Fatigue analyses of self-piercing rivets and clinch joints in lap-shear specimens of aluminum sheets

Abstract Fatigue behavior of self-piercing rivets (SPRs) and clinch joints in lap-shear specimens of 6111-T4 aluminum sheets with different thicknesses was investigated. Lap-shear specimens with SRPs and clinch joints were tested under quasi-static and cyclic loading conditions. Micrographs showed different failure modes of SPRs and clinch joints under different loading conditions. Dominant fatigue cracks were identified. The structural stress model from Tran and Pan’s recent works was adopted. The structural stress solutions at the crack initiation locations and the stress-life data of aluminum 6111-T4 were adopted to estimate fatigue lives. The fatigue life estimations show good agreement with the experimental results.

[1]  J. Pan,et al.  A fatigue crack growth model for spot welds under cyclic loading conditions , 2006 .

[2]  Ho-Kyung Kim.  Fatigue Strength Evaluation of the Clinch Joints of a Cold Rolled Steel Sheet , 2009 .

[3]  Xin Sun,et al.  Performance Optimization of Self-Piercing Rivets through Analytical Rivet Strength Estimation , 2005 .

[4]  Ne Dowling,et al.  A CRACK GROWTH APPROACH TO LIFE PREDICTION OF SPOT‐WELDED LAP JOINTS , 1998 .

[5]  Xin Sun,et al.  Fatigue Behaviors of Self-Piercing Rivets Joining Similar and Dissimilar Sheet Metals , 2007 .

[6]  M. Langseth,et al.  Self-piercing riveting connections using aluminium rivets , 2010 .

[7]  Fengchong Lan,et al.  Notice of RetractionInfluence of tooling geometric parameters on clinching joint properties for steel-aluminum hybrid car-body structures , 2010, 2010 3rd International Conference on Computer Science and Information Technology.

[8]  X. Su,et al.  Finite Element Modeling of Dissimilar Metal Self-Piercing Riveting Process , 2014 .

[9]  J. Pan,et al.  Failure modes and fatigue life estimations of spot friction welds in lap-shear specimens of aluminum 6111-T4 sheets. Part 1: Welds made by a concave tool , 2008 .

[10]  Byung-Min Kim,et al.  Parametric study on mechanical clinching process for joining aluminum alloy and high-strength steel sheets , 2010 .

[11]  Ali Fatemi,et al.  An experimental investigation of deformation and fatigue behavior of coach peel riveted joints , 2006 .

[12]  Toru Kato,et al.  Mechanism of superiority of fatigue strength for aluminium alloy sheets joined by mechanical clinching and self-pierce riveting , 2012 .

[13]  Dieter Radaj,et al.  Stress singularity, notch stress and structural stress at spot-welded joints , 1989 .

[14]  J. Pan,et al.  Fatigue behavior of dissimilar spot friction welds in lap-shear and cross-tension specimens of aluminum and steel sheets , 2010 .

[15]  Li Han,et al.  The Effect of Pre-Straining on the Mechanical Behaviour of Self-Piercing Riveted Aluminium Alloy Sheets , 2005 .

[16]  Jacek Mucha,et al.  The analysis of lock forming mechanism in the clinching joint , 2011 .

[17]  Juha Varis,et al.  The suitability of clinching as a joining method for high-strength structural steel , 2003 .

[18]  P.-C. Lin,et al.  Modeling of failure near spot welds in lap-shear specimens based on a plane stress rigid inclusion analysis , 2006 .

[19]  J. Pan,et al.  Closed-form structural stress and stress intensity factor solutions for spot welds in commonly used specimens , 2008 .

[20]  J. Pan,et al.  Mode I stress intensity factor solutions for spot welds in lap-shear specimens , 2007 .

[21]  J. Pan,et al.  Closed-form structural stress and stress intensity factor solutions for spot welds under various types of loading conditions , 2008 .

[22]  J. Pan,et al.  Fatigue behavior of aluminum 5754-O and 6111-T4 spot friction welds in lap-shear specimens , 2008 .

[23]  John H. Beynon,et al.  Feasibility of measuring residual stress profile in different self-pierce riveted joints , 2012 .

[24]  J. Pan,et al.  Fatigue behavior of spot friction welds in lap-shear and cross-tension specimens of dissimilar aluminum sheets , 2010 .

[25]  Dieter Radaj,et al.  Stress intensity factors for spot welds between plates of unequal thickness , 1991 .

[26]  Shicheng Zhang,et al.  Fracture mechanics solutions to spot welds , 2001 .

[27]  Stefano Beretta,et al.  Fatigue behaviour of tensile-shear loaded clinched joints , 2006 .

[28]  Dieter Radaj,et al.  Simplified formulae for stress intensity factors of spot welds , 1991 .

[29]  Shicheng Zhang,et al.  Stress Intensities at Spot Welds , 1997 .

[30]  Li Han,et al.  Mechanical behaviour of self-piercing riveted multi-layer joints under different specimen configurations , 2007 .

[31]  R. G. Davies,et al.  The aluminum spot weld , 1996 .

[32]  Xin Sun,et al.  Strength estimation of self-piercing rivets using lower bound limit load analysis , 2005 .

[33]  Li Han,et al.  Influence of edge distance on quality and static behaviour of self-piercing riveted aluminium joints , 2012 .

[34]  J. Kucza,et al.  Static and Fatigue Behavior of Spot-Welded 5182-0 Aluminum Alloy Sheet , 1999 .

[35]  Dieter Radaj,et al.  Stress intensity factors for spot welds between plates of dissimilar materials , 1992 .

[36]  P. Mallick,et al.  Fatigue of self-piercing riveted joints in aluminum alloy 6111 , 2003 .