@article{60592,
  abstract     = {{<jats:p>This study investigates the occurrence and mitigation of liquid metal embrittlement occurring during resistance spot welding in deep-drawn automotive components, specifically focusing on an S-Rail made from advanced high-strength steel. A simulation-based liquid metal embrittlement risk criterion based on local major component stresses was established and used to quantify and compare liquid metal embrittlement risks between different tests. Experimental and numerical analyses were conducted, revealing that springback significantly impacts liquid metal embrittlement formation. Adjustments in electrode geometry and hold time post-welding were found to mitigate liquid metal embrittlement risks. The effects of stack-up configuration and related parameter settings on liquid metal embrittlement occurrence were identified and liquid metal embrittlement was effectively prevented across both stack-up configurations. These findings advance the understanding of liquid metal embrittlement mechanisms and provide practical approaches to enhance the spot weld quality in AHSS-based body-in-whites.</jats:p>}},
  author       = {{Biegler, Max and Yang, Keke and Meschut, Gerson and Rethmeier, Michael}},
  issn         = {{1362-1718}},
  journal      = {{Science and Technology of Welding and Joining}},
  publisher    = {{SAGE Publications}},
  title        = {{{Occurrence and avoidance of liquid metal embrittlement in resistance spot welding of springback-afflicted deep-drawn components}}},
  doi          = {{10.1177/13621718251340452}},
  year         = {{2025}},
}

@inproceedings{61149,
  abstract     = {{The use of continuous fiber-reinforced thermoplastics (FRTP) in automotive industry increases due to their excellent material properties and possibility of rapid processing. The scale spanning heterogeneity of their material structure and its influence on the material behavior, however, presents significant challenges for most joining technologies, such as self-piercing riveting (SPR). During mechanical joining, the material structure is significantly altered within and around the joining zone, heavily influencing the material behavior. A comprehensive understanding of the underlying phenomena of material alteration during the SPR process is essential as basis for validating numerical simulations. This study examines the material structure at ten stages of a step-setting test of SPR with two FRTP sheets with glass-fiber reinforcement. Utilizing X-ray computed tomography (CT), the damage phenomena within different areas of the setting test are analyzed three-dimensionally and key parameters are quantified. Dominating phenomena during the penetration of the rivet into the laminate are fiber failure (FF), interfiber failure (IFF) and fiber bending, while delamination, fiber kinking and roving splitting are also observed. At the final stages, the bottom layers of the second sheet collapse and form a bulge into the cavity of the die.}},
  author       = {{Dargel, Alrik and Gröger, Benjamin and Schlichter, Malte Christian and Gerritzen, Johannes and Köhler, Daniel and Meschut, Gerson and Gude, Maik and Kupfer, Robert}},
  booktitle    = {{Proceedings of the 8th International Conference on Integrity-Reliability-Failure (IRF2025)}},
  editor       = {{Gomes, J.F. Silva and Meguid, Shaker A.}},
  isbn         = {{9789727523238}},
  keywords     = {{self-piercing riveting, computed tomography, thermoplastic composites, process-structure-interaction}},
  location     = {{Porto}},
  publisher    = {{FEUP}},
  title        = {{{Local Deformation and Failure of Composites during Self-Piercing Riveting: A CT-Based Microstructure Investigation}}},
  doi          = {{10.24840/978-972-752-323-8}},
  year         = {{2025}},
}

