scholarly journals Specimen's Geometry Related Influences on Load-Bearing Capacity of Joining Aluminium and UHSS by Innovative Shear-Clinching

2017 ◽  
Vol 6 (4) ◽  
pp. 19 ◽  
Author(s):  
Rejane Horhold ◽  
Martin Muller ◽  
Marion Merklein ◽  
Gerson Meschut
Keyword(s):  
Lightweight Design ◽  
High Strength ◽  
Single Step ◽  
Economic Conditions ◽  
Automotive Body ◽  
Joining Technology ◽  
Strength Capacity ◽  
Body In White ◽  
Design Requirements ◽  
Manganese Steels

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.

High Strength Aluminium Sheet Metal Joining by Resistance Spot Welding

2013 ◽  
Vol 765 ◽  
pp. 761-765 ◽  
Author(s):  
Rudolf Gradinger ◽  
Nikolay Sotirov ◽  
Gottfried Rettenbacher ◽  
Christoph Pangerl ◽  
Philipp Dörner ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Spot Welding ◽  
Elevated Temperatures ◽  
Stable Process ◽  
High Strength ◽  
Automotive Body ◽  
Aerospace Applications ◽  
Joining Technology ◽  
Body In White ◽  
Opening Up

Aluminium AA7075 is well known as extrusions, plate or sheet metal predominately in aerospace applications. The continuing efforts for reducing the weight but still maintaining the safety of vehicle structures are opening up the way for this alloy in automotive applications. Since this branch is very different to space as well as aircraft industries in manufacturing methods, costs and production numbers, the development of appropriate processes is necessary. After showing a high potential for deep drawing of AA7075 sheets under elevated temperatures, the joining technology options are now under investigation too. Since spot welding is very common in automotive body-in-white manufacturing, an innovative version of this process is evaluated for applicability for welding AA7075-T6 sheets to each other and to proven automotive aluminium alloys. The results of sample weldments, including mechanical static strength, micrographs, hardness, radiography and parameters for a stable process range, are presented.

Fatigue life performance of multi-material connections hybrid joined by self-piercing rivets and adhesive

2020 ◽  
Vol 62 (10) ◽  
pp. 973-978
Author(s):  
Jan Presse ◽  
Thorsten Michler ◽  
Boris Künkler
Keyword(s):  
Fatigue Life ◽  
Lightweight Design ◽  
Sheet Thickness ◽  
High Strength ◽  
Material Design ◽  
Design Solution ◽  
Cyclic Loads ◽  
Dp Steel ◽  
Joining Technology ◽  
Structural Adhesive

Abstract The multi-material design presented contains EN AW-6016 aluminum and high strength CR330Y590T-DP steel. This dissimilar combination is an example of an affordable lightweight design solution, but it requires an adapted joining technology. Hybrid joining technologies such as selfpiercing riveting (SPR) in combination with a structural adhesive enables an assembly of such dissimilar material combinations. In addition to higher manufacturing costs for mechanical joining the design process still requires a great amount of effort. This study provides a simple approach for assessing hybrid joined multi-material connections. Therefore, tests for several combinations of the most relevant parameters on fatigue life (material properties, sheet thickness, load cases) were performed under quasi-static and cyclic loads. Based on the data acquired, it is shown that the fatigue life of hybrid joined connections can be estimated by superposing the contributing fatigue life of purely SPR and purely adhesive joints.

Process Feasibility Analysis of Self-Pierce Riveting High Strength Low Alloy Steel

2010 ◽  
Author(s):  
L. Han ◽  
M. Thornton ◽  
R. Hewitt ◽  
A. Chrysanthou ◽  
M. Shergold
Keyword(s):  
Spot Welding ◽  
Hsla Steel ◽  
Sheet Material ◽  
Dissimilar Materials ◽  
High Strength ◽  
Feasibility Analysis ◽  
Low Alloy Steel ◽  
Automotive Body ◽  
Body In White ◽  
Selection Of

