@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{65488,
  author       = {{Mergheim, Julia and Wallmersperger, Thomas and Wolf, Eugen and Schlichter, Malte and Ludwig, Jean-Patrick and Friedlein, Johannes and Gerritzen, Johannes and Devulapally, Deekshith Reddy and Chen, Chin and Weiss, Deborah and Krome, Sven and Reschke, Gregor and Gude, Maik}},
  issn         = {{2666-3309}},
  journal      = {{Journal of Advanced Joining Processes}},
  publisher    = {{Elsevier BV}},
  title        = {{{Simulation-based process chain for aluminum clinched joints: Predicting geometry, strength, and failure behavior}}},
  doi          = {{10.1016/j.jajp.2026.100402}},
  year         = {{2026}},
}

@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}},
}

@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{60837,
  abstract     = {{In light of growing demands for resource efficiency and sustainability in vehicle engineering, the environmentally compatible separation of structural adhesive joints is gaining increasing relevance. This study presents a comparative analysis of two physically based debonding methods: the established hot-air process and a cryogenic cold process based on liquid nitrogen (LN2). The primary objective is to assess the ecological impact and process-related sustainability of both approaches.
Experimental investigations were conducted on a component-representative triple-sheet structure that simulates common automotive flange joints. Thermal input was applied either by convective heating using a hot air gun or by direct cooling through a contact-based LN2 tool. The resulting temperature profiles were recorded using spatially distributed thermocouples. Subsequently, the outer panel was selectively debonded to replicate a repair scenario, and the mechanical integrity of the remaining adhesive joint was evaluated through Mode I testing of L-shaped specimens. Process data served as input for an Life Cycle Assessment (LCA) according to DIN EN ISO 14040.
The cryogenic method achieved a 40% reduction in carbon footprint compared to the hot-air process (0.337 kg vs. 0.559 kg CO2-equivalents), primarily due to its shorter process time and more efficient heat transfer. While the hot-air method’s impact is mainly driven by electrical energy use, that of the cold method stems from cryogenic media consumption. Notwithstanding certain disadvantages in specific impact categories, the LN2-based process exhibits a superior overall ecological performance and signifies a promising solution for repair- and recycling-oriented adhesive separation in structural vehicle applications.}},
  author       = {{Jordan, Alex and Hermelingmeier, Lucas and Gilich, Julian and Meschut, Gerson and De Santis, Marco Sebastian and Schlüter, Alexander}},
  issn         = {{2666-3309}},
  journal      = {{Journal of Advanced Joining Processes}},
  keywords     = {{Sustainable debonding, Structural adhesives, Sustainable joining technologies, Life Cycle Assessment (LCA), Automotive repair process, Economically efficient debonding}},
  publisher    = {{Elsevier}},
  title        = {{{Comparison of the economic efficiency and sustainability of two debonding processes for structurally bonded sills}}},
  doi          = {{10.1016/j.jajp.2025.100332}},
  volume       = {{12}},
  year         = {{2025}},
}

@article{56677,
  abstract     = {{The rapid advancement in the electrification of modern vehicles has led to a continuous increase in electrical consumers for various comfort and safety functions. Ground studs serve as the electrical interface between the conductive vehicle body and the onboard network. Drawn arc stud welding is an economical and established joining process for producing ground stud joints. The circuits in the onboard network are increasingly subject to greater demands regarding current-carrying capacity and long-term stability. Reliable signal and power transmission require minimal contact resistance at the electrical connection points of the ground stud system and must withstand various operating and environmental conditions over the entire service life. In this study, a ground stud made of AlMg5, with a ZnNi-coated steel cap nut was used on a 2.0 mm thick sheet of AlMg3. The electrical connection of the ground studs was made using tinned copper cable lugs and 35 mm² cables. To analyze the electrical resistance behavior in an accelerated test, the ground studs were subjected to a superimposed load with a cyclic current profile for 1008 hours under changing climatic conditions. The results show that under the chosen operational and environmental conditions, accelerated aging and intermittent resistance behavior occur. A characteristic drop in resistance during the test indicates the failure point of the electrical connection. The cause of failure can be attributed to media penetration into the electrical contact zone. A failure of the electrical connection was observed after 512 hours.}},
  author       = {{Haak, Viktor and Yang, Keke and Meschut, Gerson}},
  issn         = {{2666-3309}},
  journal      = {{Journal of Advanced Joining Processes}},
  keywords     = {{Stud welding, aluminum grounding connection, electrical resistance, superimposed load}},
  publisher    = {{Elsevier BV}},
  title        = {{{Investigation of the electrical quality and long-term stability of aluminum ground stud connections in automotive applications}}},
  doi          = {{10.1016/j.jajp.2024.100262}},
  volume       = {{10}},
  year         = {{2024}},
}

