This document provides an overview of mechanical fastening methods for joining aluminum parts, including definitions and classifications. It discusses screw joints, folds, rivets, and clinching. Screw joints can be pierced, through, or blind holes. Folds are formed locking joints created through folding, interlocking, and pressing sheets together. Riveting includes indirect and direct methods. Blind rivets have a predetermined break point. The document aims to introduce the principal types of mechanical fastening methods for aluminum.
TALAT Lecture 4205: Testing Methods for Welded JointsCORE-Materials
This lecture gives information about the relevant non-destructive and destructive testing methods for aluminium welded joints. Background in production welding and quality assurance is assumed.
TALAT Lecture 5104: Basic Approaches to Prevent Corrosion of AluminiumCORE-Materials
This lecture describes important measures for the prevention of corrosion of unprotected, bare
aluminium. Basic knowledge of corrosion behaviour of aluminium and some knowledge of the electrochemical nature of corrosion is assumed
This lecture describes the fundamentals of bending and folding aluminium sheet; it also describes different methods in design of folding tools. Background in production engineering and sheet metal forming and familiarity with the subject matter covered in TALAT This lectures 3701- 3705 is assumed.
17. Projektowanie procesów technologicznychAdam Osa
Poradnik będzie Ci pomocny w opanowaniu umiejętności opracowywania procesów
technologicznych obróbki skrawaniem, montażu oraz projektowania prostych procesów
obróbki na tokarki CNC.
TALAT Lecture 2301: Design of Members Example 4.4: Bending moment resistance ...CORE-Materials
This 3 sentence summary provides the key details about the document:
1) The document is a 10 page example from a lecture on designing members for bending moment that analyzes the bending moment resistance of a welded hollow section with outstands using a class 4 cross section.
2) It presents the geometry, material properties, nodes, and elements of the hollow cross section and performs iterative calculations of the effective cross section area, stress distribution, and effective thicknesses accounting for any heat affected zones to determine the bending moment resistance.
3) The example is considered comprehensive because it shows calculations in detail, covers all classes of cross sections, and demonstrates how to increase effective thickness for non-fully stressed elements through
TALAT Lecture 2301: Design of Members Example 5.5: Axial force resistance of ...CORE-Materials
This 3-page document provides an example calculation for determining the axial force resistance of a laced column. It includes dimensions, material properties, and calculations of various parameters needed for the analysis. Key steps and results are shown, such as determining the effective length, flexural buckling resistance, and checking that the lacing can resist the required shear force. In the end, it is determined that the lacing can adequately resist the applied axial load of 270 kN.
This lecture helps to understand how the properties of forgings evolve during the manufacturing process. General understanding of metallurgy and deformation processes is assumed.
TALAT Lecture 4205: Testing Methods for Welded JointsCORE-Materials
This lecture gives information about the relevant non-destructive and destructive testing methods for aluminium welded joints. Background in production welding and quality assurance is assumed.
TALAT Lecture 5104: Basic Approaches to Prevent Corrosion of AluminiumCORE-Materials
This lecture describes important measures for the prevention of corrosion of unprotected, bare
aluminium. Basic knowledge of corrosion behaviour of aluminium and some knowledge of the electrochemical nature of corrosion is assumed
This lecture describes the fundamentals of bending and folding aluminium sheet; it also describes different methods in design of folding tools. Background in production engineering and sheet metal forming and familiarity with the subject matter covered in TALAT This lectures 3701- 3705 is assumed.
17. Projektowanie procesów technologicznychAdam Osa
Poradnik będzie Ci pomocny w opanowaniu umiejętności opracowywania procesów
technologicznych obróbki skrawaniem, montażu oraz projektowania prostych procesów
obróbki na tokarki CNC.
TALAT Lecture 2301: Design of Members Example 4.4: Bending moment resistance ...CORE-Materials
This 3 sentence summary provides the key details about the document:
1) The document is a 10 page example from a lecture on designing members for bending moment that analyzes the bending moment resistance of a welded hollow section with outstands using a class 4 cross section.
2) It presents the geometry, material properties, nodes, and elements of the hollow cross section and performs iterative calculations of the effective cross section area, stress distribution, and effective thicknesses accounting for any heat affected zones to determine the bending moment resistance.
3) The example is considered comprehensive because it shows calculations in detail, covers all classes of cross sections, and demonstrates how to increase effective thickness for non-fully stressed elements through
TALAT Lecture 2301: Design of Members Example 5.5: Axial force resistance of ...CORE-Materials
This 3-page document provides an example calculation for determining the axial force resistance of a laced column. It includes dimensions, material properties, and calculations of various parameters needed for the analysis. Key steps and results are shown, such as determining the effective length, flexural buckling resistance, and checking that the lacing can resist the required shear force. In the end, it is determined that the lacing can adequately resist the applied axial load of 270 kN.
This lecture helps to understand how the properties of forgings evolve during the manufacturing process. General understanding of metallurgy and deformation processes is assumed.
This lecture describes fabrication processes for superplastic forming, i.e. female and male die forming, and the criteria for selecting the correct process. General background in production engineering and material science is assumed.
This document provides an overview of application characteristics for rivet and clinch joints. It discusses design considerations such as choosing rivet diameters and distances from edges. It also covers material and tooling parameters that influence joint quality like surface finish. Testing methods are described for shear-tensile, fatigue, and impact tests. Sample geometries and results are shown. Finally, it briefly discusses cost considerations for different joining technologies.
This lecture describes the factors important for the quality assurance of adhesive joining; it gives information about the destructive and non-destructive testing methods for the quality control of adhesive joining. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
This lecture provides a background on aluminium alloys suitable for impact extrusion. It draws attention to raw material parameters which may affect the properties of impact extruded parts. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
TALAT Lecture 3801: Manufacturing Examples and FundamentalsCORE-Materials
This lecture describes the fundamentals of the superplastic behaviour phenomenon of aluminium alloys and the basic process parameters which govern the manufacturing of superplastic sheet metal parts. General background in production engineering and material science is assumed.
TALAT Lecture 3503: Finishing and other Supplementary OperationsCORE-Materials
This lecture describes supplementary fabrication measures for impact extruded parts and gives some examples of finished impacts. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
This lecture describes the detailed processes of single-step and multiple-step clinching; it shows the differences of the various clinching methods concerning the amount of shearing; it illustrates the major differences in mechanical properties of clinch joints compared with resistance spot welds. General mechanical engineering background and familiarity with the subject matter covered in TALAT This lecture 4101 is assumed.
TALAT Lecture 3505: Tools for Impact ExtrusionCORE-Materials
This lecture provides knowledge about design philosophy and tool materials for impact tools, which are a cost factor and eminently important for successful impact extrusion. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
TALAT Lecture 4702: Factors Influencing the Strength of Adhesive JointsCORE-Materials
This lecture describes the factors governing the strength of adhesive joints in order to appreciate these factors for the design of adhesively bonded joints, i.e. geometry of joint, stiffness and strength of the adjoining parts, stress distribution in the adhesive layer as well as the effects of humidity and ageing. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
TALAT Lecture 4703: Design and Calculation of Adhesive JointsCORE-Materials
This lecture describes the basic types of loadings of adhesive joints and to give examples of recommended joint designs; it shows how to calculate the strength of adhesive joints. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
TALAT Lecture 4107: General Summary and Future TrendsCORE-Materials
This lecture points out the need of data sources for designing mechanical joints; it describes concepts for FEM-Modelling of mechanical joints. General mechanical engineering background and familiarity with the subject matter covered in TALAT This lectures 4101- 4106 is assumed.
