Joinability of different thermoplastic polymers with aluminium AA6082 sheets by mechanical clinching

Abstract

The joinability of different rigid thermoplastic polymers with aluminium AA6082-T6 alloy sheets by mechanical clinching is investigated. The polymers were heated using a convective source prior of clinching. Experimental tests were conducted by varying die geometry and preheating time. The joinability window for different thermoplastic polymers including polystyrene (PS), polycarbonate (PC) and poly(methyl methacrylate) (PMMA) was determined. The mechanical behaviours of clinched connections were assessed by means of single lap shear tests. To understand the effect of process parameters on the mechanical behaviours of clinched joints, dimensional analysis was also carried out. It was turned out that mechanical clinching could be successfully employed for joining thermoplastic polymer sheets with aluminium sheets being characterized by a very short processing time and producing high strength joints as compared to competitive technologies. The formability of the aluminium alloy and the toughness of the polymer component are crucial for the success of the process. However, even materials with reduced formability were joined by modifying conveniently the preheating time and die geometry.

Testing of crimp connections made on a prototype stand

“…Aluminum alloy is a material difficult to weld with the resistance spot welding. It is still a challenge to join the aluminum sheet and the steel sheet together [3][4][5]. There are many other alternatives of aluminum alloy joining such as friction stir welding [6], adhesive joining or mechanical clinching [7][8][9].…”

Joining three car body steel sheets by clinching method

“…The high flexibility of clinching has allowed employing mechanical clinching for a wide range of materials. Currently, researches have been conducted on steels and aluminium alloys, recent developments have dealt with copper, mag- nesium, titanium alloys [15,16], carbon fiber-reinforced plastics [17] along with hybrid metal-plastic polymers [18][19][20], metal-reinforced plastics [21][22][23] and metal-wood [24]. Some of these materials were joined by hole-clinching process [25].…”

Investigations of Join-Ability and Energy Absorption of Clinched Joints in Titanium and Aluminum-Lithium Sheet Materials

“…The join-ability of different rigid thermoplastic polymers with aluminum alloy sheets by mechanical clinching has been investigated by Lambiase et al 6,7) In a recent study, a numerical model describing the evolution of ductile damage was developed to predict the onset of fracture during the clinch joining of thin aluminum sheets 8) . The effect of corrosion phenomena in critical environmental conditions on the mechanical performance of steel/aluminum hybrid clinched joints has been studied by ageing in salt spray environment 9) .…”