@article{64678, abstract = {{One of the major topics in the modern automotive industry is reducing emissions and increasing the mileage range. To tackle this challenge, on the one hand, modifying the powertrain system is a possibility, and on the other hand, lightweight design offers various possibilities. Multi-Material Design (MMD) involves designing car bodies that combine different materials that require joining. Given the variety of materials, mechanical joining processes are preferred. Especially the current development of the Giga/Mega-casting process concerning aluminium casting and the subsequent mechanical joining illustrates the challenges of this material group. In car production, aluminium castings are mainly made from aluminium-silicon (AlSi) alloys. Ultimately, the alloy system's insufficient ductility leads to crack initiation during mechanical joining. Cast parts are therefore often used in areas of the car body that are exposed to high-pressure loads. For example, self-piercing riveting (SPR) is used due to its high load-bearing capacity. In this study, improved joinability is demonstrated by influencing the microstructure through tailored solidification rates and a developed heat-treatment chain strategy adapted for hypoeutectic AlSi systems. Data on microstructure, mechanical, and joining properties are used to develop a solidification-joining correlation for the SPR process across a range of Si contents and solidification rates. The purpose is to develop the ability to produce suitable aluminium castings with sufficient joinability, thereby improving versatility.}}, author = {{Neuser, Moritz and Kaimann, Pia Katharina and Stratmann, Ina and Bobbert, Mathias and Klöckner, Johann Moritz Benedikt and Mann, Moritz and Hoyer, Kay-Peter and Meschut, Gerson and Schaper, Mirko}}, journal = {{Journal of Manufacturing Processes}}, keywords = {{Mechanical joining, Aluminium, Self-piercing riveting, Casting, Microstructure, Joinability AlSi-alloys}}, publisher = {{Elsevier}}, title = {{{Solidification-joinability correlation of hypoeutectic aluminium casting alloys for self-piercing riveting (SPR)}}}, doi = {{https://doi.org/10.1016/j.jmapro.2026.02.040}}, volume = {{164}}, year = {{2026}}, } @article{64985, abstract = {{Modern industrial development has necessitated a wide range of joining technologies. Self-pierce riveting has become a prevalent technique for sheet metal assembly, especially in automotive applications. Achieving proper joint geometry and adequate load-bearing capacity depends on appropriate tool selection and precise process control. Material properties and condition also play a significant role in process performance. To accommodate the inevitable variations in component characteristics during production, a robust and stable joining process is essential. The study focuses on investigating the influence of preformed joining partners on the joining process and the joint's load capacity. An EN AW-6014 in T4 condition, as well as an HCT590X, are used as materials for this study. For this purpose, an exemplary process chain consisting of the steps of performing, joining, and shear load testing is studied. Each process step is implemented using an FE model to predict the outcome of subsequent steps. For analysis of the influence of pre-strain, an optimisation software is used to plan and execute variations of the process. These variations are used to create a meta-model that can describe the relationships between pre-forming and characteristic parameters of subsequent process steps. The resulting model is validated by comparing simulation and experimental data. Finally, in a novel approach, the robustness of the presented process chain is analyzed in terms of a tolerable performance level for the joining partners.}}, author = {{Ludwig, Jean-Patrick and Tolke, Emil and Schlichter, Malte Christian and Bobbert, Mathias and Meschut, Gerson}}, issn = {{2666-3309}}, journal = {{Journal of Advanced Joining Processes}}, keywords = {{Self-pierce riveting, FE modelling, Plastic pre-deformation, Meta modelling}}, publisher = {{Elsevier BV}}, title = {{{Numerical analysis of the robustness of self-pierce riveting with pre-formed joining partners}}}, doi = {{10.1016/j.jajp.2026.100391}}, volume = {{13}}, year = {{2026}}, } @article{58492, abstract = {{A coupled finite plasticity ductile damage and failure model is proposed for the finite element simulation of clinch joining, which incorporates stress-state