Research Papers

A New Joining Process for Magnesium Alloys: Rotation Friction Drilling Riveting

[+] Author and Article Information
Gaokun Han

e-mail: hangaokun@126.com

Mingxing Wang

e-mail: wangmx@zzu.edu.cn

Zhongxia Liu

e-mail: liuzhongxia@zzu.edu.cn
Department of Physics,
Laboratory of Materials Physics of the Ministry of Education of China,
Zhengzhou University,
Zhengzhou, 450052, PRC

Pei-Chung Wang

Manufacturing Systems Research Lab,
General Motors Research and Development Center,
30500 Mound Road,
Warren, MI 48090
e-mail: peichung.wang@gm.com

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received May 19, 2012; final manuscript received November 27, 2012; published online May 24, 2013. Assoc. Editor: Brad L. Kinsey.

J. Manuf. Sci. Eng 135(3), 031012 (May 24, 2013) (9 pages) Paper No: MANU-12-1151; doi: 10.1115/1.4023721 History: Received May 19, 2012; Revised November 27, 2012

A new joining process for magnesium alloys, rotation friction drilling riveting (RFDR), is proposed in this paper. In RFDR operation, a semitubular rivet with a grip rod and a rivet cap rotating at high speed is brought to contact with the riveted sheets, generating frictional heat between the rivet and riveted sheets, which softens the sheet materials and enables the rivet to be drilled into the sheets under reduced force. While being inserted, the rivet pierces through the top sheet and flares into the bottom sheets due to the action of the cavity die, thereby forming a mechanical interlock between the rivet and riveted sheets. Our studies showed that RFDR of the magnesium alloy sheets could be carried out at room temperature and provided the joints with superior shear strength and fatigue property when compared with self-piercing riveting (SPR). The effects of the operating parameters of the RFDR process on the quality of the joints were also investigated in the study. The results showed that while the rivet rotating speed little affected the shear strength of RFDR joints, the rivet shank length and the downward pressure had a significant influence on the mechanical properties of the RFDR joints. Therefore, it is very important to choose the right rivet shank length and downward pressure for producing RFDR joints with high quality.

Copyright © 2013 by ASME
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Fig. 1

Rivet used in this study: (a) shape of rivet and (b) cross section of rivet

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Fig. 2

Steel base plate with a small cavity die: (a) shape of the plate and (b) cross section of the plate

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Fig. 3

Schematic of RFDR process cycle

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Fig. 4

Schematic of a single lap shear joint (dimension in mm)

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Fig. 5

Appearances and cross section of a representative RFDR joint: (a) top view of the joint, (b) top view of the joint after cutting off the grip rod, (c) bottom view of the joint, and (d) cross section of the joint

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Fig. 6

Tensile shear curves of five RFDR joints of 2 mm thick magnesium AZ31 alloy sheet

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Fig. 7

Failure mode of RFDR joints in tensile shear tests

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Fig. 8

Appearances of the RFDR joints fabricated using rivets with varying shank lengths: (a) 5.5 mm, (b) 6.5 mm, and (c) 7.5 mm

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Fig. 9

Cross sections of the RFDR joints produced using rivets with varying shank lengths: (a) 5.5 mm, (b) 6.5 mm, and (c) 7.5 mm

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Fig. 10

Effect of rivet shank length on the shear strength and interlock of RFDR joints

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Fig. 11

Failure modes of the RFDR joints fabricated using the rivets with varying shank lengths in tensile shear tests: (a) 5.5 mm, (b) 6.5 mm, and (c) 7.5 mm

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Fig. 12

Tensile shear curves of the RFDR joints fabricated using varying rivet rotating speeds

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Fig. 13

Effect of rivet rotating speed on the shear strength and interlock of RFDR joints

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Fig. 14

Effect of downward pressure on the shear strength and interlock of RFDR joints

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Fig. 15

Appearances and cross sections of the SPR joints produced at room temperature (a) and (b) and at preheating temperature of 180 °C (c) and (d)

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Fig. 16

Comparisons of the tensile shear curves (a) and the shear strengths (b) of the RFDR and SPR joints

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Fig. 17

Tensile shear failure modes of the SPR joints fabricated at room temperature (a) and at the preheating temperature of 180 °C (b) and (c)

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Fig. 18

Comparison of fatigue life curves of RFDR and SPR joints

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Fig. 19

Fatigue failure modes of the SPR joints produced at 180 °C: (a) bottom coupon fatigue fails and (b) top coupon fatigue fails

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Fig. 20

Fatigue crack propagation of an SPR joint under the maximum load of 3.0 kN: (a) crack at 27,161 cycles, (b) crack at 28,060 cycles, and (c) crack at 28,758 cycles

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Fig. 21

Fatigue failure modes of RFDR joints: (a) top coupon fractures and (b) bottom coupon fractures

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Fig. 22

Fatigue crack propagation of an RFDR joint under maximum load of 3.0 kN: (a) crack at 47,856 cycles, (b) crack at 49,376 cycles, and (c) crack at 50,285 cycles

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Fig. 23

Cross sections of the RFDR joints after a certain number of cyclic loading: (a) fatigue crack initiates from internal surface of top coupon and (b) fatigue crack penetrates top coupon




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