Self-Piercing Riveting (SPR) has been widely used in automotive Body in White (BIW) assembly as an alternative to Resistance Spot Welding (RSW), in particular for joining of dissimilar materials, for example Steels to Aluminium. A study examining the process feasibility of SPR of Aluminium alloy AA5754 and High Strength Low Alloy (HSLA) steel in various thicknesses has been conducted. It has been shown that the process is capable of joining the two materials together. However, it was also observed that the selection of rivet and die is limited when joining HSLA. The setting force required to drive the rivet into the sheet material to be joined tends to be high. This leads to potential tooling life concerns. It was also shown that the arrangement of the high strength steel joined to aluminium can have a significant effect on the process feasibility.

scholarly journals Joining of ultra-high-strength steels using resistance element welding on conventional resistance spot welding guns

2021 ◽  
Author(s):  
Heinrich Günter ◽  
Gerson Meschut
Keyword(s):  
Spot Welding ◽  
Welding Process ◽  
High Strength Steels ◽  
High Strength ◽  
Tensile Tests ◽  
Single Step ◽  
Joining Technology ◽  
Joint Properties ◽  
Resistance Element Welding ◽  
Ultra High Strength Steels

AbstractSingle-step joining of dissimilar material combinations between ultra-high-strength steels and high-strength aluminium alloys with sufficient mechanical joint properties by using conventional resistance spot welding equipment has not been reported yet. In this research paper, a novel single-step joining technology, so-called self-penetrating resistance element welding, is introduced. First, the motivation for this novel joining technology, the state of the art in joining, and the process characteristics are presented. In the results section, the welding rivet geometry is first determined using forming simulations and validated by head tensile tests. Followed by the description of the welding process and its characteristics, the mechanical joint properties are reported. The results show that a numerically optimised welding rivet geometry can guarantee sufficient joint strength. By this welding rivet geometry, a thermally assisted penetration of aluminium and therefore welding to steel is possible with and without adhesive. Furthermore, it is shown that the welding process can be designed by means of simulations. Finally, the shear tensile tests prove that an overall sufficient joint strength is ensured.

Experimental Analysis of Static Stiffness for Vehicle Body in White

2012 ◽  
Vol 248 ◽  
pp. 69-73 ◽  
Author(s):  
Shu Ming Chen ◽  
Xue Wei Song ◽  
Chuan Liang Shen ◽  
Deng Feng Wang ◽  
Wei Li
Keyword(s):  
Test Bench ◽  
Bending Stiffness ◽  
Torsional Stiffness ◽  
Vehicle Body ◽  
Torsional Angle ◽  
Static Stiffness ◽  
Torsional Deformation ◽  
Automotive Body ◽  
Body In White ◽  
Stiffness Characteristics

In order to know the static stiffness characteristics of the vehicle body in white, the bending stiffness and torsional stiffness of an automotive body in white were tested on a test bench of the static stiffness of an automotive BIW. The bending stiffness and bending deformation of the bottom of the BIW were determined. Also, the torsional stiffness and torsional deformation of the bottom of the BIW were obtained. The fitting curves and equations between loading torque and torsional angle were acquired at clockwise and counterclockwise loading, respectively.

Relationship between Microstructure and Mechanical Properties in Q&P-Steels

2016 ◽  
Vol 879 ◽  
pp. 1933-1938 ◽  
Author(s):  
Richard G. Thiessen ◽  
Georg Paul ◽  
Roland Sebald
Keyword(s):  
Mechanical Properties ◽  
Dual Phase Steel ◽  
High Strength Steels ◽  
High Strength ◽  
The Body ◽  
Advanced High Strength Steels ◽  
Passenger Safety ◽  
Back Scattering ◽  
Body In White ◽  
Expected Increase

Third-Generation advanced high strength steels are being developed with the goal of reducing the body-in-white weight while simultaneously increasing passenger safety. This requires not only the expected increase in strength and elongation, but also improved local formability. Optimizing elongation and formability were often contradictory goals in dual-phase steel developments. Recent results have shown that so-called "quench and partitioning" (Q&P) concepts can satisfy both requirements [1]. Many Q&P-concepts have been studied at thyssenkrupp Steel Europe. Thorough investigation of the microstructure has revealed relationships between features such as the amount, morphology and chemical stability of the retained austenite and the obtained mechanical properties. An evaluation of the lattice strain by means of electron-back-scattering-diffraction has also yielded a correlation to the obtained formability. The aim of this work is to present the interconnection between these microstructural features and propose hypotheses for the explanation of how these features influence the macroscopically observed properties.

Sign in / Sign up

Export Citation Format

Share Document