As lightweight automotive structures improve fuel efficiency and reduce carbon dioxide emission, they have garnered extensive attention. Vehicle mass reduction, which is a key problem for next generation eco-friendly vehicles, can significantly increase mileage. Hence, industries have committed to replace conventional materials with lightweight materials, such as advanced high strength steel. Additionally, automotive industries are hindered by challenges in the field of joining technology. A novel welding technology called resistance element welding (REW), which is an appropriate thermal-based joining method, was developed recently for joining hybrid materials with other structural steel grades. In this study, the state of the art joining and the process characteristics for dissimilar metal joints have been presented because related studies show limited investigation in this area. Following by the state of them, the principal and welding quality of REW, experimentally and numerically, are reported to give comprehensive information on the current practices and research interest related to technologies. Finally, extensive work was concentrated on portional joining optimization techniques to improve different materials.
Automobile manufacturers have recently focused their research on the concurrent improvement of fuel efficiency and stability. To implement lightweight body structures, the joining of dissimilar materials, such as advanced high-strength steel (AHSS) and carbon fiber-reinforced polymer (CFRP), is the most important, whereas fusion welding, which is the conventional welding process, is inapplicable owing to the difference in mechanical properties between materials. Thus, the development of an appropriate dissimilar material joining process is of utmost importance, considering productivity and safety.<br/>Self-piercing riveting (SPR), a representative lightweight material joining process, has no limitation in terms of applicable materials and has the advantage of improved joint strength. However, as the requirements on the mechanical properties of materials in the industry are continuously increasing, there is a need to further develop the process. Therefore, this study introduces the electromagnetic self-piercing riveting(E-SPR), a joining process that uses high electrical energy to discharge the high electrical energy charged in the capacitor to the working coil located in the head of the C-frame. In particular, this process enables high-quality joining parts to be secured by improving the formability of a material with poor formability under a high strain rate. Consequently, a simple piece of E-SPR equipment was manufactured, and an Al/Steel and Al/CFRP joint was further fabricated. The results of a preliminary test reported a quality equal to or higher than that of the previously reported SPR joint. Based on these research results, further studies on processes and equipment for commercialization will be conducted in the future.
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