@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{63020,
  abstract     = {{Zur Prüfung der mechanischen Eigenschaften von mechanisch gefügten Verbindungen wird gemäß der Normung in der Regel nur ein Fügepunkt verwendet. In diesem Beitrag wird die Prüfung von Mehrfachanordnungen von Clinchpunkten in einem modifizierten Torsionsversuch beschrieben. Bei den Fügeverbindungen der Proben aus artgleichen Werkstoffen handelt es sich um zwei Varianten symmetrischer Mehrfachanordnungen von vier Clinchpunkten mit zwei unterschiedlichen Fügepunktabständen, was zu zwei verschiedenen Längen des Wirkabstands in Bezug auf die Rotationsachse im Torsionsversuch führt. Das erste Teilziel der Untersuchung ist die Bewertung der Tragfähigkeit der Mehrfachanordnungen von Clinchpunkten unter Torsionsbeanspruchung. Ein zweites Teilziel ist die Analyse des Einflusses eines zusätzlichen Clinchpunkts, der als Drehgelenk in der Rotationsachse wirkt, auf das Tragverhalten und das Versagensverhalten der Fügeverbindung. Aus den erarbeiteten Resultaten werden Erkenntnisse zum Tragverhalten der Fügeverbindungen abgeleitet und eine Überschlagsrechnung vorgestellt, um Richtlinien zur konstruktiven Auslegung von Bauteilen aufzustellen.}},
  author       = {{Lüder, Stephan and Wolf, Eugen and Brosius, Alexander and Schmale, Hans Christian}},
  booktitle    = {{43. Vortrags- und Diskussionstagung Werkstoffprüfung 2025}},
  editor       = {{Zimmermann, Martina}},
  isbn         = {{978-3-88355-454-9}},
  keywords     = {{Clinchen, Mehrfachanordnung, Torsionsprüfung, Tragfähigkeit}},
  location     = {{Dresden}},
  pages        = {{478 -- 483}},
  title        = {{{Modifizierter Torsionsversuch zur Untersuchung des Tragverhaltens von Clinchpunktmehrfachanordnungen}}},
  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{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.</jats:p>}},
  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}},
}

@inproceedings{60645,
  abstract     = {{Die Wandlungsfähigkeit einer Prozesskette erfordert Fügeverbindungen mit gezielt einstellbaren mechanischen, elektrischen, thermischen oder chemischen Eigenschaften. Dieser Beitrag beschreibt die Untersuchungen, inwiefern beim Clinchen zweier Bleche aus der ausscheidungshärtbaren Aluminiumlegierung EN AW-6014 bereits auf Basis der Prozessüberwachung des Kraft-Weg-Verlaufs bzw. des sich daraus ergebenden Energieeintrags auf die mechanischen und elektrischen Eigenschaften der Fügeverbindung geschlossen werden kann. An einer ausgewählten Fügeaufgabe werden im Stufenversuch die gegenseitigen Abhängigkeiten der einzelnen Einflussgrößen sowie des Wärmebehandlungszustands aufgezeigt. Dabei wird zwischen den Bindemechanismen Formschluss und Kraftschluss unterschieden. Die Formschlusskomponente wird anhand der geometrischen Kenngrößen wie Bodendicke, Halsdicke und Hinterschnitt in Mikroskopieuntersuchungen an Schliffbildern und den mechanischen Eigenschaften der Fügeverbindung untersucht, die im Scherzug- und Kopfzugversuch bestimmt werden. Dazu erfolgt zudem die Charakterisierung der Versagensbilder. Zur Quantifizierung der Kraftschlusskomponente der Fügeverbindung werden das Losbrechmoment im Torsionsversuch und der elektrische Widerstand mittels Vier-Leiter-Methode ermittelt und korreliert.}},
  author       = {{Lüder, Stephan and Kalich, Jan and Oesterle, Hannes and Schmale, Hans Christian}},
  booktitle    = {{Tagung Werkstoffprüfung 2024: Werkstoffe und Bauteile auf dem Prüfstand, Prüftechnik – Kennwertermittlung – Schadensvermeidung}},
  editor       = {{Krupp, Ulrich and Steller, Ingo}},
  isbn         = {{978-3-941269-97-2}},
  keywords     = {{Clinchen, Aluminium, Stufensetzversuch, Bindemechanismus, Formschluss, Kraftschluss, Zugversuch, Torsionsversuch, Widerstandsmessung}},
  location     = {{Krefeld}},
  pages        = {{205--210}},
  title        = {{{Prozessüberwachte Eigenschaftseinstellung beim Clinchen der ausscheidungshärtbaren Aluminiumlegierung EN AW-6014}}},
  year         = {{2024}},
}

@inproceedings{60647,
  abstract     = {{Das umformtechnische Fügeverfahren Clinchen ermöglicht ein energiearmes Fügen von Blechen und dient traditionell der Übertragung mechanischer Kräfte. Neue Einsatzgebiete erfordern eine elektrische oder thermische Leitfähigkeit, sodass es notwendig ist, das Clinchen entsprechend zu qualifizieren. Es wurden Untersuchungen an Aluminiumverbindungen durchgeführt, welche mit hohen Kurzzeitströmen belastet wurden. Der Einfluss verschiedener Oberflächenvorbehandlungen wurde betrachtet. Als Charakterisierungsmethode für die Bauteile und die geclinchten Fügeverbindungen wird die Messung des elektrischen Widerstandes herangezogen. Die untersuchten Clinchverbindungen sind fähig, die im Fehlerfall auftretenden Kurzzeitströme zu übertragen. Der Oberflächenzustand übt dabei einen signifikanten Einfluss auf die Clinchpunktausbildung und damit auf deren elektrische Eigenschaften aus. Durch Messung des elektrischen Widerstandes vor und nach dem Fügen sowie nach einer Bestromung mit Fehlerströmen, kann das Kontaktverhalten qualifiziert werden.}},
  author       = {{Reschke, Gregor and Kalich, Jan and Füssel, Uwe}},
  booktitle    = {{Tagung Werkstoffprüfung 2022: Werkstoffe und Bauteile auf dem Prüfstand, Prüftechnik – Kennwertermittlung – Schadensvermeidung}},
  editor       = {{Zimmermann, Martina}},
  isbn         = {{978-3-88355-430-3}},
  keywords     = {{Clinchen, Bindemechanismen, elektrische Eigenschaften, Aluminium, Kurzzeitbestromung}},
  location     = {{Dresden}},
  pages        = {{374--379}},
  title        = {{{Methoden zur Charakterisierung der Bindemechanismen bei geclinchten elektrischen Kontakten}}},
  year         = {{2023}},
}

@article{30628,
  abstract     = {{The work carried out is based on the thesis properties of clinched joints are determined by the proportions of binding mechanisms form-closure, force-closure and material-closure. To describe the acting binding mechanisms and thus to derive the joint properties, detailed knowledge of the local effect of the individual binding mechanisms is necessary to ensure their targeted adjustment by the joining process. The targeted setting of different proportions of the binding mechanisms is achieved firstly via tool geometry and secondly via surface condition of the joined parts. An introduced form-closure component can be quantified by metallographic cross section with subsequent measurement of the quality-determining parameters such as undercut, penetration depth and neck thickness. To qualify the force-closure component, a torsional load can be applied mechanically at rotationally symmetrical clinch joints. This also allows the influence of different surface conditions on the tribological system to be quantified. Measurement of electrical resistance can reveal the binding mechanisms of force- and material-closure. These investigations are carried out on an aluminum joining part combination of the same type. As a result of these investigations, the clinched joints can be designed according to the load occurring in the later life cycle in the form of an optimum and compromise variant with regard to minimum loads to be transmitted mechanically, electrically with regard to low resistance or manufacturing with minimum energy input.}},
  author       = {{Kalich, J. and Füssel, U.}},
  journal      = {{Production Engineering}},
  title        = {{{Design of clinched joints on the basis of binding mechanisms}}},
  doi          = {{10.1007/s11740-022-01108-z}},
  year         = {{2022}},
}

