Friction Spot Joining of Aluminium Alloy AA 5052 To Pre-Holed Steel AISI 1006 By Extrusion Aluminium Into A Rivet Head Die

Isam Tareq  Abdullah

doi:10.51173/jt.v4i2.492

Authors

Isam Tareq Abdullah Engineering Technical College - Baghdad, Middle Technical University, Baghdad, Iraq.

DOI:

https://doi.org/10.51173/jt.v4i2.492

Keywords:

Friction spot joining,, AA 5052, AISI 1006, Extrusion

Abstract

This work aims to join an aluminium alloy together with a pre-holed carbon steel sheet by extrusion the aluminium through a steel hole with a rivet shape to avoid the joint pull out. AA 5052 and AISI 1006 sheets were assembled with a lap structure such that the aluminium sample was placed above the steel. A rivet head die was put under the steel hole. The aluminium was extruded through the rivet head die passing via the steel hole utilizing a friction spot technique by a rotating tool. The influence of the hole diameter, rotating speed, and plunging depth of the tool on the rivet head dimensions and joints shear force and strength were investigated by the design of experiments approach. Joint macrostructure was examined. The aluminium metal was successfully extruded with a rivet shape. The steel hole diameter displayed the most increased influence on the rivet head dimensions and the joints' shear force. Incrementing the plunging depth of the tool raised the joint's shear strength. The joined samples failed by shearing the extruded aluminium at the steel hole surface without pull-out the formed rivet head. The joining mechanism appeared with a mechanical interlock and without the formation of inter-metallic compounds between the two materials. For the first time, the AA 5052 and pre-holed AISI 1006 sheets were joined by extrusion of the aluminium during a solid rivet head. The highest shear strength of the joint exceeded those of the AA 5052 by 55%.

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