This lecture defines important terms of the process of stretch forming and it describes the basic processes of stretch forming. Background in production engineering and familiarity with the subject matter covered in TALAT This lecture 3701 is assumed.
TALAT Lecture 4701: Terms and Definitions for Adhesive BondingCORE-Materials
This lecture defines the terms and definition of adhesive bonding of metals; it describes the basic physical/chemical characteristics of adhesive bonding; it also describes the characteristics and the properties of adhesives used in metal bonding. General background in production engineering and material science, some knowledge of the physics and chemistry of metallic surfaces and polymer science is assumed.
TALAT Lecture 4601: Introduction to Brazing of Aluminium AlloysCORE-Materials
This lecture describes the characteristics of brazing aluminium and the process involved; it helps to understand the use potential and the limitations of brazing aluminium. Basic knowledge of aluminium alloys designation system, surface treatment and corrosion behaviour is assumed.
TALAT Lecture 4300: Beam Welding Processes of AluminiumCORE-Materials
The document provides information on beam welding processes for aluminium, including:
- Electron beam welding principles and process steps for deep welding. It describes terms used and discusses weldability of aluminium alloys.
- Laser welding principles and comparisons to electron beam welding. Solid-state lasers commonly used for thinner sheets while gas lasers used for thicker sheets.
- Laser cutting principles and comparisons of laser beam cutting to plasma cutting. Laser cutting well suited for aluminium.
- References 14 figures and discusses objectives of introducing beam welding and cutting techniques for aluminium. Provides overview of key beam welding and cutting topics.
This lecture gives background to calculation methods for aluminium members in order to understand the specific behavior of statically loaded aluminium alloy structures. Basic structural mechanic, design philosophy and structural aluminium alloys and product forms is assumed.
TALAT Lecture 3805: Combination of Superplastic Forming and Diffusion BondingCORE-Materials
This lecture reviews briefly the principles of diffusion bonding in combination with superplastic forming of aluminium alloys. General background in production engineering and material science is assumed.
TALAT Lecture 3702: Tribology in Cold Forming of Aluminium SheetCORE-Materials
This document provides an overview of tribology and friction in cold forming of aluminum sheet metal. It discusses:
1) The importance of friction in sheet metal drawing and the different friction zones that exist. Both low and high friction is needed in different areas to control material flow.
2) How the microtopography of the sheet surface impacts friction and the mechanisms of friction. Surface treatments can make the surface isotropic and better retain lubricant.
3) Tests used to measure friction coefficients in strip drawing tests that simulate the forming process. Surface properties greatly influence friction behavior.
4) The tribological system involves the sheet surface, tool surface, and lubricant working together to prevent adhesion. Both surface roughness
DESIGN AND FABRICATION OF WELDING FIXTURES AND POSITIONERSvivatechijri
The document describes the design and fabrication of welding fixtures and positioners. It discusses how welding fixtures are used to accurately position components during welding in mass production. The document outlines the methodology used, including modeling fixtures in CAD software, calculating forces, and analyzing precision placement of circular components. It also discusses other aspects of welding automation like manipulators and positioners. The goal is to develop a new fixture design that can accurately position components within 0.1mm for mass production welding without using robots.
IRJET- Characterization of Aluminum 7085/WC/Fly Ash Hybrid Composites for...IRJET Journal
This document summarizes research on aluminum 7085/tungsten carbide/fly ash hybrid composites for vibration applications. The composites were fabricated using stir casting and then characterized through various tests. Tensile, compression, and hardness tests showed improvements in properties with the addition of reinforcements. Tensile strength increased from 245 to 314 MPa while compressive strength increased from 1274 to 1522 MPa. Hardness also increased. Vibration testing found the composites effectively dampened vibrations compared to aluminum 7085 alone. The study demonstrated the fabrication of aluminum matrix composites with uniform dispersions of reinforcements via stir casting.
Experimental and Analytical Investigations of Friction Stir Welding of Variou...IRJET Journal
The document discusses experimental and analytical investigations of friction stir welding (FSW) of aluminum alloys. Finite element analysis will be performed to analyze FSW of aluminum 6061 and 7475 at different speeds and tool pin profiles using ANSYS. A 3D model of the welding process will be created in Pro/Engineer. Static structural analysis will determine stress, strain, and deformation, while thermal analysis will determine temperature distribution and heat flux during FSW. The effects of tool pin profile and rotational speed on weld strength will be examined.
This lecture describes fabrication processes for superplastic forming, i.e. female and male die forming, and the criteria for selecting the correct process. General background in production engineering and material science is assumed.
This document provides an overview of application characteristics for rivet and clinch joints. It discusses design considerations such as choosing rivet diameters and distances from edges. It also covers material and tooling parameters that influence joint quality like surface finish. Testing methods are described for shear-tensile, fatigue, and impact tests. Sample geometries and results are shown. Finally, it briefly discusses cost considerations for different joining technologies.
This lecture describes the factors important for the quality assurance of adhesive joining; it gives information about the destructive and non-destructive testing methods for the quality control of adhesive joining. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
This lecture provides a background on aluminium alloys suitable for impact extrusion. It draws attention to raw material parameters which may affect the properties of impact extruded parts. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
TALAT Lecture 3801: Manufacturing Examples and FundamentalsCORE-Materials
This lecture describes the fundamentals of the superplastic behaviour phenomenon of aluminium alloys and the basic process parameters which govern the manufacturing of superplastic sheet metal parts. General background in production engineering and material science is assumed.
TALAT Lecture 3503: Finishing and other Supplementary OperationsCORE-Materials
This lecture describes supplementary fabrication measures for impact extruded parts and gives some examples of finished impacts. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
This lecture describes the detailed processes of single-step and multiple-step clinching; it shows the differences of the various clinching methods concerning the amount of shearing; it illustrates the major differences in mechanical properties of clinch joints compared with resistance spot welds. General mechanical engineering background and familiarity with the subject matter covered in TALAT This lecture 4101 is assumed.
TALAT Lecture 3505: Tools for Impact ExtrusionCORE-Materials
This lecture provides knowledge about design philosophy and tool materials for impact tools, which are a cost factor and eminently important for successful impact extrusion. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
TALAT Lecture 4702: Factors Influencing the Strength of Adhesive JointsCORE-Materials
This lecture describes the factors governing the strength of adhesive joints in order to appreciate these factors for the design of adhesively bonded joints, i.e. geometry of joint, stiffness and strength of the adjoining parts, stress distribution in the adhesive layer as well as the effects of humidity and ageing. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
TALAT Lecture 4703: Design and Calculation of Adhesive JointsCORE-Materials
This lecture describes the basic types of loadings of adhesive joints and to give examples of recommended joint designs; it shows how to calculate the strength of adhesive joints. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
TALAT Lecture 4107: General Summary and Future TrendsCORE-Materials
This lecture points out the need of data sources for designing mechanical joints; it describes concepts for FEM-Modelling of mechanical joints. General mechanical engineering background and familiarity with the subject matter covered in TALAT This lectures 4101- 4106 is assumed.
