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This work evaluates the viability of applying Friction Riveting as an alternative for the assembly of components on printed circuit boards (PCBs). The popular press-fit technology for assembling components on PCBs consists of a pin inserted tightly into a relatively smaller hole, resulting in good electrical and mechanical properties. However, some limitations are highlighted, such as numerous processing steps and the need for predrilled holes. Friction Riveting is based on mechanical fastening and friction welding principles, where polymeric components are joined with metallic rivets through frictional heating and pressure. The main benefits of using Friction Riveting in PCBs compared with fit-press are (i) a reduced number of processing steps and (ii) shorter joining cycles, because there is no pre-drilling involved with fasteners anchored within the PCB in a single step. The joints were manufactured using 5 mm diameter AA-2024-T3 rivets and 1.5 mm thick glass-fiber-reinforced epoxy laminates (FR4-PCB). It is shown for the first time that it is possible to deform metallic rivets within thin composite plates at a reduced diameterto-thickness ratio. The feasibility study followed a one-factor-a-time approach for parameter screening and optical microscopy assessed joint formation of the deformed rivets inside the laminates through volumetric ratio (VR). The joints present significant deformation (VR=0.5) at the tip of the rivet inserted into overlapped PCBs plates, with thicknesses below 3.0 mm, which is considered the lowest achieved so far with Friction Riveting.
Maria Clara Farah Antunes Vilas Boas; Camila Fernanda Rodrigues; Lucian-Attila Blaga; Jorge Fernandez dos Santos; Benjamin Klusemann. Deformation and Anchoring of AA 2024-T3 rivets within thin printed circuit boards. ESAFORM 2021 2021, 1 .
AMA StyleMaria Clara Farah Antunes Vilas Boas, Camila Fernanda Rodrigues, Lucian-Attila Blaga, Jorge Fernandez dos Santos, Benjamin Klusemann. Deformation and Anchoring of AA 2024-T3 rivets within thin printed circuit boards. ESAFORM 2021. 2021; ():1.
Chicago/Turabian StyleMaria Clara Farah Antunes Vilas Boas; Camila Fernanda Rodrigues; Lucian-Attila Blaga; Jorge Fernandez dos Santos; Benjamin Klusemann. 2021. "Deformation and Anchoring of AA 2024-T3 rivets within thin printed circuit boards." ESAFORM 2021 , no. : 1.
Friction riveting (FricRiveting) is a technology for joining metallic and polymeric parts through frictional heat and pressure based on the principles of mechanical fastening and friction welding. Within this process, the joining occurs through the rotation of a metallic rivet, which is pressed onto a polymeric part while rotating at high speed, generating heat through the friction of the two materials, thus deforming and consequently anchoring the rivet inside the polymer. Compared to conventional joining techniques, FricRiveting has the advantages of fast joining cycles, no surface preparation or prior drilling required, and the joining can be produced single-sided. Without the presence of through-holes, the stress concentration is also minimized. This work aims to assess the feasibility and optimization of joining 3D printed Polyamide 6 (PA6) parts with AA6056-T6 rivets through FricRiveting. The feasibility is established by the occurrence of plastic deformation of the metallic rivet tip and thus formation o f an anchor. The joint local mechanical properties are investigated via micro-hardness maps. Process temperature history recorded through infrared thermography is subsequently correlated with the joint formation and mechanical performance. The joint tensile strength was determined through pullout tests, which provided the results for the process validation and optimization through Box-Behnken and Full Factorial Design of Experiments, thus understanding the influence of FricRiveting parameters on the resulting properties of the joints.
Paulo Henrique Dos Santos Mallmann; Lucian-Attila Blaga; Jorge Fernandez Dos Santos; Benjamin Klusemann. Friction Riveting of 3D Printed Polyamide 6 with AA 6056-T6. Procedia Manufacturing 2020, 47, 406 -412.
AMA StylePaulo Henrique Dos Santos Mallmann, Lucian-Attila Blaga, Jorge Fernandez Dos Santos, Benjamin Klusemann. Friction Riveting of 3D Printed Polyamide 6 with AA 6056-T6. Procedia Manufacturing. 2020; 47 ():406-412.
Chicago/Turabian StylePaulo Henrique Dos Santos Mallmann; Lucian-Attila Blaga; Jorge Fernandez Dos Santos; Benjamin Klusemann. 2020. "Friction Riveting of 3D Printed Polyamide 6 with AA 6056-T6." Procedia Manufacturing 47, no. : 406-412.
The present work investigates the correlation between energy efficiency and global mechanical performance of hybrid aluminum alloy AA2024 (polyetherimide joints), produced by force-controlled friction riveting. The combinations of parameters followed a central composite design of experiments. Joint formation was correlated with mechanical performance via a volumetric ratio (0.28–0.66 a.u.), with a proposed improvement yielding higher accuracy. Global mechanical performance and ultimate tensile force varied considerably across the range of parameters (1096–9668 N). An energy efficiency threshold was established at 90 J, until which, energy input displayed good linear correlations with volumetric ratio and mechanical performance (R-sq of 0.87 and 0.86, respectively). Additional energy did not significantly contribute toward increasing mechanical performance. Friction parameters (i.e., force and time) displayed the most significant contributions to mechanical performance (32.0% and 21.4%, respectively), given their effects on heat development. For the investigated ranges, forging parameters did not have a significant contribution. A correlation between friction parameters was established to maximize mechanical response while minimizing energy usage. The knowledge from Parts I and II of this investigation allows the production of friction riveted connections in an energy efficient manner and control optimization approach, introduced for the first time in friction riveting.
