Abstract
The present work explores the feasibility of single-phase friction riveting on unreinforced thermoplastics. In single phase, the load is kept constant throughout the process, avoiding the forging phase with higher axial force, used in the conventional process. This process variant can constitute an answer when payload restrictions exist. The results demonstrate the feasibility of single-phase friction riveting on unreinforced polyetherimide plates joined by AA2024 rivets with 5 mm of diameter. A Box-Behnken design of experiments and analysis of variance were used to set parameter matrix and understand the correlations between parameters and joint properties. A large variation of the mechanical energy input was observed (151–529 J). Over-deformation and material rupture were observed in higher energy conditions. Lower energy input yielded a bell-shaped rivet plastic deformation, corresponding to the best performance. The maximum process temperatures varied between 461 and 509 °C. This friction riveting process variant allowed a considerable high mechanical strength to be achieved, with ultimate tensile force of 7486 N, comparable with the two-phase friction riveting process, albeit applying lower axial forces, such as 2400 N. Within the investigated conditions, this study proves the feasibility of the single-phase process, achieving good global mechanical performance and energetically efficient conditions, without forging phase.
Highlights
In recent years, several industries, such as transport, have been introducing less conventional solutions to their designs
The present work aims at evaluating the possibility of joining AA2024-T351 with PEI by single-phase friction riveting, using force control and time limits, which until now had yet to be investigated
The mechanical energy input used to produce each of the investigated joints was determined using Eq 1, following the same approach as Pina Cipriano et al [17] and other authors working with friction riveting [24]
Summary
Several industries, such as transport, have been introducing less conventional solutions to their designs. Hybrid connections between nonweldable dissimilar materials have been traditionally performed by mechanical fastening, adhesive bonding, or combinations of both [1, 2] Both these technologies present drawbacks and design compromises. Friction riveting has been developed based on both mechanical fastening and friction welding principles, as a technology capable of establishing mechanical connections between dissimilar materials [9], namely metals and polymers/ composites. The present work aims at evaluating the possibility of joining AA2024-T351 with PEI by single-phase friction riveting, using force control and time limits, which until now had yet to be investigated. This process variant would not make use of a second phase after the initial friction one. The final geometry of the rivet is assessed by performing several measurements on the inserted metallic rivet, as seen in the figure
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