Research Papers: JOINING

Friction Stir Blind Riveting for Joining Dissimilar Cast Mg AM60 and Al Alloy Sheets

[+] Author and Article Information
Junying Min

Department of Mechanical Engineering,
University of Hawaii at Manoa,
Honolulu, HI 96822
e-mail: junying.min@gmail.com

Jingjing Li, Weiming Wang

Department of Mechanical Engineering,
University of Hawaii at Manoa,
Honolulu, HI 96822

Blair E. Carlson, Yongqiang Li, James F. Quinn

General Motors Research & Development,
Warren, MI 48095-9055

Jianping Lin

School of Mechanical Engineering,
Tongji University,
Shanghai 201804, China
e-mail: jplin58@tongji.edu.cn

1Corresponding authors.

2Present address: Ruhr-Universität Bochum, Lehrstuhl für Produktionssysteme (LPS), Universitätsstraße 150, D-44780 Bochum, Germany.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received August 20, 2014; final manuscript received March 14, 2015; published online September 4, 2015. Assoc. Editor: Yannis Korkolis.

J. Manuf. Sci. Eng 137(5), 051022 (Sep 04, 2015) (9 pages) Paper No: MANU-14-1437; doi: 10.1115/1.4030156 History: Received August 20, 2014

A new one-sided joining method, friction stirring blind riveting (FSBR) was successfully implemented to form lap-shear joints for dissimilar metals from pairs of 3.05 mm thick cast Mg AM60, rolled 1.5 mm thick Al AA6022, and extruded 3.15 mm thick Al AA6082 specimens. The concept of this process is riveting the two workpieces with reduced force under frictional heat and fastening the workpieces through blind riveting once the rivet is fully inserted. In this research, the process was experimentally analyzed and optimized for four joint combinations. It was demonstrated that switching the positions of Mg and Al alloy specimens has a significant effect on the process window and maximum tensile load of the joints. Three quality issues of the FSBR joints were observed and discussed. During tensile testing, the sheet closer to the rivet tail work-hardens due to tail forming process but has worse loading condition than the sheet closer to the rivet head. For AA6xxx sheets, precipitate hardening due to frictional heat is another strengthening mechanism in FSBR compared to the conventional riveting process, which leads to higher tensile loads in FSBR joints.

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Grahic Jump Location
Fig. 1

Illustration of FSBR process. (a) The rotating blind rivet is approaching the workpieces, (b) frictional penetration of the rivet, (c) pulling out the mandrel, and (d) completion. (c) and (d) form the rivet tail, which is called tailing forming process in this work.

Grahic Jump Location
Fig. 2

(a) Die installed on the CNC machine. (b) 30 mm × 100 mm specimens fixed on the die. (c) Illustration for the force and torque analysis during friction stirring.

Grahic Jump Location
Fig. 3

Illustration for the microhardness measurement on the AM60

Grahic Jump Location
Fig. 4

A semifinished AM60-AA6022 joint at ω = 9000 rpm and f = 600 mm/min

Grahic Jump Location
Fig. 5

Load–displacement curves of AM60-AA6022 joints by FSBR at: (a) ω = 3000 rpm, (b) ω = 6000 rpm, and (c) ω = 9000 rpm compared with that of the predrilled joint (PreD). (d) A fractured FSBR joint at ω = 9000 rpm and f = 780 mm/min and (e) a fractured predrilled joint.

Grahic Jump Location
Fig. 6

(a) Load–displacement curves of AA6022-AM60 joints compared with the predrilled one. (b) Fractured FSBR joint at ω = 9000 rpm and f = 270 mm/min (left) and predrilled joint (right), the view from the bottom.

Grahic Jump Location
Fig. 7

(a) Load–displacement curves of AM60-AA6082 joints compared with the predrilled one. (b) Fractured FSBR joint at ω = 9000 rpm and f = 270 mm/min (left) and predrilled joint (right), the view from the top.

Grahic Jump Location
Fig. 8

(a) Load–displacement curves of AA6082-AM60 joints compared with the predrilled one. (b) Fractured FSBR joint at ω = 9000 rpm and ω = 120 mm/min (left) and predrilled joint (right).

Grahic Jump Location
Fig. 9

The comparison of the microhardness results. “Base”: the base material of AM60; “PreD1”: the AM60 in the predrilled AA6082-AM60 joint; “PreD2”: the AM60 in the predrilled AA6022-AM60 joint; “FSBR”: the AM60 in the AA6022-AM60 joint by FSBR with a spindle speed of 9000 rpm and a feed rate of 780 mm/min.

Grahic Jump Location
Fig. 10

Comparison of the maximum tensile load of: (a) AM60-AA6022 and AA6022-AM60 joints and (b) AM60-AA6082 and AA6082-AM60 joints. (c) Side views of fractured AA6022-AM60 and AA6082-AA6022 joints by FSBR.




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