@article{58807,
  abstract     = {{One of the most important strategies for reducing CO2 emissions in the mobility sector is lightweight construction. In particular, the car body offers several opportunities for weight reduction. Multi-material designs are increasingly being applied to select the most suitable material for the respective load and ultimately achieve synergy effects. For example, aluminium castings are used at the nodes of a spaceframe body. Subsequently, these are joined with profiles to form the bodyshell. To join different materials mechanical joining techniques, such as semi-tubular self-piercing riveting, are deployed. According to the current state of the art, cracks occur in the aluminium castings during the mechanical joining process as a result of the high degree of deformation. Although the aluminium casting alloys of the AlSi-system exhibit low ductility, these alloys reveal excellent castability. In particular, the ability to cast thin structural parts is enabled by the low liquidus point of the near eutectic aluminium casting alloys.
This study addresses the mechanical joining properties of the near eutectic aluminium casting alloy AlSi12, depending on different microstructures. These are achieved by annealing processes and modifying agents. Through an adapted heat treatment, the previously lamellar morphology can be transformed into a globular morphology, which leads to increased ductility and prevents the formation of cracks during the self-piercing riveting (SPR). The joinability is investigated using different die geometries, whereas the joint formation is analysed regarding crack initiation. To evaluate the increased ductility, microstructural and mechanical tests are performed and finally, a microstructure-joinability correlation is established.}},
  author       = {{Neuser, Moritz and Holtkamp, Pia Katharina and Hoyer, Kay-Peter and Kappe, Fabian and Yildiz, Safak and Bobbert, Mathias and Meschut, Gerson and Schaper, Mirko}},
  journal      = {{The Journal of Materials: Design and Applications, Part L}},
  keywords     = {{aluminium, casting, microstructure, joinability, self-piercing riveting}},
  location     = {{Porto, Portugal}},
  publisher    = {{Sage Publications}},
  title        = {{{Mechanical properties and joinability of the near-eutectic aluminium casting alloy AlSi12}}},
  doi          = {{10.1177/14644207251319922}},
  year         = {{2025}},
}

@inproceedings{60290,
  abstract     = {{The constantly increasing demand for climate protection and resource conservation requires innovative and versatile joining processes that improve adaptability to the joining task and robustness to enable flexible manufacturing on a production line. Therefore, the versatile SPR (V-SPR) and tumbling SPR (T-SPR) were developed. Using the example of a mixed material combination HCT590X+Z (t0 = 1.0 mm) / EN AW-6014 T4 (t0 = 2.0 mm), these processes were examined and compared with regard to the binding mechanisms form closure and force closure using micrographs, non-destructive resistance measurements and destructive torsion tests. For this purpose, a new sample geometry was defined, and the methods were adapted to the SPR process variants.</jats:p>}},
  author       = {{Lüder, Stephan and Holtkamp, Pia Katharina and Wituschek, Simon and Bobbert, Mathias and Meschut, Gerson and Lechner, Michael and Schmale, Hans Christian}},
  booktitle    = {{Materials Research Proceedings}},
  editor       = {{Meschut, Gerson and Bobbert, Mathias and Duflou, Joost and Fratini, Livan and Hagenah, Hinnerk and Martins, Paulo A. F. and Merklein, Marion and Micari, Fabrizio}},
  issn         = {{2474-395X}},
  keywords     = {{Joining, Self-Piercing Riveting, Sheet Metal}},
  location     = {{Paderborn}},
  pages        = {{101 -- 108}},
  publisher    = {{Materials Research Forum LLC}},
  title        = {{{Analysis of the binding mechanisms depending on versatile process variants of self-piercing riveting}}},
  doi          = {{10.21741/9781644903551-13}},
  volume       = {{52}},
  year         = {{2025}},
}

@inproceedings{59878,
  abstract     = {{<jats:p>Abstract. In the development of advanced lightweight automotive solutions, self-piercing riveting (SPR) offers the possibility of joining multi-material structures to fulfil a wide variety of requirements. With regard to the entire process chain, production-related pre-deformations of the parts to be joined can influence the geometric shape and load capacity of SPR joints. Various studies have investigated the influence of pre-stretched sheet materials, in the sense of pre-drawing processes, on the formation of SPR joints. The impact of pre-stretching sheet metals on the formation of their geometrical characteristics and the shear-tensile strength of SPR processes was observed [1]. Pre-rolled semi-finished products are also joined together in mixed material automotive structures, e.g. tailor rolled blanks. This work aims to investigate the influence of pre-rolled joining parts on the geometric formation and load-carrying capacity of SPR joints. For this purpose, sheets of metal are cold-formed using a rolling process to induce a defined strain-hardening state in the material and then joined in various combinations. As the degree of deformation increases, the rolling of samples can lead to minimal accumulation of damage in the sheet materials, which can influence the joint behaviour. The rolling process, as well as the subsequent joining process, are also investigated by FEM. The influence of pre-rolled semi-finished products on the strength of the SPR joints is investigated.</jats:p>}},
  author       = {{Schlichter, Malte Christian and Harabati, Özcan and Ludwig, Jean-Patrick and Böhnke, Max and Bielak, Christian Roman and Bobbert, Mathias and Meschut, Gerson}},
  booktitle    = {{Materials Research Proceedings}},
  issn         = {{2474-395X}},
  publisher    = {{Materials Research Forum LLC}},
  title        = {{{Experimental and numerical investigation of the influence of rolling-induced sheet metal deformation on SPR joints}}},
  doi          = {{10.21741/9781644903599-148}},
  volume       = {{54}},
  year         = {{2025}},
}

