Abstract
Friction forge riveting (FFR) has been developed for connecting titanium alloy and aluminum alloy with titanium rivets, although the weak formation of rivet during this process is still a key issue that should be solved properly. In this study, a thermomechanical coupling model was established in DEFORM-3D based on the practical thermal cycle of rivet during FFR process. Furthermore, the temperature and stress fields were also revealed in detail. The results showed that by reducing the loading speed of friction tool in the first 1 mm stroke, the flash defects and root defects caused by insufficient filling of the driven rivet head can be effectively avoided, and the joint mechanical performance including strength and service life was also improved. With the optimized FFR parameters, perfect joints were obtained without surface flash, holes or tunnels.
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