New die concept for self-pierce riveting materials with limited ductility

Lightweight materials, such as aluminum die castings, are used more and more for automotive applications. Due to the limited weldability, joining these materials by self-pierce riveting has been established. The challenge in this regard is that these materials, especially new high strength aluminum die castings, have a limited ductility, while the joining processes locally induce large plastic deformations. Consequently, joining by forming of these materials can be accompanied by cracks, which develop during the forming operation. This paper shows the experimental and numerical investigation of a new die concept for self-pierce riveting materials with limited ductility. At the new tool concept the riveting die is separated and a movable die element is used. This element allows that the parts are superimposed with compressive stresses during the self-pierce riveting process. In the paper it can be shown, that in contrast to the conventional process crack-free joints can be generated by using the new tool concept. Determination of the joining parameters and the die design was supported by simulative investigations. Additionally, the new and the conventional self-pierce riveting process are compared on the basis of results from the experimental investigations.