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Modeling and experimental validation of friction self-piercing riveted aluminum alloy to magnesium alloy

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Abstract

Friction self-piercing riveting (F-SPR) process has been proposed to achieve crack-free joining of low-ductility materials by combining SPR process with the concept of friction stir processing. The inhibition of cracking in an F-SPR joint is related to the in-process temperature as well as plastic deformation of materials, which are controlled by the process parameters, i.e., spindle speed and feed rate. However, the relationship between F-SPR process parameters and the temperature characteristics within the joint has not been established. In the current study, a coupled thermal-mechanical model based on solid mechanics was setup to study the F-SPR process of aluminum alloy and magnesium alloy. Temperature and strain rate-dependent material models and preset crack surface method were integrated in the model and geometry comparisons were conducted for model validation. Based on this model, the evolutions of temperature and plastic deformation in the rivet and the sheets of an F-SPR joint were obtained to reveal the formation mechanism of the joint. The temperature distribution and evolution of the sheet materials were correlated with F-SPR process parameters, and a critical spinning speed of 2000 rpm at a feed rate of 1.35 mm/s was determined capable of inhibiting cracking in the magnesium sheet.

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Funding

The authors would like to thank the financial support of the National Natural Science Foundation of China (Grant Nos. U1564204 and U1764251) and the National Key Research and Development Program of China (Grant No. 2016YFB0101606-08).

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Authors and Affiliations

  1. Shanghai Key Laboratory of Digital Manufacture for Thin-walled Structures, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, People’s Republic of China

    YunWu Ma, Ming Lou, YongBing Li & ZhongQin Lin

  2. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, People’s Republic of China

    YunWu Ma, YongBing Li & ZhongQin Lin

Authors
  1. YunWu Ma
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  2. Ming Lou
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  3. YongBing Li
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  4. ZhongQin Lin
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Corresponding author

Correspondence to YongBing Li.

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Recommended for publication by Commission III - Resistance Welding, Solid State Welding, and Allied Joining Process

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Ma, Y., Lou, M., Li, Y. et al. Modeling and experimental validation of friction self-piercing riveted aluminum alloy to magnesium alloy. Weld World 62, 1195–1206 (2018). https://doi.org/10.1007/s40194-018-0614-6

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  • DOI: https://doi.org/10.1007/s40194-018-0614-6

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