This lecture defines important terms of the process of stretch forming and it describes the basic processes of stretch forming. Background in production engineering and familiarity with the subject matter covered in TALAT This lecture 3701 is assumed.
TALAT Lecture 4701: Terms and Definitions for Adhesive BondingCORE-Materials
This lecture defines the terms and definition of adhesive bonding of metals; it describes the basic physical/chemical characteristics of adhesive bonding; it also describes the characteristics and the properties of adhesives used in metal bonding. General background in production engineering and material science, some knowledge of the physics and chemistry of metallic surfaces and polymer science is assumed.
TALAT Lecture 4601: Introduction to Brazing of Aluminium AlloysCORE-Materials
This lecture describes the characteristics of brazing aluminium and the process involved; it helps to understand the use potential and the limitations of brazing aluminium. Basic knowledge of aluminium alloys designation system, surface treatment and corrosion behaviour is assumed.
TALAT Lecture 4300: Beam Welding Processes of AluminiumCORE-Materials
The document provides information on beam welding processes for aluminium, including:
- Electron beam welding principles and process steps for deep welding. It describes terms used and discusses weldability of aluminium alloys.
- Laser welding principles and comparisons to electron beam welding. Solid-state lasers commonly used for thinner sheets while gas lasers used for thicker sheets.
- Laser cutting principles and comparisons of laser beam cutting to plasma cutting. Laser cutting well suited for aluminium.
- References 14 figures and discusses objectives of introducing beam welding and cutting techniques for aluminium. Provides overview of key beam welding and cutting topics.
This lecture gives background to calculation methods for aluminium members in order to understand the specific behavior of statically loaded aluminium alloy structures. Basic structural mechanic, design philosophy and structural aluminium alloys and product forms is assumed.
TALAT Lecture 3805: Combination of Superplastic Forming and Diffusion BondingCORE-Materials
This lecture reviews briefly the principles of diffusion bonding in combination with superplastic forming of aluminium alloys. General background in production engineering and material science is assumed.
TALAT Lecture 3702: Tribology in Cold Forming of Aluminium SheetCORE-Materials
This document provides an overview of tribology and friction in cold forming of aluminum sheet metal. It discusses:
1) The importance of friction in sheet metal drawing and the different friction zones that exist. Both low and high friction is needed in different areas to control material flow.
2) How the microtopography of the sheet surface impacts friction and the mechanisms of friction. Surface treatments can make the surface isotropic and better retain lubricant.
3) Tests used to measure friction coefficients in strip drawing tests that simulate the forming process. Surface properties greatly influence friction behavior.
4) The tribological system involves the sheet surface, tool surface, and lubricant working together to prevent adhesion. Both surface roughness
DESIGN AND FABRICATION OF WELDING FIXTURES AND POSITIONERSvivatechijri
The document describes the design and fabrication of welding fixtures and positioners. It discusses how welding fixtures are used to accurately position components during welding in mass production. The document outlines the methodology used, including modeling fixtures in CAD software, calculating forces, and analyzing precision placement of circular components. It also discusses other aspects of welding automation like manipulators and positioners. The goal is to develop a new fixture design that can accurately position components within 0.1mm for mass production welding without using robots.
IRJET- Characterization of Aluminum 7085/WC/Fly Ash Hybrid Composites for...IRJET Journal
This document summarizes research on aluminum 7085/tungsten carbide/fly ash hybrid composites for vibration applications. The composites were fabricated using stir casting and then characterized through various tests. Tensile, compression, and hardness tests showed improvements in properties with the addition of reinforcements. Tensile strength increased from 245 to 314 MPa while compressive strength increased from 1274 to 1522 MPa. Hardness also increased. Vibration testing found the composites effectively dampened vibrations compared to aluminum 7085 alone. The study demonstrated the fabrication of aluminum matrix composites with uniform dispersions of reinforcements via stir casting.
Experimental and Analytical Investigations of Friction Stir Welding of Variou...IRJET Journal
The document discusses experimental and analytical investigations of friction stir welding (FSW) of aluminum alloys. Finite element analysis will be performed to analyze FSW of aluminum 6061 and 7475 at different speeds and tool pin profiles using ANSYS. A 3D model of the welding process will be created in Pro/Engineer. Static structural analysis will determine stress, strain, and deformation, while thermal analysis will determine temperature distribution and heat flux during FSW. The effects of tool pin profile and rotational speed on weld strength will be examined.
Non destructuctive testing friction stir wleds of aluminiummarcionilo neri
This document discusses non-destructive testing techniques for detecting imperfections in friction stir welds of aluminium alloys. It describes how friction stir welding works and some of the key parameters. Various non-destructive testing developments are presented, including an integrated system that uses multiple NDT techniques and fuzzy logic to detect imperfections, and an innovative eddy current probe system capable of detecting imperfections around 50 μm in size. Samples of aluminium alloys with and without defects were produced using different friction stir welding tools to test and validate the NDT systems.
IRJET - Mathematical Modelling to Predict Bead Geometry and Shape Relationshi...IRJET Journal
This document presents a study that develops a mathematical model to predict bead geometry and shape relationships for MIG welded aluminum 1200 plates. The study uses design of experiments to investigate the effects of welding speed, voltage, and wire feed rate on weld width, height of reinforcement, and reinforcement form factor. 15 experiments were conducted according to a central composite face centered design. The results were analyzed using response surface methodology and ANOVA to develop and validate the mathematical model relating the input and response parameters.
Overview on Welding Fixtures, Welding Joints, Welding Defects and CO2 arc wel...IRJET Journal
This document provides an overview of welding fixtures, welding joints, welding defects, and CO2 arc welding. It discusses common welding fixtures used to securely position workpieces for different welding processes. It describes the main types of welding joints according to the American Welding Society and gives examples. The document also outlines several common welding defects and how they are detected. Finally, it provides details about CO2 arc welding, including how a filler material is used to achieve deep penetration during welding.
Automotive Applications of Welding Technology – A StudyIJMER
Welding is invariably used in the automotive industries for joining variety of structural
components and engine parts. The constant demand for new improved material requirement for
automotive applications necessitates the development of innovative joining techniques. In this paper, the
welding techniques commonly adapted in the automotive industries are discussed. Illustrative diagrams
and specific automotive applications are included in the paper. The novel technique of joining dissimilar
metals viz., magnetic pulse welding is also discussed. The latest update on medium frequency welding
method used by auto manufacturers is also presented with its technical and operational merits
IRJET- Modeling & Analysis of a 100CC I.C. Engine Connecting RODIRJET Journal
1) The document describes modeling and static structural analysis of a 100cc internal combustion engine connecting rod using SOLIDWORKS and ANSYS.
