Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design

Hui Huang; Yong Chae Lim; Yiyu Wang; Yuan Li; Zhili Feng

doi:10.3390/jmmp7060216

Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design

Hui Huang, Yong Chae Lim, Yiyu Wang, Yuan Li, Zhili Feng

Materials Joining

Research output: Contribution to journal › Article › peer-review

1 Scopus citations

Abstract

Unique friction-based self-piercing riveting (F-SPR) was employed to join high-strength, low-ductility aluminum alloy 7055 for lightweight vehicle applications. This study aimed to maximize the joint strength of the AA7055 F-SPR joint while avoiding cracking issues due to low ductility at room temperature. A fully coupled Eulerian–Lagrangian (CEL) model was employed to predict the process temperature during F-SPR, and the temperature field was then mapped onto a 2D axisymmetric equivalent model for accelerated numerical analysis. The geometry, dimensions, and material strength of the rivet, as well as the depth of the die cavity and plunging depth, were investigated to enhance joint formation. Also, a static finite-element analysis model was developed to predict and analyze the stress distribution in the rivet under different mechanical testing loading conditions. Overall, the numerical model showed good agreement with the experiment results, such as joint formation and mechanical joint strength. With the aid of virtual fabrication through numerical modeling, the joint design iterations and process development time of F-SPR were greatly reduced regarding the goal of lightweight, high-strength aluminum joining.

Original language	English
Article number	216
Journal	Journal of Manufacturing and Materials Processing
Volume	7
Issue number	6
DOIs	https://doi.org/10.3390/jmmp7060216
State	Published - Dec 2023

Funding

This manuscript was authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. The DOE will provide public access to the results of this federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan (accessed on 20 November 2023)). U.S. Department of Energy Office of Energy Efficiency and Renewable Energy, Vehicle Technology Office under contract DE-AC05-00OR22725.

Funders	Funder number
U.S. Department of Energy Office of Energy Efficiency and Renewable Energy, Vehicle Technology Office	DE-AC05-00OR22725
U.S. Department of Energy

Keywords

crack-free joint
friction self-piercing riveting
high-strength
interlocking distance
low-ductility aluminum alloy
numerical modeling
solid-state joining

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10.3390/jmmp7060216

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@article{338c704d8ddc436d9699cecfd0f4e692,

title = "Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design",

abstract = "Unique friction-based self-piercing riveting (F-SPR) was employed to join high-strength, low-ductility aluminum alloy 7055 for lightweight vehicle applications. This study aimed to maximize the joint strength of the AA7055 F-SPR joint while avoiding cracking issues due to low ductility at room temperature. A fully coupled Eulerian–Lagrangian (CEL) model was employed to predict the process temperature during F-SPR, and the temperature field was then mapped onto a 2D axisymmetric equivalent model for accelerated numerical analysis. The geometry, dimensions, and material strength of the rivet, as well as the depth of the die cavity and plunging depth, were investigated to enhance joint formation. Also, a static finite-element analysis model was developed to predict and analyze the stress distribution in the rivet under different mechanical testing loading conditions. Overall, the numerical model showed good agreement with the experiment results, such as joint formation and mechanical joint strength. With the aid of virtual fabrication through numerical modeling, the joint design iterations and process development time of F-SPR were greatly reduced regarding the goal of lightweight, high-strength aluminum joining.",

keywords = "crack-free joint, friction self-piercing riveting, high-strength, interlocking distance, low-ductility aluminum alloy, numerical modeling, solid-state joining",

author = "Hui Huang and Lim, {Yong Chae} and Yiyu Wang and Yuan Li and Zhili Feng",

note = "Publisher Copyright: {\textcopyright} 2023 by the authors.",

year = "2023",

month = dec,

doi = "10.3390/jmmp7060216",

language = "English",

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AU - Huang, Hui

AU - Lim, Yong Chae

AU - Wang, Yiyu

AU - Li, Yuan

AU - Feng, Zhili

PY - 2023/12

Y1 - 2023/12

N2 - Unique friction-based self-piercing riveting (F-SPR) was employed to join high-strength, low-ductility aluminum alloy 7055 for lightweight vehicle applications. This study aimed to maximize the joint strength of the AA7055 F-SPR joint while avoiding cracking issues due to low ductility at room temperature. A fully coupled Eulerian–Lagrangian (CEL) model was employed to predict the process temperature during F-SPR, and the temperature field was then mapped onto a 2D axisymmetric equivalent model for accelerated numerical analysis. The geometry, dimensions, and material strength of the rivet, as well as the depth of the die cavity and plunging depth, were investigated to enhance joint formation. Also, a static finite-element analysis model was developed to predict and analyze the stress distribution in the rivet under different mechanical testing loading conditions. Overall, the numerical model showed good agreement with the experiment results, such as joint formation and mechanical joint strength. With the aid of virtual fabrication through numerical modeling, the joint design iterations and process development time of F-SPR were greatly reduced regarding the goal of lightweight, high-strength aluminum joining.

AB - Unique friction-based self-piercing riveting (F-SPR) was employed to join high-strength, low-ductility aluminum alloy 7055 for lightweight vehicle applications. This study aimed to maximize the joint strength of the AA7055 F-SPR joint while avoiding cracking issues due to low ductility at room temperature. A fully coupled Eulerian–Lagrangian (CEL) model was employed to predict the process temperature during F-SPR, and the temperature field was then mapped onto a 2D axisymmetric equivalent model for accelerated numerical analysis. The geometry, dimensions, and material strength of the rivet, as well as the depth of the die cavity and plunging depth, were investigated to enhance joint formation. Also, a static finite-element analysis model was developed to predict and analyze the stress distribution in the rivet under different mechanical testing loading conditions. Overall, the numerical model showed good agreement with the experiment results, such as joint formation and mechanical joint strength. With the aid of virtual fabrication through numerical modeling, the joint design iterations and process development time of F-SPR were greatly reduced regarding the goal of lightweight, high-strength aluminum joining.

KW - crack-free joint

KW - friction self-piercing riveting

KW - high-strength

KW - interlocking distance

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KW - numerical modeling

KW - solid-state joining

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ER -

Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design

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