Analyses of Friction Stir Riveting Processes: A Review

Khan, Haris Ali; Li, Jingjing; Shao, Chenhui

doi:10.1115/1.4036909

Cited by 19 publications

(3 citation statements)

References 64 publications

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“…Furthermore, several variations in FSW have been proposed for specific spot-joining applications. For example, friction bit joining (FBJ) [6][7][8][9] has been successfully employed to join high-strength Al alloy and CFRP to dual-phase steels. It has also been combined with adhesive bonding to enhance the mechanical strength of Al/steel and CFRP/steel joints and improve galvanic corrosion resistance in dissimilar material joints.…”

Section: Introductionmentioning

confidence: 99%

Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design

Huang,

Lim,

Wang

et al. 2023

JMMP

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Unique friction-based self-piercing riveting (F-SPR) was employed to join high-strength, low-ductility aluminum alloy 7055 for lightweight vehicle applications. This study aimed to maximize the joint strength of the AA7055 F-SPR joint while avoiding cracking issues due to low ductility at room temperature. A fully coupled Eulerian–Lagrangian (CEL) model was employed to predict the process temperature during F-SPR, and the temperature field was then mapped onto a 2D axisymmetric equivalent model for accelerated numerical analysis. The geometry, dimensions, and material strength of the rivet, as well as the depth of the die cavity and plunging depth, were investigated to enhance joint formation. Also, a static finite-element analysis model was developed to predict and analyze the stress distribution in the rivet under different mechanical testing loading conditions. Overall, the numerical model showed good agreement with the experiment results, such as joint formation and mechanical joint strength. With the aid of virtual fabrication through numerical modeling, the joint design iterations and process development time of F-SPR were greatly reduced regarding the goal of lightweight, high-strength aluminum joining.

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Section: Introductionmentioning

confidence: 99%

Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design

Huang,

Lim,

Wang

et al. 2023

JMMP

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“…Simplicity and efficiency are also concerns in joining [3]. Conventionally, riveting was widely used for the joining of similar and dissimilar materials [4][5][6]. However, this method has some critical issues, such as twisting of the rivet, complexity of the process, high-productivity cycle time, and additional process costs [7].…”

Section: Introductionmentioning

confidence: 99%

A Novel Approach to Friction Drilling Process: Experimental and Numerical Study on Friction Drill Joining of Dissimilar Materials AISI304/AL6061

Dehghan

Abbasi

Baharudin

et al. 2022

Metals

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Joining dissimilar materials is always a challenging and interesting topic for researchers and industries. Friction drill joining, as a solid-state process, is a novel approach to connecting similar and dissimilar materials. Dissimilar metals, especially ultra-high-strength steels and aluminum alloys, are used significantly for the mass reduction of automotive bodies, and to reduce CO2 emissions in the automotive industry. In the current work, a friction drill joining technique for joining AISI304 and Al6061 was experimentally and numerically studied. A technique for improving joint strength, load-clamping modification, and tool movement was also introduced. The required thrust force is measured, and it is proven that adding sheet layers does not significantly affect the required thrust force. To understand and identify the mechanism of the process, and its material behaviour, material stirring and formation in the joint region were analyzed. A thermo-mechanical finite element model was also developed, and the thermal stress, plastic strain, and temperature were studied. A numerical comparison between joints formed under normal and improvement conditions was conducted, and the significant effect of the improvement conditions on joint strength and formed-bush quality was found. Based on the findings, the great potential of using friction drill joining for joining dissimilar materials is confirmed.

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“…Several articles have reviewed different aspects of FSW, such as the joining of dissimilar materials [10][11][12], FSW for joining particular alloys such as Aluminum and Magnesium or processes [13][14][15], design and details of FSW tools [16,17] and numerical analysis of the FSW process [18][19][20]. However, despite the importance of quality control of joints produced using FSW, there are very few articles which discuss and describe the variety of defects which can occur in FSW and the non-destructive testing (NDT) techniques that have been used or evaluated for inspection of FSW [4,6].…”

Section: Introductionmentioning

confidence: 99%

Investigation of Nondestructive Testing Methods for Friction Stir Welding

Taheri

Kilpatrick

Norvalls

et al. 2019

Metals

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Friction stir welding is a method of materials processing that enables the joining of similar and dissimilar materials. The process, as originally designed by The Welding Institute (TWI), provides a unique approach to manufacturing—where materials can be joined in many designs and still retain mechanical properties that are similar to, or greater than, other forms of welding. This process is not free of defects that can alter, limit, and occasionally render the resulting weld unusable. Most common amongst these defects are kissing bonds, wormholes and cracks that are often hidden from visual inspection. To identify these defects, various nondestructive testing methods are being used. This paper presents background to the process of friction stir welding and identifies major process parameters that affect the weld properties, the origin, and types of defects that can occur, and potential nondestructive methods for ex-situ detection and in-situ identification of these potential defects, which can then allow for corrective action to be taken.

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Analyses of Friction Stir Riveting Processes: A Review

Cited by 19 publications

References 64 publications

Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design

Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design

A Novel Approach to Friction Drilling Process: Experimental and Numerical Study on Friction Drill Joining of Dissimilar Materials AISI304/AL6061

Investigation of Nondestructive Testing Methods for Friction Stir Welding

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