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Advances in Clinching Technology for Joining of Different Materials, Exploitation, and Strength-Testing Methods

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Advanced Materials Characterization".

Deadline for manuscript submissions: closed (28 February 2021) | Viewed by 25523

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Prof. Dr. Jacek Mucha

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Department of Mechanical Engineering, Faculty of Mechanical Engineering and Aeronautics, Rzeszów University of Technology, 35-959 Rzeszów, Poland
Interests: mechanical joining; joining sheets; mechanical-testing; materials-processing; mechanical-properties; finite-element-analysis; manufacturing-engineering; tool wear in metal forming processes
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Dr. Lubos Kascak

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Department of Technologies, Materials and Computer Aided Production, Faculty of Mechanical Engineering, Technical University of Košice, Mäsiarska 74, 04001 Kosice, Slovakia
Interests: mechanical joining; clinching; resistance spot welding; adhesive bonding; hybrid joining
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Dr. Francesco Lambiase

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Department of Industrial and Information Engineering and Economics, University of L’Aquila, via G. Gronchi 18, Zona Industriale di Pile, 67100 L’Aquila, AQ, Italy
Interests: advanced joining processes (friction assisted, friction stir, laser assisted) of hybrid structures made of metals and polymer/composite materials; flexible forming processes on metals and polymers (incremental forming, vacuum forming, additive manufacturing, laser forming, etc.)
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Dear Colleagues,

Designing and manufacturing products without using joints is impossible in most cases. Appropriate association and joining of each part of the products enables production on a functional form, which is able to meet the requirements of the consumers while maintaining the economic aspects of production. In general, the assembly process allows to obtain product structures with simple, very complex, and sometimes sophisticated spatial construction. In the mounting process, the use of separable joints, such as screw joints or bolt joints, is still popular. However, the use of inseparable joints is becoming more and more popular. They are cheaper and their processing time is shorter. From year to year, the demand for construction material with improved physicochemical and exploitation characteristics increases. Thus, the greatest research progress is observed in the area of materials science. The newly developed materials generate the need to improve and develop joining systems.

Product and process innovations cause changes in designing and manufacturing processes. Due to the increasing emphasis on economic and technological aspects, more and more companies are revising their approach to the concept of designing and manufacturing joints used to connect components made of new materials.

The main objective, in the field of fastening technologies, is the possibility of developing and offering a comprehensive joining solution of new materials, with different physicochemical properties, which will improve the economics of the manufacturing process. The main aims of improving old solutions and making new achievements of joining technologies are:

- Increasing the availability of new materials use;

- The improvement of the reliability of joints and their manufacturing process;

- Increasing profitability and process automation;

- Increasing the quality and repeatability of the joining process;

- The possibility to join more than two material layers;

- Increasing corrosion resistance in the joints area;

- Miniaturization;

- Increase of static and dynamic joint strength.

The use of the clinching joining process in automated manufacturing processes is increasing. The advantages of clinching joint use have made companies more and more willing to use well-developed and proven solutions. Thus, they can reduce assembly process time and costs. Undoubtedly, it is due to these advantages that the clinching process is used for series production of car bodies. The use of pressed joints helps to minimize assembly time or even eliminate additional operations related to the preparation of joining elements. It allows to join two, three, and even more material layers in a very short time. Joining by pressing is effective for assembly materials with significantly different mechanical properties. Joining materials, especially with different mechanical properties, requires an individual approach to choosing the tool shape and geometry. Hence, in literature, many studies on using clinching technologies for joining materials with different properties, thickness, and combinations can be found.

This Special Issue includes original research and review works regarding the aspects of joining technologies for steel, non-ferrous metal alloys, composites, hybrid materials, and other modern materials. This edition will allow to present the newest achievements related to joints strength tests, with the corrosion resistant, and with new developments in clinching technologies. Hence, new information about the trends in clinching systems applications for joining new materials with different physical and chemical properties will be included. The aspects of different environmental and strength tests conditions will be presented.

