Local deformation and failure of composites during self-piercing riveting: a CT based microstructure investigation

Research output: Contribution to book/Conference proceedings/Anthology/ReportConference contributionContributedpeer-review

Abstract

The use of continuous fiber-reinforced thermoplastics (FRTP) in automotive industry increases due to their excellent material properties and possibility of rapid processing. The scale spanning heterogeneity of their material structure and its influence on the material behavior, however, presents significant challenges for most joining technologies, such as self-piercing riveting (SPR). During mechanical joining, the material structure is significantly altered within and around the joining zone, heavily influencing the material behavior. A comprehensive understanding of the underlying phenomena of material alteration during the SPR process is essential as basis for validating numerical simulations. This study examines the material structure at ten stages of a step-setting test of SPR with two FRTP sheets with glass-fiber reinforcement. Utilizing X-ray computed tomography (CT), the damage phenomena within different areas of the setting test are analyzed three-dimensionally and key parameters are quantified. Dominating phenomena during the penetration of the rivet into the laminate are fiber failure (FF), interfiber failure (IFF) and fiber bending, while delamination, fiber kinking and roving splitting are also observed. At the final stages, the bottom layers of the second sheet collapse and form a bulge into the cavity of the die.

Details

Original languageEnglish
Title of host publicationProceedings of the 8th International Conference on Integrity-Reliability-Failure (IRF2025)
EditorsJ.F. Silva Gomes , Shaker A. Meguid
PublisherFEUP-Faculty of Engineering, University of Porto
ChapterTrack A: Composite and Advanced Materials
Pages41-52
Number of pages12
ISBN (print)978-972-752-323-8
Publication statusPublished - 15 May 2025
Peer-reviewedYes

Conference

Title8th International Conference on Integrity, Reliability and Failure of Engineering Systems and Materials
Abbreviated titleIRF2025
Conference number8
Duration15 - 18 July 2025
Website
LocationUniversity of Porto
CityPorto
CountryPortugal

External IDs

ORCID /0000-0003-1370-064X/work/196674061
ORCID /0000-0002-0820-8936/work/196678333
ORCID /0000-0002-0169-8602/work/196678965

Keywords

Keywords

  • Self-piercing riveting, computed tomography, thermoplastic composites, process-structure- interaction