Abstract
This work proposes a micro-shear clinching process by laser shock for joining similar and dissimilar metal foils. The joint appearance and cross-section were investigated to determine basic process parameters. The soft punch thickness was 100 μm. The numbers of laser pulses on the upper and lower foil sides were set as two and one, respectively. Joint deformation was divided into three stages and we investigated the deformation law of the joints. The process windows of the Al foil combinations were acquired to determine a reasonable range of process parameters for obtaining qualified joints. The mechanical properties and failure modes of different joints were analyzed to identify the process characteristics. Mechanical properties were related to shear test directions and were influenced by upper and lower foil thicknesses. One failure mode was observed in the parallel shear test, and four failure modes were observed in the perpendicular shear test. These modes were determined by the differences between upper and lower foil thicknesses. Results showed that the proposed process can be used to join Al and Cu foils successfully. The laws governing the mechanical properties and failure modes of dissimilar materials were similar to those governing the mechanical properties and failure modes of similar materials.
Highlights
The traditional mechanical clinching process has notable benefits, such as rapidity, wide applicability, high dependability, energy savings, and environmental friendliness.Abundant literature has been published for mechanical clinching to improve the feasibility and application of the process involving numerical and experimental investigations
Basic parameters are constant for joining different materials, which and would directly and greatly influence process parameters are constant for joining different materials, which would directly and greatly the joint deformation and efficiency of process
28, 28, four kinds of failure modes areare observed in the perpendicular shear illustrated in Figure four kinds of failure modes observed in the perpendicular shear test
Summary
The traditional mechanical clinching process has notable benefits, such as rapidity, wide applicability, high dependability, energy savings, and environmental friendliness. The author [12] studied the mechanical clinching of galvanized high-strength steel (H220PD+Z) and investigated the wear of the punch and the die with different coatings. Pedreschi et al [17] introduced a press-joining process with a rectangular mold for cold-formed steel structures They studied the influences of shear test direction, joint number, raw material thickness and strength, shearing edge width, and different thickness combinations. Abe et al [27] utilized rectangular shear clinching to join ultra-high-strength steel In this process, the upper plate is locally sheared, and the lower plate remains intact. The above realized micro mechanical joining by laser shock forming all need a material removal process and has a complicated joint deformation requirement.
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