Single-sided friction riveting process of aluminum sheet to profile structure without prefabricated hole

Abstract

Aluminum profile structures are extensively used in the transportation industry and pose a considerable challenge to single-sided spot joining technologies. The widely used Huck BOM® riveting process requires prefabricated holes and thus significantly increases cost and reduces efficiency. In this study, a novel single-sided friction riveting (SSFR) process with an internal-threaded semi-tubular rivet is proposed to realize a screwed-solid state hybrid joining of aluminum sheet to profile structure without prefabricated holes. The results show that the upper trapped metal is welded with the lower profile structure under the thermal-mechanical coupled action generated by rivet stirring. The internal thread could facilitate material filling into the rivet cavity and form a mechanical interlock, so as to realize the single-sided joining between the sheet and the profile without prefabricated holes. The one-stage SSFR process could form shear texture and promote continuous dynamic recrystallization, but lead to excessive material softening and internal cracking. A two-stage process including friction softening and screw tightening could better coordinate the effects of heat and force, thereby avoiding cracking and refining grains in the stirring zone. Finally, the tensile-shear and cross-tension peak loads were respectively improved by 9.0 % and 29.3 %, compared to the joints with one-stage process and non-structural rivet.