Influencing factors and research progress of self-piercing riveting process for resin matrix composite
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摘要: 复合材料和轻质高强金属相结合的混合材料车身结构使用成为汽车轻量化的重要途径，复合材料之间及其与异质材料间的有效连接则是混合材料车身制造的关键环节。自冲铆工艺以其优质高效的特点，在复合材料连接中展现出优势和良好适用性，得到了广泛的关注和研究。总结近年来复合材料自冲铆连接的研究成果发现：复合材料与铝合金薄板自冲铆接头强度多集中在4 kN上下，强度值范围可以与金属板件间的自冲铆接头相媲美；而影响接头性能的主要因素有母材性能、铆钉结构、铆接工艺参数及服役条件等；改善接头性能的关键在于提升复合材料板的强度、降低复合材料内部铆接损伤缺陷及改善钉脚与下板的机械内锁结合性能；此外，自冲铆接头复合以胶接工艺，能够显著提升接头的综合性能。Abstract: The application of hybrid material body structure combined with composite material and lightweight or high strength metal is an important way of automobile lightweight, and the effective connection between composites and heterogeneous materials has become the key link of hybrid material body manufacturing. Self-piercing riveting (SPR) technology, with its high quality and efficiency, shows advantages and good applicability in composite material connection and has received extensive attention and research. Summarizing the research results of composite SPR connection in recent years, it is found that: The strength values of SPR joints between composite materials and aluminum alloy sheets are mostly concentrated at about 4 kN, which is comparable to that of SPR joints between metal plates. The main factors affecting the joint performance are the property of base material, rivet structure, riveting process parameters and service condition, meanwhile, the key points to improve the joint performance are to enhance the strength of the composite sheet, reduce the internal riveting damage and defects of the composite material, and improve the mechanical internal locking combination between the rivet foot and the lower sheet. In addition, when the SPR joint combined with bonding process, its comprehensive performance can be significantly improved.
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图 2 典型自冲铆铆钉(a)及接头结构(b)示意图
Figure 2. Typical section structure of the rivet (a) and joint (b) of SPR
D—Head diameter; L—Leg length; D1—Inner diameter; θ—Blade angle
图 12 预开孔自冲铆接头与常规自冲铆接头破坏模式[26]：(a) 预开孔自冲铆上基板挤压破坏；(b) 预开孔自冲铆下基板拉脱破坏；(c) 常规自冲铆上基板挤压破坏；(d) 常规自冲铆下基板拉脱破坏
Figure 12. Failure modes of pre-holed SPR joint and regular SPR joint[26]: (a) Bearing of upper sheet in pre-holed SPR joint; (b) Pull-through from lower sheet in pre-holed SPR joint; (c) Bearing of upper sheet in regular SPR joint; (d) Pull-through from lower sheet in regular SPR joint
表 1 复合材料自冲铆连接工艺研究进展
Table 1. Research progress of composite SPR process
Year Process Joining material Sheets thickness/mm Rivet length/mm Maximum load/kN Energy
absorption/JFailure mode Ref. 2012 SPR CFRP-Al 1.5-2.7 6.5 About 3.5 — Pull-through from top sheet, or net tension of the lower sheet [49] 2012 Double rivet SPR CFRP-Al 1.5-2.7 — About 7.8 — Net tension of top sheet [55] 2012 Modified SPR CFRP-CFRP 3.2 (Total) 10.8 About 8.0 — Pull-through from top sheet [58] 2013 SPR-bonded hybrid CFRP-Al 1.5-2.7 6.5 About 5.8 About 23 Pull-through from top sheet [42] 2015 SPR GFRP-Al 3.0-2.0 6.5 About 3.7 — Bearing of top sheet [32] 2015 SPR GFRP-Al 2.0-2.0 — — — [33] 2016 SPR GFRP-Al 2.0-2.0 — 4.58 — Pull-through from or net tension of top sheet [65] 2017 SPR CFRP-Al 2.1-2.0 10.0 4.5 — Bearing [34] 2017 SPR GFRP-Al 2.5-2.5 6.0 4 — Net tension of lower sheet [47] 2019 SPR CFRP-Al 2.5-2.5 6.0 4.5 — Pull-through from top sheet [45] 2018 SPR CFRP-Al 2.0-1.5 — 2.61 8.3 Pull-through from lower sheet [30] 2019 SPR-bonded hybrid CFRP-Al 2.0-2.0 — About 12 About 35 Bearing of or pull-through from top sheet + adhesive interface failure [41] 2019 SPR CFRP-Al 2.0-2.0 6.5 4.2 — Pull-through from lower sheet [44] 2019 SPR CFRP-Al 2.0-2.0 6.0 3.45 17.1 Pull-through from lower sheet [22] 2020 SPTR CFRP-Al 2.5-2.5 9.5 About 4.8 — — [60] 2020 SPR GFRP-Al 2.0-2.0 — 3.78 10.2 Pull-through from lower sheet [62] 2020 Pre-holed SPR CFRP-Ti 2.0-1.5 5.5 2.5 14 Pull-through from top sheet [26] 2020 SPR-bonded hybrid CFRP-H62 Cu 1.5-1.5 6.0 4.06 6.3 Pull-through from top sheet + adhesive interface failure [35] 2020 SPR C/GFRP-Al 2.7-2.5 7.0 3.79 — Fastener failure [69] 2021 Post-curing SPR CFRP-Al 1.28-2.0 5.5 2.22 — Pull-through from lower sheet [43] 2021 SPR CFRP-Al 3.0-3.0 9.0 About 4.3 — Pull-through from top sheet [59] 2021 Warm SPR CFRP-Al 1.0-2.0 5.0 1.9 9.7 Pull-through from top sheet [54] 2022 SPR CFRP-Al 2.5-2.5 7.0 4.4 28.4 Pull-through from lower sheet [56] Notes: SPTR—Self-piercing-through riveting. 
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