Joining of Aluminium Alloy and Mild Steel Sheets Using Mechanical Clinching

2007 ◽  
Vol 561-565 ◽  
pp. 1043-1046 ◽  
Author(s):  
Y. Abe ◽  
T. Kato ◽  
Kenichiro Mori
Keyword(s):  
Mild Steel ◽  
Aluminium Alloy ◽  
Deformation Behaviour ◽  
Sheet Thickness ◽  
Alloy Sheet ◽  
Total Thickness ◽  
Steel Sheets ◽  
Lower Sheet ◽  
Mechanical Clinching ◽  
The Difference

The aluminium alloy and mild steel sheets were joined with mechanical clinching. Deforming behaviour of the two sheets during the clinching was observed from finite element simulation and an experiment to avoid defects. The fracture of the upper sheet, necking and separation are caused by the small upper sheet thickness in the thick total thickness, the small lower sheet thickness in the thick total thickness and the small lower sheet thickness, respectively. The joining range for the combination of the upper aluminium alloy sheet of and the lower steel sheet of is larger than that of the reverse combination. The effect of the difference between the flow stresses of the two sheets on the deformation behaviour was examined.

scholarly journals Mechanical clinching and self-pierce riveting for sheet combination of 780-MPa high-strength steel and aluminium alloy A5052 sheets and durability on salt spray test of joints

2021 ◽  
Vol 113 (1-2) ◽  
pp. 59-72
Author(s):  
Yohei Abe ◽  
Ken-ichiro Mori
Keyword(s):  
Aluminium Alloy ◽  
High Strength Steel ◽  
Salt Spray ◽  
High Strength ◽  
Alloy Sheet ◽  
Galvanized Steel ◽  
Load Reduction ◽  
Minimum Thickness ◽  
Steel Sheets ◽  
Mechanical Clinching

AbstractTo increase the usage of high-strength steel and aluminium alloy sheets for lightweight automobile body panels, the joinability of sheet combinations including a 780-MPa high-strength steel and an aluminium alloy A5052 sheets by mechanical clinching and self-pierce riveting was investigated for different tool shapes in an experiment. All the sheet combinations except for the two steel sheets by self-pierce riveting, i.e., the two steel sheets, the two aluminium alloy sheets, and the steel-aluminium alloy sheets, were successfully joined by both the joining methods without the gaps among the rivet and the sheets. Then, to show the durability of the joined sheets, the corrosion behaviour and the joint strength of the aged sheets by a salt spray test were measured. The corrosion and the load reduction of the clinched and the riveted two aluminium alloy sheets were little. The corrosion of the clinched two steel sheets without the galvanized layer progressed, and then the load after 1176 h decreased by 85%. In the clinched two galvanized steel sheets, the corrosion progress slowed down by 24%. In the clinched steel and aluminium alloy sheets, the thickness reduction occurred near the minimum thickness of the upper sheet and in the upper surface on the edge of the lower aluminium alloy sheet, whereas the top surface of the upper sheet and the upper surface of the lower sheet were mainly corroded in the riveted joint. The load reduction was caused by the two thickness reductions, i.e., the reduction in the minimum thickness of the upper sheet and the reduction in the flange of the aluminium alloy sheet. Although the load of the clinched steel without the galvanized coating layer and aluminium alloy sheets decreased by about 20%, the use of the galvanized steel sheet brought the decrease by about 11%. It was found that the use of the galvanized steel sheets is effective for the decrease of strength reduction due to corrosion.

scholarly journals Mechanical Clinching and Self-Pierce Riveting of Thin Three Sheets of 5000 Series Aluminium Alloy and 980 MPa Grade Cold Rolled Ultra-High Strength Steel

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 4741
Author(s):  
Yohei Abe ◽  
Takato Maeda ◽  
Daiki Yoshioka ◽  
Ken-ichiro Mori
Keyword(s):  
Finite Element ◽  
Aluminium Alloy ◽  
High Strength ◽  
Alloy Sheet ◽  
Steel Sheets ◽  
Element Simulation ◽  
Ultra High Strength Steel ◽  
Mechanical Clinching ◽  
Cold Rolled ◽  
Three Sheets

One thin 5000 series aluminium alloy sheet and two thin 980 MPa grade cold rolled ultra-high strength steel sheets were joined by self-pierce riveting and mechanical clinching processes. The joinabilities for a combination of the aluminium and steel sheets in both processes were investigated for different die shapes in the experiment and finite element simulation. In self-pierce riveting, the three sheets were successfully joined for both combinations of the upper and lower aluminium alloy sheets by optimizing the shapes of a die and rivet. In mechanical clinching, the three sheets were successfully joined by an optimum die for the configuration of the upper aluminium alloy sheet. On the other hand, the three sheets for the configuration of the lower aluminium alloy sheet were not joined even by optimizing the die shape in the both finite element simulation and experiment, because the material flow of the steel sheets was insufficient to form the two interlocks. The tension-shear loads for the clinched and riveted sheets with the adhesive were almost the same, because the load for the adhesive was the highest. In the cross-tension test, however, the load by the adhesive was comparatively small.

