Residual Stresses and Plastic Deformation in Self-Pierce Riveting of Dissimilar Aluminum-to-Magnesium Alloys
Abstract
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 modelmore »
- Authors:
-
- Univ. of Alabama, Tuscaloosa, AL (United States)
- Ford Motor Co., Detroit, MI (United States)
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Publication Date:
- Research Org.:
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Sponsoring Org.:
- USDOE
- OSTI Identifier:
- 1486971
- Grant/Contract Number:
- AC05-00OR22725
- Resource Type:
- Accepted Manuscript
- Journal Name:
- SAE International Journal of Materials and Manufacturing (Online)
- Additional Journal Information:
- Journal Name: SAE International Journal of Materials and Manufacturing (Online); Journal Volume: 11; Journal Issue: 2; Journal ID: ISSN 1946-3987
- Publisher:
- SAE International
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE
Citation Formats
Moraes, Joao F. C., Su, Xuming, Brewer, Luke N., Fay, Brian J., Bunn, Jeffrey R., Sochalski-Kolbus, Lindsay, and Barkey, M. E. Residual Stresses and Plastic Deformation in Self-Pierce Riveting of Dissimilar Aluminum-to-Magnesium Alloys. United States: N. p., 2018.
Web. doi:10.4271/05-11-02-0015.
Moraes, Joao F. C., Su, Xuming, Brewer, Luke N., Fay, Brian J., Bunn, Jeffrey R., Sochalski-Kolbus, Lindsay, & Barkey, M. E. Residual Stresses and Plastic Deformation in Self-Pierce Riveting of Dissimilar Aluminum-to-Magnesium Alloys. United States. https://doi.org/10.4271/05-11-02-0015
Moraes, Joao F. C., Su, Xuming, Brewer, Luke N., Fay, Brian J., Bunn, Jeffrey R., Sochalski-Kolbus, Lindsay, and Barkey, M. E. Fri .
"Residual Stresses and Plastic Deformation in Self-Pierce Riveting of Dissimilar Aluminum-to-Magnesium Alloys". United States. https://doi.org/10.4271/05-11-02-0015. https://www.osti.gov/servlets/purl/1486971.
@article{osti_1486971,
title = {Residual Stresses and Plastic Deformation in Self-Pierce Riveting of Dissimilar Aluminum-to-Magnesium Alloys},
author = {Moraes, Joao F. C. and Su, Xuming and Brewer, Luke N. and Fay, Brian J. and Bunn, Jeffrey R. and Sochalski-Kolbus, Lindsay and Barkey, M. E.},
abstractNote = {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.},
doi = {10.4271/05-11-02-0015},
journal = {SAE International Journal of Materials and Manufacturing (Online)},
number = 2,
volume = 11,
place = {United States},
year = {Fri Mar 16 00:00:00 EDT 2018},
month = {Fri Mar 16 00:00:00 EDT 2018}
}
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Figure 1: Self-pierce riveting process scheme [10].
Figures / Tables found in this record: