PLUGG - Self-piercing riveting in non compatible materials

Purpose and goal

The project´s goal was to develop a concept for a joining method for non-ductile materials in future multi-material products. The idea was to create a mechanical joint by use a self piercing rivet by supplying a ductile coin (plugg) on the die side. The project has shown that the concept with using self-piercing riveting with a ´Plugg´ does works. And this can be done in a existing riveting equipments. However, the method need a Plugg-feeding system to be developed for implementation. The results from the project open to fixate or join structures of multi-material in an effective manner.

Expected results and effects

The project results have shown that the concept works by using self-piercing riveting, which is a well known joining method, in new material combinations. This will increase the need to take the plugg-concept further to reach higher TRL level in order to be able to deliver a process that Swedish automotive industry can proceed with to take it to implementation. The effect of this project are that the Swedish automotive industry one step closer to be able to switch to the next paradigm shift for Multi-material constructions, and this will result in lighter vehicles, and less CO2 emissions.

Planned approach and implementation

The project developed test matrixes and the results were used to minimize the number of rivet geometries for the further testing in the project. To verify the initial results were new methods elected in order to test and verify the concept with plug. Experiments were made for corrosion testing to show where corrosion can occur in structures with mixed materials that have different electrochemical potential. Simulation studies have verified with physical testing. A parameter study has been done that shows which variables affect rivet geometries responses variables.