Friction self-piercing riveting (F-SPR) process has shown advantages over fusion welding, solid state welding, and traditional mechanical joining processes in joining dissimilar materials. Because of the thermo-mechanical nature of F-SPR process, formation of the joint is determined by both riveting force and softening degree of materials to be joined. However, it is still not clear that how exactly the riveting force and generated frictional heat jointly influence mechanical interlocking formation and crack inhibition during F-SPR process. To address these issues, F-SPR process was applied to join 2.2 mm-thick aluminum alloy AA6061-T6 to 2.0 mm-thick magnesium alloy AZ31B. The correlation of riveting force, torque responses, and energy input with joint quality was investigated systematically under a wide range of process parameter combinations. It was found that a relatively greater final peak force and higher energy input were favorable to produce sound joints. Based on that, a two-stage F-SPR method was proposed to better control the energy input and riveting force for improved joint quality. The joints produced by the two-stage method exhibited significantly improved lap-shear strength, i.e., 70% higher than traditional self-piercing riveting (SPR) joints and 30% higher than previous one-stage F-SPR joints. This research provides a valuable reference for further understanding the F-SPR joint formation mechanism and conducting process optimization.
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October 2018
Research-Article
Effects of Process Parameters on Crack Inhibition and Mechanical Interlocking in Friction Self-Piercing Riveting of Aluminum Alloy and Magnesium Alloy
YunWu Ma,
YunWu Ma
Shanghai Key Laboratory of Digital
Manufacture for Thin-Walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
Manufacture for Thin-Walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
Search for other works by this author on:
GuanZhong He,
GuanZhong He
Shanghai Key Laboratory of Digital
Manufacture for Thin-walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
Manufacture for Thin-walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
Search for other works by this author on:
Ming Lou,
Ming Lou
Shanghai Key Laboratory of Digital
Manufacture for Thin-walled Structures,
Shanghai Jiao Tong University,
Shanghai 200240, China
Manufacture for Thin-walled Structures,
Shanghai Jiao Tong University,
Shanghai 200240, China
Search for other works by this author on:
YongBing Li,
YongBing Li
Shanghai Key Laboratory of Digital
Manufacture for Thin-walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: yongbinglee@sjtu.edu.cn
Manufacture for Thin-walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: yongbinglee@sjtu.edu.cn
Search for other works by this author on:
ZhongQin Lin
ZhongQin Lin
Shanghai Key Laboratory of Digital
Manufacture for Thin-walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
Manufacture for Thin-walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
Search for other works by this author on:
YunWu Ma
Shanghai Key Laboratory of Digital
Manufacture for Thin-Walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
Manufacture for Thin-Walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
GuanZhong He
Shanghai Key Laboratory of Digital
Manufacture for Thin-walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
Manufacture for Thin-walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
Ming Lou
Shanghai Key Laboratory of Digital
Manufacture for Thin-walled Structures,
Shanghai Jiao Tong University,
Shanghai 200240, China
Manufacture for Thin-walled Structures,
Shanghai Jiao Tong University,
Shanghai 200240, China
YongBing Li
Shanghai Key Laboratory of Digital
Manufacture for Thin-walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: yongbinglee@sjtu.edu.cn
Manufacture for Thin-walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: yongbinglee@sjtu.edu.cn
ZhongQin Lin
Shanghai Key Laboratory of Digital
Manufacture for Thin-walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
Manufacture for Thin-walled Structures,
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
1Corresponding author.
Manuscript received March 12, 2018; final manuscript received June 26, 2018; published online July 27, 2018. Assoc. Editor: Wayne Cai.
J. Manuf. Sci. Eng. Oct 2018, 140(10): 101015 (10 pages)
Published Online: July 27, 2018
Article history
Received:
March 12, 2018
Revised:
June 26, 2018
Citation
Ma, Y., He, G., Lou, M., Li, Y., and Lin, Z. (July 27, 2018). "Effects of Process Parameters on Crack Inhibition and Mechanical Interlocking in Friction Self-Piercing Riveting of Aluminum Alloy and Magnesium Alloy." ASME. J. Manuf. Sci. Eng. October 2018; 140(10): 101015. https://doi.org/10.1115/1.4040729
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