2) Various materials were analyzed including aluminum alloys, steel, and a metal matrix composite. The connecting rod was subjected to a 400N force.
3) Analysis found the metal matrix composite had the least deformation but higher cost, while an aluminum alloy provided good results at lower cost for connecting rods.
Experimental Investigation On Tin Based Babbitt Composite MaterialIRJET Journal
This document discusses an experimental investigation of tin-based babbitt composite materials. Babbitt alloys are commonly used for manufacturing journal bearings but have relatively low fatigue strength and moderate wear resistance. To address these limitations, silicon carbide particles are incorporated into the babbitt matrix at concentrations of 2%, 4%, and 6% using stir casting. Wear tests are conducted on the composite materials and pure babbitt under varying loads and speeds. The results show that a composite with 4% SiC exhibits the lowest wear compared to the other materials tested. Reinforcing babbitt with silicon carbide improves its mechanical properties and makes it more suitable for use in bearings with high operating stresses.
Optimization of Laser Beam Welding On Titanium Materialvivatechijri
The use of titanium materials in some sections of mass-produced automobiles and in the aerospace
sector has increased recently. Titanium materials however, are distinguished by difficult surface roughness,
high melting point, dimensional stability, good thermal expansion, and high oxygen reactivity, overshadowing
traditional production methods. To this purpose, the need for more advanced methods for the development of
low-cost titanium materials is pressing. For the manufacture of titanium materials, many joining methods have
been considered over the years. However, due to its efficiency, high specific heat input, and efficiency, laser
beam welding offers an effective alternative for titanium welding. To present, the strength of the laser-welded
titanium materials can be close to the original material under optimum operating conditions; some processing
issues, such as lower elongation and shock resistance combined with lower fatigue properties, are still present.
The laser beam welding on titanium materials is checked in this research work. There are also various types of
parameters tested, such as nozzle size, focal length, pulse frequency and pulse duration. Experiment design is
applied using the Taguchi method design method. The research will be carried out after the design of the
experiment using the Taguchi Process, and the optimum result will be chosen.
CASTING DEFECTS ANALYSIS OF SWASH PLATE (PVB10 YOKE) USING SIMULATIONIRJET Journal
This document discusses using casting simulation software to analyze and reduce defects in castings of a swash plate component (PVB10 Yoke). It conducted four trials over multiple months: the first using traditional methods resulted in 42.5% rejection due to shrinkage porosity and other defects. The second trial placed a core but rejection remained high. The third trial used casting simulation software which identified riser size as the cause of shrinkage porosity. The fourth trial increased riser size, resulting in only 5% rejection. Using simulation enabled identifying the root cause of defects and reducing the rejection rate from 42.5% to 5% for the swash plate casting.
WELDLINE STRENGTH ANALYSIS THEORETICAL PREDICTIVE MODEL WITH THE USE OF MOLDL...IRJET Journal
Weld lines, also called knit lines, are defects that occur when melt flows collide in an injection mold. They can weaken parts. This document presents a predictive model for analyzing weld line strength using Moldflow simulation. It describes how weld lines form from fountain flow and discusses parameters like gate location, temperature, and pressure that influence strength. A case study applies the method to a component that was breaking. Moldflow identified stresses, which were input to structural analysis. Modified gate location and ribs increased strength and safety factor. The model allows objective weld line strength prediction to avoid defects.
IRJET- A Review Paper on the Production Line of an Aluminum Alloy Wheel Manuf...IRJET Journal
This document summarizes a research paper on improving quality in an aluminum alloy wheel manufacturing industry. It discusses defects commonly found during the manufacturing process such as shrinkage, non-metallic inclusions, micro-cavities, and gas holes. Quality control tools like check sheets, Pareto diagrams, and cause-effect diagrams are used to analyze defects. Major causes of defects found were shrinkage, non-metallic inclusions, and micro-cavities. Fishbone diagrams were used to evaluate specific causes of shrinkage defects during casting. Overall, the document reviews the aluminum alloy wheel production process and quality improvement methods using quality control tools.
This document is a seminar report on orbital welding submitted by Anshad Ali in partial fulfillment of the requirements for a Bachelor of Technology degree in Mechanical Engineering. It includes an abstract, table of contents, acknowledgements, introduction, literature review, fundamentals of orbital pipe welding, applications of orbital welding, advantages and disadvantages, conclusion, and future scope. It provides an overview of orbital welding technology and processes.
This document discusses research into improving the mechanical properties of aluminum-zinc alloys through the addition of silicon carbide particles. Specifically, it examines the effects of adding silicon carbide to an aluminum-zinc alloy matrix on properties like strength, hardness, and wear resistance. The research finds that adding silicon carbide particles leads to significant increases in the alloy's ultimate tensile strength and hardness. These silicon carbide particle-reinforced metal matrix composites show potential for applications that require high wear resistance, such as in the automotive and aerospace industries.
IRJET- Review Paper on Single Bolt Configuration with Different AdhesiveIRJET Journal
This document discusses a review of single bolt configurations with different adhesives. It begins by introducing composite materials like carbon fiber reinforced plastic (CFRP) that are used in aircraft structures. Next, it discusses previous studies on bolted and bonded composite joints that investigated factors like joint strength and load sharing. The document then outlines the methodology used, which involves designing models in CATIA and analyzing them in ANSYS under tensile loading. Finally, it discusses fiber reinforced composites and their increasing use in industries like aerospace and automotive to replace aluminum and provide weight savings. In summary, the document reviews research on bolted and bonded composite joints and discusses modeling their behavior under load.
Conductive Composites such as carbon fiber reinforced composites are increasingly used in safety critical aerospace applications. The catastrophic macro structural failure of composite structures initiates from a micro level failure event such as fiber breaks. The ability to detect damage early on can improve the safety level and reliability of composite structures. A multilevel self-sensing damage detection techniques ability to detect damage at various length scales are numerically explored using COMSOL multiphysics software. The simulation methodology and results are reported highlighting the multilevel damage detection capability. The electrode configuration and detection sensitivity is also reported.
ONGOING PROGRESS IN ADVANCED WELDING PROCESSES AND MATERIALSRamamSingh
The Primary dynamic for welding process development is the need to improve the total cost effectiveness of joining operations in fabrication and manufacturing industries. Many of the traditional welding techniques described are regarded as costly and hazardous, but it is possible to improve both of these aspects by employing some of the advanced process developments.
Discusses some of the role and future direction of welding technology, welding materials, productivity and efficiency, education and safety having an impact on future growth in welding technology. Analysis of key needs of some manufacturing industries has been researched. It also provides a good foundation for future research of the developmental direction of advanced welding processes and materials in manufacturing industries.
This lecture provides a view of types of joints in aluminium structures and how to design and calculate frequently used joints. Basic structural mechanics and knowledge of design philosophy, structural aluminium alloys and product forms is assumed.
