PNNL

Abstract

A mechanically robust joining method for Mg/Al and Mg/CFRP could enable multi-material assemblies that decrease vehicle weight while offering more flexibility for designers. However, certain challenges exist for joining Mg/Al and Mg/CFRP. Mechanical joining, such as conventional riveting, clinching and bolting do not form a metallurgical bond between the fastener and metal sheet being fastened. Large differences in physical and mechanical properties of metals and polymers make joining Al or Mg to CFRP challenging via various welding techniques. With solid-state and fusion based welding, rapid formation of brittle intermetallic compounds at the Mg/Al interface lead to interfacial fracture under mechanical loading. In this study, a Rotational Hammer Rivet (RHR) technique was developed to fabricate Mg/CFRP and Mg/Al joints. With RHR technique, direct joining between Mg/Al and Mg/CFRP were replaced by joining Mg rivet head and top Mg sheet. Through heat generated by plastic deformation of an Mg rivet, RHR creates a metallurgical bond between rivet head and Mg sheet which seals corrosive electrolyte from penetrating around the rivet head.