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Friction plug-riveting spot welding process of steel/aluminum dissimilar materials and the joint formation mechanism

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Abstract

The welding characteristics of 7075 aluminum alloy and DP980 dual-phase steel sheet were systematically studied by the friction plug-riveting spot welding technology. The effects of different welding parameters on the weld formation, tensile strength, and microstructure of welded joints were analyzed. The complete metallurgical joining interface was formed between the rivet and steel plate. A partial metallurgical joining interface was formed between the circumferential surface of the rivet shaft and the aluminum alloy close to the steel sheet. However, the position of the rivet head did not form a metallurgical joining with the aluminum alloy. During the welding process, the area of the rivet interface underwent severe plastic deformation by frictional heat and down pressure; thus, there was a violent interaction between the plastically deformed metal and the surrounding aluminum alloy. The molten aluminum infiltrated into the rivet at the most of sample joints. The penetration of aluminum had a negative effect on the shear load. The maximum shear load of the joint was 14.374 kN. There were two types of fractures: the internal fracture of the rivet and the fracture of the steel/steel friction interface. When the fracture mode was an internal fracture of the rivet, the shear load was generally greater than the steel/steel friction interface.

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Funding

The authors gratefully acknowledge financial support from the National Natural Science Foundation of China (no. 51875037).

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Authors and Affiliations

  1. School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing, 100083, People’s Republic of China

    Jianyu Li, Yajia Liu, Shuai Gong, Shuhai Chen, Jian Yang & Jihua Huang

  2. The College of Mechanical Engineering and Applied Electronics Technology, Beijing University of Technology, Beijing, 100124, People’s Republic of China

    Shujun Chen & Xiaoqing Jiang

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  1. Jianyu Li
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  2. Yajia Liu
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  3. Shuai Gong
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  5. Jian Yang
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Contributions

Li Jianyu: preparation, creation, and presentation of the published work, specifically writing the initial draft. Liu Yajia: conducting a research, specifically performing the experiments, and data collection. Gong Shuai: construction of theoretical friction model. Chen Shuhai: acquisition of the financial support for the project leading to this publication. Huang Jihua: development or design of methodology. Chen Shujun: oversight and leadership responsibility for the research activity planning and execution. Jiang Xiaoqing: critical review, commentary, and revision

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Correspondence to Shuhai Chen.

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Li, J., Liu, Y., Gong, S. et al. Friction plug-riveting spot welding process of steel/aluminum dissimilar materials and the joint formation mechanism. Int J Adv Manuf Technol 128, 1243–1254 (2023). https://doi.org/10.1007/s00170-023-11999-6

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  • DOI: https://doi.org/10.1007/s00170-023-11999-6

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