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The effects of three profiles on the mechanical properties and grain size of self-piercing riveting joints using ultrasonic welding

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Abstract

Ultrasonic welding has become a key joining approach in batteries and energy vehicles. This work reports the optimization in static property and stability of self-piercing riveting joints which is becoming the most versatile way to join microstructures. Tool heads of three different knurling profiles (e.g., A, B, and C) are used to perform ultrasonic composite with riveting. Based on tensile-shear tests, SEM, EDS, XRD, and Vickers microhardness analysis were conducted to investigate the comparative study of the fracture morphology, element distribution, phase structure, and hardness. The results indicated that all three types of knurling generate solid phase welding at the sheet joints. Thus, it improved the forming quality and mechanical properties of self-piercing riveting joints. The C-shaped welding tool head has advantageous effect on optimizing the mechanical properties of joints. Further, it enhanced the average peak load by 25.6%, the average failure displacement by 31.1%, and the average energy absorption by 88.8%. The microscopic results showed that a large amount of oxides are precipitated at the edge of welding joints when the B-shape knurling tool is used. The distribution of the hardness value of joints horizontal line is “M” shape. Besides, the coarse grains in the joint area and the interplanar space increase significantly after ultrasonic welding which softens the sheet.

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Funding

This research is supported by National Natural Science Foundation of China (Grant No. 12104324); Postdoctoral Science Foundation of China (No. 2021M703392); Scientific Research Startup Fund for Shenzhen High-Caliber Personnel of SZPT (No.6022310046K); Postdoctoral Startup Fund of Shenzhen Polytechnic University (No. 6021330001K and No. 6022331008K).

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Authors and Affiliations

  1. Institute of Ultrasonic Technology, Shenzhen Polytechnic University, Shenzhen, 518055, China

    Guo Zixin, Lun Zhao, Zeshan Abbas, Huo Xiaole, Lin Sen & Wang Haibo

  2. Surface Engineering Institute, University of Science and Technology Liaoning, Anshan, 114051, China

    Guo Zixin & Guo Yuanyuan

  3. Key Laboratory for Micro/Nano Technology and System of Liaoning Province, Dalian University of Technology, Dalian, 116024, China

    Zeshan Abbas

  4. Department of Mechanical Engineering, Blekinge Institute of Technology, 37179, Karlskrona, Sweden

    Md Shafiqul Islam

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  1. Guo Zixin
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  2. Lun Zhao
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  4. Guo Yuanyuan
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  7. Wang Haibo
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Correspondence to Lun Zhao.

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Zixin, G., Zhao, L., Abbas, Z. et al. The effects of three profiles on the mechanical properties and grain size of self-piercing riveting joints using ultrasonic welding. Int J Adv Manuf Technol 129, 4869–4882 (2023). https://doi.org/10.1007/s00170-023-12567-8

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