Abstract
Economic conditions as well as comfort and safety-related requirements lead to lightweight design especially in automotive body-in-white production processes. The consequential multi-material mix limits the reliability of conventional thermal joining technologies. Innovative mechanical joining technologies need to be established. Following the lightweight-design requirements, next step for weight-reduction would be the renunciation of additional elements. Clinching technologies support this idea by creating a form- and force-fitting joint, but are limited to the formability of the joining partners. Joining by forming without additional elements even of hot formed ultra-high-strength manganese steels and ductile aluminium can be realised by shear-clinching. A precisely coordinated tool setup initialises a crack in the die-sided material with limited formability without harming the punch-sided ductile aluminium. This paper presents current and detailed investigations of the influences of mechanical loads on strength capacity of multi-material joints using shear-clinching technologies. The results clearly show the promising potential and challenges of this innovative single-step joining technology for multi-material mixes.
Highlights
Saving energy or resources during production process or reducing the carbon dioxide exhaustion when being in use lead to multi-material mixes in car body-structures
This paper presents current and detailed investigations of the influences of mechanical loads on strength capacity of multi-material joints using shear-clinching technologies
The results clearly show the promising potential and challenges of this innovative single-step joining technology for multi-material mixes
Summary
Saving energy or resources during production process or reducing the carbon dioxide exhaustion when being in use lead to multi-material mixes in car body-structures. With regard to an efficient interaction of decreasing resources and suitably tailored materials with different added alloy elements and the implementation of high developed modern materials, innovative joining technologies are required. The efficiency of resistant spot welding is no longer a unique selling point for automotive joining technologies when joining e.g. aluminium and steel. Current technologies manage to join multi-material mixes with one brittle joining partner by arranging it where no formability is necessary or by pre-holing it. Mechanical clinching joins multi-material mixes even of ultra-high-strength steel (UHSS) in multi-stage processes without additional joining elements. Shear-clinching technologies can realise a round-point joint of UHSS in a single-stage process (Busse et al, 2010). For a reliable and predictable process, the robustness has to be proven under laboratory conditions regarding several influencing factors
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