DESIGN AND ANALYSIS OF MULTIFACE HYDRAULIC BENDING MACHINE DIEIRJET Journal
This document discusses the design and analysis of a multifaceted hydraulic bending machine die. It begins with an introduction to bending machine operations and describes how existing die designs require multiple dies and more time/space. The proposed new die design would combine multiple bending shapes into a single die to reduce material usage, errors, and improve efficiency. The document then analyzes the proposed die design using finite element analysis software to simulate stresses and strains on sample materials. Results found the new die design reduced stresses on materials compared to existing designs. In conclusion, the bending die process was determined to be important for manufacturing and the new integrated die design improved production over previous methods.
Similar to TALAT Lecture 4101: Definition and Classification of Mechanical Fastening Methods (20)
Series of powerpoint slides showing three different drawing processes used in the manufacture of wires, rod, tubes and drinks cans. The slides are adapted from the University of Liverpool "Materials Processing" lectures [MATS214] by Dr J. Wilcox.
The document describes several test geometries used to determine the failure strengths of composite materials, including the Double Cantilever Beam test for mode I failure, the End Notch Flexure test for mode II failure, and the Mixed-mode Interlaminar Fracture test for mixed mode I/II failure. It also lists the Single Cantilever Beam test for skin debonding energy in composite sandwiches, the Centre Notch Flexure test for thin skin debonding, and the Interlaminar Shear Strength test, a three point bend test to determine shear strength.
The document describes several common composite manufacturing techniques including wet lay-up, vacuum bagging, compression moulding, filament winding, pultrusion, and resin transfer moulding. Each technique involves different processes for combining fibres and resin such as applying layers by hand, using pressure and heat, winding fibres onto a rotating mandrel, pulling fibres through a resin bath, or injecting resin into a mould containing dry fibres. The techniques are suited for different part geometries and production volumes.
The role of technology in sporting performanceCORE-Materials
The lecture answers the questions of how much effect does engineering technology have on sport, is technology only used to increase performance and what are the "new technologies" being introduced. Courtesy of Prof Claire Davies, School of Metallurgy and Materials, University of Birmingham.
The chapter describes principles of the chemical analysis in the SEM and TEM. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
The chapter gives insight into the scanning electron microscope technique. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
The chapter gives insight into the transmission electron microscope technique. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
The chapter explains the diffraction of electrons and demonstrates what it can reveal. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
Electrons and their interaction with the specimenCORE-Materials
The chapter explains the behaviour of electrons within a specimen and shows how they interact with the atoms of the sample. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
The chapter gives the comparison of electron microscopy with other imaging and analysis techniques. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
The chapter gives the basic principles of microscopy. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
TALAT Lecture 5301: The Surface Treatment and Coil Coating of AluminiumCORE-Materials
This lecture describes the continuous coil coating processes for aluminium in sufficient detail in order to understand the industrial coating technology and its application potential. General background in materials engineering and familiarity with the subject matter covered in TALAT This lectures 5100 and 5200 is assumed.
This lecture describes the processes of electroless, electrolytic, as well as physical and chemical vapour deposition of metals on the aluminium surface in order to achieve variations in its surface properties for functional and decorative purposes. Some knowledge of the surface properties of metals, metallurgy and electrochemistry of aluminium and familiarity with the subject matter covered in TALAT This lectures 5101, 5102, 5105 is assumed.
This lecture describes the process of anodic oxidation of aluminium, which is one of the most unique and commonly used surface treatment techniques for aluminium; it illustrates the weathering behaviour of anodized surfaces. Some familiarity with the subject matter covered in TALAT This lectures 5101- 5104 is assumed.
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This lecture helps to understand the general principles, methods, properties and applications of plating on aluminium. Some knowledge in general electrochemistry is assumed.
TALAT Lecture 5103: Corrosion Control of Aluminium - Forms of Corrosion and P...CORE-Materials
This document discusses various forms of corrosion that can affect aluminium and aluminium alloys. It describes general corrosion that can occur in acid and neutral solutions. It also covers localized corrosion such as pitting, crevice, filiform, and biological corrosion. Factors influencing galvanic and intergranular corrosion are presented. The document also discusses mechanically assisted degradation like erosion, fretting corrosion, and corrosion fatigue. It concludes with descriptions of stress corrosion cracking and hydrogen embrittlement.
TALAT Lecture 5102: Reactivity of the Aluminium Surface in Aqueous SolutionsCORE-Materials
This lecture provides better understanding of the electrochemistry of aluminium; it gives an introduction to the other lectures. Some knowledge in aluminium metallurgy, simple chemistry (thermodynamics and kinetics), electricity and general electrochemistry is assumed.
TALAT Lecture 5101: Surface Characteristics of Aluminium and Aluminium AlloysCORE-Materials
This lecture provides a realistic view of the aluminium surface in order to understand the need for "effective" surface treatment. Some knowledge in aluminium metallurgy is assumed.
Strategies for Effective Upskilling is a presentation by Chinwendu Peace in a Your Skill Boost Masterclass organisation by the Excellence Foundation for South Sudan on 08th and 09th June 2024 from 1 PM to 3 PM on each day.
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Answers about how you can do more with Walmart!"
A review of the growth of the Israel Genealogy Research Association Database Collection for the last 12 months. Our collection is now passed the 3 million mark and still growing. See which archives have contributed the most. See the different types of records we have, and which years have had records added. You can also see what we have for the future.
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This document provides an overview of wound healing, its functions, stages, mechanisms, factors affecting it, and complications.
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2. 4101 Definition and Classification of Mechanical
Fastening Methods
Table of Contents
4101 Definition and Classification of Mechanical Fastening
Methods ......................................................................................................................... 2
4101.01 Introductory Remarks............................................................................. 3
Tendency of Developments in the Joining Technology...........................................3
Joining Systems for Thin-walled Aluminium Components.....................................4
Aims of the Mechanical Fastening Processes ..........................................................4
Classification of Mechanical Fastenings Used in the Fabrication Technology ......5
Elementary and Combined Joints ............................................................................6
4101.02 Screw Joints............................................................................................... 6
Construction Types for Screw Joints .......................................................................6
Requirements for Screw Joints ................................................................................7
Types of Screw Joints for Thin Sheets.....................................................................7
Working Principle of Flow-Drilling Screws............................................................8
Screw Joints for Aluminium Profiles.......................................................................9
4101.03 Folds ......................................................................................................... 10
Steps in the Folding Process for Straight-Edged Sheets ........................................10
Widths of Overlaps in Folded Joints......................................................................10
4101.04 Rivet Joints ............................................................................................. 11
Joining by Riveting ................................................................................................11
Rivet Types for the Indirect Riveting of Aluminium.............................................12
Commercially Available Rivet Forms and their Fields of Application .................13
Working Principle of a Blind (Pop) Rivet .............................................................13
Choice of Fastening Elements for Mechanical Fastening Methods.......................14
4101.05 Clinching.................................................................................................. 15
Schematic Illustration of Clinching Joints, with or without Local Incision ..........15
An Aluminium Car Door Aggregate Carrier with Clinch Joints ...........................16
4101.06 Summary.................................................................................................... 17
Comparison of the Technological Characteristics of Fastening Methods .............17
4101.07 Literature/References .............................................................................. 18
4101.08 List of Figures............................................................................................ 19
TALAT 4101 2
3. Joining is in many cases an important and often critical process step in the
manufacturing of aluminium components from shaped sheet and/or profiles. Mechanical
fabricating processes fulfil the ever increasing demands on the joining quality and
reproducibility during manufacturing as well as quality assurance. These have low
investment costs, are easy to use and can be easily adapted for automatic processes.
