journal article·2023-09Open access

Load-Bearing Capacities and Fracture Modes of Self-Piercing-Riveted, Adhesive-Bonded and Riv-Bonded Aluminum Joints at Quasi-Static and Cyclic Loadings

Josef Domitner, Zahra Silvayeh, Jožef Predan, Peter Auer, Jennifer Stippich, Christof Sommitsch, Nenad Gubeljak

Abstract

Abstract The load-bearing capacities of (i) self-piercing-riveted, (ii) adhesive-bonded and (iii) hybrid riv-bonded lap joints of commercial 1.5-mm-thick EN AW-6016-T4 sheets were compared under both quasi-static and cyclic shear-tensile loads. The joints were heat-treated to cure the adhesive and to peak-age the aluminum alloy. The joint quality/integrity was assessed based on characteristic cross-sectional features and hardness maps. Riveted joints showed notably lower static strength and fatigue performance than riv-bonded joints. Hence, the adhesive layer provided the main contribution to both the static and the cyclic load-bearing capacities of riv-bonded joints, whereas rivets contributed only little. However, if bonding was insufficient the potential capacity of the joints could not be exploited. Under quasi-static loading fracture occurred at the joint; therefore, joints of high quality/integrity were important. Even under cyclic loading at high load amplitudes fracture occurred at the joint, but at comparatively low load amplitudes fracture rather occurred at the sheets next to the joint. Hence, the joint quality/integrity mainly determines the static fracture and the low-cycle fatigue fracture, whereas the sheet properties mainly determine the high-cycle fatigue fracture.
Source: crossref · Quality: baseline

Research context

OpenAlex topics: Advanced Welding Techniques Analysis · Fatigue and fracture mechanics · Mechanical Behavior of Composites

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (50)

