Research Progress on Self-piercing Riveting of Fiber Reinforced Polymers and Aluminium Alloy Sheets
LIU Yang1, ZHUANG Weimin1, XIE Dongxuan2
1 State Key Laboratory of Automotive Simulation and Control, Jilin University, Changchun 130022, China 2 FAW-Volkswagen Auto. Co., Ltd., Changchun 130011, China
Abstract: To reduce vehicle exhaust emissions and improve energy efficiency, lightweight automotive bodies are a mainstream trend of automotive design and manufacture. In recent years, new lightweight materials such as aluminium alloys, magnesium alloys, titanium alloys and fiber reinforced polymers (FRP) have been widely used in automotive and aerospace industries due to their low density, high specific strength and stiffness. FRP have high specific modulus, corrosion resistance, excellent thermophysical and fatigue properties, as well as the advantages of damping and easy to design, and the application of FRP in automobiles is continually expands. With the application of light materials in automotive bodies, the multi-material structures put challenges to the joining technology. Resistance spot welding, laser welding, traditional riveting and adhesive bonding are commonly joining technologies used for automotive bodies. With the application of aluminium body and multi-material body, new joining technologies such as self-piercing riveting (SPR), mechanical clinching and friction stir welding have been popularized and applied. In engineering applications, FRP are often connected with aluminium alloys. SPR, as a new technology for joining light sheets, provides a solution for the connection between composites and metals. The damage of FRP in riveting region will be induced during SPR process, which affects the appearance and mechanical properties of the joints. Therefore, the damage of composite materials and its effect on joint performance are the core issues concerned by automotive enterprises. At present, the research on SPR of composite materials mainly focuses on the joining of carbon fiber composites, glass fiber composites with aluminium alloys. The matrix of the FRP studied is epoxy resin and polyamide. The tissue of the reinforced fibers can be divided into short-cut type, braided type and unidirectional type. As a kind of thermosetting matrix, epoxy resin-base fiber reinforced composites can only be placed as upper sheets to achieve effective joining, while thermoplastic resin matrix composites with better ductility can be used as upper or lower sheet. The for-ming process of the joints affects the damage degree of the composite materials. The use of rivet with the round head, increasing riveting speed and controlling the height of the rivet head higher than the surface of the upper sheet can reduce the damage of the composite materials, and lead to the joints obtain better mechanical properties. This review offers a retrospection of the research efforts with respect to the SPR of composite materials and aluminium alloys. The forming quality, riveting damage, mechanical properties, failure modes and numerical simulation of the joints are discussed, and the prospect of related research ideas and methods are suggested in order to provide a reference for the application of fiber reinforced polymers in automobive body.
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2020, Vol. 34 
