Research on mechanical clinching process for dissimilar aluminum alloy sheets with inclined surface

Abstract

In this work, dissimilar aluminum alloy sheets with inclined surfaces were joined by flat-clinching process. Three types of aluminum alloy sheets, namely AA1060, AA5052 and AA6061, were employed to produce six types of clinched joints. Further, the mechanical properties of all clinched joints were investigated experimentally. Moreover, the failure evolution process and energy absorption capacity of clinched joints under static loading were also evaluated. From the experimental results, more outstanding performance of mechanical properties was observed for the joints made by the upper sheet with higher tensile strength. A new type of failure mode, never reported in previous studies, appeared in failed AA6-1 joint, which is termed as pull-off tearing failure mode. It is found that both in terms of safety and bearing load the material with higher tensile strength is more suitable for the upper layer when joining dissimilar aluminum alloy sheets with inclined surface by flat-clinching process. The process proposed in this work is particularly suitable for the joining the thick sheet and for the industrial occasion which requires a flat surface on both sides of the connected sheets after joining. This work is contribute to expand the case in industrial practice of the mechanical clinching process and improve the joined quality of the clinched joint.