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Cipriano, Goncalo Pina
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document
Friction Riveting – Single-phase Process Variant
Abstract
Friction Riveting can be used to produce multi-material metallic-insert dissimilar connections. In general, the process aims to be used as an alternative connection method, reducing the usage of mechanical fasteners and adhesives. In single-phase friction riveting a simpler approach is used to join the materials in comparison to the more conventional multi-phase process. A basic application of the process consists of joining a featureless cylindrical metallic cylindrical rivet to a non-reinforced polymeric plate. The single-phase variant does not make use of a higher load phase – i.e. a forging phase – designed to promote extra plastic deformation of the metallic rivet. As such, it can constitute a solution to applications where the normal load applied to the materials must be kept at lower values. In the same manner as the multi-phase friction riveting, this process can be applied to join non-reinforced and reinforced thermoplastics and thermosets. These having been successfully joined with metals such as aluminum, steel and titanium. This work demonstrates that is possible to join AA2024 rivets, with 5 mm of diameter, to non-reinforced polyetherimide plates. A Box-Behnken design-of-experiments and statistical analysis were used to set the parameter matrix and understand the correlations between the process parameters used and the resulting joint properties. The parameters used resulted in a large variation of mechanical energy input (151 – 529 J). Higher-energy joining conditions led to rivet over-deformation and material rupture. Lower energy input corresponded to the best performing joints, characterized by a bell-shaped rivet plastic deformation. Joints performed achieved a maximum ultimate tensile force of 7486 N. The results allow for single-phase friction riveting to be established as an alternative joining process.