dependency and regularisation by gradient-enhancement of the damage variable. Ductile damage is determined based on a failure indicator governed by a failure surface in stress space. The latter is exemplary chosen as a combination of the Hosford–Coulomb and Cockcroft–Latham–Oh failure criteria for the high and low stress triaxiality range, respectively, to cover the wide stress range encountered in forming. Damage is coupled to elasto-plasticity to capture the damage-induced degradation of the stiffness and flow stress. This affects the material behaviour up to failure, thereby realistically altering the stress state. Consequently, especially for highly ductile materials, where substantial necking and localisation precede material fracture, the failure prediction is enhanced. The resulting stress softening is regularised by gradient-enhancement to obtain mesh-objective results. The analysis of a modified punch test experiment emphasises how the damage-induced softening effect can strongly alter the actual stress state towards failure. Moreover, the impact of successful regularisation is shown, and the applicability of the damage and failure model to clinch joining is proven.}}, author = {{Friedlein, Johannes and Mergheim, Julia and Steinmann, Paul}}, issn = {{0022-5096}}, journal = {{Journal of the Mechanics and Physics of Solids}}, keywords = {{Finite plasticity, Ductile damage, Gradient-enhancement, Stress-state dependency, Failure}}, publisher = {{Elsevier BV}}, title = {{{Modelling of stress-state-dependent ductile damage with gradient-enhancement exemplified for clinch joining}}}, doi = {{10.1016/j.jmps.2025.106026}}, volume = {{196}}, year = {{2025}}, } @article{64157, author = {{Friedlein, Johannes and Steinmann, Paul and Mergheim, Julia}}, issn = {{0168-874X}}, journal = {{Finite Elements in Analysis and Design}}, publisher = {{Elsevier BV}}, title = {{{One-way coupled staggered implementation of gradient-enhanced damage models coupled to thermoplasticity}}}, doi = {{10.1016/j.finel.2025.104471}}, volume = {{253}}, year = {{2025}}, } @article{59872, abstract = {{Lightweight design is a driving concept in modern automotive engineering to minimize resource consumption over a vehicle's lifecycle through multi-material design, which relies on the use of joining techniques in car body fabrication. Multi-material design and the increasing trend towards producing large structural components using the megacasting process pose considerable challenges, particularly in the mechanical joining of aluminium-silicon (AlSi) castings. These castings typically exhibit low ductility and are prone to cracking when mechanically joined. Based on the excellent castability of hypoeutectic AlSi alloys, these are applied in sand casting and die casting as well as in megacasting. With a silicon content between 7 wt% and 12 wt%, these AlSi-alloys have a plate-like silicon phase that initiates cracks during mechanical joining. To enhance the joinability of castings, the research hypothesis is that improved solidification conditions enable a significant modification in the microstructure and therefore, increase the mechanical properties. During the manufacture of the castings using the sand casting process, the solidification conditions within the structural elements are varied to modify the microstructure to obtain castings with graded microstructure. The castings are evaluated using mechanical, microstructural and joining testing methods and finally, a microstructure-joinability correlation is established.}}, author = {{Neuser, Moritz and Schlichter, Malte Christian and Hoyer, Kay-Peter and Bobbert, Mathias and Meschut, Gerson and Schaper, Mirko}}, journal = {{44th Conference of the International Deep Drawing Research Group (IDDRG 2025)}}, keywords = {{Joining, Casting, Self-pierce riveting, Aluminium casting alloy}}, location = {{Lissabon (Portugal)}}, title = {{{Mechanical joinability of microstructurally graded structural components manufactured from hypoeutectic aluminium casting alloys}}}, doi = {{10.1051/matecconf/202540801081}}, volume = {{408}}, year = {{2025}}, } @inproceedings{59878, abstract = {{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.}}, 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}}, } @inproceedings{60977, 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.