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Extent of interlocking and metallurgical bonding in friction riveting of aluminum alloy to steel

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Abstract

In this study, the joining of 6061-T6 aluminum alloy and DP590 steel using a M42 steel rivet via friction riveting technique is investigated. The surface morphology and microstructure characterization reveal the formation of an anchor zone that imparts mechanical interlock as well as the formation of metallurgical bonds at the interface of aluminum and steel. A combination of interlocking and bonding results in the achievement of a high load-carrying capacity of 5.7 kN during lap shear testing at room temperature. A finite element-based computational model was developed which accurately predicted the lap shear response of the joint. The model revealed that the metallurgical bond formed during fric-riveting adds 39% peak load strength to the joint. An extensive microstructural investigation, post-lap-shear fractography, and the modeling results, together provided insights on the joint failure mechanism. This study highlights that friction riveting is a promising method for aluminum-to-steel dissimilar joining, which is important for lighweighing automotive vehicles for energy efficiency.

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Funding

This work was supported by the U.S. Department of Energy’s Vehicle Technology Office (DOE/VTO). Pacific Northwest National Laboratory is operated by Battelle Memorial Institute for the DOE under contract DE-AC05-76RL01830. The authors would like to thank Nathan Canfield, Anthony Guzman, Angel Ortiz, Ethan Nickerson, and Robert Seffens for their technical assistance.

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Authors and Affiliations

  1. Pacific Northwest National Laboratory, 902 Battelle Boulevard, P.O. Box 999, MSIN K2-03, WA, 99354, Richland, USA

    Abhinav Srivastava, Hrishikesh Das, Daniel Ramirez Tamayo, Lei Li, Mayur Pole, Ayoub Soulami, Jorge F. dos Santos, Keerti S. Kappagantula & Md. Reza-E-Rabby

  2. Materials Science and Engineering Department, North Carolina State University, Raleigh, NC, 27695-7907, USA

    Bharat Gwalani

Authors
  1. Abhinav Srivastava
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Contributions

All authors contributed to different phase of this study. Abhinav Srivastava: Investigation, Writing—original draft, Hrishikesh Das: Investigation, Writing—review & editing, Daniel Ramirez Tamayo: Formal analysis, Writing—review & editing. Lei Li: Formal analysis, Writing—review & editing. Mayur Pole: Investigation, Writing—review & editing. Bharat Gwalani: Investigation, Writing—review & editing. Ayoub Soulami: Supervision, Formal analysis. Jorge F. dos Santos: Conceptualization, Supervision, Writing—review & editing. Keerti S. Kappagantula: Funding acquisition, Conceptualization Writing—review & editing. *Md. Reza-E-Rabby: Supervision, Conceptualization, Investigation, Methodology, Writing—review & editing.

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Correspondence to Md. Reza-E-Rabby.

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The authors declare no conflict of interest. The authors have no relevant financial or non-financial interests to disclose. The views and opinions of the authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights.

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Srivastava, A., Das, H., Tamayo, D.R. et al. Extent of interlocking and metallurgical bonding in friction riveting of aluminum alloy to steel. Int J Adv Manuf Technol 128, 2899–2911 (2023). https://doi.org/10.1007/s00170-023-12111-8

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