Finite Element Simulation of Self-Piercing Riveting of Three Aluminium Alloy Sheets

2007 ◽  
Vol 340-341 ◽  
pp. 1461-1466 ◽  
Author(s):  
T. Kato ◽  
Y. Abe ◽  
Kenichiro Mori
Keyword(s):  
Finite Element ◽  
Aluminium Alloy ◽  
Finite Element Simulation ◽  
Resistance Welding ◽  
Total Thickness ◽  
Steel Sheets ◽  
Lower Sheet ◽  
Element Simulation ◽  
Simulation And Experiment ◽  
Cross Tension

The joinability of three aluminium alloy sheets using a self-piercing rivet was evaluated from a finite element simulation and experiment. The self-piercing riveting is hopeful as replacement of spot resistance welding generally used for steel sheets, because it is not easy to apply the resistance welding to joining of three aluminium alloy sheets due to the high thermal conductivity. Defects in the riveting are categorized into the penetration through the lower sheet, the necking of the lower sheet and the short overlap of sheets to obtain optimum joining conditions. The penetration and the necking are caused by small total thickness. The short overlap tends to occur as the ratio of lower sheet and total thickness is small. In addition, the cross-tension test was simulated by the finite element method to evaluate the joint strength.

Effect of hook characteristics on the fracture behaviour of dissimilar friction stir welded aluminium alloy and mild steel sheets

2018 ◽  
Vol 24 (2) ◽  
pp. 178-184 ◽  
Author(s):  
Tianhao Wang ◽  
Harpreet Sidhar ◽  
Rajiv S. Mishra ◽  
Yuri Hovanski ◽  
Piyush Upadhyay ◽  
...  
Keyword(s):  
Mild Steel ◽  
Aluminium Alloy ◽  
Fracture Behaviour ◽  
Friction Stir ◽  
Steel Sheets

scholarly journals CLINCHING HOT-DIP GALVANIZED STEEL COMBINED WITH ALUMINIUM ALLOY

2015 ◽  
Vol 21 (4) ◽  
pp. 321 ◽  
Author(s):  
Emil Spisak ◽  
Lubos Kascak ◽  
Rene Kubik ◽  
Janka Majernikova
Keyword(s):  
Aluminium Alloy ◽  
Aluminium Alloys ◽  
High Performance ◽  
Galvanized Steel ◽  
Metallographic Analysis ◽  
Steel Sheets ◽  
Mechanical Clinching ◽  
Alternative Techniques ◽  
Body Production ◽  
Joining Process

<p class="AMSmaintext">Combination of steel sheets and aluminium alloys in components are widely used in various industrial areas because of their high performance. At times it is not possible to join this material combination utilizing conventional joining techniques, especially welding methods, therefore other alternative techniques are developed. One of the alternatives are mechanical clinching as a cold joining process. The paper evaluates the properties of clinched joints. The following materials utilized in automotive industry in car body production were used in the joining process: hot-dip galvanized steel sheet H220PD (thickness of 0.8 mm) and aluminium alloys EN AW 5754 (0.8 mm). The following tests were performed to evaluate the properties of the clinched joints: tension test – to determine the load bearing capacities and the force-elongation diagrams; microhardness test – to determine the changes in the materials joined by clinching; and a metallographic analysis observing the clinched joints’ structures. Clinching proved to be suitable methods for joining the observed combination of hot-dip galvanized steel and aluminium alloy.</p>

An Experimental Study on 3D Forming of Sheet Metal Using Plasma Arc

2005 ◽  
Vol 475-479 ◽  
pp. 3943-3946 ◽  
Author(s):  
Wen Ji Xu ◽  
Jian Cheng Fang ◽  
F. Liu ◽  
Gui Bing Pang
Keyword(s):  
Experimental Study ◽  
Mild Steel ◽  
Sheet Metal ◽  
Experimental Results ◽  
Plasma Arc ◽  
Flexible Forming ◽  
Steel Sheets ◽  
The Future ◽  
The Difference ◽  
Linear Scanning

For the development of flexible forming using plasma arc (FFUPA), it is extremely necessary to investigate the forming rules of curvilinear scanning and multipath combined scanning. In this paper, the difference between circular scanning and linear scanning and the influence of sheet metal geometry on forming effect have been discussed. In the experiments, circle, ring and rectangle mild steel sheets with thickness of 0.8mm are taken as workpieces and the experimental results show that nonlinear prolonged surface can be obtained by curvilinear scanning and there exists the obvious difference between circular scanning and linear scanning. Afterwards, the reason of the difference mentioned above is concisely analyzed. Finally, some suggestions are presented for the future investigation.

Sign in / Sign up

Export Citation Format

Share Document