A review on mechanical and metallurgical joining by plastic deformation

Abstract

The substitution of traditional materials with lightweight materials in vehicle structures requires the development of new joining techniques which are capable of joining un-weldable alloys as well as dissimilar materials. Although conventional joining techniques such as fusion welding, adhesive bonding and mechanical fastening have matured in recent decades, their use for some of the above applications is limited. In this paper, recently developed joining techniques based on plastic deformation are presented and discussed. These techniques are divided into two categories, those based on mechanical interlocking and those based on metallurgical bonding. The first category covers clinching, self-pierce riveting and some innovative joining methods, and the second category covers friction stir welding and its variants. The focus of this study is on process development, process control and monitoring, process modelling, and joint characterization techniques. Finally, the two categories are compared, and their potential is discussed.