Quality Tests of Hybrid Joint–Clinching and Adhesive—Case Study

Abstract

Inseparable joints are widely used in machine and vehicle construction. Hybrid joints include bonding with sheet metal clinching. This combination reduces costs as well as the time of production compared to welded joints. Tests on the samples made of DC01 sheets were carried out. A case study was conducted on four research series. For each series, the shear forces of the joint were measured. The first series consisted of adhesive bonding, and the second and third series consisted of hybrid bonding, during which the sheet metal clinching joint was developed immediately after the completion of adhesive application and after full joint formation. The last test series only includes sheet metal clinching. In the series where bonding was used, the homogeneity of the prepared joints was analysed using the ultrasonic echo technique. The shear strength of the bonded joints was 476 N, whereas the shear strength of sheet metal clinching was 965 N. For the hybrid joint, the average forces were 1085 N (for the specimens in which the lap joint was made after the joint was fully cured) and 1486 N (for the specimens in which the lap joints were made immediately after the adhesive was applied). It was discovered that the clinching of the steel sheets significantly increases the strength of the joint. The stabilisation of the joint causes better crosslinking conditions. This results in an increase in the strength of the hybrid joint.

Prediction of phase composition and mechanical properties Fe–Cr–C–B–Ti–Cu hardfacing alloys: Modeling and experimental Validations

“…It allowed to reduce a consumption of electricity used for welding materials melting due to a chemical heat generation. According to research, an introduction of exothermic addition in the core filler is an effective measure to improve the uniformity of flux-cored wire melting [ 48 , 117 , 118 ]. Besides, the introduction of an exothermic addition increases the deposition rate [ 49 ], improves the morphology of the weld bead [ 51 , 119 ], arc process efficiency [ 119 ] and the hardfacing process stability [ 120 ].…”

Evaluation of Adhesive Joints Using Ultrasonic Rayleigh Waves

“…A particularly significant share of adhesive joints is observed in the automotive industry [ 9 , 10 , 11 ]. These joints are used in numerous applications in the manufacturing stage of cars, vans, trucks and buses (urban two axle, articulated and tourist buses).…”

“…Such extensive use of bonding in the construction of buses is due to their considerable size and the vibrations generated during operation, which are well damped by adhesives. Adhesive joints in vehicle construction are often combined with welded [15], spot welded [16] or shaped joints, such as clinching [9]. Combining are often combined with welded [15], spot welded [16] or shaped joints, such as clinching [9].…”

Ultrasonic Features for Evaluation of Adhesive Joints: A Comparative Study of Interface Defects

“…Various configurations of ultrasonic methods based on the measurement of the difference in amplitude of reflected signals from defective and non-defective interfaces have been used to detect interface defects [ 12 , 13 , 14 , 15 , 16 ]. In addition, the following ultrasonic features, which characterize the signal response, were extracted to evaluate the adhesive quality: phase shift [ 12 ], ratio coefficients of peak-to-peak amplitudes [ 2 ], the decibel drop between ultrasonic pulses [ 17 , 18 ], maximum correlation between pulse response and excitation signals to obtain time reversal signals of Lamb waves [ 19 ], mean value, root mean square, standard deviation, skewness, kurtosis and crest factor, as well as modal frequency, modal mode and damping [ 20 ]. A number of works have been carried out using numerical evaluations and modeling to study the feasibility of different NDT methods [ 2 , 7 , 21 , 22 ].…”