@article{60300,
  abstract     = {{This study focuses on the phenomenological change in material strength caused by a specific heat treatment and the subsequent analysis of the influence on the clinching process and the resulting joint properties. For this purpose, three series of tests were performed. In the first series of tests, the influence of heat treatment up to 340 °C on the mechanical properties of an age-hardenable AlMgSi alloy was investigated. Holding time and temperature were varied and the material strength was evaluated by tensile and hardness tests. Two strength-increasing and two strength-reducing heat treatment parameters were identified. In the second series of tests, selected heat treatment parameters were applied to a larger number of specimens and the joint strength was investigated by shear and head tensile tests. In the shear tensile test, mainly the properties of the punch-side material have an influence on the resulting joint strength. A change in strength of the die-side material can be neglected. In contrast, the properties of both sheets are important in the head tensile test. The strength of the joint will only increase if the strength of both sheets is increased. In general, a strength increasing heat treatment resulted in higher joint strength. In the third series of tests, the factor of punch displacement was considered, which was demonstrated to directly influence the formation of the clinched joint geometry.}},
  author       = {{Steinfelder, Christian and Rempel, Dennis and Brosius, Alexander}},
  issn         = {{2666-3309}},
  journal      = {{Journal of Advanced Joining Processes}},
  keywords     = {{Joining by forming, Clinching, EN AW-6014, Heat treatment, Load-bearing capacity}},
  publisher    = {{Elsevier BV}},
  title        = {{{Influence of the material properties on the clinching process and the resulting load-bearing capacity of the joint}}},
  doi          = {{10.1016/j.jajp.2024.100263}},
  volume       = {{10}},
  year         = {{2024}},
}

@article{54649,
  author       = {{Borgert, Thomas and Nordieker, Ansgar Bernhard and Wiens, Eugen and Homberg, Werner}},
  issn         = {{2666-3309}},
  journal      = {{Journal of Advanced Joining Processes}},
  publisher    = {{Elsevier BV}},
  title        = {{{Investigations to improve the tool life during thermomechanical and incremental forming of steel auxiliary joining elements}}},
  doi          = {{10.1016/j.jajp.2024.100185}},
  volume       = {{9}},
  year         = {{2024}},
}

@article{51167,
  author       = {{Duderija, B. and Sahin, F. and Meinderink, D. and Calderón-Gómez, J.C. and Schmidt, H.C. and Homberg, W. and Grundmeier, G. and González-Orive, A.}},
  issn         = {{2666-3309}},
  journal      = {{Journal of Advanced Joining Processes}},
  keywords     = {{Mechanical Engineering, Mechanics of Materials, Engineering (miscellaneous), Chemical Engineering (miscellaneous)}},
  publisher    = {{Elsevier BV}},
  title        = {{{Electropolymerization of acrylic acid on steel for enhanced joining by plastic deformation}}},
  doi          = {{10.1016/j.jajp.2023.100181}},
  volume       = {{9}},
  year         = {{2023}},
}

@article{34253,
  abstract     = {{Lightweight construction has increasingly become the focus of scientific research in recent years, not least due to
the constantly increasing fuel price, which is a key factor in the economic viability of many companies. In this
respect, the use of hybrid structures, made of dissimilar materials offers many advantages. However, such hybrid
structures often have undesirable side effects. For example, brittle intermetallic phases are formed when
aluminum and steel are welded. Clinching as a mechanical joining process does not produce such intermetallic
phases since the connection is realized through form and force closure. In this process, a punch passes through
two or more sheets and forms them into a permanent joint in a die. In the present work, the corrosion phenomena
of an aluminum-steel clinched joint have been investigated by both experiments and numerical simulations in
order to explain the superior fatigue behavior of pre-corroded joints. Therefore, the clinched joints have been
corroded by a three-week salt-spray test. In addition, the electric potential and the von Mises stress are calculated
under the assumption of a static loading. The results of both experiments and numerical simulations can explain
the improvement in the fatigue behavior of the corroded specimens. This phenomenon can be attributed to the
accumulation of corrosion products in small gaps between the joined metal sheets.}},
  author       = {{Harzheim, Sven and Ewenz, Lars and Zimmermann, Martina and Wallmersperger, Thomas}},
  issn         = {{2666-3309}},
  journal      = {{Journal of Advanced Joining Processes}},
  keywords     = {{Mechanical Engineering, Mechanics of Materials, Engineering (miscellaneous), Chemical Engineering (miscellaneous)}},
  publisher    = {{Elsevier BV}},
  title        = {{{Corrosion Phenomena and Fatigue Behavior of Clinched Joints: Numerical and Experimental Investigations}}},
  doi          = {{10.1016/j.jajp.2022.100130}},
  volume       = {{6}},
  year         = {{2022}},
}