@article{52201,
  author       = {{Han, Daxin and Kappe, Fabian and Vorderbrüggen, Julian and Jendrny, Jörg and Gorr, Eugen and Meschut, Gerson}},
  issn         = {{1526-6125}},
  journal      = {{Journal of Manufacturing Processes}},
  keywords     = {{Industrial and Manufacturing Engineering, Management Science and Operations Research, Strategy and Management}},
  pages        = {{92--108}},
  publisher    = {{Elsevier BV}},
  title        = {{{Single-step self-punching lockbolt process for aluminum sheets without pre-hole}}},
  doi          = {{10.1016/j.jmapro.2024.02.043}},
  volume       = {{116}},
  year         = {{2024}},
}

@inproceedings{52215,
  author       = {{Carillo Beber, Vinicius and Fernandes, Pedro and Nagel, Christof and Köster, Christian and Matzenmiller, Anton and Hecht, Mathias and Baumgartner, Jörg and Melz, Tobias and Tews, Karina and Çavdar, Serkan and Meschut, Gerson}},
  booktitle    = {{24. Kolloquium: Gemeinsame Forschung in der Klebtechnik}},
  location     = {{Köln}},
  title        = {{{Lebensdauerprognose für Stahlklebverbindungen bei multiaxialer Belastung mit Phasenverschiebung, veränderlicher Mittelspannung und variablen Amplituden}}},
  year         = {{2024}},
}

@inproceedings{52212,
  author       = {{Tews, Karina and Teutenberg, Dominik and Meschut, Gerson and Buczek, Moritz and Duffe, Tobias and Kullmer, Gunter}},
  booktitle    = {{24. Kolloquium: Gemeinsame Forschung in der Klebtechnik}},
  location     = {{Köln}},
  title        = {{{Bruchmechanisches Schnittebenenkonzept zur lebensdauergerechten Auslegung von hyperelastischen Klebverbindungen bei multiaxialen und variablen Belastungsamplituden}}},
  year         = {{2024}},
}

@inproceedings{52359,
  author       = {{Chudalla, Nick and Schmolke, Tobias and Meschut, Gerson and Spohr, Sebastian and Eckstein, Lutz and Brunner-Schwer, Christian and Rethmeier, Michael and Nothelfer-Richter, Rolf and Hilt, MIchael}},
  booktitle    = {{24. Kolloquium: Gemeinsame Forschung in der Klebtechnik}},
  location     = {{Köln}},
  title        = {{{Konzeptentwicklung für ein Stahlbatteriegehäuse unter besonderer Berücksichtigung der Fügetechnik und des Korrosionsschutzes}}},
  year         = {{2024}},
}

@inproceedings{52403,
  author       = {{Al Trjman, Mohamad and Meschut, Gerson and Salten, Alexander Heinrich Johannes and Kenig, Eugeny Y.}},
  location     = {{Köln}},
  title        = {{{Methodenentwicklung zur Simulation des Viscous Fingering in Klebverbindungen von stahlintensiven Mischbaustrukturen}}},
  year         = {{2024}},
}

@article{50726,
  abstract     = {{<jats:p>Resistance spot‐welded joints containing press‐hardened steels are seen to exhibit a fracture mode called total dome failure, where the weld nugget completely separates from one steel sheet along the weld nugget edge. The effect of weld nugget shape and material property gradients is studied based on damage mechanics modeling and experimental validation to shed light on the underlying influencing factors. For a three‐steel‐sheet spot‐welded joint combining DP600 (1.5 mm)–CR1900T (1.0 mm)–CR1900T (1.0 mm), experiments under shear loading reveal that fracture occurs in the DP600 sheet along the weld nugget edge. In subsequent numerical simulation studies with damage mechanics models whose parameters are independently calibrated for every involved material configuration, three variations of the geometrical joint configuration are considered—an approximation of the real joint, one variation with a steeper weld nugget shape, and one variation with a less pronounced gradient between weld nugget material and heat‐affected zone material properties. The results of the finite‐element simulations show that a shallower weld nugget and a more pronounced material gradient lead to a faster increase of plastic strain at the edge of the weld nugget and promote the occurrence of total dome failure.</jats:p>}},
  author       = {{Schuster, Lilia and Olfert, Viktoria and Sherepenko, Oleksii and Fehrenbach, Clemens and Song, Shiyuan and Hein, David and Meschut, Gerson and Biro, Elliot and Münstermann, Sebastian}},
  issn         = {{1611-3683}},
  journal      = {{steel research international}},
  keywords     = {{Materials Chemistry, Metals and Alloys, Physical and Theoretical Chemistry, Condensed Matter Physics}},
  publisher    = {{Wiley}},
  title        = {{{Influences of Weld Nugget Shape and Material Gradient on the Shear Strength of Resistance Spot‐Welded Joints}}},
  doi          = {{10.1002/srin.202300530}},
  year         = {{2024}},
}

