Self-piercing riveting connections using aluminium rivets

Abstract

a b s t r a c tThe development of the self-piercing riveting (SPR) technology in recent years has broadened the application of the technology in the automobile industry. However, the SPR process currently utilises high-strength steel rivets; and the combination between steel rivets with an aluminium car body makes recycling a challenge. The possibility of replacing a steel self-piercing rivet with an aluminium one has thus been raised as an interesting topic. Within this framework, the objective of the present paper is to provide an experimental database on the riveting process using an aluminium self-piercing rivet. An experimental programme has been carried out, where two similar sheets in aluminium alloy 6060 in three different tempers (temper W, temper T4, and temper T6) have been joined by using a self-piercing rivet in three different alloys, i.e. 6082-T6, 7108-T5, and 7278-T6. The influence of the die shape on the SPR of aluminium sheets using aluminium rivets was also considered. Conventional rivets and dies according to the Boellhoff standards were employed. The test results were exploited in terms of the riveting force-displacement curves and cross-sectional geometries of the riveted joints. The test data were also used to validate a 2D-axisymmetric model, which was originally developed at SIMLab for modelling the riveting process using a steel rivet. Finally, the mechanical behaviour of a riveted connection using an aluminium rivet under quasi-static loading conditions (i.e. combined pure shear and pure opening loads) was experimentally studied and compared with corresponding tests using a steel rivet in terms of forcedisplacement curves.

Smarter–lighter–greener: research innovations for the automotive sector

“…The multi-disciplinary research into self-pierce riveting, enabling its introduction into the industry, has been global, involving companies including Audi, BMW, General Motors, Peugeot-Citroën and Jaguar Land Rover and research groups in Australia [16], China [17], France [18], Germany [19], Italy [20], Japan [21], Norway [22], Poland [23], Slovakia [24], UK and USA [25]. Resistance spot welding had traditionally been ignored as it was impossible to control in lightweight materials, and there was no guarantee that joints would be reliable.…”

Recent development in finite element analysis of self-piercing riveted joints

“…The effectiveness of the designed rivet die was evaluated from an experiment. Hoang et al [40] investigated the possibility of replacing steel self-piercing rivets with aluminum ones, when using a conventional die in accordance with the Boellhoff standards. An experimental program was carried out.…”

Experimental investigation and design method for the shear strength of self-piercing rivet connections in thin-walled steel structures

“…1. Schematic diagram of the forming process of a SPR joint [10] The previous research on SPR joints has been concentrated on the forming mechanism and fatigue behavior for ductile thick steel plates [8,9,11], the study on SPR connections with thin-walled steel sheets is limited. Mucha and Lennon [2,12] studied various connections using SPRs, selfdrilling screws, clinching and blind rivets.…”