Abstract
One thin 5000 series aluminium alloy sheet and two thin 980 MPa grade cold rolled ultra-high strength steel sheets were joined by self-pierce riveting and mechanical clinching processes. The joinabilities for a combination of the aluminium and steel sheets in both processes were investigated for different die shapes in the experiment and finite element simulation. In self-pierce riveting, the three sheets were successfully joined for both combinations of the upper and lower aluminium alloy sheets by optimizing the shapes of a die and rivet. In mechanical clinching, the three sheets were successfully joined by an optimum die for the configuration of the upper aluminium alloy sheet. On the other hand, the three sheets for the configuration of the lower aluminium alloy sheet were not joined even by optimizing the die shape in the both finite element simulation and experiment, because the material flow of the steel sheets was insufficient to form the two interlocks. The tension-shear loads for the clinched and riveted sheets with the adhesive were almost the same, because the load for the adhesive was the highest. In the cross-tension test, however, the load by the adhesive was comparatively small.
Highlights
The use of multi-materials in the automobile body has been increasing to reduce the weight of automobiles, and steel sheets, aluminium alloy sheets and carbon fiber reinforced plastics are used for automobile body parts
The joinabilities for the combination of the aluminium and steel sheets in both processes were investigated for different die shapes in the experiment and finite element simulation, and were investigated forriveted different shapes joints in the were experiment and finite simulation, and the strengths of the anddie clinched compared in theelement experiment
The three sheets in both the sheet configurations were successfully joined by self-pierce riveting with the optimum die and rivet
Summary
The use of multi-materials in the automobile body has been increasing to reduce the weight of automobiles, and steel sheets, aluminium alloy sheets and carbon fiber reinforced plastics are used for automobile body parts. For the corrosion resistance and the seal in joints, the joining processes without fracture in a sheet or more sheets such as friction stir welding, self-pierce riveting, mechanical clinching and adhesive bonding are attractive. Self-pierce riveting, mechanical clinching and these joining processes with an adhesive are the alternative methods to join the sheet configuration for one aluminium alloy sheet and two steel sheets. The effect of coatings on the quality and the behavior of self-pierce riveted joints between 5000 series aluminium alloy and high strength steel sheets was investigated [16]. 5000 series aluminium alloy and high strength steel sheets by self-pierce riveting and welding was compared [22]. The three sheets including the high strength steel and the aluminium alloy sheets in the thick lower sheet were joined by self-pierce riveting [25]. The joint strengths with and without adhesive were compared
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