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A single-class joiningJoining process known asFriction self-piercing riveting “friction self-piercing riveting (F-SPR)” has been developed for joiningJoining various low-ductility lightweight materials on a laboratory scale. The frictional heat generated during the F-SPR process improved local ductility, resulting in crack-free joints and robust mechanical performance. This innovative joiningJoining technology was further advanced through the scale-up of the process using a new system with several key features (e.g., automatic rivet feeding and clamping system, vacuum system) toward industry readiness. The new integrated F-SPR systems were effectively demonstrated for joiningJoining different material combinations (e.g., carbon fiber composite to 7075 Al alloy, 7075 Al alloy to 7075 Al alloy, and 7075 Al alloy to casting AlCasting Al Aural 5) with a unified technique. Crack-free jointCrack free joint with adequate mechanical interlocking resulted in good mechanical joint strength for each material combination. Then, the process was successfully scaled up by producing multiple joints without any cracks on larger CFC-Al and Al-Al components by the new integrated system, bringing it closer to industrial application.

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Scale-Up of Friction Self-piercing Riveting Process for Multi-material Joints

  • 会议论文

  • 发表日期：

    2025年

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  • Yong Chae Lim,
  • Tianzhao Wang,
  • Yiyu Wang,
  • Jeremy Slade,
  • Sammy Ojo,
  • Zhili Feng

摘要

A single-class joiningJoining process known asFriction self-piercing riveting “friction self-piercing riveting (F-SPR)” has been developed for joiningJoining various low-ductility lightweight materials on a laboratory scale. The frictional heat generated during the F-SPR process improved local ductility, resulting in crack-free joints and robust mechanical performance. This innovative joiningJoining technology was further advanced through the scale-up of the process using a new system with several key features (e.g., automatic rivet feeding and clamping system, vacuum system) toward industry readiness. The new integrated F-SPR systems were effectively demonstrated for joiningJoining different material combinations (e.g., carbon fiber composite to 7075 Al alloy, 7075 Al alloy to 7075 Al alloy, and 7075 Al alloy to casting AlCasting Al Aural 5) with a unified technique. Crack-free jointCrack free joint with adequate mechanical interlocking resulted in good mechanical joint strength for each material combination. Then, the process was successfully scaled up by producing multiple joints without any cracks on larger CFC-Al and Al-Al components by the new integrated system, bringing it closer to industrial application.