Comparison of Self-Pierce Riveting, Resistance Spot Welding and Spot Friction Joining for Aluminium Automotive Sheet

Abstract

This work compares three aluminium sheet joining processes to determine their capability, efficiency and cost for mass production applications in automotive structures and closures. The joining processes investigated are Resistance Spot Welding (RSW), SelfPierce Riveting (SPR) and Spot Friction Joining (SFJ). Quantitative comparisons have been made on the basis of tensile strength (shear and peel), process time, equipment price and running cost.RSW is the most commonly employed joining method for steel sheet in the automotive industry. Its principle benefits are high speed and low cost operation, plus the ability to weld a wide range of joint configurations with the same gun. The main process limitations for aluminium are weld consistency and electrode-life, though recent work has shown that both of these can be largely overcome with regular electrode polishing [1,2]

A comparison of the mechanical behaviour of self-piercing riveted and resistance spot welded aluminium sheets for the automotive industry

“…It is generally recognised that the short life of the welding electrodes and the associated reduction in weld quality as the electrodes degrade [4,5,6] present major challenges when welding aluminium. The work previously undertaken by the University of Warwick [7,8] has proved that significant improvements in electrode life and consequently weld quality can be achieved by rigorous process control. Therefore RSW of aluminium can be a viable volume manufacturing technology.…”

Macroscopic strength and failure properties of flow-drill screw connections

“…The lapjoint specimen was used in the tests, with two connections in each sample. Briskham et al (2006) performed lap-shear and peeling tests to assess the functional suitability of self-piercing rivet, resistance spot weld and spot friction joint connections for use in aluminium automotive structures. Langrand et al (2002) carried out experimental studies on the behaviour of blind rivets, which are commonly used in modern fighters and commercial aircraft frameworks.…”

Resistance spot welding of dissimilar alloys 1008 low carbon steel5052 aluminum alloy

“…As a technique for joining sheet metal components, RSW is much quicker than riveting, see Ref. (Briskham et al, 2006). The components being joined are not weakened since no holes are drilled in.…”