Residual Stresses and Plastic Deformation in Self-Pierce Riveting of Dissimilar Aluminum-to-Magnesium Alloys

J. F.C. Moraes, J. B. Jordon, Xuming Su, Luke N. Brewer, Brian J. Fay, J. R. Bunn, Lindsay Sochalski-Kolbus, M. E. Barkey

Research output: Contribution to journalArticlepeer-review

11 Scopus citations

Abstract

In this work, the complex relationship between deformation history and residual stresses in a magnesium-to-aluminum self-pierce riveted (SPR) joint is elucidated using numerical and experimental approaches. Non-linear finite element (FE) simulations incorporating strain rate and temperature effects were performed to model the deformation in the SPR process. In order to accurately capture the deformation, a stress triaxiality-based damage material model was employed to capture the sheet piercing from the rivet. Strong visual comparison between the physical cross-section of the SPR joint and the simulation was achieved. To aid in understanding of the role of deformation in the riveting process and to validate the modeling approach, several experimental measurements were conducted. To quantify the plastic deformation from the piercing of the rivet, micro hardness mapping was performed on a cross-section of the SPR joint. The FE model showed very strong correlation to the experimental hardness mapping results suggesting the nonlinear model captured the plastic deformation with high accuracy. To measure the elastic residual stresses in the SPR joint, neutron and x-ray diffraction mapping techniques were conducted and in general, the FE model correlated well to the trends and magnitudes of the elastic stresses. While some error occurred in between the model and the neutron and x-ray diffraction results, the numerical approach developed in this study shows potential as a tool for understanding SPR behavior as well as optimizing the process parameters.

Original languageEnglish
JournalSAE International Journal of Materials and Manufacturing
Volume11
Issue number2
DOIs
StatePublished - 2018

Funding

The authors would like to recognize of the United States Auto- motive Materials partnership (USAMP) Magnesium Front End R&D project, including Joy Forsmark, Allan Luo, Jim Quinn, A.K. Khosrovaneh, M. Guo, Yung-Li lee, and Robert McCune, for their helpful discussions. This material is based upon work supported by the Department of Energy, National Energy Technology Laboratory under Award Number No. DE-EE0005660. This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. Such support does not constitute an endorsement by the Department of Energy of the work or the views expressed herein. This work utilized resources owned and maintained by the Central Analytical Facility, which is supported by The University of Alabama.

Keywords

  • Finite element analysis
  • Plastic deformation
  • Residual stresses
  • Self-pierce riveting

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