Show source-provided references
1. W.S. Miller, L. Zhuang, J. Bottema, A.J. Wittebrood, P. De Smet, A. Haszler, and A. Vieregge, Recent Development in Aluminium Alloys for the Automotive Industry, Mater. Sci. Eng. A, 2000, 280, p 37–49.10.1016/S0921-5093(99)00653-X ↗
2. J. Hirsch, Recent Development in Aluminium for Automotive Applications, Trans. Nonferrous Met. Soc. China, 2014, 24, p 1995–2002.10.1016/S1003-6326(14)63305-7 ↗
3. M. Pouranvari and S.P.H. Marashi, Critical Review of Automotive Steels Spot Welding: Process, Structure and Properties, Sci. Technol. Weld. Join., 2013, 18(5), p 361–403.10.1179/1362171813Y.0000000120 ↗
4. S.M. Manladan, F. Yusof, S. Ramesh, M. Fadzil, Z. Luo, and S. Ao, A Review on Resistance Spot Welding of Aluminum Alloys, Int. J. Adv. Manuf. Technol., 2017, 90, p 605–634.10.1007/s00170-016-9225-9 ↗
5. J.E. Gould, Joining Aluminum Sheet in the Automotive Industry: A 30 Year History, Weld. J., 2012, 91, p 23–34.
6. X. He, I. Pearson, and K. Young, Self-Pierce Riveting for Sheet Materials: State of the Art, J. Mater. Process. Technol., 2008, 199, p 27–36.10.1016/j.jmatprotec.2007.10.071 ↗
7. D. Li, A. Chrysanthou, I. Patel, and G. Williams, Self-Piercing Riveting: A Review, Int. J. Adv. Manuf. Technol., 2017, 92, p 1777–1824.10.1007/s00170-017-0156-x ↗
8. S. Maggiore, M.D. Banea, P. Stagnaro, and G. Luciano, A Review of Structural Adhesive Joints in Hybrid Joining Processes, Polymers, 2021, 13, p 3961.10.3390/polym13223961 ↗
9. R. Haque, Quality of Self-Piercing Riveting (SPR) Joints from Cross-Sectional Perspective: A Review, Arch. Civ. Mech. Eng., 2018, 18, p 83–93.10.1016/j.acme.2017.06.003 ↗
10. Y. Xu, Effects of Factors on Physical Attributes of Self-Piercing Riveted Joints, Sci. Technol. Weld. Join., 2006, 11(6), p 666–671.10.1179/174329306X131866 ↗
11. D. Li, L. Han, A. Chrysanthou, M. Shergold, and G. Williams, The effect of setting velocity on the static and fatigue strengths of self-piercing riveted joints for automotive applications, in Proceedings on TMS Annual Meeting (2014), p 557–564.10.1002/9781118889879.ch67 ↗
12. R. Porcaro, A.G. Hanssen, M. Langseth, and A. Aalberg, Self-Piercing Riveting Process: An Experimental and Numerical Investigation, J. Mater. Process. Technol., 2006, 171, p 10–20.10.1016/j.jmatprotec.2005.05.048 ↗
13. M. Carandente, R.J. Dashwood, I.G. Masters, and L. Han, Improvements in Numerical Simulation of the SPR Process Using a Thermo-Mechanical Finite Element Analysis, J. Mater. Process. Technol., 2016, 236, p 148–161.10.1016/j.jmatprotec.2016.05.001 ↗
14. F. Hönsch, J. Domitner, C. Sommitsch, B. Götzinger, and M. Kölz, Numerical Simulation and Experimental Validation of Self-Piercing Riveting (SPR) of 6xxx Aluminium Alloys for Automotive Applications, J. Phys. Conf. Ser., 2018, 1063, p 012081.10.1088/1742-6596/1063/1/012081 ↗
15. X. Sun and M.A. Khaleel, Performance Optimization of Self Piercing Rivets through Analytical Rivet Strength Estimation, J. Manuf. Process., 2005, 7(1), p 83–93.10.1016/S1526-6125(05)70085-2 ↗
16. X. Sun and M.A. Khaleel, Strength Estimation of Self-Piercing Rivets Using Lower Bound Limit Load Analysis, Sci. Technol. Weld. Join., 2005, 10(5), p 624–635.10.1179/174329305X57491 ↗
17. D. Li, L. Han, M. Thornton, and M. Shergold, Influence of Edge Distance on Quality and Static Behaviour of Self-Piercing Riveted Aluminium Joints, Mater. Des., 2012, 34, p 22–31.10.1016/j.matdes.2011.07.046 ↗