}}, 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}}, } @inproceedings{60978, abstract = {{The present study is an experimental analysis of the influence of pre-forming on the failure behaviour of clinched specimens under quasi-static and cyclic loading conditions. In this context, the geometric formation of the clinched joints is taken into account, with regard to the loading behaviour. The study also includes a comparison of the failure behaviour of quasi-static and cyclic tested specimen. Testing is done on non-pre-deformed and pre-deformed specimens. For this purpose, experimental investigations are carried out on two material combinations consisting of HCT590X steel sheet and EN AW-6014 T4 aluminium sheet. The focus is on the fatigue analysis of the clinched joints. The aim is to identify the failure modes under cyclic loading and the crack formation with regard to forming operations prior to the joining process. The investigations show that the cyclic load-bearing behaviour of the HCT590X joints is reduced by introducing a plastic pre-deformation of the to be joined parts.}}, author = {{Schlichter, Malte Christian and Harabati, Özcan 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 = {{{Investigation on manufacturing-induced pre-deformation on the fatigue behaviour of clinched joints}}}, doi = {{10.21741/9781644903551-16}}, volume = {{52}}, year = {{2025}}, } @inproceedings{59587, abstract = {{Abstract. As a widely used sheet metal in clinched joints within the automotive industry, the aluminum alloy EN AW-6014 has been the focus of numerous studies. High-cycle fatigue (HCF) is a critical aspect when assessing the durability of clinched joints. In the present work, the HCF behavior of EN AW-6014 T4 was explored both experimentally and numerically. To model the fatigue behavior, Lemaitre’s two-scale damage model was used. Two key parameters, damage strength and damage exponent, are necessary for numerical investigations of HCF behavior. These parameters were determined through experiments with flat specimens and subsequently validated within a numerical model of clinched joints. The numerical results for fatigue match the experimental ones of the clinched joints quite well.}}, author = {{Chen, Chin and Schlichter, Malte Christian and Harzheim, Sven and Hofmann, Martin and Bobbert, Mathias and Meschut, Gerson and Wallmersperger, Thomas}}, booktitle = {{Materials Research Proceedings}}, issn = {{2474-395X}}, publisher = {{Materials Research Forum LLC}}, title = {{{High-cycle fatigue testing and parameter identification for numerical simulation of aluminum alloy EN AW-6014}}}, doi = {{10.21741/9781644903551-23}}, volume = {{52}}, year = {{2025}}, } @inproceedings{60002, abstract = {{This study focuses on damage modeling across different mechanical joining processes within a process chain, specifically using clinching and self-pierce riveting (SPR). The aim is to apply a comprehensive model that captures the damage mechanisms and interactions in these technologies, optimizing them for enhanced performance and durability of aluminum joints. A GISSMO damage model was utilized, based on the stress states occurring during the joining process and a newly introduced damage testing method. This model was applied to both clinching and SPR processes. A detailed analysis of the stress states provided insights into their effect on the material. By incorporating these insights into the GISSMO model, improved accuracy in damage prediction was achieved. The model's application to clinching and SPR demonstrated its effectiveness in optimizing aluminum joint performance and durability, ensuring that the processes can be finely tuned to minimize damage and enhance joint quality.}}, author = {{Harabati, Özcan and Bielak, Christian Roman and Böhnke, Max and Schlichter, Malte Christian and Brockmeier, Marc and Bobbert, Mathias and Meschut, Gerson}}, booktitle = {{Materials Research Proceedings}}, issn = {{2474-395X}}, publisher = {{Materials Research Forum LLC}}, title = {{{Cross-process damage modeling: A process-chain case study of clinching and self-pierced riveting for aluminum connections}}}, doi = {{10.21741/9781644903551-19}}, volume = {{52}}, year = {{2025}}, } @article{59584, author = {{Friedlein, Johannes and Lüder, Stephan and Kalich, Jan and Schmale, Hans Christian and Böhnke, Max and Schlichter, Malte Christian and Bobbert, Mathias and Meschut, Gerson and Steinmann, Paul and Mergheim, Julia}}, issn = {{2666-3309}}, journal = {{Journal of Advanced Joining Processes}}, publisher = {{Elsevier BV}}, title = {{{Application of stress-state-dependent