Net shaped substrate material for substrate joint

Abstract

An assembly includes an upper substrate, a lower substrate, and a self-piercing rivet. The lower substrate defines a preformed interior cavity and a preformed exterior profile adjacent the interior cavity to define a variable thickness wall. The self-piercing rivet extends through the upper substrate and into the preformed interior cavity of the lower substrate.

What is claimed is: 
     
         1 . An assembly comprising:
 an upper substrate;   a lower substrate defining a preformed interior cavity and a preformed exterior profile adjacent the interior cavity to define a variable thickness wall; and   a self-piercing rivet extending through the upper substrate and into the preformed interior cavity of the lower substrate.   
     
     
         2 . The assembly according to  claim 1 , wherein the preformed interior cavity of the lower substrate is not plastically deformed after installation of the self-piercing rivet. 
     
     
         3 . The assembly according to  claim 1 , wherein the preformed interior cavity of the lower substrate is plastically deformed after installation of the self-piercing rivet. 
     
     
         4 . The assembly according to  claim 1 , wherein the lower substrate is an aluminum casting or an aluminum extrusion. 
     
     
         5 . The assembly according to  claim 1 , wherein the lower substrate is a composite material. 
     
     
         6 . The assembly according to  claim 1 , wherein the preformed interior cavity defines a circular trench having a raised central region. 
     
     
         7 . The assembly according to  claim 1 , wherein the preformed exterior profile defines a closed cylinder. 
     
     
         8 . The assembly according to  claim 7 , wherein the preformed exterior profile further defines a radiused area extending between a lower surface of the lower substrate and the cylinder. 
     
     
         9 . The assembly according to  claim 1 , wherein the preformed interior cavity is configured to direct flaring of the self-piercing rivet. 
     
     
         10 . A dimpled substrate for use in an assembly having joined substrates, the dimpled substrate defining at least one preformed interior cavity and at least one preformed exterior profile adjacent the interior cavity to define a variable thickness wall, wherein the preformed interior cavity is configured to receive a fastening system that plastically deforms at least one of the substrates during joining. 
     
     
         11 . The substrate according to  claim 10 , wherein the dimpled substrate defines a plurality of preformed interior cavities and a corresponding plurality of preformed exterior profiles, the plurality of preformed interior cavities being evenly spaced. 
     
     
         12 . The substrate according to  claim 10 , wherein the lower substrate is an aluminum casting or an aluminum extrusion. 
     
     
         13 . The substrate according to  claim 10 , wherein the lower substrate is a composite material. 
     
     
         14 . The substrate according to  claim 10 , wherein the preformed interior cavity defines a circular trench having a raised central region. 
     
     
         15 . The substrate according to  claim 10 , wherein preformed exterior profile defines a closed cylinder. 
     
     
         16 . An assembly comprising:
 an upper substrate;   a lower substrate defining a plurality of preformed interior cavities and a corresponding plurality of preformed exterior profiles adjacent the interior cavities to define variable thickness walls therebetween; and   a plurality of self-piercing rivets extending through the upper substrate and into the preformed interior cavities of the lower substrate,   wherein the preformed interior cavities are configured to direct flaring of the self-piercing rivets.   
     
     
         17 . The assembly according to  claim 16 , wherein the lower substrate is an aluminum casting or an aluminum extrusion. 
     
     
         18 . The assembly according to  claim 16 , wherein the lower substrate is a composite material. 
     
     
         19 . The assembly according to  claim 16 , wherein preformed exterior profiles define closed cylinders. 
     
     
         20 . A motor vehicle having the assembly according to  claim 16 .