Patent ID: 8662141

Claim:
A method of adapting a casting or molding process to prepare one or more joining regions in a cast or molded article for receiving a self-piercing rivet without damage to the article and thereby forming a sound joint for attachment of the article to a workpiece, the cast or molded article being formed in a mold cavity having opposing surfaces: the method comprising; identifying one or more intended joining regions on the cast or molded article; positioning a metal insert with two opposing surfaces and adapted to plastically deform without cracking while receiving one or more self-piercing rivets into the mold cavity at each of the one or more intended joining regions with each of the opposing surfaces of each insert contacting one of the opposing mold cavity surfaces, the inserts having features for mechanically engaging with the casting to secure the inserts to the casting, the inserts having solidus temperatures, and ductilities suited for penetration and deformation by a self-piercing rivet so as to form a riveted joint; filling the mold cavity with a flowable casting alloy or moldable polymer material at a temperature less than the solidus temperature of the inserts; and cooling the casting alloy or moldable polymer material to about room temperature to form the cast or molded article and to mechanically engage the inserts with the article, the insert being positioned in the cast or molded article so as to enable face-to-face contact of a first of the insert opposing surfaces with a joining surface of the workpiece and to make accessible a second of the insert opposing surfaces for receiving a self-piercing rivet.