18. D. Li, Influence of Local Surface Texture by Tool Impression on the Self-Piercing Riveting Process and the Static Lap Shear Strength, J. Manuf. Process., 2017, 29, p 298–309.10.1016/j.jmapro.2017.08.003 ↗
19. F. Hönsch, J. Domitner, C. Sommitsch, and B. Götzinger, Modeling the Failure Behavior of Self-Piercing Riveting Joints of 6xxx Aluminum Alloy, J. Mater. Eng. Perform., 2020, 29, p 4888–4897.10.1007/s11665-020-04894-8 ↗
20. M. Fu and P.K. Mallick, Fatigue of Self-Piercing Riveted Joints in Aluminum Alloy 6111, Int. J. Fatigue, 2003, 25, p 183–189.10.1016/S0142-1123(02)00115-9 ↗
21. K. Iyer, S.J. Hu, F.L. Brittman, P.C. Wang, D.B. Hayden, and S.P. Marin, Fatigue of Single- and Double-Rivet Self-Piercing Riveted Lap Joints, Fatigue Fract. Eng. Mater. Struct., 2005, 28, p 997–1007.10.1111/j.1460-2695.2005.00938.x ↗
22. X. Sun, E.V. Stephens, and M.A. Khaleel, Fatigue Behaviors of Self-Piercing Rivets Joining Similar and Dissimilar Sheet Metals, Int. J. Fatigue, 2007, 29, p 370–386.10.1016/j.ijfatigue.2006.02.054 ↗
23. D. Li, L. Han, M. Thornton, and M. Shergold, Influence of Rivet to Sheet Edge Distance on Fatigue Strength of Self-Piercing Riveted Aluminium Joints, Mater. Sci. Eng. A, 2012, 558, p 242–252.10.1016/j.msea.2012.07.119 ↗
24. K. Mori, Y. Abe, and T. Kato, Mechanism of Superiority of Fatigue Strength for Aluminium Alloy Sheets Joined by Mechanical Clinching and Self-Pierce Riveting, J. Mater. Process. Technol., 2012, 212, p 1900–1905.10.1016/j.jmatprotec.2012.04.017 ↗
25. P. Lin, Z. Su, W. Lai, and J. Pan, Fatigue Behavior of Self-Piercing Rivets and Clinch Joints in Lap-Shear Specimens of Aluminum Sheets, SAE Int. J. Mater. Manuf., 2013, 6(2), p 293–298.10.4271/2013-01-1024 ↗
26. Z.-M. Su, P.-C. Lin, W.-J. Lai, and J. Pan, Fatigue Analyses of Self-Piercing Rivets and Clinch Joints in Lap-Shear Specimens of Aluminum Sheets, Int. J. Fatigue, 2015, 72, p 53–65.10.1016/j.ijfatigue.2014.09.022 ↗
27. S.-H. Kang and H.-K. Kim, Fatigue Strength Evaluation of Self-Piercing Riveted Al-5052 Joints under Different Specimen Configurations, Int. J. Fatigue, 2015, 80, p 58–68.10.1016/j.ijfatigue.2015.05.003 ↗
28. L. Zhao, X. He, B. Xing, Y. Lu, F. Gu, and A. Ball, Influence of Sheet Thickness on Fatigue Behavior and Fretting of Self-Piercing Riveted Joints in Aluminum Alloy 5052, Mater. Des., 2015, 87, p 1010–1017.10.1016/j.matdes.2015.08.121 ↗
29. L. Huang, H. Guo, Y. Shi, S. Huang, and X. Su, Fatigue Behavior and Modeling of Self-Piercing Riveted Joints in Aluminum Alloy 6111, Int. J. Fatigue, 2017, 100, p 274–284.10.1016/j.ijfatigue.2017.03.006 ↗
30. D.-H. Choi, D.-W. Han, and H.-K. Kim, Fatigue Life Estimation of Self-Piercing Riveted Aluminum Joints under Mixed-Mode Loading, Int. J. Fatigue, 2017, 97, p 20–28.10.1016/j.ijfatigue.2016.12.019 ↗
31. J.F.C. Moraes, H.M. Rao, J.B. Jordon, and M.E. Barkey, High Cycle Fatigue Mechanisms of Aluminum Self-Piercing Riveted Joints, Fatigue Fract. Eng. Mater. Struct., 2018, 41, p 57–70.10.1111/ffe.12648 ↗
32. H. Fricke and M. Israel, Simulation von Hybridfügeprozessen–Unterschiedliche Werkstoffe prozesssicher verbinden, Adhäsion, 2011, 55(7–8), p 24–29.
33. R. Neugebauer, M. Israel, B. Mayer, and H. Fricke, Numerical and Experimental Studies on the Clinch-bonding and Riv-bonding Process, Key Eng. Mater., 2012, 504–506, p 771–776.10.4028/www.scientific.net/KEM.504-506.771 ↗
