High-strength alloys and ever-thinner gauges are complicating the process of fastening sheet metal assemblies. Sheet metal is still the material of choice for auto body components, white goods, electrical enclosures and other products. However, the need to reduce weight and decrease cost is forcing engineers to specify thinner materials and lighter alloys. Where engineers once used 1-millimeter thick sheets, they are now using sheets that are 0.7 millimeter or even thinner. In many cases, extra fastening elements and manufacturing steps are necessary to use screws to assemble materials that are 0.25 times thinner or less than the nominal diameter of the fastener.
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