@article{43021,
  author       = {{Duderija, B. and González-Orive, A. and Schmidt, H.C. and Calderón, J.C. and Hordych, I. and Maier, H.J. and Homberg, W. and Grundmeier, G.}},
  issn         = {{2666-3309}},
  journal      = {{Journal of Advanced Joining Processes}},
  keywords     = {{Mechanical Engineering, Mechanics of Materials, Engineering (miscellaneous), Chemical Engineering (miscellaneous)}},
  publisher    = {{Elsevier BV}},
  title        = {{{Electrografting of BTSE: Zn films for advanced steel-aluminum joining by plastic deformation}}},
  doi          = {{10.1016/j.jajp.2022.100137}},
  volume       = {{7}},
  year         = {{2022}},
}

@article{31828,
  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 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{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{32275,
  author       = {{Meschut, G. and Merklein, M. and Brosius, A. and Drummer, D. and Fratini, L. and Füssel, U. and Gude, M. and Homberg, W. and Martins, P.A.F. and Bobbert, M. and Lechner, M. and Kupfer, R. and Gröger, B. and Han, D. and Kalich, J. and Kappe, F. and Kleffel, T. and Köhler, D. and Kuball, C.-M. and Popp, J. and Römisch, D. and Troschitz, J. and Wischer, C. 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{51193,
  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 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{51196,
  author       = {{Meschut, G. and Merklein, M. and Brosius, A. and Drummer, D. and Fratini, L. and Füssel, U. and Gude, M. and Homberg, W. and Martins, P.A.F. and Bobbert, M. and Lechner, M. and Kupfer, R. and Gröger, B. and Han, D. and Kalich, J. and Kappe, F. and Kleffel, T. and Köhler, D. and Kuball, C.-M. and Popp, J. and Römisch, D. and Troschitz, J. and Wischer, C. 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{34069,
  author       = {{Schramm, Britta and Martin, Sven and Steinfelder, Christian and Bielak, Christian Roman and Brosius, Alexander and Meschut, Gerson and Tröster, Thomas and Wallmersperger, Thomas and Mergheim, Julia}},
  issn         = {{2666-3309}},
  journal      = {{Journal of Advanced Joining Processes}},
  keywords     = {{Mechanical Engineering, Mechanics of Materials, Engineering (miscellaneous), Chemical Engineering (miscellaneous)}},
  publisher    = {{Elsevier BV}},
  title        = {{{A Review on the Modeling of the Clinching Process Chain - Part I: Design Phase}}},
  doi          = {{10.1016/j.jajp.2022.100133}},
  volume       = {{6}},
  year         = {{2022}},
}

@article{34068,
  author       = {{Schramm, Britta and Friedlein, Johannes and Gröger, Benjamin and Bielak, Christian Roman and Bobbert, Mathias and Gude, Maik and Meschut, Gerson and Wallmersperger, Thomas and Mergheim, Julia}},
  issn         = {{2666-3309}},
  journal      = {{Journal of Advanced Joining Processes}},
  keywords     = {{Mechanical Engineering, Mechanics of Materials, Engineering (miscellaneous), Chemical Engineering (miscellaneous)}},
  publisher    = {{Elsevier BV}},
  title        = {{{A Review on the Modeling of the Clinching Process Chain - Part II: Joining Process}}},
  doi          = {{10.1016/j.jajp.2022.100134}},
  year         = {{2022}},
}

@article{34070,
  author       = {{Schramm, Britta and Harzheim, Sven and Weiß, Deborah and Joy, Tintu David and Hofmann, Martin and Mergheim, Julia and Wallmersperger, Thomas}},
  issn         = {{2666-3309}},
  journal      = {{Journal of Advanced Joining Processes}},
  keywords     = {{Mechanical Engineering, Mechanics of Materials, Engineering (miscellaneous), Chemical Engineering (miscellaneous)}},
  publisher    = {{Elsevier BV}},
  title        = {{{A Review on the Modeling of the Clinching Process Chain - Part III: Operational Phase}}},
  doi          = {{10.1016/j.jajp.2022.100135}},
  year         = {{2022}},
}