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In the current study, the mechanical clinching process of the Al5052/polyoxymethylene (POM) hybrid structure has been explored. The influence of diverse forming forces on the forming process of Al5052/POM hybrid joints was discussed. The geometric parameters were measured to analyzed the forming ability of the hybrid joints. The tensile-shear test and energy absorption calculation are accomplished to estimate the joinability and reliability of joints. The failure microstructure was observed to analyze the failure mechanism. The conclusions have shown that the hybrid structure between Al5052-H32 and POM sheets can be effectively connected through mechanical clinching technology (MCT) as the forming force is greater than 22 kN. Two failure modes were observed in the tensile-shear testing, including button separation and neck fracture. Increasing the forming force led to the enhancement of the joint strength and energy absorption. Nonetheless, the tensile-shear load is basically uncharged when the forming force is large.

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A novel dieless clinching process free of blank holder was proposed in this study. This novel clinching process applied to joining Al5052 sheets under the forming forces from 24 to 54 kN was investigated experimentally. The joint geometrical characteristics, static mechanical strength, energy absorption and failure modes were revealed. From the results, the sound joints can be produced under various forming forces from 24 to 54 kN. With the forming force increasing, the neck thickness was increased continually while the interlock value remained almost constant. On the other hand, the protrusion height of clinched joint was reduced continually with the forming force increasing. Both the tensile strength and shear strength were enhanced with the forming force increasing. Under the forming force of 54 kN, the tensile strength and the shear strength were 1249 and 1107 kN, respectively. In general, a larger joining force leads to a better clinched joint with lower protrusion height and higher mechanical strength.

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Clinching technology can join thin sheets of various materials, including aluminum alloy, magnesium alloy, steel, titanium alloy, and polymers. Nowadays, with the popularization of the lightweight concept and the application of various sheet materials in manufacturing, clinching technology has highlighted the advantages of being able to adapt to the joining of different sheet materials. With its unique advantages, clinching technology gains wide development space in the field of metal sheet connection. The application of clinching technology in various sheet materials is summarized and analyzed. The clinching process of special materials is also discussed. In addition, some unaddressed issues in the clinching process of special materials are identified in this paper.

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