Fastenerless-Riveting Utilizing Friction Stir Forming for Dissimilar Materials Joining

2017 ◽  
Vol 751 ◽  
pp. 186-191 ◽  
Author(s):  
Takahiro Ohashi ◽  
Hamed Mofidi Tabatabaei ◽  
Tadashi Nishihara

This paper proposes a new joining approach for dissimilar materials, called ‘the fastenerless-riveting,’ employing the friction stir forming (FSF). The FSF is a friction stir process invented by Nishihara in 2002. In FSF, a substrate material was put on a die firstly. Next, friction stirring was conducted on the back surface of the material. The material then deformed and precisely filled the cavity of the die due to high pressure and heat caused by the friction stirring. The authors utilized the FSF approach to generate rivet like joints as followings. First, a substrate which is capable for friction stirring, i.e. an aluminum alloy plate, was put on a dissimilar material plate having holes, i.e. a steel plate. The authors call the former ‘the host member,’ the latter ‘a joined member.’ These members were put on a die having the cavity to fabricate the head of the rivet-like structure. Then FSF was conducted to form the stems and heads of the structure. Joint members are able to be stacked within the forming limit. In the study, the authors firstly conducted the proof of the concept (PoC) tests to generate rivet-like structure between steel and aluminum alloy plate and between CFRP and aluminum alloy plate, then investigated the forming conditions, i.e. tool feed rate, tool pass and the corresponding results, including the volume of the generated stem and head of the individual rivet-like structure. 3mm-thick A5083P-O aluminum alloy plates was utilized as the host member, and a 0.7mm-thick SPCE steel plate and a 0.8mm-thick CFRP plate as the joined members.

2020 ◽  
Vol 858 ◽  
pp. 33-38
Author(s):  
Takahiro Ohashi ◽  
Kenta Wakiyama ◽  
Hamed Mofidi Tabatabaei ◽  
Tadashi Nishihara

In this paper, the authors propose a design for the mechanical joining of dissimilar materials by employing rivet-like structures fabricated by friction-stir forming (FSF) considering the stress concentration on the joined material. The authors have utilized the FSF approach to generate rivet-like joints as follows. First, a substrate material (an aluminum alloy plate) was placed on a joined dissimilar-material plate containing prepared holes, i.e., a steel plate. Afterwards, these materials were placed on a die containing the cavity to fabricate the head of the rivet-like structure. FSF was then conducted to form the stems and heads of the rivet-like structure from the substrate material. Unlike conventional riveting, fastener was not considered necessary for the process; therefore, choosing different diameters of the prepared holes with multiple joints for the optimization of their structural design was easier. It is known that two auxiliary holes neighboring a main hole on either side reduce the stress concentration on the rim of the main hole. In this study, the authors applied the “round-hole-array design” on rivet-like joints fabricated by FSF. The authors examined the design of two smaller prepared holes with a commercial Finite element analysis (FEA) software for the rivet-like joint containing a 4 mm-diameter hole on a joined plate. To prove this, a 3 mm-thick A5083P-O aluminum alloy plate and a 0.7 mm-thick and 20 mm-wide SPCE steel plate was joined with the suggested design, and the strength and fracture of the joints were investigated using the tensile shear test. As a result, all joints were destroyed by the facture of the prepared holes, and it was confirmed that their strength was improved by the round-hole-array design.


2019 ◽  
Vol 803 ◽  
pp. 50-54
Author(s):  
Takahiro Ohashi ◽  
Kento Okuda ◽  
Hamed Mofidi Tabatabaei ◽  
Tadashi Nishihara

This paper provides a framework for the transcription of the surface of a mirror-finished die onto a metal plate by friction stir forming (FSF). In FSF, a material is put on a die, then friction stirring was conducted on its back surface for the transcription of the profile of the die onto the material. In this paper, a mirror-polished die of JIS SUS304 stainless steel with surface roughness Sz 0.014 mm and a probe-less friction-stirring tool in 18 mm shoulder diameter were employed for the experiment. A5083P-O aluminum plates, 3 mm thick, were utilized as base metals for the transcription. The authors varied tool spindle speed and tool feed rate to evaluate the forming results. Consequently, a mirror-finished surface under the friction-stirring tool was successfully transferred from the die to the aluminum alloy plate. The roughness of the base metal before processing was Sz 0.022 mm and that of the processed metal was Sz 0.012–0.016 mm. Higher spindle speed and faster feed rate resulted in a smoother surface; it is thought that high spindle speed and faster feed rate should be effective for higher contact pressure between a die and a material.


