A decision tree approach for energy efficient friction riveting of polymer/metal multi-material lightweight structures

Abstract

Friction riveting has emerged out as a promising candidate for joining polymers to metals, since it is energy efficient, fast and eco-friendly without material wastage and pre and post processing and cleaning. For sustainable manufacturing of car ports, automobile panels and aircraft structures, there is a need for joining of polycarbonate to AA 6063 using friction riveting technique. Hence in the present work, Polycarbonate/AA 6063 combination is joined employing friction riveting with a new slotted end rivet. Microstructural examination reveals a visible deformation during the penetration of AA 6063 rivet that provides excellent anchoring. Decision tree is an exploration approach that is applied on friction riveting experimentation data and it has derived meaningful information out of testing data to reach the maximum possible tensile load carrying capacity by a friction riveted joint within the production constrains. The maximum tensile load of 5.75 kN can be achieved when rotational speed, friction time and depth of friction riveting are kept above at 2050 rpm, 37.5 sec and 9 mm respectively. It is helpful in industries during selection of different combination of process parameters to obtain the desirable joining strength. • Successful joining of dissimilar Polycarbonate to AA 6063. • Friction riveting with new slotted end rivet profile. • Decision tree approach, for judicial selection of processing conditions. • Micro-structural investigation on bonding mechanism at the interface.