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.

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

Self-pierce riveting for sheet materials: State of the art

Self-piercing riveting (SPR) is a cold mechanical joining process used to join two or more sheets of materials by driving a rivet piercing through the top sheet or the top and middle sheets and subsequently lock into the bottom sheet under the guidance of a suitable die. SPR is currently the main joining method for aluminium and mixed-material lightweight automotive structures. SPR was originated half century ago, but it only had significant progress in the last 25 years due to the requirement of joining lightweight materials, such as aluminium alloy structures, aluminium-steel structures and other mixed-material structures, from the automotive industry. Compared with other conventional joining methods, SPR has many advantages including no pre-drilled holes required, no fume, no spark and low noise, no surface treatment required, ability to join multi-layer materials and mixed materials and ability to produce joints with high static and fatigue strengths. In this paper, research investigations that have been conducted on self-piercing riveting will be extensively reviewed. The current state and development of SPR process is reviewed and the influence of the key process parameters on joint quality is discussed. The mechanical properties of SPR joints, the corrosion behaviour of SPR joints, the distortion of SPR joints and the simulation of SPR process and joint performance are reviewed. Developing reliable simulation methods for SPR process and joint performance to reduce the need of physical testing has been identified as one of the main challenges.

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Self-piercing riveting-a review

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

Self-piercing riveting (SPR) is a high-speed mechanical fastening technique for joining sheet components. It has drawn more attention in recent years because it can join some advanced materials that are dissimilar, coated and hard to weld, such as aluminum sheets. Research results have shown that SPR improves joint properties in aluminum and steels. However, there has been concern that there might be dimensional issues due to relatively large material flows at SPR joint configurations. This paper presents the latest research progress in the assembly dimensional prediction area, using experimental data and finite element analysis results. It is found that the joint distortion of SPR as tested is much larger than that from resistance spot welding (RSW), and the inclusion of SPR joint distortion is generally needed for accurate global assembly predictions. To include the local SPR effect, a new algorithm to represent the SPR distortion has been developed. The new algorithm can be incorporated into special finite element analysis codes such as EAVS (elastic assembly variation simulation) to efficiently predict body assembly dimensions where spot joining processes are involved.

Wu Yang

Papers

Assembly dimensional prediction for self-piercing riveted aluminum panels