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Classification and variation of fracture modes in laser shock hole-clinching

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Abstract

Laser shock hole-clinching is a high–strain rate mechanical joining process in which the metal foils are joined together based on plastic deformation generated by a laser-induced shock wave. In the process, fracture is a typical defect and seriously influences the clinching quality and production efficiency of joints. However, the classification and variation of fracture modes in laser shock hole-clinching are of less concern. In this study, the fracture mode of Cu-Fe joints in laser shock hole-clinching was experimentally investigated. Both optical microscopy and scanning electron microscopy were adopted to analyze the fracture surface morphology of clinched joints. The influence of laser power density, laser spot diameter, the initial grain size and thickness of metal foil, and spacer height on the fracture mode of joints was evaluated. It is revealed that the temperature increase caused by high–strain rate plastic deformation has no impact on the fracture behavior of the joining partners. Fracture always occurs on joining partner I, and it can be divided into four modes, including bottom surface fracture, bottom corner fracture, neck fracture, and mixed fracture. It is found that fracture on the bottom surface is seldom seen but mixed fracture accounts for most of the cracked specimens. Neck tensile fracture rarely appears alone, and it usually exists accompanied by fracture on the bottom corner. The fracture mode varies from a tensile fracture mode on the bottom corner to a mixed fracture mode and then to a shear fracture mode on the neck with the enhancement of laser power density. In addition, the initial grain size of joining partner I has a significant impact on the fracture mode of clinched joints. The fracture mode varies from bottom corner fracture to mixed fracture in relation to the change of mechanical properties of metal foil with an enlarged grain size. However, the mixed fracture mode always appears with the enlargement of both laser spot diameter and spacer height.

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Funding

This work is supported by the National Natural Science Foundation of China (No. 52075299), Natural Science Foundation of Shandong Province (No. ZR2020ME149), and the Fundamental Research Funds of Shandong University (2018JC042).

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Authors and Affiliations

  1. Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials (Ministry of Education), School of Materials Science and Engineering, Shandong University, Jinan, 250061, People’s Republic of China

    Chao Zheng, Shushuai Liu, Yiliang Zhang, Guoqun Zhao & Zhong Ji

  2. Key Laboratory of Extraordinary Bond Engineering and Advanced Materials Technology, School of Materials Sciences and Engineering, Yangtze Normal University, Chongqing, 408100, People’s Republic of China

    Yunhu Zhu

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  1. Chao Zheng
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  2. Shushuai Liu
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Contributions

Chao Zheng: Conceptualization, writing—original draft preparation, writing—revision

Shushuai Liu: Methodology, writing—revision

Yunhu Zhu: Investigation

Yiliang Zhang: Investigation, writing—original draft preparation

Guoqun Zhao: Supervision, writing—review

Zhong Ji: Writing—review

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Correspondence to Chao Zheng.

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Zheng, C., Liu, S., Zhu, Y. et al. Classification and variation of fracture modes in laser shock hole-clinching. Int J Adv Manuf Technol 114, 3005–3020 (2021). https://doi.org/10.1007/s00170-021-07088-1

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