Prof. Dr. Jacek Mucha
Dr. Lubos Kascak
Dr. Francesco Lambiase
Guest Editors

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Keywords

Clinching
Joining composites
Hybrid joints
Joints characterization and testing
Joint corrosion and joint strength
Modifications of clinching joining technologies

Published Papers (9 papers)

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Research

25 pages, 8621 KiB

Open AccessArticle

Research on the Influence of the AW 5754 Aluminum Alloy State Condition and Sheet Arrangements with AW 6082 Aluminum Alloy on the Forming Process and Strength of the ClinchRivet Joints

by Jacek Mucha, Ľuboš Kaščák and Waldemar Witkowski

Materials 2021, 14(11), 2980; https://doi.org/10.3390/ma14112980 - 31 May 2021

Cited by 18 | Viewed by 2266

Abstract

Clinching joints with an additional deformable rivet are modifications of the clinching joints. The clinch riveting (CR) joint is formed indirectly by a deformable rivet. The research included an analysis of CR joints’ forming process for aluminum alloy sheets made of AW 6082 in T6 state condition and AW 5754 in three different state conditions: H11, H22 and H24. As a result of forming the joint for various sheet arrangements, the highest value of blocking the upper sheet in the lower sheet (t_u) was obtained for the arrangements with two 5754-H24 aluminum alloy sheets. For such a large interlock parameter t_u, the greatest thinning of lower sheet (t_n) was obtained, which influenced the maximum tensile shear force and the joint failure mechanism. Based on the load-displacement diagrams obtained from the static shear test of lap joints, the total energy of failure and energy to achieve the maximum load capacity were calculated. The highest energy absorption to achieve the maximum load capacity, in the case of the same sheet materials, was obtained for the 5754-H11 aluminum alloy sheets. On the other hand, among the tested combinations, the highest value of energy absorption (for the joint maximum load capacity) was obtained for the sheet arrangement: top sheet AW 6082-T6 and the bottom AW 5754-H24. The highest value of the total energy up to fracture was obtained when the material of the top sheet was AW 6082-T6, and the bottom AW 5754-H22. For each sheet arrangement, a similar analysis of the joint strength parameters, interlock parameters and forming force were made. Full article

(This article belongs to the Special Issue Advances in Clinching Technology for Joining of Different Materials, Exploitation, and Strength-Testing Methods)

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18 pages, 14905 KiB

Open AccessArticle

Clinching of Thermoplastic Composites and Metals—A Comparison of Three Novel Joining Technologies

by Benjamin Gröger, Juliane Troschitz, Julian Vorderbrüggen, Christian Vogel, Robert Kupfer, Gerson Meschut and Maik Gude

Materials 2021, 14(9), 2286; https://doi.org/10.3390/ma14092286 - 28 Apr 2021

Cited by 18 | Viewed by 3118

Abstract

Clinching continuous fibre reinforced thermoplastic composites and metals is challenging due to the low ductility of the composite material. Therefore, a number of novel clinching technologies has been developed specifically for these material combinations. A systematic overview of these advanced clinching methods is given in the present paper. With a focus on process design, three selected clinching methods suitable for different joining tasks are described in detail. The clinching processes including equipment and tools, observed process phenomena and the resultant material structure are compared. Process phenomena during joining are explained in general and compared using computed tomography and micrograph images for each process. In addition the load bearing behaviour and the corresponding failure mechanisms are investigated by means of single-lap shear tests. Finally, the new joining technologies are discussed regarding application relevant criteria. Full article

(This article belongs to the Special Issue Advances in Clinching Technology for Joining of Different Materials, Exploitation, and Strength-Testing Methods)

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11 pages, 5059 KiB

Open AccessArticle

In Situ Computed Tomography—Analysis of a Single-Lap Shear Test with Clinch Points

by Daniel Köhler, Robert Kupfer, Juliane Troschitz and Maik Gude

Materials 2021, 14(8), 1859; https://doi.org/10.3390/ma14081859 - 09 Apr 2021

Cited by 14 | Viewed by 1959

Abstract

As lightweight design gains more and more attention, time and cost-efficient joining methods such as clinching are becoming more popular. A clinch point’s quality is usually determined by ex situ destructive analyses such as microsectioning. However, these methods do not yield the detection of phenomena occurring during loading such as elastic deformations and cracks that close after unloading. Alternatively, in situ computed tomography (in situ CT) can be used to investigate the loading process of clinch points. In this paper, a method for in situ CT analysis of a single-lap shear test with clinched metal sheets is presented at the example of a clinched joint with two 2 mm thick aluminum sheets. Furthermore, the potential of this method to validate numerical simulations is shown. Since the sheets’ surfaces are locally in contact with each other, the interface between both aluminum sheets and therefore the exact contour of the joining partners is difficult to identify in CT analyses. To compensate for this, the application of copper varnish between the sheets is investigated. The best in situ CT results are achieved with both sheets treated. It showed that with this treatment, in situ CT is suitable to properly observe the three-dimensional deformation behavior and to identify the failure modes. Full article

