Emerging trends in manufacturing such as light weighting, increased performance and functionality increases the use of multi-material, hybrid structures and thus the need for joining of dissimilar materials. The properties of the different materials are jointly utilised to achieve product performance. The joining processes can, on the other hand be challenging due to the same different properties. This paper reviews and summarizes state of the art research in joining dissimilar materials. Current and emerging joining technologies are reviewed according to the mechanisms of joint formation, i.e.; mechanical, chemical, thermal, or hybrid processes. Methods for process selection are described and future challenges for research on joining dissimilar materials are summarized.

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Joining of dissimilar materials

http://plast.me.tut.ac.jp/present/joining_CIRP.pdf

Joining by plastic deformation

This paper investigates comprehensive knowledge regarding joining CFRP and aluminium alloys in available literature in terms of available methods, bonding processing and mechanism and properties. The methods employed comprise the use of adhesive, self-piercing rivet, bolt, clinching and welding to join only CFRP and aluminium alloys. The non-thermal joining methods received great attention though the welding process has high potential in joining these materials. Except adhesive bonding and welding, other joining methods require the penetration of metallic pins through joining parts and therefore, surface preparation is unimportant. No model is found to predict the properties of jointed structures, which makes it difficult to select one over another in applications. The choice of bonding methods depends primarily on the specific applications. The load-bearing mechanism of bolted joints is predominantly the friction that is the first stage resistance. Hybrid joints performance is enhanced by combining rivets, clinch or bolts with adhesives.

/pdf/joining-of-carbon-fibre-reinforced-polymer-cfrp-composites-b1dn74dni2.pdf

Joining of carbon fibre reinforced polymer (CFRP) composites and aluminium alloys-A review

Joining by forming—A review on joint mechanisms, applications and future trends

Driven by increasing costs for energy and raw material and especially by the European CO2-emission laws, automotive industry faces the challenge to develop more lightweight and at the same time still rigid and crash-stable car bodies, that are affordable for large-scale production. The implementation of weight-reduced constructions depends not only on the availability of lightweight materials and related forming technologies, but also on cost-efficient and reliable joining technologies suitable for multi-material design. This article discusses the challenges and requirements for these technologies, based on the example of joining aluminium with press-hardened boron steels, what is considered as a very important material combination for affordable future lightweight mobility. Besides a presentation of recent developments for extending the process limits of conventional mechanical joining methods, new promising technologies such as resistance element welding are introduced. In addition, the performance, advantages, and disadvantages of the presented technologies are compared and discussed.

/pdf/innovative-and-highly-productive-joining-technologies-for-1iogrbvczi.pdf

Toru Kato

Papers

Joining of high strength steel and aluminium alloy sheets by mechanical clinching with dies for control of metal flow

Self-piercing riveting of high tensile strength steel and aluminium alloy sheets using conventional rivet and die

Joinability of aluminium alloy and mild steel sheets by self piercing rivet

Mechanism of superiority of fatigue strength for aluminium alloy sheets joined by mechanical clinching and self-pierce riveting

Mechanical clinching of ultra-high strength steel sheets and strength of joints