@inproceedings{54142,
  author       = {{Beule, Felix and Al Trjman, Mohamad and Teutenberg, Dominik and Meschut, Gerson}},
  location     = {{Shanghai}},
  title        = {{{Method development (modelling, simulation, characterisation) in adhesive bonding technology}}},
  year         = {{2024}},
}

@inproceedings{54240,
  author       = {{Gilich, Julian and Meschut, Gerson and Gröger, Benjamin and Wiebicke, Felix and Koch, Ilja and Gude, Maik}},
  booktitle    = {{14. Doktorandenseminar Klebtechnik}},
  location     = {{Kassel}},
  title        = {{{Experimentelle und numerische Analyse des Fließverhaltens von hochviskosen Wärmeleitstoffen im Fertigungsprozess}}},
  year         = {{2024}},
}

@inproceedings{56087,
  author       = {{Beule, Felix and Teutenberg, Dominik and Meschut, Gerson}},
  booktitle    = {{The 16th International Conference on the Science and Technology of Adhesion and Adhesives}},
  location     = {{Oxford, UK}},
  title        = {{{Numerical modelling of the influence of viscous fingering on the mechanical properties of structural adhesive joints}}},
  year         = {{2024}},
}

@article{54847,
  abstract     = {{The widespread adoption of ultra-high strength steels, due to their high bulk resistivity, intensifies expulsion issues in resistance spot welding (RSW), deteriorating both the spot weld and surface quality. This study presents a novel approach to prevent expulsion by employing a preheating current. Through characteristic analysis of joint formation under critical welding current, the importance of plastic material encapsulation around the weld nugget (plastic shell) at high temperatures in preventing expulsion is highlighted. To evaluate the effect of preheating on the plastic shell and understand its mechanism in expulsion prevention, a two-dimensional welding simulation model for dissimilar ultra-high strength steel joints was established. The results showed that optimal preheating enhances the thickness of the plastic shell, improving its ability to encapsulate the weld nugget during the primary welding phase, thereby diminishing expulsion risks. Experimental validation confirmed that by employing the optimal preheating current, the maximum nugget diameter was enhanced to 9.42 mm, marking an increase of 13.4 % and extending the weldable current range by 27.5 %. Under quasi-static cross-tensile loading, joints with preheating demonstrated a 7.9 % enhancement in maximum load-bearing capacity compared to joints without preheating, showing a reproducible and complete pull-out failure mode within the heat-affected zone. This study offers a prevention method based on underlying mechanisms, providing a new perspective for future research on welding parameter optimization with the aim of expulsion prevention.}},
  author       = {{Yang, Keke and El-Sari, Bassel and Olfert, Viktoria and Wang, Zhuoqun and Biegler, Max and Rethmeier, Michael and Meschut, Gerson}},
  issn         = {{1526-6125}},
  journal      = {{Journal of Manufacturing Processes}},
  keywords     = {{Expulsion Resistance spot welding Finite element modelling Preheating Weldable current range Ultra-high strength steel}},
  pages        = {{489--502}},
  publisher    = {{Elsevier BV}},
  title        = {{{Expulsion prevention in resistance spot welding of dissimilar joints with ultra-high strength steel: An analysis of the mechanism and effect of preheating current}}},
  doi          = {{10.1016/j.jmapro.2024.06.034}},
  volume       = {{124}},
  year         = {{2024}},
}

