Long-Term Behavior of Clinched Electrical Contacts

Research output: Contribution to journalResearch articleContributedpeer-review



Joining by forming operations presents powerful and complex joining techniques. Clinching is a well-known joining process for use in sheet metalworking. Currently, clinched joints are focusing on mechanically enhanced connections. Additionally, the demand for integrating electrical requirements to transmit electrical currents will be increased in the future. This integration is particularly important, for instance, in the e-mobility sector. It enables connecting battery cells with electrical joints of aluminum and copper. Systematic use of the process-specific advantages of this joining method opens up the possibility to find and create electrically optimized connections. The optimization for the transmission of electrical currents will be demonstrated for clinched joints by adapting the tool geometry and the clinched joint design. Based on a comparison of the electrical joint resistance, the limit use temperature is defined for the joining materials used based on the microstructural condition and the aging condition due to artificial aging. As a result of the investigations carried out, reliable current transmission at a constant conductor temperature of up to 120 °C can be achieved for clinched copper–copper joints. In the case of pure aluminum joints and mixed joints of aluminum and copper, long-term stable current transmission can be ensured up to a conductor temperature of 100 °C.


Original languageEnglish
Article number1651
Number of pages16
Issue number10
Publication statusPublished - Oct 2022

External IDs

WOS 000875316300001
ORCID /0000-0002-4793-8800/work/150330528


Research priority areas of TU Dresden

DFG Classification of Subject Areas according to Review Boards

Subject groups, research areas, subject areas according to Destatis


  • binding mechanism, clinching, contact behavior, electrical contacts, performance factor, Clinching, Contact behavior, Binding mechanism, Performance factor, Electrical contacts

Library keywords