ductile damage and failure model to clinch joining for a wide range of tool and material combinations}}}, doi = {{10.1016/j.jajp.2025.100299}}, volume = {{11}}, year = {{2025}}, } @inproceedings{60440, abstract = {{The versatile self-pierce riveting (V-SPR) is a further development of semi-tubular self-pierce riveting. V-SPR enables adaptation to changing boundary conditions, such as a change in the material thickness combination, without varying the rivet die combination due to increased punch actuation and the use of multi-range capable rivets [1]. The inner punch first sets the rivet. The outer punch then forms the rivet head to the respective sheet thickness. For this, the rivet requires a hard shank and a ductile rivet head, which is achieved by an inductive local hardening process [2]. Until now, the joint formation of rivets with graded hardness profile has been challenging to estimate in the FEM simulation due to the inhomogeneous material conditions in the rivet. In this study, a method capable of reproducing the experimentally determined hardness levels of rivets in detail is shown. This FE model enables the realistic modelling of the mechanical properties of the rivet on the basis of the hardness profile in order to predict the correct deformation processes and stresses during the riveting process. First, the detailed experimental hardness mapping of the locally heat-treated rivets is transferred into the FE model. The FEM material model can predict the local strength of the rivet based on hardness by scaling the flow curves. To estimate the predictive capability of the FEM model, the joint formation of rivets with different graded hardness profiles is compared experimentally and simulative. Based on the validated model, the influence of different rivet hardness profiles on the joint formation is analysed numerically. By adapting the material model, a high level of correlation between the experiment's joint formation and the simulation can be achieved.}}, author = {{Holtkamp, Pia Katharina and Bielak, Christian Roman and Bobbert, Mathias and Meschut, Gerson}}, booktitle = {{Materials Research Proceedings}}, issn = {{2474-395X}}, publisher = {{Materials Research Forum LLC}}, title = {{{Simulation of the joining process of graded hardened multi-range capable rivets}}}, doi = {{10.21741/9781644903599-153}}, volume = {{54}}, year = {{2025}}, } @inproceedings{62079, abstract = {{This paper investigates two modeling approaches for the simulation of the deformation and decomposition behavior of preconsolidated rovings above the thermoplastic matrix{\textquoteright} melting temperature. This is crucial for capturing the local material structure after processes introducing highly localized deformation such as mechanical joining processes between metal and fiber reinforced thermoplastics (FRTP). A generic finite element (FE) model is developed, incorporating interfaces discretized through either cohesive zone (CZ) elements or Coulomb friction-based contacts. The material parameters for the FE elements are derived from the initial stiffness of a statistical volume element (SVE) at micro scale modelled with an Arbitrary-Lagrange-Eulerian method for three load cases. The CZ properties calculated are based on the shear viscosity of the composite. The CZ and contact modelling approaches are evaluated using three load cases of the SVE, comparing force-displacement curves. Under simple loading conditions, such as normal pressure tension and bending, both methods produce similar results; however, in complex load cases, the CZ approach shows clear advantages in handling interface interactions and shows robust simulations. The CZ approach thus presents a promising method for simulating roving decomposition in FRTP-metal joining applications above the matrix{\textquoteright} melting temperature.}}, author = {{Gröger, Benjamin and Gerritzen, Johannes and Hornig, Andreas and Gude, Maik}}, booktitle = {{Sheet Metal 2025}}, editor = {{Meschut, G. and Bobbert, M. and Duflou, J. and Fratini, L. and Hagenah, H. and Martins, P. and Merklein, M. and Micari, F.