34. H. Fricke and T. Vallée, Numerical Modeling of Hybrid-Bonded Joints, J. Adhes., 2016, 92, p 652–664.10.1080/00218464.2015.1100995 ↗
35. D. Landgrebe, B. Mayer, S. Niese, H. Fricke, I. Neumann, M. Ahnert, and T. Falk, Adhesive Distribution and Global Deformation between Hybrid Joints, Key Eng. Mater., 2015, 651–653, p 1465–1471.10.4028/www.scientific.net/KEM.651-653.1465 ↗
36. L. Potgorschek, J. Domitner, F. Hönsch, C. Sommitsch, and S. Kaufmann, Numerical Simulation of Hybrid Joining Processes: Self-Piercing Riveting Combined with Adhesive Bonding, Proc. Manuf., 2020, 47, p 413–418.
37. Y. Liu, L. Han, H. Zhao, and X. Liu, Numerical Modelling and Experimental Investigation of the Riv-Bonding Process, J. Mater. Process. Technol., 2021, 288, p 116914.10.1016/j.jmatprotec.2020.116914 ↗
38. Y. Liu, L. Han, H. Zhao, and X. Liu, Experimental Investigation of the Adhesive Layer’s Impact on the Riv-Bonding Process and Joint Quality, Thin-Walled Struct., 2021, 167, p 108255.10.1016/j.tws.2021.108255 ↗
39. J. Domitner, P. Auer, J. Stippich, Z. Silvayeh, S. Jessernig, L. Peiser, F. Hönsch, and C. Sommitsch, Riv-Bonding of Aluminum Alloys with High-Strength Steels against the Favorable Joining Direction, J. Mater. Eng. Perform., 2022, 31, p 6970–6979.10.1007/s11665-022-06647-1 ↗
40. F. Moroni, A. Pirondi, and F. Kleiner, Experimental Analysis and Comparison of the Strength of Simple and Hybrid Structural Joints, Int. J. Adhes. Adhes., 2010, 30, p 367–379.10.1016/j.ijadhadh.2010.01.005 ↗
41. X. He, B. Xing, K. Zeng, F. Gu, and A. Ball, Numerical and Experimental Investigations of Self-Piercing Riveting, Int. J. Adv. Manuf. Technol., 2013, 69, p 715–721.10.1007/s00170-013-5072-0 ↗
42. H. Jiang, Y. Liao, S. Gao, G. Li, and J. Cui, Comparative Study on Joining Quality of Electromagnetic Driven Self-Piercing Riveting, Adhesive and Hybrid Joints for Al/Steel Structure, Thin-Walled Struct., 2021, 164, p 107903.10.1016/j.tws.2021.107903 ↗
43. F. Moroni, Fatigue Behaviour of Hybrid Clinch-Bonded and Self-Piercing Rivet Bonded Joints, J. Adhes., 2019, 95(5–7), p 577–594.10.1080/00218464.2018.1552586 ↗
44. G. Wu, D. Li, W.-J. Lai, Y. Shi, H. Kang, Y. Peng, and X. Su, Fatigue Behaviors and Mechanism-Based Life Evaluation on SPR-Bonded Aluminum Joint, Int. J. Fatigue, 2021, 142, p 105948.10.1016/j.ijfatigue.2020.105948 ↗
45. J. Domitner, Z. Silvayeh, J. Predan, F. Jerenec, P. Auer, J. Stippich, L. Ferlič, P. Štefane, C. Sommitsch, and N. Gubeljak, Influence of the Sheet Edge Condition on the Fracture Behavior of Riv-Bonded Aluminum–Magnesium Joints, Key Eng. Mater., 2022, 926, p 1541–1548.10.4028/p-001s3t ↗
46. STANLEY® Engineered Fastening, Tucker GmbH, Self Piercing Rivet Catalog and Die Overview T-Numbers, (Gießen, Germany, 2017).
47. Sika Automotive GmbH, Product Data Sheet SikaPower®-498/3 Crash-Resistant Metal Adhesive (Hamburg, Germany, 2016).
48. Y.K. Chen, L. Han, A. Chrysanthou, and J.M. O’Sullivan, Fretting Wear in Self-Piercing Riveted Aluminium Alloy Sheet, Wear, 2003, 255, p 1463–1470.10.1016/S0043-1648(03)00274-6 ↗
49. L. Huang, J. Bonnen, J. Lasecki, H. Guo, and X. Su, Fatigue and Fretting of Mixed Metal Self-Piercing Riveted Joint, Int. J. Fatigue, 2016, 83, p 230–239.10.1016/j.ijfatigue.2015.10.018 ↗
50. L. Huang, Y. Shi, H. Guo, and X. Su, Fatigue Behavior and Life Prediction of Self-Piercing Riveted Joint, Int. J. Fatigue, 2016, 88, p 96–110.10.1016/j.ijfatigue.2016.03.015 ↗