@article{34252,
  abstract     = {{Clinching is the manufacturing process of joining two or more metal sheets under high plastic deformation by form and force closure without thermal support and auxiliary parts. Clinch connections are applicable to difficult-to-join hybrid material combinations, such as steel and aluminum. Therefore, this technology is interesting for the application of AISI 304 components, as this material is widely used as a highly formable sheet material. A characteristic feature of AISI 304 is its metastability, i.e., the face-centered cubic (fcc) γ-austenite can transform into a significantly stronger body-centered cubic (bcc) α’-martensite under plastic deformation. This work investigates the effect of heat treatment—a process that involves the formation of an oxidation layer on the sheet surface—on the forming process during joining and the resulting mechanical properties of clinch joints made from AISI 304. For this purpose, different joints made from non-heat treated and heat-treated sheets were examined using classical metallography and advanced SEM techniques, accompanied by further investigations, such as hardness and feritscope measurements. The shear tensile strength was determined, and the fracture behavior of the samples was investigated. Clear influences of heat-treatment-induced surface roughness on the joint geometry and strength were observed.}},
  author       = {{Zeuner, André Till and Ewenz, Lars and Kalich, Jan and Schöne, Sebastian and Füssel, Uwe and Zimmermann, Martina}},
  issn         = {{2075-4701}},
  journal      = {{Metals}},
  keywords     = {{General Materials Science, Metals and Alloys}},
  number       = {{9}},
  publisher    = {{MDPI AG}},
  title        = {{{The Influence of Heat Treatment on the Microstructure, Surface Roughness and Shear Tensile Strength of AISI 304 Clinch Joints}}},
  doi          = {{10.3390/met12091514}},
  volume       = {{12}},
  year         = {{2022}},
}

@article{34251,
  abstract     = {{Joining by forming operations presents powerful and complex joining techniques. Clinching is a well-known joining process for use in sheet metalworking. Currently, clinched joints are focusing on mechanically enhanced connections. Additionally, the demand for integrating electrical requirements to transmit electrical currents will be increased in the future. This integration is particularly important, for instance, in the e-mobility sector. It enables connecting battery cells with electrical joints of aluminum and copper. Systematic use of the process-specific advantages of this joining method opens up the possibility to find and create electrically optimized connections. The optimization for the transmission of electrical currents will be demonstrated for clinched joints by adapting the tool geometry and the clinched joint design. Based on a comparison of the electrical joint resistance, the limit use temperature is defined for the joining materials used based on the microstructural condition and the aging condition due to artificial aging. As a result of the investigations carried out, reliable current transmission at a constant conductor temperature of up to 120 °C can be achieved for clinched copper–copper joints. In the case of pure aluminum joints and mixed joints of aluminum and copper, long-term stable current transmission can be ensured up to a conductor temperature of 100 °C.}},
  author       = {{Kalich, Jan and Matzke, Marcus and Pfeiffer, Wolfgang and Schlegel, Stephan and Kornhuber, Ludwig and Füssel, Uwe}},
  issn         = {{2075-4701}},
  journal      = {{Metals}},
  keywords     = {{General Materials Science, Metals and Alloys}},
  number       = {{10}},
  publisher    = {{MDPI AG}},
  title        = {{{Long-Term Behavior of Clinched Electrical Contacts}}},
  doi          = {{10.3390/met12101651}},
  volume       = {{12}},
  year         = {{2022}},
}

@inproceedings{34250,
  abstract     = {{As a joining-by-forming process, clinching and the use of functional elements enable low-energy joining of components through form, force, and, under certain conditions, material closure. In addition to the transmission of mechanical forces, these joining processes can be qualified for additional electrical contact within the scope of functional integration for electro-mobile applications. For this purpose, maximizing the force and material closure is necessary to ensure a long-term, stable transmission of electrical currents. To this end, the electrical properties of the joints were optimized. The investigations carried out show the long-term behavior under normal operating conditions and the short-circuit case.}},
  author       = {{Füssel, Uwe and Schlegel, Stephan and Reschke, Gregor and Kalich, Jan}},
  booktitle    = {{SFU/ICAFT 2022}},
  publisher    = {{MDPI}},
  title        = {{{Electrical Contacting of Aluminum Bus Bars Using Clinching and Functional Elements}}},
  doi          = {{10.3390/engproc2022026005}},
  year         = {{2022}},
}