4101.01 Introductory Remarks
• Tendency of developments in the joining technology
• Joining systems for thin-walled aluminium components
• Aims of the mechanical fastening processes
• Classification of mechanical fastenings used in the fabrication technology
• Elementary and combined joints
Tendency of Developments in the Joining Technology
Due to technological and economical pressures, a large number of fabricating companies
have to reconsider their concepts regarding joining technologies used for joining in
aluminium constructions.
The aim of new and newest developments in fastening techniques is to introduce
methods for fastening new materials, and to improve both reliability as well as economy
of the process (Figure 4101.01.01).
Main Aims of Improvements and New
Developments in the Joining Technology
To Improve the Economics and Degree of Automation
To Improve the Reliability of the Joining Process
To Make Joining Technologies Available for new Materials
and Fields of Application
Source: Bahre
alu
Tendency of Developments in the Joining Technology 4101.01.01
Training in Aluminium App lication Technologies
TALAT 4101 3
4. Joining Systems for Thin-walled Aluminium Components
According to the development trends, two main methods can be used for joining
aluminium: the "classical" (proven, standard) and "new" (less known and seldom used)
methods.
Besides this rather imprecise definition, a further classification is possible, based on the
geometry of the process and on the possibility of joining different materials and, for that
matter, non-metallic materials with each other (see Figure 4101.01.02).
"Joints of Light Constructions"
"Classical" "New"
A;C;D B;C;D
Detachable Screwing Clamping
B;C A;C;D A;C;D
Conditionally
Detachable Folding Riveting Clinching
B B;C A;(C) (A);B
Undetachable Inert Gas Laser
Adhesive Spot Welding
Welding Welding
Geometry of Joints Suitable for
A: Local Points C: Unrelated Materials
B: Over Large Areas D: Non-Metallic Materials
Source: Singh
Joining Systems for Thin-Walled
alu
Aluminium Components 4101.01.02
Training in Aluminium Application Technologies
Aims of the Mechanical Fastening Processes
Mechanical fastening methods are gaining in popularity, both in the assembly as well as
for mass production, in fabricating processes where a "predictable" fastening technology
is absolutely essential.
Especially when joining aluminium, mechanical fastening methods can meet the
increasing demands on joint quality and reproducibility during production and at the
same time allow the production quality to be tested using non-destructive methods
(Figure 4101.01.03). Typical for all mechanical fastening methods is that the joints can
be made with none or hardly any heating.
TALAT 4101 4
5. Classification of Mechanical Fastenings Used in the Fabrication Technology
Depending on the joining principle used, a large number of joint designs are possible.
As one can see from the systematic of the joining principles, the method of producing
the individual joints forms the basis for the classification, with each process having its
advantages and disadvantages (see Figure 4101.01.04).
Mechanical Fastening of Aluminium
Joining Sheets and/ or Profiles by Forming Material Locally
to Produce a Force or Form Locking Joining Element
Joining without the Application of Heat, Thereby Saving
Energy and Protecting the Environment
Joining Materials and Combinations there of which are
Normally Difficult to Fasten Together
Fabricating Reproducible Joining Elements Having a
Defined Joining Quality
Source: Budde
alu
Aims of the Mechanical Fastening Process 4101.01.03
Training in Aluminium Application Technologies
Main Joining Group
Fabrication Process
Classification of
Joining
Pressing Joining by
Together Forming
Joining Methods"
"Mechanical
Screwing Cinching Folding Riveting
Source: DIN 8593, Part 0
alu
Classification of Mechanical Fastenings Used
Training in Aluminium Application Technologies in the Fabrication Technology 4101.01.04
If an aluminium construction has to compete with a steel construction, then it is
important to consider the aspects of manufacturing technology, joining techniques and
economy. Due to the lower modulus of elasticity, an aluminium component will have a
lower rigidity than the corresponding steel component of the same dimensions.
Mechanical fastening methods can, however, be used to overcome this shortcoming, at
least partly.
Because of their good combinations of properties, the following joining methods have
proven to be especially suitable: screwing, clinching, bordering, folding and riveting.
TALAT 4101 5
6. Elementary and Combined Joints
Mechanical fastening methods will not be considered here on the basis of the older
viewpoints. They are defined here as joining technologies in which the parts are joint
using a force or form locking method like in clinching or riveting. These exclude joints
in which there is an (inter)locking of materials as in welding and adhesive joining.
The quasi form locking joint is obtained by a plastic deformation process. Such joints
incorporate the advantages of both form locking (transmitting large forces) and the force
locking (reducing play) type of joints (Figure 4101.01.05).
Material Locking Force Locking Form Locking
Joints Joints Joints
Quasi-Form Locking
Joints
Source: Roth
alu
Elementary and Combined Joints 4101.01.05
Training in Aluminium Application Technologies
4101.02 Screw Joints
• Construction types for screw joints
• Requirements for screw joints
• Types of screw joints for thin sheets
• Working principle of flow-drilling screws
• Screw joints for aluminium profiles
Construction Types for Screw Joints
Screw joints belong to the group of detachable joints. These can be designed as pierced,
through or blind-hole joints (Figure 4101.02.01). If appropriate measures are taken
against corrosion, screw joints are suitable for shaped sheet components and /or
aluminium sections and profiles.
The joining elements should be made of corrosion resistant stainless steel (steel group
A2/A4). Since aluminium alloys have relatively lower compressive strengths, the
contact surfaces must be protected by using washers under the screw and the nut.
TALAT 4101 6
7. Requirements for Screw Joints
Screw joints consist of multiple elements each of which has to fulfil various
requirements at the same time.
In order to design durable, safe and cheap screw joints which fulfil the requirements for
different applications, systematically arranged information and other helps must be
available.
Application parameters for screw joints can be set up by systematically listing the main
requirements for design, calculation and corrosion protection (Figure 4101.02.02).
Pierced and Protruding
Joints
Screw, Washer and
Aluminium Nut Made of
Stainless Steel
Pierced Joints Blind Hole Joints
Source: Beitz
alu
Construction Types for Screw Joints 4101.02.01
Training in Aluminium Application Technologies
Determining the Main Factors which Influence the Design,
Calculation and Corrosion Protection of Screw Joints
1. General Information about the Construction, Fastenings and Parts to be Fastened
2. Assembling Process
3. Mechanical and Chemical Stressing
4. Physical Influencing Factors
5. Life Expectancy - Safety -Reliability
6. Additional Requirements
7. Previous Design and Usable Experience
8. Economy
Source: Sieling
alu
Requirements for Screw Joints 4101.02.02
Training in Aluminium Application Technologies
Types of Screw Joints for Thin Sheets
TALAT 4101 7
8. In addition to the screw-and-nut fastening methods, thin sheets can be joint together
using a number of threaded fasteners, the most popular being sheet metal screws of the
self-locking, self-tapping types (Figure 4101.02.03).