2017 ◽  
Vol 748 ◽  
pp. 202-206 ◽  
Author(s):  
Takahiro Ohashi ◽  
Hamed Mofidi Tabatabaei ◽  
Tadashi Nishihara

This paper describes utilization of friction-stir forming (FSF) to generate a single wall on an aluminum alloy plate. The proposed process is as follows. The authors placed a material plate on a die having a variable-width groove and conducted friction stirring on its back surface. The material filled the cavity due to high pressure and heat caused by friction stirring. This process can be applied to generate thermal plate-fins and rib structures. The present study investigates the forming conditions and the corresponding results including the height limit of walls to obtain reference data for applications. In the experiment, a 3mm-thick JIS A5083P-O aluminum plate was utilized as the substrate. With a grove of less than 0.2mm-width, the wall was difficult to generate. The maxim height of the 0.2mm-thick wall formed by FSF was 2.8mm, and its aspect ratio was 14, which was difficult to form using conventional forging. Overall, the relationship between groove width of the die cavity and aspect ratio of maximum wall height to wall thickness followed the fractional curvature. This results implies that the deformable material volume generated by friction stirring is a key factor for wall height.


2021 ◽  
Vol 1042 ◽  
pp. 3-8
Author(s):  
Mitsuhiro Watanabe ◽  
Shinpei Sasako

Dissimilar metal lap joining of A5052 aluminum alloy plate and C1100 pure copper plate was performed by using friction stir spot welding. The rotating welding tool, which was composed of a probe part and a shoulder part, was plunged from the aluminum alloy plate which was overlapped on the copper plate, and residual aluminum alloy thickness under the probe part of the welding tool after plunging of the welding tool was controlled in the range from 0 mm to 0.4 mm. The strength of the welding interface was evaluated by using tensile-shear test. Microstructure of the welding interface was examined by using an optical microscope and a field emission scanning electron microscope. The welding was achieved at the residual aluminum alloy thickness under the probe part of the welding tool below 0.3 mm. The welded area was formed at aluminum alloy/copper interface located under the probe part of the welding tool, and its width increased with decreasing the residual aluminum alloy thickness. A characteristic laminate structure was produced in the copper matrix near the welding interface. In the joint fabricated at the residual aluminum alloy thickness below 0.1 mm, hook of Cu was formed at edge of the welded area. The fracture did not occur at the welding interface. A remarkable improvement in strength was observed in the joint fabricated at the residual aluminum alloy thickness below 0.1 mm. The formation of laminate structure and hook is considered to result in joint strength improvement.


2017 ◽  
Vol 730 ◽  
pp. 253-258 ◽  
Author(s):  
Takahiro Ohashi ◽  
Hamed Mofidi Tabatabaei ◽  
Tadashi Nishihara

This paper reports friction-stir forming (FSF) of cylindrical pin embossments on JIS A5083 aluminum alloy medium gauge plate. A substrate material was put on an emboss die and conducted friction stirring on its back surface. The die has 1mm diameter and 0.5mm deep fine holes at 1.5mm pitch on its top, and the material successfully filled them due to high pressure and heat caused by friction stirring. Three tools having different shoulder diameter were utilized to investigate the deformable area with a single pass. As a consequence, faster spindle speed, slower tool feed rate, and larger tool shoulder contribute to a wider range of completely formed pins. Extrusion of the material to the die cavity seemed to be mostly limited under the area of the shoulder. The ratios of the band width of the complete pins to the shoulder diameter were increased with the larger diameter of the shoulder of the FSF tool. Therefore, a larger shoulder was more effective for wide-range embossing with a single pass. In addition, we evaluated the shape of formed pins with a non-contact 3D measurement system. Accuracy of the height of the completely formed pins was within ±0.013mm, which was comparable with machining.


2014 ◽  
Vol 590 ◽  
pp. 249-253 ◽  
Author(s):  
Chuan Hong Luo ◽  
Ting Chen ◽  
Wei Ping Peng

The joint of 2219-T6 aluminum alloy plate was obtained by friction stir welding, and the microstructures and mechanical properties of the joint were investigated. The causes of the weakened joint strength in friction stir welding were analyzed and summarized correspondingly. The tensile properties show that the transverse tensile strength of the joint can reach about 70% of the base metal and the elongation can reach about 7%. The main reason of the weakened strength is due to the plastic damage of metal, followed by the defects generated in the nugget zone and the growth of θ phase in the heat affected zone.


2016 ◽  
Vol 723 ◽  
pp. 148-153 ◽  
Author(s):  
Takahiro Ohashi ◽  
Hamed Mofidi Tabatabaei ◽  
Tetta Ikeya ◽  
Tadashi Nishihara

This paper proposes a new forming process for gear racks featuring a tooth-surface stiffening layer. The proposed process is as follows. First, a JIS A5083P aluminum alloy plate on which a surface modifier of WC particles and vaseline paste had been applied was put on a gear-rack die. Next, friction stirring was conducted on the back surface of the plate. The material then deformed and precisely filled the cavity of the die. WC particles were embedded into the surface of the aluminum alloy matrix due to high pressure and heat caused by friction stirring. The forming conditions and the corresponding results, including the distribution of WC perticles on the tooth surface, are investigated in the study. WC particles were embedded near the surface mechanically, and only a very few particles were observed inside the matrix. With an undefill condition, WC particles are concentrated on the rear surface of the tooth, which contacts the tail side of the die. In contrast, No significant particle density differences were observed among the profile of teeth with a fully filled condition in the die cavity.


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