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Rivet types widening12/28/2023 ![]() ![]() In modern car body manufacturing, mechanical joining is usually combined with adhesive bonding to improve both static and dynamic properties of the joints. However, intermetallic phases are completely absent in mechanical joining based on plastic deformation of the components at room temperature, such as self-piercing riveting (SPR), mechanical clinching and hemming (Ref 10, 11, 12). However, the thermally-induced formation of coarse-grained, layered intermetallic phases at the welding spot, which are susceptible to crack propagation, makes this process unsuitable for joining aluminum alloys with steels in series production (Ref 5, 6).įormation of brittle intermetallic phases in aluminum-to-steel welding can be suppressed by means of other welding technologies (Ref 7, 8, 9). Resistance spot welding (RSW) has predominantly been used as standard process for joining steels in the automotive industry (Ref 4). Integrating dissimilar materials in lightweight car bodies requires reliable and cost-efficient joining processes (Ref 3). In this context, a common approach is to substitute conventional mild steels with high-strength steels (HSS) and with aluminum alloys in the body-in-white (BIW), but without diminishing the crashworthiness of cars for maintaining the passenger safety (Ref 2). Multi-material lightweight design of car bodies can substantially contribute to improve the efficiency of fossil fuels and thus to reduce CO 2 emissions. In recent decades, reducing greenhouse gases in order to limit global warming has emerged as greatest ecological challenge for the modern transportation sector (Ref 1). Good agreement of joint cross sections and force-displacement curves between experiments and simulations confirms that the presented numerical model of riv-bonding is suitable for predicting both the joinability of aluminum alloys with HSS and the final quality of hybrid joints. The viscoelastic properties of the liquid adhesive layer between the sheets were substituted with “equivalent” elastoplastic properties to model the adhesive as solid with strain rate-dependent flow behavior. ![]() ![]() Moreover, riv-bonding of two joint configurations was exemplarily modeled using the Simufact Forming finite element (FE) software. Therefore, riv-bonding of four joint configurations including different aluminum alloy sheets (AW-6014-PX, AW-6451-T4), HSS sheets (HC420LA, HC450X) and rivet types (C5.3×8.0-H4, U5.5×5.0-H6) was experimentally investigated. In order to exploit the advantages offered by multi-material design, this work studies the feasibility of joining aluminum alloys with high-strength steels (HSS) against the favorable joining direction by using self-piercing riveting (SPR) combined with adhesive bonding, so-called riv-bonding. ![]()
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