AA7xxx series aluminum alloys have great potentials in mass saving of vehicle bodies due to pretty high specific strength. However, the use of these high strength materials poses significant challenges to the traditional self-piercing riveting (SPR) process. To address this issue, a novel process, friction self-piercing riveting (F-SPR), was applied to join aluminum alloy AA7075-T6 sheets. The effects of the spindle speed and rivet feed rate on F-SPR joint cross section geometry evolution, riveting force, and energy input were investigated systematically. It was found that the rivet shank deformation, especially the buckling of the shank tip before penetrating through the top sheet, has significant influence on geometry and lap shear failure mode of the final joint. A medium rivet feed rate combined with a high spindle speed was prone to produce a defect-free joint with sound mechanical interlocking. F-SPR joints with the failure mode of rivet shear fracture were observed to have superior lap shear peak load and energy absorption over the joints with mechanical interlock failure. The optimized F-SPR joint in this study exhibited 67.6% and 13.9% greater lap shear peak load compared with SPR and refill friction stir spot welding joints, respectively, of the same sheets. This research provides a valuable reference for further understanding the F-SPR process.
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April 2019
Research-Article
Joint Formation and Mechanical Performance of Friction Self-Piercing Riveted Aluminum Alloy AA7075-T6 Joints
Yun Wu Ma,
Yun Wu Ma
Shanghai Key Laboratory of Digital Manufacture for Thin-Walled Structures,
State Key Laboratory of Mechanical System and Vibration,
Shanghai 200240,
e-mail: myw3337@sjtu.edu.cn
State Key Laboratory of Mechanical System and Vibration,
Shanghai Jiao Tong University
,Shanghai 200240,
PR China
e-mail: myw3337@sjtu.edu.cn
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Yong Bing Li,
Yong Bing Li
1
Shanghai Key Laboratory of Digital Manufacture for Thin-Walled Structures,
State Key Laboratory of Mechanical System and Vibration,
Shanghai 200240,
e-mail: yongbinglee@sjtu.edu.cn
State Key Laboratory of Mechanical System and Vibration,
Shanghai Jiao Tong University
,Shanghai 200240,
PR China
e-mail: yongbinglee@sjtu.edu.cn
1Corresponding author.
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Zhong Qin Lin
Zhong Qin Lin
Shanghai Key Laboratory of Digital Manufacture for Thin-Walled Structures,
State Key Laboratory of Mechanical System and Vibration,
Shanghai 200240,
e-mail: zqlin@sjtu.edu.cn
State Key Laboratory of Mechanical System and Vibration,
Shanghai Jiao Tong University
,Shanghai 200240,
PR China
e-mail: zqlin@sjtu.edu.cn
Search for other works by this author on:
Yun Wu Ma
Shanghai Key Laboratory of Digital Manufacture for Thin-Walled Structures,
State Key Laboratory of Mechanical System and Vibration,
Shanghai 200240,
e-mail: myw3337@sjtu.edu.cn
State Key Laboratory of Mechanical System and Vibration,
Shanghai Jiao Tong University
,Shanghai 200240,
PR China
e-mail: myw3337@sjtu.edu.cn
Yong Bing Li
Shanghai Key Laboratory of Digital Manufacture for Thin-Walled Structures,
State Key Laboratory of Mechanical System and Vibration,
Shanghai 200240,
e-mail: yongbinglee@sjtu.edu.cn
State Key Laboratory of Mechanical System and Vibration,
Shanghai Jiao Tong University
,Shanghai 200240,
PR China
e-mail: yongbinglee@sjtu.edu.cn
Zhong Qin Lin
Shanghai Key Laboratory of Digital Manufacture for Thin-Walled Structures,
State Key Laboratory of Mechanical System and Vibration,
Shanghai 200240,
e-mail: zqlin@sjtu.edu.cn
State Key Laboratory of Mechanical System and Vibration,
Shanghai Jiao Tong University
,Shanghai 200240,
PR China
e-mail: zqlin@sjtu.edu.cn
1Corresponding author.
Manuscript received April 3, 2018; final manuscript received December 23, 2018; published online February 27, 2019. Assoc. Editor: Gracious Ngaile.
J. Manuf. Sci. Eng. Apr 2019, 141(4): 041005 (11 pages)
Published Online: February 27, 2019
Article history
Received:
April 3, 2018
Revision Received:
December 23, 2018
Accepted:
December 23, 2018
Citation
Ma, Y. W., Li, Y. B., and Lin, Z. Q. (February 27, 2019). "Joint Formation and Mechanical Performance of Friction Self-Piercing Riveted Aluminum Alloy AA7075-T6 Joints." ASME. J. Manuf. Sci. Eng. April 2019; 141(4): 041005. https://doi.org/10.1115/1.4042568
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