Self-piercing riveting of aluminium–lithium alloy sheet materials

Abstract

The self-piercing riveting (SPR) of 1420 aluminium-lithium alloy sheets is investigated. Static tests with lap-shear loads and fatigue tests using the tension-tension loading mode were applied to obtain the joint performances and failure modes. The mechanism analysis regarding failure and fretting was employed using a scanning electron microscope (SEM) and an energy dispersive X-ray spectroscopy (EDX). The 1420 Al-Li alloy sheets can be joined effectively using SPR. The fatigue load-fatigue life curve with a 95% confidence level is obtained using a variation coefficient method. The joints failed in the rivet pulled out from the locked sheet in static trials, and the locked sheet fractured during the fatigue tests. The fretting wear can be observed at the contact interface between the rivet tail and the locked sheet or between both sheets at different load levels. The fretting region changes at a high or low load level, and it is highly relevant to the fatigue rupture paths.

Service life estimation of self‐piercing riveted joints by linear damage accumulation

“…Debris mainly occurs at the beginning of cyclic loading and consists of dissolved aluminum particles that quickly oxidize to Al 2 O 3 , as shown by EDX analysis. Iyer et al, 22 Han et al, 23 Li et al, 24 and Zhang et al 25 also proved fretting in SPR joints.…”

An Overview of Self-piercing Riveting Process with Focus on Joint Failures, Corrosion Issues and Optimisation Techniques

“…As fretting damage progresses, stress concentration can build up at these areas leading to the nucleation of a fatigue crack, and then fracture. Hence, the presence of fretting can significantly degrade the fatigue life [88][89][90][91].…”

Experimental investigation of the adhesive layer’s impact on the Riv-Bonding process and joint quality

“…For instance, Rao et al [11] studied the failure modes and fatigue strength of the SPR joints with the carbon fibre reinforced polymer (CFRP) top sheet and the AA6111 bottom sheet under different loading conditions. Zhang et al [12] evaluated the shear strength and fatigue life of SPR joints with 1420 aluminium-lithium alloy sheets. Huang et al [13] developed a 3D simulation model using ABAQUS to predict the crack initiation, crack growth and the final fatigue life of SPR joints with aluminium alloy 6111-T4 sheets.…”