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Friction Stir Blind Riveting of Dissimilar Materials.

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Title:Friction Stir Blind Riveting of Dissimilar Materials.
Authors:Wang, Wei-Ming
Contributors:Mechanical Engineering (department)
Date Issued:May 2017
Publisher:University of Hawaiʻi at Mānoa
Abstract:oining of dissimilar materials receives great attentions to broaden the implementation of
lightweight components for vehicle applications. Friction stir blind riveting (FSBR), as a newly
developed method, shows potentials in joining dissimilar metals and thermoplastic composites
for complex structures. In this process, a rotating blind rivet is applied to soften and penetrate
two workpieces with frictional heat. The rotation stops after the head of blind rivet contacts the
top surface of workpiece, and then the mandrel is pulled up and breaks off at the setting force.
Finite element is one of the best technique to observe material flow and temperature during a
friction stir process; nevertheless, the main issue to simulate FSBR process is the large
deformation of work materials. Therefore, FEM coupled with smoothed particle hydrodynamics
(SPH) was utilized to simulate FSBR process for joining magnesium and aluminum alloys. To
validate the model, plunge force and torque were compared to experimental measurements. The
history of temperature, von Mises stress, and material flow of workpieces are available in this
SPH-FEM model.
To broaden the application of FSBR, the knowledge of mechanical properties and failure
mechanisms of FSBR joints is required. Three optimal configurations of FSBR lap joints,
including aluminum, magnesium, and a carbon-fiber reinforced polymeric composite (CFRP),
were studied in this dissertation. In situ nondestructive testing method, acoustic emission (AE),
was applied to identify the deformation zone and failure mode of FSBR lap joints under uniaxial
tensile loading. Scanning electron microscopy (SEM) was also performed to analyze the
fractured microstructures.
Post-corrosion mechanical behavior of dissimilar material joints is a primary consideration
for their applications subjected to a corrosive environment. In this study, it was found that for
CFRP constituent exposed joints, the dominated failure mode was tension failure and there was
no loss in strength observed under current corrosion condition; however, exposed Mg/Al joints
depicted a complex failure mechanism where failure was caused by bearing force and secondary
bending during tensile tests, and degradation in strength was observed.
Description:Ph.D. Thesis. University of Hawaiʻi at Mānoa 2017.
URI:http://hdl.handle.net/10125/62530
Rights:All UHM dissertations and theses are protected by copyright. They may be viewed from this source for any purpose, but reproduction or distribution in any format is prohibited without written permission from the copyright owner.
Appears in Collections: Ph.D. - Mechanical Engineering


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