Scale-Up of Friction Self-piercing Riveting Process for Multi-material Joints

Yong Chae Lim; Tianzhao Wang; Yiyu Wang; Jeremy Slade; Sammy Ojo; Zhili Feng

doi:10.1007/978-3-031-80896-8_22

Scale-Up of Friction Self-piercing Riveting Process for Multi-material Joints

Yong Chae Lim, Tianzhao Wang, Yiyu Wang, Jeremy Slade, Sammy Ojo, Zhili Feng

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

1 Scopus citations

Abstract

A single-class joiningJoiningprocess known asFriction self-piercing riveting “friction self-piercing riveting (F-SPR)” has been developed for joiningJoining various low-ductility lightweight materials on a laboratory scale. The frictional heat generated during the F-SPR process improved local ductility, resulting in crack-free joints and robust mechanical performance. This innovative joiningJoining technology was further advanced through the scale-up of the process using a new system with several key features (e.g., automatic rivet feeding and clamping system, vacuum system) toward industry readiness. The new integrated F-SPR systems were effectively demonstrated for joiningJoining different material combinations (e.g., carbon fiber composite to 7075 Al alloy, 7075 Al alloy to 7075 Al alloy, and 7075 Al alloy to casting AlCasting Al Aural 5) with a unified technique. Crack-free jointCrack free joint with adequate mechanical interlocking resulted in good mechanical joint strength for each material combination. Then, the process was successfully scaled up by producing multiple joints without any cracks on larger CFC-Al and Al-Al components by the new integrated system, bringing it closer to industrial application.

Original language	English
Title of host publication	Friction Stir Welding and Processing XIII
Editors	Yuri Hovanski, Yutaka Sato, Piyush Upadhyay, Nilesh Kumar, Anton A. Naumov
Publisher	Springer Science and Business Media Deutschland GmbH
Pages	255-263
Number of pages	9
ISBN (Print)	9783031808951
DOIs	https://doi.org/10.1007/978-3-031-80896-8_22
State	Published - 2025
Event	13th symposium on Friction Stir Welding and Processing, FSWP 2025, held as part of the TMS Annual Meeting and Exhibition, TMS 2025 - Las Vegas, United States Duration: Mar 23 2025 → Mar 27 2025

Publication series

Name	Minerals, Metals and Materials Series
ISSN (Print)	2367-1181
ISSN (Electronic)	2367-1696

Conference

Conference	13th symposium on Friction Stir Welding and Processing, FSWP 2025, held as part of the TMS Annual Meeting and Exhibition, TMS 2025
Country/Territory	United States
City	Las Vegas
Period	03/23/25 → 03/27/25

Funding

This research was financially sponsored by the US Department Energy, Vehicle Technologies Office, as part of the Joining Core Program. Oak Ridge National Laboratory is managed by UT-Battelle, LLC, for the US Department of Energy under Contract DE-AC05-00OR22725. The authors sincerely thank Alan Frederick and Jack Ward Jr. from the Materials Joining Group for their technical support. The authors also express their gratitude to Eric Boettcher at Honda R&D America for his technical guidance and to Ford Motor for supplying the casting Al Aural 5. Notice: This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with theUS Department of Energy (DOE). The US government retains and the publisher, by accepting the article forpublication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide licenseto publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes.DOE will provide public access to these results of federally sponsored research in accordance with the DOE PublicAccess Plan (http://energy.gov/downloads/doe-public-access-plan).

Keywords

7xxx Al
Carbon fiber reinforced polymer
Casting Al
Crack-free joint
Friction self-piercing riveting

Access to Document

10.1007/978-3-031-80896-8_22

Cite this

Lim, Y. C., Wang, T., Wang, Y., Slade, J., Ojo, S., & Feng, Z. (2025). Scale-Up of Friction Self-piercing Riveting Process for Multi-material Joints. In Y. Hovanski, Y. Sato, P. Upadhyay, N. Kumar, & A. A. Naumov (Eds.), Friction Stir Welding and Processing XIII (pp. 255-263). (Minerals, Metals and Materials Series). Springer Science and Business Media Deutschland GmbH. https://doi.org/10.1007/978-3-031-80896-8_22

Lim, Yong Chae ; Wang, Tianzhao ; Wang, Yiyu et al. / Scale-Up of Friction Self-piercing Riveting Process for Multi-material Joints. Friction Stir Welding and Processing XIII. editor / Yuri Hovanski ; Yutaka Sato ; Piyush Upadhyay ; Nilesh Kumar ; Anton A. Naumov. Springer Science and Business Media Deutschland GmbH, 2025. pp. 255-263 (Minerals, Metals and Materials Series).

