skip to main content
OSTI.GOV title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: Residual Stresses and Plastic Deformation in Self-Pierce Riveting of Dissimilar Aluminum-to-Magnesium Alloys

Journal Article · · SAE International Journal of Materials and Manufacturing (Online)
 [1];  [2];  [1];  [1];  [3];  [3];  [3]
  1. Univ. of Alabama, Tuscaloosa, AL (United States)
  2. Ford Motor Co., Detroit, MI (United States)
  3. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
+ Show Author Affiliations

In this study, the complex relationship between deformation history and residual stresses in a magnesium-to-aluminum self-pierce riveted (SPR) joint is elucidated using numerical and experimental approaches. Non-linear finite element (FE) simulations incorporating strain rate and temperature effects were performed to model the deformation in the SPR process. In order to accurately capture the deformation, a stress triaxiality-based damage material model was employed to capture the sheet piercing from the rivet. Strong visual comparison between the physical cross-section of the SPR joint and the simulation was achieved. To aid in understanding of the role of deformation in the riveting process and to validate the modeling approach, several experimental measurements were conducted. To quantify the plastic deformation from the piercing of the rivet, micro hardness mapping was performed on a cross-section of the SPR joint. The FE model showed very strong correlation to the experimental hardness mapping results suggesting the nonlinear model captured the plastic deformation with high accuracy. To measure the elastic residual stresses in the SPR joint, neutron and x-ray diffraction mapping techniques were conducted and in general, the FE model correlated well to the trends and magnitudes of the elastic stresses. While some error occurred in between the model and the neutron and x-ray diffraction results, the numerical approach developed in this study shows potential as a tool for understanding SPR behavior as well as optimizing the process parameters.

Research Organization:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Organization:
USDOE
Grant/Contract Number:
AC05-00OR22725
OSTI ID:
1486971
Journal Information:
SAE International Journal of Materials and Manufacturing (Online), Vol. 11, Issue 2; ISSN 1946-3987
Publisher:
SAE InternationalCopyright Statement
Country of Publication:
United States
Language:
English

Figures / Tables (12)

Figure 1(p. 1)figure Figure 1
Figure 2(p. 2)figure Figure 2
Figure 3(p. 3)figure Figure 3
Figure 4(p. 3)figure Figure 4
Figure 5(p. 4)figure Figure 5
Figure 6(p. 5)figure Figure 6
Figure 7(p. 5)figure Figure 7
Figure 10(p. 6)figure Figure 10
Figure 8(p. 6)figure Figure 8
Figure 9(p. 6)figure Figure 9
Figure 11(p. 7)figure Figure 11
Figure 12(p. 7)figure Figure 12

Similar Records

Self-Pierce Riveting Through 3 Sheet Metal Combinations
Journal Article · Wed May 04 00:00:00 EDT 2011 · AIP Conference Proceedings · OSTI ID:1486971
Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design
Journal Article · Fri Dec 01 00:00:00 EST 2023 · Journal of Manufacturing and Materials Processing · OSTI ID:1486971
+2 more
Joining of Lightweight Dissimilar Materials by Friction Self-Piercing Riveting
Conference · Fri Feb 01 00:00:00 EST 2019 · OSTI ID:1486971
+1 more

Related Subjects

36 MATERIALS SCIENCE