An Overview of Self-piercing Riveting Process with Focus on Joint Failures, Corrosion Issues and Optimisation Techniques

Ang, Hua Qian

doi:10.1186/s10033-020-00526-3

Cited by 41 publications

(15 citation statements)

References 133 publications

(287 reference statements)

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“…SPR has many advantages including low noise, no fume, no surface treatment required, no spark, ability to join multi-layer materials and mixed materials and ability to produce joints with high fatigue strength [ 11 ]. Compared with other joining techniques such as FSSW, RFSSW, resistance spot welding and clinching, SPR has proven to be an effective process to join dissimilar materials, from aluminium with composite to aluminium with advanced high strength steels [ 12 ]. Several of the key parameters that affect the quality of an SPR joint and some assistive technologies that have the potential of improving the quality of a joint were discussed by Haque [ 13 ].…”

Section: Introductionmentioning

confidence: 99%

Investigation into the Effect of RFSSW Parameters on Tensile Shear Fracture Load of 7075-T6 Alclad Aluminium Alloy Joints

et al. 2021

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The aim of the investigations was to determine the effect of parameters of refill friction stir spot welding (RFSSW) on the fracture load and failure mechanisms of the resulting joint. RFSSW joints were made in 7075-T6 Alclad aluminium alloy sheets using different welding parameters. The load capacity of joints was determined under tensile/shear loadings. Finite element-based numerical simulations of the joint-loading process were carried out, taking into account the variability of elasto-plastic properties of weld material through the joint cross-section. The influence of welding parameters on selected phenomena occurring during the destruction of the joint is presented. The considerations were supported by a fractographic analysis based on SEM images of fractures. It was found that there is a certain optimal amount of heat generated, which is necessary to produce the correct joint in terms of its load capacity. This value should not be exceeded, because it leads to weakening of the base material and thus to a reduction in the strength of the joint. Samples subjected to uniaxial tensile shear load showed three types of failure mode (tensile fracture, shear fracture, plug type fracture) depending on the tool rotational speed and duration of welding. Prediction of the fracture mode using FE-based numerical modelling was consistent with the experimental results. The samples that were damaged due to the tensile fracture of the lower sheet revealed a load capacity (LC) of 5.76 KN. The average value of LC for the shear fracture failure mechanism was 5.24 kN. The average value of the LC for plug-type fracture mode was 5.02 kN. It was found that there is an optimal amount of heat generated, which is necessary to produce the correct joint in terms of its LC. Excessive overheating of the joint leads to a weakening of the base metal and thus a reduction in the strength of the joint. Measurements of residual stresses along the axis specimens showed the presence of stresses with a certain constant value for the welded area on the side of the 1.6 mm thick plate.

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Section: Introductionmentioning

confidence: 99%

Investigation into the Effect of RFSSW Parameters on Tensile Shear Fracture Load of 7075-T6 Alclad Aluminium Alloy Joints

et al. 2021

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“…At the same time, the further development of self-piercing riveting is essential to provide solutions to combine advanced materials in the future. 11 Thus, innovative rivet materials with enhanced ductility that provide a sufficient strength to join high-strength materials must be used. 6 The use of rivet materials other than boron steels has already been subject of investigations in the past.…”

Section: Introductionmentioning

confidence: 99%

Process-adapted temperature application within a two-stage rivet forming process for high nitrogen steel

Kuball

Uhe

Meschut

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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Mechanical joining technologies like self-piercing riveting are gaining importance with regard to environmental protection, as they enable multi-material design and lightweight construction. A new approach is the use of high nitrogen steel as rivet material, which allows to omit the usually necessary heat treatment and coating and thus leads to a shortening of the process chain. Due to the high strain hardening, however, high tool loads must be expected. Thus, appropriate forming strategies are needed. Within this contribution, the influence of applying different temperatures for each forming stage in a two-stage rivet forming process using the high nitrogen steel 1.3815 is investigated. The findings provide a basic understanding of the influence of the temperature management when forming high nitrogen steel. For this purpose, the rivets are not formed at the same temperature in each stage, but an elevated temperature is applied selectively. Different process routes are investigated. First, cups are manufactured in stage 1 at room temperature, followed by stage 2 at 200°C. Second, cups are formed in stage 1 at 200°C and used for stage 2 at room temperature. By comparing the findings with results when applying the same temperature in both stages, it is shown that the temperature during the first forming operation has an effect on the forming behaviour during the second forming stage. The required forming forces and the resulting rivet hardness can be influenced by process-adapted temperature application. Furthermore, the causes for the temperature impact on the residual cup thickness in stage 1 are evaluated by a cause and effect analysis, which provides a deeper process understanding. The thermal expansion of the tool and the billet as well as the improved forming behaviour at 200°C are identified as the main influencing causes on the achieved residual cup thickness.

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Section: Introductionmentioning

confidence: 99%

“…Ang [10] provided an overview of semi-hollow stamped riveting with a focus on joint failure, corrosion issues and optimization techniques. In his overview, he noted that there is a high potential for cracking during joining, especially in brittle materials such as magnesium and aluminum die casting [10]. While it is already known from various studies that the cracks in magnesium die casting can be avoided by preheating [11], this approach has not yet been researched for aluminum die casting.…”

Section: Introductionmentioning

confidence: 99%

Clinching of inductively heated aluminum die casting

Yarcu

Behrens

Huebner

et al. 2022

Prod. Eng. Res. Devel.

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The aim of the investigations described in this article is to improve the clinching of aluminum die casting. The focus is on clinching an aluminum die casting alloy by local heat treatment and hence to join them in a process-safe manner. For this purpose, a heating strategy is used to warm up the die casting alloys to reduce temporarily and reversibly the elongation and the yield strength in the material. In preliminary investigations, three different heating strategies (heating plate, resistance heating and inductive heating) have been investigated. Induction heating has been selected as the most suitable method due to the short heating time and the production of crack-free clinch points. In this paper, two clinching tool systems (one with a flexible die, one with a rigid die) were used. For these tools, two inductors with different diameter were manufactured. The effects of each inductor and clinching tool on an aluminum die casting alloy, such as heating time and crack behavior, were investigated. Surface images of the clinch points in regard to the heat treatment temperature were analyzed. Furthermore, the characteristic parameters of the joints such as interlock, bottom thickness and neck thickness were examined. In addition, the strength of the joined parts was investigated by head tension tests. The results of the developed method showed that it is possible to produce crack-free clinching joints below 6 s. Furthermore, the local heating led to an increasing interlock resulting in a 26% increase of the head tensile strength.

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An Overview of Self-piercing Riveting Process with Focus on Joint Failures, Corrosion Issues and Optimisation Techniques

Cited by 41 publications

References 133 publications

Investigation into the Effect of RFSSW Parameters on Tensile Shear Fracture Load of 7075-T6 Alclad Aluminium Alloy Joints

Investigation into the Effect of RFSSW Parameters on Tensile Shear Fracture Load of 7075-T6 Alclad Aluminium Alloy Joints

Process-adapted temperature application within a two-stage rivet forming process for high nitrogen steel

Clinching of inductively heated aluminum die casting

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