld Bonding (Weldbonding)

Resistance weld bonding is a combined joining process with adhesive bonding and resistance welding. The adhesive is applied to the faying surfaces of sheets to be welded, and subsequently, a resistance spot weld is made through the sheets before curing the adhesive. The joint can have good strength from the spot welding and good stiffness from the adhesive bonding.

Related publications with SORPAS®:

simulation model for resistance weld bonding
SORPAS 3D simulation model for RWB (Figure 5 from Resistance spot weld bonding of steel sheets)

Resistance Element Welding (Resistance Spot Riveting)

Resistance element welding is a combined joining process with resistance welding and riveting. An auxiliary rivet element needs to be inserted into the pre-made hole in the upper sheet or inserted by pre-punching. Afterward, the electrodes apply force and current to the rivet and lower sheet to create a weld. It is possible to join a wide range of dissimilar materials, including aluminum, sandwich material, thermoplastic composites with steel.

Related publications with SORPAS®:

simulation model for resistance element welding
SORPAS simulation model for RSR, (Figure 4 from Joining of Thermoplastic Composites with Metals Using Resistance Element) Welding

Riv bonding

Riv bonding is a combination of riveting and adhesive bonding

Clinch bonding

Clinch bonding is a combination of clinching and adhesive bonding. The adhesive is usually applied first to one of the parts. After the components are joined together, a clinching process follows. Clinch bonding doesn’t provide strength as strong as riveting or spot welding. Therefore it is used for joining in areas where the structural loads are rather low. One of the challenges in clinch bonding is to reduce the formation of adhesive pockets. The liquid adhesive squeezed out during the clinching process can form a pocket which reduced the required clamping force.