@article{34215,
  abstract     = {{Clinching as a mechanical joining technique allows a fast and reliable joining of metal sheets in large-scale production. An efficient design and dimensioning of clinched joints requires a holistic understanding of the material, the joining process and the resulting properties of the joint. In this paper, the process chain for clinching metal sheets is described and experimental techniques are proposed to analyze the process-microstructure-property relationships from the sheet metal to the joined structure. At the example of clinching aluminum EN AW 6014, characterization methods are applied and discussed for the following characteristics: the mechanical properties of the sheet materials, the tribological behavior in the joining system, the joining process and the resulting material structure, the load-bearing behavior of the joint, the damage and degradation as well as the service life and crack growth behavior. The compilation of the characterization methods gives an overview on the advantages and weaknesses of the methods and the multiple interactions of material, process and properties during clinching. In addition, the results of the analyses on EN AW 6014 can be applied for parameterization and validation of simulations.}},
  author       = {{Kupfer, Robert and Köhler, Daniel and Römisch, David and Wituschek, Simon and Ewenz, Lars and Kalich, Jan and Weiß, Deborah and Sadeghian, Behdad and Busch, Matthias and Krüger, Jan Tobias and Neuser, Moritz and Grydin, Olexandr and Böhnke, Max and Bielak, Christian Roman and Troschitz, Juliane}},
  issn         = {{2666-3309}},
  journal      = {{Journal of Advanced Joining Processes}},
  keywords     = {{Mechanical Engineering, Mechanics of Materials, Engineering (miscellaneous), Chemical Engineering (miscellaneous)}},
  publisher    = {{Elsevier BV}},
  title        = {{{Clinching of Aluminum Materials – Methods for the Continuous Characterization of Process, Microstructure and Properties}}},
  doi          = {{10.1016/j.jajp.2022.100108}},
  volume       = {{5}},
  year         = {{2022}},
}

@article{34216,
  abstract     = {{Mechanical joining technologies are increasingly used in multi-material lightweight constructions and offer opportunities to create versatile joining processes due to their low heat input, robustness to metallurgical incompatibilities and various process variants. They can be categorised into technologies which require an auxiliary joining element, or do not require an auxiliary joining element. A typical example for a mechanical joining process with auxiliary joining element is self-piercing riveting. A wide range of processes exist which are not requiring an auxiliary joining element. This allows both point-shaped (e.g., by clinching) and line-shaped (e.g., friction stir welding) joints to be produced. In order to achieve versatile processes, challenges exist in particular in the creation of intervention possibilities in the process and the understanding and handling of materials that are difficult to join, such as fiber reinforced plastics (FRP) or high-strength metals. In addition, predictive capability is required, which in particular requires accurate process simulation. Finally, the processes must be measured non-destructively in order to generate control variables in the process or to investigate the cause-effect relationship. This paper covers the state of the art in scientific research concerning mechanical joining and discusses future challenges on the way to versatile mechanical joining processes.}},
  author       = {{Meschut, Gerson and Merklein, M. and Brosius, A. and Drummer, D. and Fratini, L. and Füssel, U. and Gude, M. and Homberg, Werner and Martins, P.A.F. and Bobbert, Mathias and Lechner, M. and Kupfer, R. and Gröger, B. and Han, Daxin and Kalich, J. and Kappe, Fabian and Kleffel, T. and Köhler, D. and Kuball, C.-M. and Popp, J. and Römisch, D. and Troschitz, J. and Wischer, Christian and Wituschek, S. and Wolf, M.}},
  issn         = {{2666-3309}},
  journal      = {{Journal of Advanced Joining Processes}},
  keywords     = {{Mechanical Engineering, Mechanics of Materials, Engineering (miscellaneous), Chemical Engineering (miscellaneous)}},
  publisher    = {{Elsevier BV}},
  title        = {{{Review on mechanical joining by plastic deformation}}},
  doi          = {{10.1016/j.jajp.2022.100113}},
  volume       = {{5}},
  year         = {{2022}},
}

