Abstract
This study investigates the quality of self-piercing riveted joints between vibration-damping aluminum (Al) and other dissimilar materials, namely aluminum alloy (AL5052-H32), steel alloy (GA590DP), and carbon-reinforced plastic (CFRP). The effects of die types (flat, cone, and nipple) on the geometrical characteristics and mechanical performance of the joints are studied using a cross-section examination and tensile shear load testing. The failure modes of each joint are also presented, showing the nature of the forces leading to the joint failures. The results indicate that, for all configurations, adequate joining between vibration-damping Al with AL5052-H32 is expected with a maximum shear load up to 3.28 kN. A shear load up to 3.6 kN was measured for the joints with GA590DP panels with acceptable top and bottom seal characteristics. A vibration-damping Al panel can only be positioned at the bottom when riveting with CFRP due to the brittle nature of CFRP. A tensile shear load up to 2.26 kN was found, which is the lowest amongst the materials tested in this study.
Highlights
Self-piercing riveting (SPR) is a method used for mechanically attaching similar or dissimilar materials [1]
There were defects present for the configuration when the vibration-damping Al panel was positioned on the bottom, the panels remained joined; tensile shear tests were carried out
The results show that a maximum tensile shear load of 2.8 kN results for the joint formed using die type B but is significantly lower compared with that of the joint with the highest cross-sectional quality
Summary
Self-piercing riveting (SPR) is a method used for mechanically attaching similar or dissimilar materials [1]. Sci. 2020, 10, 5947 overall weight reduction of the vehicles The use of such dissimilar materials requires efficient means of joining, since the conventional fusion joining methods are not applicable. The mechanical characteristics of self-piercing riveted joints in multiple layers composed of aluminum (AA6111 and NG5754) and steel alloys (HSLA350) were studied by Han et al [24]. The bonding quality of self-piercing riveted joints of vibration-damping steel and aluminum alloy was recently studied by our group [26]. To the best of the authors’ knowledge, no comprehensive study has been performed for SPR between novel materials used in the automotive industry such as vibration-damping aluminum (Al), aluminum alloy, steel alloy, and carbon-reinforced plastic (CFRP). We investigate the geometrical characteristics and mechanical performance of the SPR of vibration-damping Al with aluminum alloy (AL5052-H32), steel alloy (GA590DP), and thermoset CFRP. The joint qualities (or joining strengths) were determined using a series of tensile shear load tests, and the failure modes were examined to shed light on the critical forces acting on the joints that eventually lead to their failures
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