@inproceedings{58384,
  abstract     = {{<jats:p>Abstract. Structures made of aluminum die casting are being used in increasing quantities as well as component sizes for various applications. Due to the size of the components, heat treatment of the cast parts following the casting process is omitted in order to meet dimensional accuracy requirements and reduce production costs. From such an approach, challenges arise with regard to the mechanical joining of these aluminum die-cast structures. On one hand, the absence of heat treatment results in a general decrease in ductility. On the other hand, the increasing size of the components introduces process-related tolerances regarding the quality of the casting, including the presence of air or gas inclusions, and significant variations in ductility within the component. These factors present challenges for mechanical joining technologies, such as the potential risk of crack-related defects during the joining process. For the robust mechanical joining of such materials, the development and validation of suitable joining strategies for aluminum die cast components is presented in this paper. A preparatory step involving localized heat treatment in the joining area is implemented to enhance the suitability of the casting material for mechanical joining. The objective is to generate an improved ductility state in the aluminum die casting material, enabling crack-free joining through self-pierce riveting. Additionally, the formability of the aluminum die casting material is characterized using a specially developed ductility testing method. This allows the prediction of potential crack-related defects during mechanical joining. The methods described are developed using the AlSi10MnMg material in its as-cast state and applied to the self-pierce riveting process. </jats:p>}},
  author       = {{Kraus, Christian and Böhnke, Max and Drossel, Welf-Guntram and Meschut, Gerson}},
  booktitle    = {{Materials Research Proceedings}},
  issn         = {{2474-395X}},
  location     = {{Toulouse}},
  publisher    = {{Materials Research Forum LLC}},
  title        = {{{Development of new strategies for the mechanical joining of components made of aluminum die casting}}},
  doi          = {{10.21741/9781644903131-190}},
  volume       = {{41}},
  year         = {{2024}},
}

@inproceedings{58382,
  author       = {{Striewe, Marius and Bähr, Philipp and Meschut, Gerson and Hein, David and Sommer, Silke}},
  booktitle    = {{14. Kolloquium: Gemeinsame Forschung in der Mechanischen Fügetechnik}},
  title        = {{{Ersatzmodellentwicklung zur Berücksichtigung der lokalen Fügeelementkinematik in mechanisch gefügten Verbindungen für die Bauteilauslegung im stahlintensiven Karosseriebau}}},
  year         = {{2024}},
}

@book{58403,
  author       = {{Mayer, Bernd and Nagel, Christof and Fernandes, Pedro Henrique Evangelista and Matzenmiller, Anton and Köster, Christian and Melz, Tobias and Baumgartner, Jörg and Hecht, Matthias and Tews, Karina and Çavdar, Serkan and Meschut, Gerson}},
  publisher    = {{Forschungsvereinigung Stahlanwendung e.V.}},
  title        = {{{Lebensdauerprognose für Stahlklebverbindungen bei multiaxialer Belastung mit Phasenverschiebung, veränderlicher Mittelspannung und variablen Amplituden}}},
  volume       = {{1427}},
  year         = {{2024}},
}

@inproceedings{52216,
  author       = {{Tews, Karina and Teutenberg, Dominik and Meschut, Gerson}},
  booktitle    = {{DECHEMA Workshop für Klebstoffanwender: Simulation von Klebverbindungen}},
  location     = {{Köln}},
  title        = {{{Mechanisches Verhalten: Charakterisierung von Klebstoffen}}},
  year         = {{2024}},
}

@unpublished{58441,
  abstract     = {{This study presents a numerical approach using a 3D finite element model to quantify the remaining clamp load of a plastic nut joint after a specific time. The viscoelastic relaxation of a thermoplastic nut, which is predominantly screwed on a welding stud, is described by a material card using Prony Series. Prony Series are derived from experimental Dynamical Mechanical Analysis with different moisture and fiber contents of the thermoplastic. Since plastic nuts usually do not have preformed threads, the increased temperatures and resulting stresses from the thread-forming process are considered in the simulation. Firstly, the FE model is verified by substrate stress relaxation tests. Subsequently, experimental clamp load measurements with miniature compression load cells verify the clamp load prediction. Finally, the developed model is used to analyze the clamp load distribution within the threads}},
  author       = {{Wippermann, Jan and Meschut, Gerson}},
  publisher    = {{Springer Science and Business Media LLC}},
  title        = {{{Numerical modeling of clamp load relaxation of plastic nuts under varying moisture and fiber content}}},
  year         = {{2024}},
}