(This article belongs to the Special Issue Advances in Clinching Technology for Joining of Different Materials, Exploitation, and Strength-Testing Methods)

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22 pages, 26644 KiB

Open AccessArticle

Mechanical Clinching and Self-Pierce Riveting of Thin Three Sheets of 5000 Series Aluminium Alloy and 980 MPa Grade Cold Rolled Ultra-High Strength Steel

by Yohei Abe, Takato Maeda, Daiki Yoshioka and Ken-ichiro Mori

Materials 2020, 13(21), 4741; https://doi.org/10.3390/ma13214741 - 23 Oct 2020

Cited by 34 | Viewed by 2989

Abstract

One thin 5000 series aluminium alloy sheet and two thin 980 MPa grade cold rolled ultra-high strength steel sheets were joined by self-pierce riveting and mechanical clinching processes. The joinabilities for a combination of the aluminium and steel sheets in both processes were investigated for different die shapes in the experiment and finite element simulation. In self-pierce riveting, the three sheets were successfully joined for both combinations of the upper and lower aluminium alloy sheets by optimizing the shapes of a die and rivet. In mechanical clinching, the three sheets were successfully joined by an optimum die for the configuration of the upper aluminium alloy sheet. On the other hand, the three sheets for the configuration of the lower aluminium alloy sheet were not joined even by optimizing the die shape in the both finite element simulation and experiment, because the material flow of the steel sheets was insufficient to form the two interlocks. The tension-shear loads for the clinched and riveted sheets with the adhesive were almost the same, because the load for the adhesive was the highest. In the cross-tension test, however, the load by the adhesive was comparatively small. Full article

(This article belongs to the Special Issue Advances in Clinching Technology for Joining of Different Materials, Exploitation, and Strength-Testing Methods)

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12 pages, 3832 KiB

Open AccessArticle

Equal Load-Carrying Design of Lapped Joints of Al–Cu Dissimilar Materials

by Zhihao Chen, Jianxiao Ma, Hongyuan Fang, Zhida Ni and Ping Wang

Materials 2020, 13(19), 4293; https://doi.org/10.3390/ma13194293 - 25 Sep 2020

Viewed by 1511

Abstract

In order to avoid the adverse effects of additional moment and stress concentration of traditional lap joints, a new lap joint was put forward, according to the concept of “equal load-carrying”. Through static analysis and brazing characteristics consideration, the equal load-carrying design method of Al–Cu lap joint based on brazing method was established. Through three types of brazing, the relationship among two fracture modes, brazing process and static tension curve of lap joint, was analyzed. The results demonstrated that the selection of solder was required to simultaneously meet the requirements of brazability and mechanical properties. A certain relationship existed between the fracture mode of the lap joint and the static tensile curve, while the segments of the static tensile curve corresponded to the fracture paths of the two fracture modes. When the brazing holding time was quite short, the interface bonding was poor, while the bearing capacity of the joint was low; when the holding time was suitable, the bearing capacity of the joint reached the corresponding highest, while the fracture mode conformed to the equal load-carrying design; when the brazing holding time was quite long, the bearing capacity of the joint remained at a high level, but the fracture mode was the same as the holding time was quite short. Full article

(This article belongs to the Special Issue Advances in Clinching Technology for Joining of Different Materials, Exploitation, and Strength-Testing Methods)

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17 pages, 5977 KiB

Open AccessArticle

Preheated (Heat-Assisted) Clinching Process for Al/CFRP Cross-Tension Specimens

by Pai-Chen Lin, Jun-Chang Fang, Jia-Wei Lin, Xuan Van Tran and Yern-Chee Ching

Materials 2020, 13(18), 4170; https://doi.org/10.3390/ma13184170 - 19 Sep 2020

Cited by 28 | Viewed by 2699

Abstract

Effects of processing parameters on preheated (heat-assisted) clinching process to join aluminum alloy 5052-H32 (AA5052) and thermoplastic carbon-fiber-reinforced-plastic (TP-CFRP) sheets for cross-tension (CT) specimens were first studied. Preheating was critical since brittle TP-CFRP could be softened to avoid fracturing or cracking during clinching process. Four processing parameters, including punching force, die depth, heating mode, and heating temperature, were considered. Quasi-static tests and microscope observations were taken to evaluate AA5052/TP-CFRP clinch joints in CT specimens and determine appropriate processing parameters for fatigue tests. Finally, fatigue data and failure mode of clinch joints in CT specimens were obtained and discussed. Full article