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title = "Scale-Up of Friction Self-piercing Riveting Process for Multi-material Joints",

abstract = "A single-class joiningJoiningprocess known asFriction self-piercing riveting “friction self-piercing riveting (F-SPR)” has been developed for joiningJoining various low-ductility lightweight materials on a laboratory scale. The frictional heat generated during the F-SPR process improved local ductility, resulting in crack-free joints and robust mechanical performance. This innovative joiningJoining technology was further advanced through the scale-up of the process using a new system with several key features (e.g., automatic rivet feeding and clamping system, vacuum system) toward industry readiness. The new integrated F-SPR systems were effectively demonstrated for joiningJoining different material combinations (e.g., carbon fiber composite to 7075 Al alloy, 7075 Al alloy to 7075 Al alloy, and 7075 Al alloy to casting AlCasting Al Aural 5) with a unified technique. Crack-free jointCrack free joint with adequate mechanical interlocking resulted in good mechanical joint strength for each material combination. Then, the process was successfully scaled up by producing multiple joints without any cracks on larger CFC-Al and Al-Al components by the new integrated system, bringing it closer to industrial application.",

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Lim, YC , Wang, T , Wang, Y, Slade, J, Ojo, S & Feng, Z 2025, Scale-Up of Friction Self-piercing Riveting Process for Multi-material Joints. in Y Hovanski, Y Sato, P Upadhyay, N Kumar & AA Naumov (eds), Friction Stir Welding and Processing XIII. Minerals, Metals and Materials Series, Springer Science and Business Media Deutschland GmbH, pp. 255-263, 13th symposium on Friction Stir Welding and Processing, FSWP 2025, held as part of the TMS Annual Meeting and Exhibition, TMS 2025, Las Vegas, United States, 03/23/25. https://doi.org/10.1007/978-3-031-80896-8_22

Scale-Up of Friction Self-piercing Riveting Process for Multi-material Joints. / Lim, Yong Chae ; Wang, Tianzhao ; Wang, Yiyu et al.
Friction Stir Welding and Processing XIII. ed. / Yuri Hovanski; Yutaka Sato; Piyush Upadhyay; Nilesh Kumar; Anton A. Naumov. Springer Science and Business Media Deutschland GmbH, 2025. p. 255-263 (Minerals, Metals and Materials Series).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

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AU - Lim, Yong Chae

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AU - Wang, Yiyu

AU - Slade, Jeremy

AU - Ojo, Sammy

AU - Feng, Zhili

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PY - 2025

Y1 - 2025

N2 - A single-class joiningJoiningprocess known asFriction self-piercing riveting “friction self-piercing riveting (F-SPR)” has been developed for joiningJoining various low-ductility lightweight materials on a laboratory scale. The frictional heat generated during the F-SPR process improved local ductility, resulting in crack-free joints and robust mechanical performance. This innovative joiningJoining technology was further advanced through the scale-up of the process using a new system with several key features (e.g., automatic rivet feeding and clamping system, vacuum system) toward industry readiness. The new integrated F-SPR systems were effectively demonstrated for joiningJoining different material combinations (e.g., carbon fiber composite to 7075 Al alloy, 7075 Al alloy to 7075 Al alloy, and 7075 Al alloy to casting AlCasting Al Aural 5) with a unified technique. Crack-free jointCrack free joint with adequate mechanical interlocking resulted in good mechanical joint strength for each material combination. Then, the process was successfully scaled up by producing multiple joints without any cracks on larger CFC-Al and Al-Al components by the new integrated system, bringing it closer to industrial application.

AB - A single-class joiningJoiningprocess known asFriction self-piercing riveting “friction self-piercing riveting (F-SPR)” has been developed for joiningJoining various low-ductility lightweight materials on a laboratory scale. The frictional heat generated during the F-SPR process improved local ductility, resulting in crack-free joints and robust mechanical performance. This innovative joiningJoining technology was further advanced through the scale-up of the process using a new system with several key features (e.g., automatic rivet feeding and clamping system, vacuum system) toward industry readiness. The new integrated F-SPR systems were effectively demonstrated for joiningJoining different material combinations (e.g., carbon fiber composite to 7075 Al alloy, 7075 Al alloy to 7075 Al alloy, and 7075 Al alloy to casting AlCasting Al Aural 5) with a unified technique. Crack-free jointCrack free joint with adequate mechanical interlocking resulted in good mechanical joint strength for each material combination. Then, the process was successfully scaled up by producing multiple joints without any cracks on larger CFC-Al and Al-Al components by the new integrated system, bringing it closer to industrial application.

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KW - Carbon fiber reinforced polymer

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Lim YC , Wang T , Wang Y, Slade J, Ojo S , Feng Z. Scale-Up of Friction Self-piercing Riveting Process for Multi-material Joints. In Hovanski Y, Sato Y, Upadhyay P, Kumar N, Naumov AA, editors, Friction Stir Welding and Processing XIII. Springer Science and Business Media Deutschland GmbH. 2025. p. 255-263. (Minerals, Metals and Materials Series). doi: 10.1007/978-3-031-80896-8_22

Scale-Up of Friction Self-piercing Riveting Process for Multi-material Joints

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