}}, isbn = {{978-1-64490-354-4}}, keywords = {{Finite Element Method (FEM), Process, Thermoplastic Fiber Reinforced Plastic}}, pages = {{268–275}}, publisher = {{Materials Research Forum LLC, Materials Research Foundations}}, title = {{{Modeling approaches for the decomposition behavior of preconsolidated rovings throughout local deformation processes}}}, doi = {{10.21741/9781644903551-33}}, year = {{2025}}, } @inproceedings{62080, abstract = {{The failure behavior of fiber reinforced polymers (FRP) is strongly influenced by their microstructure, i.e. fiber arrangement or local fiber volume content. However, this information cannot be directly used for structural analyses, since it requires a discretization on micrometer level. Therefore, current failure theories do not directly account for such effects, but describe the behavior averaged over an entire specimen. This foundation in experimentally accessible loading conditions leads to purely theory based extension to more complex stress states without direct validation possibilities. This work aims at leveraging micro-scale simulations to obtain failure information under arbitrary loading conditions. The results are propagated to the meso-scale, enabling efficient structural analyses, by means of machine learning (ML). It is shown that the ML model is capable of correctly assessing previously unseen stress states and therefore poses an efficient tool of exploiting information from the micro-scale in larger simulations.}}, author = {{Gerritzen, Johannes and Hornig, Andreas and Gude, Maik}}, booktitle = {{Sheet Metal 2025}}, editor = {{Meschut, G. and Bobbert, M. and Duflou, J. and Fratini, L. and Hagenah, H. and Martins, P. and Merklein, M. and Micari, F.}}, isbn = {{978-1-64490-354-4}}, keywords = {{Failure, Fiber Reinforced Plastic, Machine Learning}}, pages = {{260–267}}, publisher = {{Materials Research Forum LLC, Materials Research Foundations}}, title = {{{Efficient failure information propagation under complex stress states in fiber reinforced polymers: From micro- to meso-scale using machine learning}}}, doi = {{10.21741/9781644903551-32}}, year = {{2025}}, } @article{62081, author = {{Gerritzen, Johannes and Gröger, Benjamin and Zscheyge, Matthias and Hornig, Andreas and Gude, Maik}}, issn = {{0264-1275}}, journal = {{Materials & Design}}, publisher = {{Elsevier BV}}, title = {{{3D viscoelastic plastic model coupled with a continuum damage formulation for fiber reinforced polymers}}}, doi = {{10.1016/j.matdes.2025.114969}}, volume = {{260}}, 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{63828, author = {{Gerritzen, Johannes and Chopra, Kunal and Reschke, Gregor and Hornig, Andreas and Brosius, Alexander and Gude, Maik}}, issn = {{2666-3309}}, journal = {{Journal of Advanced Joining Processes}}, publisher = {{Elsevier BV}}, title = {{{Quality assurance of clinched joints using explainable machine learning}}}, doi = {{10.1016/j.jajp.2025.100368}}, volume = {{13}}, 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.}}, 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{60285, abstract = {{This paper examines the impact of a rotationally superimposed punch stroke on the binding mechanisms of clinched joints of aluminum sheets. As part of the development of a method for ensuring the versatility of clinching, an additional rotational movement of the punch was introduced as a control variable to influence friction in the mechanical joining process. The effect of rotational superimposition on the force-displacement curve of the clinching processes was investigated using four test variants with different kinematics. The primary objective was to evaluate the binding mechanisms that maintain the integrity of the clinched joint. To evaluate the force closure of the resulting joint, two testing methods were employed throughout the course of the research, non-destructive resistance measurement using four-wire sensing method and destructive torsion testing. A crucial factor influencing the efficacy of the process is surface cleanliness, as contaminants between joining partners can impede the effectiveness of the clinched joint. Therefore, all specimens were meticulously cleaned prior to experimentation. This method exhibits promising potential in creating clinched joints that align with the demands of flexible manufacturing environments.}}, author = {{Lüder, Stephan and Wolf, Eugen and Schmale, Hans Christian and Brosius, Alexander}}, booktitle = {{MATEC Web of Conferences}}, issn = {{2261-236X}}, keywords = {{Joining, Sheet Metal, Tribology, Clinching}}, location = {{Lisbon}}, publisher = {{EDP Sciences}}, title = {{{Investigation of the impact of a rotationally superimposed punch stroke on the binding mechanisms of a clinched joint}}}, doi = {{10.1051/matecconf/202540801086}}, volume = {{408}}, year = {{2025}}, }