(This article belongs to the Special Issue Advances in Clinching Technology for Joining of Different Materials, Exploitation, and Strength-Testing Methods)

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34 pages, 12766 KiB

Open AccessArticle

An Experimental Study on Micro-Shear Clinching of Metal Foils by Laser Shock

by Xinding Li, Xiao Wang, Zongbao Shen, Youjuan Ma and Huixia Liu

Materials 2019, 12(9), 1422; https://doi.org/10.3390/ma12091422 - 01 May 2019

Cited by 10 | Viewed by 2408

Abstract

This work proposes a micro-shear clinching process by laser shock for joining similar and dissimilar metal foils. The joint appearance and cross-section were investigated to determine basic process parameters. The soft punch thickness was 100 μm. The numbers of laser pulses on the upper and lower foil sides were set as two and one, respectively. Joint deformation was divided into three stages and we investigated the deformation law of the joints. The process windows of the Al foil combinations were acquired to determine a reasonable range of process parameters for obtaining qualified joints. The mechanical properties and failure modes of different joints were analyzed to identify the process characteristics. Mechanical properties were related to shear test directions and were influenced by upper and lower foil thicknesses. One failure mode was observed in the parallel shear test, and four failure modes were observed in the perpendicular shear test. These modes were determined by the differences between upper and lower foil thicknesses. Results showed that the proposed process can be used to join Al and Cu foils successfully. The laws governing the mechanical properties and failure modes of dissimilar materials were similar to those governing the mechanical properties and failure modes of similar materials. Full article

(This article belongs to the Special Issue Advances in Clinching Technology for Joining of Different Materials, Exploitation, and Strength-Testing Methods)

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16 pages, 16013 KiB

Open AccessArticle

Modeling and Experimental Research on Resistance Spot Welded Joints for Dual-Phase Steel

by Dawei Zhao, Yuanxun Wang, Peng Zhang and Dongjie Liang

Materials 2019, 12(7), 1108; https://doi.org/10.3390/ma12071108 - 03 Apr 2019

Cited by 21 | Viewed by 4541

Abstract

Dual-phase steel has been employed in the automotive industry as it has the advantages of high strength, satisfying ductility, low yield ratio, and so on. A novel framework for the weld nugget size prediction and control using finite element modeling and experimental research was proposed in this paper. The two-dimensional axisymmetric numerical analysis model was established and the phase transition on thermal expansion coefficient was taken into account. The whole welding process was simulated and discussed using thermal elastic-plastic theory. To validate the predictive methods of developed weld nugget size and confirmation experiments were implemented with the same input parameters in the ranges of process parameters. The simulated weld nugget sizes were in good agreement with the experimental results except for extreme welding conditions. The microstructure of the welding zone was also investigated based on metallographic experiments and temperature field analysis. The welding parameters were adjusted using the model proposed in this paper so as to obtain the nugget size with pull out failure mode. Full article

(This article belongs to the Special Issue Advances in Clinching Technology for Joining of Different Materials, Exploitation, and Strength-Testing Methods)

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21 pages, 8343 KiB

Open AccessArticle

Designing and Testing Cold-Formed Rounded Connections Made on a Prototype Station

by Michał Rejek, Nikodem Wróbel, Jolanta Królczyk and Grzegorz Królczyk

Materials 2019, 12(7), 1061; https://doi.org/10.3390/ma12071061 - 31 Mar 2019

Cited by 5 | Viewed by 2776

Abstract

This paper presents the design of cold-formed rounded connections between a tube and a connecting block and the analysis of test results that were carried out with six fabricated samples. The joints manufactured on a specially designed prototype station were made by forming tools that were adjusted to connecting elements regarding the diameter and the shape. All of the samples prepared for this study were of the same diameters relating to the diameter of a hole in a connecting block and the outer diameter of a pipe flange. However, they were different concerning the height of the connecting block flange. The article presents features of joints that were manufactured with a designed forming tool on the prototype station. The achieved connections were examined in destructive testing (Micrography, Tensile Strength Test) and in non-destructive testing (Leakage Test). The research project aims were to state the differences in energy consumption of made connections and extend the concept of cold-formed rounded connections. Furthermore, this article presents the effects of FEA simulation of the cold-formed joint based on the results of destructive and non-destructive tests. Full article

(This article belongs to the Special Issue Advances in Clinching Technology for Joining of Different Materials, Exploitation, and Strength-Testing Methods)

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