With the help of screw-and-nut fasteners, it is possible to create large clamping forces.
Sheet metal screws, on the other hand, are used to eliminate the drilling operation for
the final assembly, whereby the screw cuts out its own hole.
Screw/ Nut
Flowing-Drill Screw
Pressed Nut Flow-Hole Forming
Spring Nut Collar Forming
Thin Sheet Screw
Sheet Screw
Source: Steeg Drilling Screw
alu
Training in Aluminium Application Technologies
Types of Screw Joints for Thin Sheets 4101.02.03
Working Principle of Flow-Drilling Screws
A drawback of most sheet metal screw joint is the very limited load bearing length of
the screw. Improvements can be made by forming cylindrical collars during the shaping
process.
In the flow-drilling process, a carbide tipped tapered and unthreaded punch rotating at
high speed is forced down to pierce through the metal, deforming it plastically and
creating a collared hole. A thread can then be tapped in this hole (Figure 4101.02.04).
TALAT 4101 8
9. 1. Heating 4. Threading
5. Screwing
2. Piercing
3. Forming 6. Tightening
Through Hole Screw
Source: Steeg
alu
Working Principle of Flow-Drilling Screws 4101.02.04
Training in Aluminium Application Technologies
Screw Joints for Aluminium Profiles
Stainless steel sheet metal screws are most often used for joining light metal alloys.
Prefabricated profiles are being increasingly used for aluminium constructions. The
profiles have longitudinal and transverse screw channels (or grooves) to take up the
stainless steel sheet metal screws (Figure 4101.02.05).
Longitudinal Transverse
Connection Connection
Aluminium Profil
with Incorporated
Screw Channel
Aluminium Sheet
Stainless Steel Screw
with Sheet-Screw Threading
Source: Bauer
alu
Screw Joints for Aluminium Profiles 4101.02.05
Training in Aluminium Application Technologies
TALAT 4101 9
10. 4101.03 Folds
• Steps in the folding process for straight-edged sheets
• Widths of overlaps in folded joints
Steps in the Folding Process for Straight-Edged Sheets
Bordering and folding techniques in a number of variations are traditionally used for
joining aluminium effectively.
Form locked joints are created using the following steps: folding manually or
automatically, interlocking, pressing together and locking by displacing the sheet edges
(Figure 4101.03.01).
Folding
Interlocking
Pressing Together
Displacement
Locking
Source: Hoesch Company Documents
alu
Steps in the Folding Process for Straight-Edged Sheets 4101.03.01
Training in Aluminium Application Technologies
If this fastening method is carried out properly, the protective oxide film is not damaged
so that the surface remains protected.
Widths of Overlaps in Folded Joints
Depending on the application, various folding forms can be made, the width of the fold
being of special importance for individual parts in handicraft. Whereas narrow folds
have low strength and tightness, too large overlaps amount to a waste of material
(Figure 4101.03.02)
TALAT 4101 10
11. With optimal fold thicknesses, the maximum strength attainable then depends mainly on
the fold type as well as quality and thickness of the material.
Wrong ! Wrong !
Aluminium Sheets
Right !
Overlaps Width
Source: Hoesch Company Documents
alu
Widths of Overlaps in Folded Joints 4101.03.02
Training in Aluminium Application Technologies
4101.04 Rivet Joints
• Joining by riveting
• Rivet types for the indirect riveting of aluminium
• Commercially available rivet forms and their fields of application
• Working principle of a blind (pop) rivet
• Choice of fastening elements for mechanical fastening methods
Joining by Riveting
For a long period of time, riveting was considered to be outdated and uneconomical.
Recently, however, riveting is being rediscovered as a rational technology of high
quality especially for special-purpose applications in the aerospace industry.
Aluminium can be joined using the indirect and direct riveting methods (Figure
4101.04.01).
In the indirect riveting process the parts to be joined are clamped together with rivets
using an auxiliary joining element. In direct riveting, one of the parts to be joint is itself
designed to act as the auxiliary component so that a separate one is not necessary.
TALAT 4101 11
12. Indirect Riveting Direct Riveting
Sheet / Profile Part
Pin
Auxiliary Solid
Rivet
Source: Liebig
alu
Joining by Riveting 4101.04.01
Training in Aluminium Application Technologies
Rivet Types for the Indirect Riveting of Aluminium
Currently, four different types of indirect rivets are used for producing undetachable
(permanent) joints: solid rivets, blind (Chobert or pop) rivets, huck bolts (screw rivets)
and punch rivets, whereby the rivet groups are classified primarily according to their
operational reliability (Figure 4101.04.02).
Solid Riveting Huck Bolting Blind Riveting
Rivet Head Rivet Head
Predetermined
Rivet Shaft Break Point
Rivet Shaft
Rivet Mandrel
Closing Head Closing Collet Rivet Sleeve
Source: Hoffer
alu
Rivet Types for the Indirect Riveting of Aluminium 4101.04.02
Training in Aluminium Application Technologies
TALAT 4101 12
13. Solid rivets are one-piece joining elements in which the rivet shaft is plastically formed
into the closing head. Such rivets can only be used for components which are accessible
from both sides.
Huck bolts (screw rivets) are used for highly stressed rivet joints. Since screw rivets are
made of high strength materials which cannot be formed easily during assembly, a
closing collet (self-locking nut) is fixed on to the rivet.
Blind (Chobert, pop) rivets, including the multi-functional types, consist of one or more
elements and require only one accessible side for mounting.
Punch rivets are designed to be self-piercing, making it unnecessary to form holes
previously in the parts to be fastened.
Commercially Available Rivet Forms and their Fields of Application
Rivets are classified according to the shape of the rivet head formed during the riveting.
For sheet metal and light constructions which do not need rivets of greater than 8 mm
diameter, closing heads with the same form as the rivet heads can be used. Aluminium
rivets having a diameter of up to 8 mm can be fairly easily cold worked (Figure
4101.04.03).
Countersunk Rivet Halfround Rivet Mushroom Rivet
For Smooth
For Generally Surface
Thick Used Rivet Riveting on the
Materials Head Form Head Side
Flat Rivet Tube Rivet Oval-Headed
Countersunk Rivet
For Cases in
For Cases in
For Light Which Only Low
Which The
Sheet Impact Forming
Protruding Head
Structures Force May be
Should be Small
Used
Source: Alusingen Company Documents
Commercially Available Rivet Forms
alu
4101.04.03
Training in Aluminium Application Technologies and Their Fields of Application
Working Principle of a Blind (Pop) Rivet
Just like many other innovative rivet developments, the blind rivet was developed in the
aircraft industry. Generally, blind rivets consist of a hollow shaft and a pull-stem
(mandrel) which serves as a tool for forming the closing head.
TALAT 4101 13
14. The rivet is mounted by pulling the stem out with a special tool, whereby the stem head
is drawn into the protruding rivet material to form the closing head (Figure 4101.04.04).
