Extent of interlocking and metallurgical bonding in friction riveting of aluminum alloy to steel

Srivastava, Abhinav; Das, Hrishikesh; Tamayo, Daniel Ramirez; Li, Lei; Pole, Mayur; Gwalani, Bharat; Soulami, Ayoub; dos Santos, Jorge F.; Kappagantula, Keerti S.; Reza-E-Rabby, Md

doi:10.1007/s00170-023-12111-8

Title: Extent of interlocking and metallurgical bonding in friction riveting of aluminum alloy to steel

Journal Article · 09 August 2023 · International Journal of Advanced Manufacturing Technology

DOI: https://doi.org/10.1007/s00170-023-12111-8 · OSTI ID:2202426

Srivastava, Abhinav ^[1]; Das, Hrishikesh ^[1]; Tamayo, Daniel Ramirez ^[1];

^[1]; Pole, Mayur ^[1]; Gwalani, Bharat ^[2];

^[1]; dos Santos, Jorge F. ^[1];

^[1];

^[1]

Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)
North Carolina State University, Raleigh, NC (United States)

In this study, the joining of 6061-T6 aluminum alloy and DP590 steel using a M42 steel rivet via friction riveting technique is investigated. The surface morphology and microstructure characterization reveal the formation of an anchor zone that imparts mechanical interlock as well as the formation of metallurgical bonds at the interface of aluminum and steel. A combination of interlocking and bonding results in the achievement of a high load-carrying capacity of 5.7 kN during lap shear testing at room temperature. A finite element-based computational model was developed which accurately predicted the lap shear response of the joint. The model revealed that the metallurgical bond formed during fric-riveting adds 39% peak load strength to the joint. An extensive microstructural investigation, post-lap-shear fractography, and the modeling results, together provided insights on the joint failure mechanism. In conclusion, this study highlights that friction riveting is a promising method for aluminum-to-steel dissimilar joining, which is important for lighweighing automotive vehicles for energy efficiency.

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Research Organization:: Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Vehicle Technologies Office (VTO)

Grant/Contract Number:: AC05-76RL01830

OSTI ID:: 2202426

Report Number(s):: PNNL-SA--180851

Journal Information:: International Journal of Advanced Manufacturing Technology, Journal Name: International Journal of Advanced Manufacturing Technology Journal Issue: 7-8 Vol. 128; ISSN 0268-3768

Publisher:: SpringerCopyright Statement

Country of Publication:: United States

Language:: English

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