Fatigue and fretting of mixed metal self-piercing riveted joint

Huang, Li; Bonnen, John; Lasecki, John; Guo, Hao; Su, Xuming

doi:10.1016/j.ijfatigue.2015.10.018

Cited by 51 publications

(32 citation statements)

References 23 publications

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“…In the case that rivet interlocks are not strong enough, rivet being pulled out of the bottom sheet can also happen during fatigue. For SPR joints with aluminium and high-strength steel or highstrength steel to high-strength steel, failure at rivet during fatigue is also possible [133].…”

Section: Failure Of Spr Jointsmentioning

confidence: 99%

“…All authors mentioned above believed that fretting damaged the material interfaces and caused crack initiation and thus reduced the fatigue life. Huang et al [133] studied the fatigue of SPR joints with AA6111 T4 joined to HSLA340, and their results showed that fretting might play an important role during crack initiation on sheet materials and rivet shank. However, a study by Li et al [95] based on 2 mm AA5754 + 2 mm AA5754 stack showed that although fretting can damage material surfaces and accelerate crack initiation, for the SPR joints studied, the influence of fretting on the fatigue strength was not significant, because failure did not always occur at the fretting area.…”

Section: Failure Of Spr Jointsmentioning

confidence: 99%

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Self-piercing riveting-a review

Chrysanthou

Imran

et al. 2017

Int J Adv Manuf Technol

229

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Self-piercing riveting (SPR) is a cold mechanical joining process used to join two or more sheets of materials by driving a rivet piercing through the top sheet or the top and middle sheets and subsequently lock into the bottom sheet under the guidance of a suitable die. SPR is currently the main joining method for aluminium and mixed-material lightweight automotive structures. SPR was originated half century ago, but it only had significant progress in the last 25 years due to the requirement of joining lightweight materials, such as aluminium alloy structures, aluminium-steel structures and other mixed-material structures, from the automotive industry. Compared with other conventional joining methods, SPR has many advantages including no pre-drilled holes required, no fume, no spark and low noise, no surface treatment required, ability to join multi-layer materials and mixed materials and ability to produce joints with high static and fatigue strengths. In this paper, research investigations that have been conducted on self-piercing riveting will be extensively reviewed. The current state and development of SPR process is reviewed and the influence of the key process parameters on joint quality is discussed. The mechanical properties of SPR joints, the corrosion behaviour of SPR joints, the distortion of SPR joints and the simulation of SPR process and joint performance are reviewed. Developing reliable simulation methods for SPR process and joint performance to reduce the need of physical testing has been identified as one of the main challenges.

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Section: Failure Of Spr Jointsmentioning

confidence: 99%

Section: Failure Of Spr Jointsmentioning

confidence: 99%

Self-piercing riveting-a review

Chrysanthou

Imran

et al. 2017

Int J Adv Manuf Technol

229

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“…The superior fatigue life performance of the CFRP to aluminium 6111 T82 SPR lap-shear joints compared to AA6111-to-AA6111 lap-shear joints may be attributed, in part, to the absence of fretting damage in the former. In several studies of metal-to-metal SPR lap-shear joints, fretting has been observed to be one of the dominant causes for crack initiation and significantly accelerated the crack growth in these SPR lap-shear joints [8,10,[28][29][30]. Even though fretting was also observed in SPR lap-shear joints of aluminum to glass-fiber reinforced thermoplastic composite [23], no traces of fretting were observed in any of the SPR lap-shear test specimens tested in this study.…”

Section: Fatigue Testmentioning

confidence: 46%

“…Self-piercing riveting (SPR) is a high speed mechanical fastening technique where a tubular rivet is pierced through the top sheet and partially through the bottom overlapping sheet which are held against a die of asymmetrical cavity [5]. SPR is widely used by several automotive manufacturers as an economical and effective technique to join aluminum vehicle bodies [6][7][8][9]. SPR joints of aluminum to aluminum [6,[10][11][12][13][14], magnesium to magnesium [15], and aluminum to steel [16][17][18] alloys have shown superior peel and fatigue strength compared to RSW joints.…”

Section: Introductionmentioning

confidence: 99%

Tensile and fatigue behaviour of self-piercing rivets of CFRP to aluminium for automotive application

Kang¹,

Rao²,

Zhang³

et al. 2016

IOP Conf. Ser.: Mater. Sci. Eng.

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Numerical simulation and experimental validation of self-piercing riveting (SPR) of 6xxx aluminium alloys for automotive applications F Hönsch, J Domitner, C Sommitsch et al. Abstract. In this study, the tensile and fatigue behaviour of self-piercing rivets (SPRs) in carbon fibre reinforced plastic (CFRP) to aluminium 6111 T82 alloys were evaluated. An average maximum lap-shear tensile load capacity of 3858 N was achieved, which is comparable to metal-to-metal SPR lap-shear joints. The CFRP-Al SPRs failed in lap-shear tension due to pull-out of the rivet head from the CFRP upper sheet. The CFRP-Al SPR lapshear specimens exhibited superior fatigue life compared to previously studied aluminium-toaluminium SPR lap-shear joints. The SPR lap-shear joints under fatigue loads failed predominantly due to kinked crack growth along the width of the bottom aluminium sheet. The fatigue cracks initiated in the plastically deformed region of the aluminium sheet close to the rivet shank in the rivet-sheet interlock region. Scatter in fatigue life and failure modes was observed in SPR lap-shear specimens tested close to maximum tensile load.

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“…The SPR technique is a high‐speed mechanical fastening process that has been increasingly used to join aluminum and hard to weld materials . The SPR process has been studied widely and implemented by several automobile manufacturers as an economical and effective technique to join aluminum vehicle bodies …”

Section: Introductionmentioning

confidence: 99%

High cycle fatigue mechanisms of aluminum self‐piercing riveted joints

Moraes

Rao

Jordon

et al. 2017

Fatigue Fract Eng Mat Struct

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A study examining the fatigue failure mechanism of self-piercing riveted (SPR) joints between aluminum alloy 6111-T4 and 5754-O is presented in this paper. In particular, the high-cycle fatigue behavior of the SPR joints in the lap-shear configuration is characterized. Experimental fatigue testing revealed that failure of SPR joints occurred because of cracks propagating through the sheet thickness at locations away from the rivet. In-depth postmortem analysis showed that significant fretting wear occurred at the location of the fatigue crack initiation. Energy dispersive X-ray of the fretting debris revealed the presence of aluminum oxide that is consistent with fretting initiated fatigue damage. High-fidelity finite element analysis of the SPR process revealed high surface contact pressure at the location of fretting-initiated fatigue determined by postmortem analysis of failed coupons. Furthermore, fatigue modeling predictions of the number of cycles to failure based on linear elastic fracture mechanics supports the conclusion that fretting-initiated fatigue occurred at regions of high surface contact pressure and not at locations of nominal high-stress concentration at the rivet.

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Fatigue and fretting of mixed metal self-piercing riveted joint

Cited by 51 publications

References 23 publications

Self-piercing riveting-a review

Self-piercing riveting-a review

Tensile and fatigue behaviour of self-piercing rivets of CFRP to aluminium for automotive application

High cycle fatigue mechanisms of aluminum self‐piercing riveted joints

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