Joining is a key enabler for a successful application of thermoplastic composites (TPC) in future multi-material systems. To use joining technologies, such as resistance welding for composite-metal joints, auxiliary joining elements (weld inserts) can be integrated into the composite and used as an interface. The authors pursue the approach of embedding metal weld inserts in TPC during compression moulding without fibre damage. The technology is based on the concept of moulding holes by a pin and simultaneously placing the weld insert in the moulded hole. Subsequently, the composite component can be joined with metal structures using conventional spot welding guns. For this purpose, two different types of weld inserts were embedded in glass fibre reinforced polypropylene sheets and then welded to steel sheets. A simulation of the welding process determined suitable welding parameters. The quality of the joints was analysed by microsections before and after the welding process. In addition, the joint strength was evaluated by chisel tests as well as single-lap shear tests for the different weld insert designs. It could be shown that high-quality joints can be achieved by using the innovative technology and that the load-bearing capacity is significantly influenced by the weld inserts head design.

Clinching continuous fibre reinforced thermoplastic composites and metals is challenging due to the low ductility of the composite material. Therefore, a number of novel clinching technologies has been developed specifically for these material combinations. A systematic overview of these advanced clinching methods is given in the present paper. With a focus on process design, three selected clinching methods suitable for different joining tasks are described in detail. The clinching processes including equipment and tools, observed process phenomena and the resultant material structure are compared. Process phenomena during joining are explained in general and compared using computed tomography and micrograph images for each process. In addition the load bearing behaviour and the corresponding failure mechanisms are investigated by means of single-lap shear tests. Finally, the new joining technologies are discussed regarding application relevant criteria.

Recent developments in automotive and aircraft industry towards a multi-material design pose challenges for modern joining technologies due to different mechanical properties and material compositions of various materials such as composites and metals. Therefore, mechanical joining technologies like clinching are in the focus of current research activities. For multi-material joints of metals and thermoplastic composites thermally assisted clinching processes with advanced tool concepts are well developed. The material-specific properties of fibre-reinforced thermoplastics have a significant influence on the joining process and the resulting material structure in the joining zone. For this reason, it is important to investigate these influences in detail and to understand the phenomena occurring during the joining process. Additionally, this provides the basis for a validation of a numerical simulation of such joining processes. In this paper, the material structure in a joint resulting from a thermally assisted clinching process is investigated. The joining partners are an aluminium sheet and a thermoplastic composite (organo sheet). Using computed tomography enables a three-dimensional investigation that allows a detailed analysis of the phenomena in different joining stages and in the material structure of the finished joint. Consequently, this study provides a more detailed understanding of the material behavior of thermoplastic composites during thermally assisted clinching.

AlSi casting alloys combine excellent castability with high strength. Hence, this group of alloys is often used in the automotive sector. The challenge for this application is the brittle character of these alloys which leads to cracks during joint formation when mechanical joining technologies are used. A rise in ductility can be achieved by a considerable increase in the solidification rate which results in grain refinement. High solidification rates can be realized in twin–roll casting (TRC) by water‐cooled rolls. Therefore, a hypoeutectic EN AC–AlSi9 (for European Norm ‐ aluminum cast product) is manufactured by the TRC process and analyzed. Subsequently, joining investigations are performed on castings in as‐cast and heat‐treated condition using the self‐piercing riveting process considering the joint formation and the load‐bearing capacity. Due to the fine microstructure, the crack initiation can be avoided during joining, while maintaining the joining parameters, especially by specimens in heat treatment conditions. Furthermore, due to the extremely fine microstructure, the load‐bearing capacity of the joint can be significantly increased in terms of the maximum load‐bearing force and the energy absorbed.