@article{30643,
  abstract     = {{The multi-material design and the adaptability of a modern process chain require joining connections with specifically adjustable mechanical, thermal, chemical, or electrical properties. Previous considerations primarily focused on the mechanical properties. The multitude of possible combinations of requirements, materials, and component- and joining-geometry makes an empirical determination of these joining properties for the clinching process impossible. Based on the established and empirical procedure, there is currently no model that takes into account all questions of joinability—i.e., the materials (suitability for joining), design (security of joining), and production (joining possibility)—that allows a calculation of the properties that can be achieved. It is therefore necessary to describe the physical properties of the joint as a function of the three binding mechanisms—form closure, force closure, and material closure—in relation to the application. This approach illustrates the relationships along the causal chain “joint requirement-binding mechanism-joining parameters” and improves the adaptability of the mechanical joining technology. Geometrical properties of clinch connections of the combination of aluminum and steel are compared in a metallographic cross-section. The mechanical stress state of the rotationally symmetrical clinch points is qualified with a torsion test and by measuring the electrical resistance in the base material, in the clinch joint, and during the production cycle (after clinching, before precipitation hardening and after precipitation hardening).}},
  author       = {{Kalich, J. and Füssel, U.}},
  journal      = {{Journal of Manufacturing and Materials Processing}},
  pages        = {{105}},
  title        = {{{Influence of the production process on the binding mechanism of clinched aluminum steel mixed compounds}}},
  doi          = {{10.3390/jmmp5040105}},
  volume       = {{5}},
  year         = {{2021}},
}

@article{30648,
  abstract     = {{In clinching, the combinations of requirements, materials, component dimensions and tools influence the resulting joint geometry and the resulting bonding mechanisms. These in turn affect the property profile of the joint. For example, it is possible to use different tools to flexibly adapt clinching points to the respective required load regime. Clinching points dimensioned in this way can be geometrically similar, but have different mechanical stress states, which leads to different properties in terms of load-bearing behavior. Within the scope of this work, the clinching process with different tools in optimal and compromise design and its effect on the force and form-closure component, is investigated in a torsion test of the clinched connection. Clinched steel sheets with two thicknesses and joining directions are analyzed. Virtual experiments are carried out using finite element analyses (FEA) of the joining process and are followed by a springback simulation. Subsequently, the surface pressure between the two joining partners in the clinching points is calculated on the basis of the results from the FEA and the transmittable moment of the connection, as an indicator for the force-closure component, is determined. Finally, the experimental and simulated data are compared and discussed.}},
  author       = {{Steinfelder, C. and Kalich, J. and Brosius, A. and Füssel, U.}},
  journal      = {{IOP Conference Series: Materials Science and Engineering}},
  pages        = {{012003}},
  title        = {{{Numerical and experimental investigation of the transmission moment of clinching points}}},
  doi          = {{10.1088/1757-899x/1157/1/012003}},
  volume       = {{1157}},
  year         = {{2021}},
}

@article{30663,
  abstract     = {{The use of clinch joints, e.g. vehicle structures, is determined by the reliability of the joint and its strength properties - in particular the fatigue strength. Clinch connections offer the advantage over form-closure and force-closure processes that they can also be used for hybrid material combinations. In order to be able to evaluate the influence of the geometry parameters such as e.g. undercut, neck thickness or also base thickness on the fatigue behavior, three clinch connections (in optimum and compromise design) with different tool parameters were designed and examined using the example of a joining task with aluminum sheet material. For this purpose, fatigue curves (F-N curves) in the range of high to very high numbers of load cycles (N = 105 to 107) were determined. In this load cycle range, a so-called "neck fracture" is mainly to be expected as the type of failure, whereas for quasi-static tests, a “buckling” is more likely to occur. The tests were carried out on single-cut overlapping shear tensile specimens. Metallographic and scanning electron microscopic examinations of the joints and the fracture surfaces served to identify the crack initiation site and to clarify the respective type of failure. Significant differences in the damage behaviour of the three clinching variants could be shown. This observation enables one step into the direction of fully understanding the relationship along the causal chain "joint requirements - joining process - fatigue strength". Thus the adaptability of the clinching process can be improved. }},
  author       = {{Ewenz, L. and Kalich, J. and Zimmermann, M. and Füssel, U.}},
  journal      = {{Key Engineering Materials}},
  pages        = {{65--72}},
  title        = {{{Effect of Different Tool Geometries on the Mechanical Properties of Al-Al Clinch Joints}}},
  doi          = {{10.4028/www.scientific.net/kem.883.65}},
  volume       = {{883}},
  year         = {{2021}},
}