When the pulling force exceeds a certain level, the stem breaks at a predetermined
position (notched or break-stem). The breaking point can be chosen to lie either in the
shaft or at the rivet head.
Fixed Rivet
Placing Building Breaking Head Break Shaft Break
Rivet Closing Head Mandrel
Source: Stoewer
alu
Working Principle of a Blind (Pop) Rivet 4101.04.04
Training in Aluminium Application Technologies
Choice of Fastening Elements for Mechanical Fastening Methods
Mechanical fasteners using auxiliary fastening elements should be chosen so that both
fastener and the components to be joint are compatible as far as corrosion and recycling
aspects are concerned. It follows that the parts which come in contact with each other
must have similar electrochemical potentials and the material combination used must be
tolerant with respect to recycling (Figure 4101.04.05).
TALAT 4101 14
15. Choice of Material for Joining Elements for the
Mechanical Fastening of Aluminium Constructions
Because of reasons of corrosion, parts which come into contact
with each other should have similar electrochemical potentials.
Because of reasons of recycling, the materials of the parts
involved should be compatible.
Choice of Fastening Elements for Mechanical
alu
4101.04.05
Training in Aluminium Application Technologies Fastening Methods
Fastening elements made of copper or brass are not suitable for joining aluminium parts.
In an environment where the joints are subjected to weathering or chemical attack, the
parts must be isolated from the fastening elements, both for aluminium parts of different
alloys as well as for composite constructions.
4101.05Clinching
• Schematic illustration of clinching joints, with or without local incision
• An aluminium car door aggregate carrier with clinch joints
Schematic Illustration of Clinching Joints, with or without Local Incision
Although clinching is now widely accepted and used as a "new" process for fastening
aluminium shaped sheet components and profile components as undetachable
(permanent) joints, the rules and guidelines governing this type of fastening method
have still to be defined.
Clinching covers processes for direct joining in which the material undergoes a local
plastic deformation with or without local incision (Figure 4101.05.01).
The term clinching covers various processes known more popularly by their trade
names.
TALAT 4101 15
16. Clinching Joint Element
Clinching
With Local Incision Without Local Incision
Incision Followed Displacement Followed
by Flattening by Flow Forming
Cold Compressing
Source: Budde
alu Schematic Illustration of Clinching Joints,
Training in Aluminium Application Technologies with or without Local Incision 4101.05.01
An Aluminium Car Door Aggregate Carrier with Clinch Joints
The technology for fastening methods based on clinching and the "newer" riveting
processes is being developed continuously, so that an ever increasing use of these
joining methods can be safely expected in the years to come.
Presently, the most well known example for a mass produced component using the
clinching fastening method is the door aggregate carrier for the AUDI 80/90 in which
two aluminium sheet forms are clinched together (Figure 4101.05.02).
TALAT 4101 16
17. 2 Aluminium Shells
100 mm
36 Clinch Elements
Source: Schmid
An Aluminium Car Door Aggregate Carrier
alu
4101.05.02
Training in Aluminium Application Technologies with Clinch Joints
4101.06 Summary
• Comparison of the technological characteristics of fastening methods
Comparison of the Technological Characteristics of Fastening Methods
Riveting and clinching are typical examples for mechanical fastening methods.
The above mentioned fastening methods are most promising since, compared to the
"conventional" fastening methods, these are easier to use, have shorter pressing times
and the parts to be joint are subjected to a lower heat stress (Figure 4101.06.01).
TALAT 4101 17
18. Comparison of the Technological Characteristics
of Fastening Methods
Joining
Technology Adhesive Spot Welding Clinching Riveting
Joining
Characteristic
Technology very complicated limited limited
Process parameters complicated
- time short to long very short very short short to long
- temperature relatively low very high very low very low
- pressure low to high relatively high relatively high relatively high
Source: Budde
Comparison of the Technological Characteristics
alu
4101.06.01
Training in Aluminium Application Technologies of Fastening Methods
4101.07 Literature/References
1. Bahre, R. Verbindungstechnik für dünne Bauteile. Technica 35 (1986) 10, 61-66
2. Singh, S. Fügen von Aluminiumwerkstoffen im Automobilbau. Ingenieur-
Werkstoffe 2 (1991) 3, 45-48
3. Budde, L. Untersuchungen zur Kombination quasi-formschlüssiger und
stoffschlüssiger Verbindungsverfahren. Dissertation Uni-GH-Paderborn, 1989
4. N.N. Fertigungsverfahren Fügen; Einordnung, Unterteilung, Begriffe. DIN 8593,
Teil 0.
5. Klein, B. Fügetechnologien des Maschinenbaus. Der Konstrukteur (1986) 11, 6-14
6. Roth, K. Systematik fester Verbindungen als Grundlage für ihre sinnvolle
Anwendung und Weiterentwicklung. VDI-Berichte Nr. 360, 7-19
7. Beitz, W. Generelle Gestaltungsempfehlungen für Schraubenverbindungen. VDI-Z
125 (1983) 6, 257-263
TALAT 4101 18
19. 8. Sieling, P. Drehschlagbetätigte Einsatzwerkzeuge. Verbindungstechnik (1977) 7/8,
13-24
9. Steeg, H.B. Rationalisierungspotential Dünnblechverschraubung. VDI-Berichte Nr.
883, 215-239
10. Bauer, C.O. Wege zu sicheren und wirtschaftlichen Schraubenverbindungen. VDI-
Z 124 (1982) 18, 67-76
11. Liebig, H.P. Nieten und Durchsetzfügen. Blech Rohre Profile 39 (1992) 3, 220-221
12. Hoffer, K. Systemoptimierte Verbindungen im Flugzeugbau. VDI-Berichte 360, 31-
43
4101.08 List of Figures
Figure No. Figure Title (Overhead)
4101.01.01 Tendency of Developments in the Joining Technology
4101.01.02 Joining Systems for Thin-Walled Aluminium Components
4101.01.03 Aims of the Mechanical Fastening Process
4101.01.04 Classification of Mechanical Fastenings Used in the Fabrication Technology
4101.01.05 Elementary and Combined Joints
4101.02.01 Construction Types for Screw Joints
4101.02.02 Requirements for Screw Joints
4101.02.03 Types of Screw Joints for Thin Sheets
4101.02.04 Working Principle of Flow-Drilling Screws
4101.02.05 Screw Joints for Aluminium Profiles
4101.03.01 Steps in the Folding Process for Straight-Edged Sheets
4101.03.02 Widths of Overlaps in Folded Joints
4101.04.01 Joining by Riveting
4101.04.02 Rivet Types for the Indirect Riveting of Aluminium
4101.04.03 Commercially Available Rivet Forms and their Fields of Application
4101.04.04 Working Principle of a Blind (Pop) Rivet
4101.04.05 Choice of Fastening Elements for Mechanical Fastening Methods
4101.05.01 Schematic Illustration of Clinching Joints, with or without Local Incision
4101.05.02 An Aluminium Car Door Aggregate Carrier with Clinch Joints
4101.06.01 Comparison of the Technological Characteristics of Fastening Methods
TALAT 4101 19