Aluminum alloys have been increasingly adopted in the fabrication of automotive body structures as an integral component of mass savings strategy. However, mixed use of dissimilar aluminum alloys, such as sheet metals, castings, and extrusions, poses significant challenges to the existing joining technologies, especially in regard to single-sided joint access. To address this issue, the current study applied the friction stir blind riveting (FSBR) process to join 1.2 mm-thick AA6022-T4 aluminum alloy to 3 mm-thick Aural-2 cast aluminum. A newly developed, robot mounted, servo-driven, FSBR equipment and the procedure using it to make FSBR joints were introduced systematically. The effect of rivet feed rate and spindle speed on joint formation and cross section geometry was investigated, and it was found that a high spindle speed and a low rivet feed rate, i.e., high heat input, are prone to produce good joints, and that low heat input can cause severe problems related to insufficient softening of the sheets. The rivet deformation, especially the notch location on the mandrel relative to the shank has significant influence on lap-shear strength and fracture mode of the final joints. A rivet pull-out fracture mode was observed at higher rivet feed rates and lower spindle speeds and exhibited significantly improved energy absorption capability, i.e., 62% higher compared to traditional blind riveted (BR) joints.
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June 2018
Research-Article
Effect of Process Parameters on Joint Formation and Mechanical Performance in Friction Stir Blind Riveting of Aluminum Alloys
YunWu Ma,
YunWu Ma
State Key Laboratory of Mechanical System
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
Search for other works by this author on:
YongBing Li,
YongBing Li
State Key Laboratory of Mechanical System
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: yongbinglee@sjtu.edu.cn
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: yongbinglee@sjtu.edu.cn
Search for other works by this author on:
Blair E. Carlson,
Blair E. Carlson
Manufacturing Systems Research Lab,
General Motors Global R&D,
General Motors Global R&D,
30500 Mound Road
, Warren, MI 48090
Search for other works by this author on:
ZhongQin Lin
ZhongQin Lin
State Key Laboratory of Mechanical System
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
Search for other works by this author on:
YunWu Ma
State Key Laboratory of Mechanical System
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
YongBing Li
State Key Laboratory of Mechanical System
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: yongbinglee@sjtu.edu.cn
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: yongbinglee@sjtu.edu.cn
Blair E. Carlson
Manufacturing Systems Research Lab,
General Motors Global R&D,
General Motors Global R&D,
30500 Mound Road
, Warren, MI 48090
ZhongQin Lin
State Key Laboratory of Mechanical System
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
1Corresponding author.
Manuscript received August 6, 2017; final manuscript received January 15, 2018; published online March 13, 2018. Assoc. Editor: Yannis Korkolis.
J. Manuf. Sci. Eng. Jun 2018, 140(6): 061007 (11 pages)
Published Online: March 13, 2018
Article history
Received:
August 6, 2017
Revised:
January 15, 2018
Citation
Ma, Y., Li, Y., Carlson, B. E., and Lin, Z. (March 13, 2018). "Effect of Process Parameters on Joint Formation and Mechanical Performance in Friction Stir Blind Riveting of Aluminum Alloys." ASME. J. Manuf. Sci. Eng. June 2018; 140(6): 061007. https://doi.org/10.1115/1.4039118
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