This thesis presents a comprehensive investigation into the feasibility and optimization of self-piercing riveting (SPR) for joining high-ductility die-cast aluminum alloy Nemalloy HE700 in F temper (as-cast) condition to dissimilar sheet materials, namely wrought aluminum alloy 6082-T6 and dual-phase steel DP600. The study demonstrates successful SPR joining of HE700 to these materials, with optimized process parameters and joint quality meeting automotive industry standards. Systematic experimental studies were conducted to investigate the effects of key SPR process parameters, including die geometry, ring groove depth, rivet hardness, and length, on joint quality and performance. Microstructural characterization revealed distinct patterns of grain flow and localized hardening in HE700 around the rivet and die features, providing insights into its deformation characteristics.
Finite element simulations, incorporating advanced material models such as Johnson-Cook plasticity and failure for AA6082 and DP600, and Voce hardening with Gurson-Tvergaard-Needleman void damage model for HE700, were developed and extensively validated against experimental results. The simulations accurately predicted potential failure sites in HE700, aligning with experimental observations of crack initiation. Numerical parametric studies demonstrated the intricate effects of process parameters and material properties on the stress and strain distributions, material flow, and damage accumulation during SPR.
The research contributes to the growing body of knowledge on advanced joining techniques for dissimilar materials, supporting vehicle lightweighting efforts. It establishes a comprehensive methodology integrating experiments, microstructural characterization, and simulations for studying and optimizing SPR processes for low ductility casting alloys, serving as a blueprint for future research and industrial implementation. The findings demonstrate the viability and potential of SPR technology for integrating high-ductility die-cast aluminum alloy HE700 into lightweight automotive body structures, paving the way for its wider industrial adoption. / Thesis / Master of Applied Science (MASc) / This research explores the potential of using a novel high-ductility aluminum alloy, Nemalloy HE700, in self-piercing riveting (SPR) - a modern joining technique for automotive manufacturing. The study aims to optimize the SPR process for joining HE700 to other commonly used automotive materials, such as aluminum alloys and high-strength steels, without compromising joint quality. By conducting practical experiments and computer simulations, the research identifies the best process parameters, such as rivet design and die shape, that result in strong, reliable joints meeting automotive industry standards. The findings demonstrate the successful use of HE700 in SPR, offering a promising solution for creating lighter, more fuel-efficient vehicles. This work contributes to the development of advanced joining technologies for sustainable transportation, making vehicles more environmentally friendly while maintaining high performance and safety standards.
| Identifer | oai:union.ndltd.org:mcmaster.ca/oai:macsphere.mcmaster.ca:11375/29755 |
| Date | January 2024 |
| Creators | Guo, Yunsong |
| Contributors | Jain, Mukesh, Shankar, Sumanth, Mechanical Engineering |
| Source Sets | McMaster University |
| Language | English |
| Detected Language | English |
| Type | Thesis |
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