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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Polyoxymethylene (POM), as an energy‐saving material, is widely applied in the manufacturing field. Yet, research on the rectangular clinching process between metal and POM sheets is still lacking. In this paper, the rectangular clinching process for POM and Al5052‐H32 plates was investigated. The feasibility of the metal–polymer hybrid component had been analyzed in terms of diverse forming forces and diverse joint layout angles, respectively. The mechanical characteristics were appraised by the lap‐shear test. The failure modes of rectangular clinched joints produced under diverse forming conditions had also been analyzed. The results showed that the optimal forming force of rectangular clinched joints was 14 kN, in which the lap‐shear strength was 1090 N. Furthermore, the rectangular clinched joints produced under the joint layout angle of 90° could withstand the maximum lap‐shear load (1415 N) under the optimal forming force. The failure mode was the separation of two plates and the fracture of the bridge structures.

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