Mechanical joining

As demands for lightweighting, electrification, and sustainability increase, so do the requirements for how we join materials. Combining different material types—such as steel, aluminum, and composites—requires robust and efficient joining methods that not only hold the structure together but also ensure proper function.

At RISE, we offer deep expertise in mechanical joining. We act as an independent partner helping you navigate from material selection and method validation to quality-assured production.

We help you all the way

Whether you are facing a new design project or want to streamline an existing production line, we can support your process. We offer, among other things:

Selection of joining method: We evaluate which technique is best suited for your specific material combinations and requirement specifications.
Functional requirements: We help you ensure specific properties in the joint, such as mechanical strength, electrical conductivity for grounding and current transfer, or sealing to protect sensitive electronics and batteries.
Process optimization: Development, optimization and fine-tuning of process parameters to ensure robust production and minimize scrap.
Energy efficiency: Analysis of joining processes to identify energy savings and reduce the climate footprint.

Increased quality, product features and productivity

Our research in joining studies new process variants and materials, as well as how different parameters influence and can be optimized to provide increased quality, improved properties, and higher productivity. In our testbeds, we also offer companies the opportunity to test new ideas in a production-like environment.

Methods and materials

We work with advanced material combinations, including ultra-high-strength steel, aluminum alloys, castings, and fiber composites. Our expertise covers a wide spectrum of cold joining methods, including:

Self-Piercing Riveting (SPR)
Clinching
Flow drill screwing (FDF / FDS)
Blind riveting and other mechanical joints
Plasma pin joining / Tucker Plasma Joining

Simulation and digital development

To shorten lead times and reduce the need for physical prototypes, we utilize advanced simulations.

Process simulation: We simulate the joining process itself to predict material flow and the risk of crack formation.
Property simulation: Calculation of the joint's strength and behavior under load in the finished structure.

Quality assurance and testing

A secure joint is a prerequisite for a safe product. We have equipment and methods to verify quality both in the lab and on the production line:

Functional testing: Verification of tightness against liquids and gases as well as measurement of electrical contact resistance in joints.
Non-destructive testing (NDT): Methods to inspect joints without affecting the part.
Destructive testing: Tensile testing, fatigue testing, and cross-section analyses (macro/micro).
Process monitoring: We develop systems for real-time monitoring of joining processes, where we can utilize AI and machine learning to detect deviations and predict maintenance needs.

Our resources

In our labs, we have access to industrial equipment for both joining and advanced testing. This allows us to perform tests in environments that mimic actual production, providing you with reliable decision support before investing in your own equipment.