Gonçalo Pina Cipriano; Lucian A. Blaga; Jorge F. Dos Santos; Pedro Vilaça; Sergio T. Amancio-Filho. Fundamentals of Force-Controlled Friction Riveting: Part II—Joint Global Mechanical Performance and Energy Efficiency. Materials 2018, 11, 2489 .
AMA StyleGonçalo Pina Cipriano, Lucian A. Blaga, Jorge F. Dos Santos, Pedro Vilaça, Sergio T. Amancio-Filho. Fundamentals of Force-Controlled Friction Riveting: Part II—Joint Global Mechanical Performance and Energy Efficiency. Materials. 2018; 11 (12):2489.
Chicago/Turabian StyleGonçalo Pina Cipriano; Lucian A. Blaga; Jorge F. Dos Santos; Pedro Vilaça; Sergio T. Amancio-Filho. 2018. "Fundamentals of Force-Controlled Friction Riveting: Part II—Joint Global Mechanical Performance and Energy Efficiency." Materials 11, no. 12: 2489.
This work presents a systematic study on the correlations between process parameters and rivet plastic deformation, produced by force-controlled friction riveting. The 5 mm diameter AA2024 rivets were joined to 13 mm, nominal thickness, polyetherimide plates. A wide range of joint formations was obtained, reflecting the variation in total energy input (24–208 J) and process temperature (319–501 °C). The influence of the process parameters on joint formation was determined, using a central composite design and response surface methodology. Friction time displayed the highest contribution on both rivet penetration (61.9%) and anchoring depth (34.7%), and friction force on the maximum width of the deformed rivet tip (46.5%). Quadratic effects and two-way interactions were significant on rivet anchoring depth (29.8 and 20.8%, respectively). Bell-shaped rivet plastic deformation—high mechanical interlocking—results from moderate energy inputs (~100 J). These geometries are characterized by: rivet penetration depth of 7 to 9 mm; maximum width of the deformed rivet tip of 9 to 12 mm; and anchoring depth higher than 6 mm. This knowledge allows the production of optimized friction-riveted connections and a deeper understanding of the joining mechanisms, further discussed in Part II of this work.
Gonçalo Pina Cipriano; Lucian A. Blaga; Jorge F. Dos Santos; Pedro Vilaça; Sergio T. Amancio-Filho. Fundamentals of Force-Controlled Friction Riveting: Part I—Joint Formation and Heat Development. Materials 2018, 11, 2294 .
AMA StyleGonçalo Pina Cipriano, Lucian A. Blaga, Jorge F. Dos Santos, Pedro Vilaça, Sergio T. Amancio-Filho. Fundamentals of Force-Controlled Friction Riveting: Part I—Joint Formation and Heat Development. Materials. 2018; 11 (11):2294.
Chicago/Turabian StyleGonçalo Pina Cipriano; Lucian A. Blaga; Jorge F. Dos Santos; Pedro Vilaça; Sergio T. Amancio-Filho. 2018. "Fundamentals of Force-Controlled Friction Riveting: Part I—Joint Formation and Heat Development." Materials 11, no. 11: 2294.
In the current work, process-related thermo-mechanical changes in the rivet microstructure, joint local and global mechanical properties, and their correlation with the rivet plastic deformation regime were investigated for Ti-6Al-4V (rivet) and glass-fiber-reinforced polyester (GF-P) friction-riveted joints of a single polymeric base plate. Joints displaying similar quasi-static mechanical performance to conventional bolted joints were selected for detailed characterization. The mechanical performance was assessed on lap shear specimens, whereby the friction-riveted joints were connected with AA2198 gussets. Two levels of energy input were used, resulting in process temperatures varying from 460 ± 130 °C to 758 ± 56 °C and fast cooling rates (178 ± 15 °C/s, 59 ± 15 °C/s). A complex final microstructure was identified in the rivet. Whereas equiaxial α-grains with β-phase precipitated in their grain boundaries were identified in the rivet heat-affected zone, refined α′ martensite, Widmanstätten structures and β-fleck domains were present in the plastically deformed rivet volume. The transition from equiaxed to acicular structures resulted in an increase of up to 24% in microhardness in comparison to the base material. A study on the rivet material flow through microtexture of the α-Ti phase and β-fleck orientation revealed a strong effect of shear stress and forging which induced simple shear deformation. By combining advanced microstructural analysis techniques with local mechanical testing and temperature measurement, the nature of the complex rivet plastic deformational regime could be determined.
Natascha Z. Borba; Conrado R. M. Afonso; Lucian Blaga; Jorge F. Dos Santos; Leonardo B. Canto; Sergio T. Amancio-Filho. On the Process-Related Rivet Microstructural Evolution, Material Flow and Mechanical Properties of Ti-6Al-4V/GFRP Friction-Riveted Joints. Materials 2017, 10, 184 .
AMA StyleNatascha Z. Borba, Conrado R. M. Afonso, Lucian Blaga, Jorge F. Dos Santos, Leonardo B. Canto, Sergio T. Amancio-Filho. On the Process-Related Rivet Microstructural Evolution, Material Flow and Mechanical Properties of Ti-6Al-4V/GFRP Friction-Riveted Joints. Materials. 2017; 10 (2):184.
Chicago/Turabian StyleNatascha Z. Borba; Conrado R. M. Afonso; Lucian Blaga; Jorge F. Dos Santos; Leonardo B. Canto; Sergio T. Amancio-Filho. 2017. "On the Process-Related Rivet Microstructural Evolution, Material Flow and Mechanical Properties of Ti-6Al-4V/GFRP Friction-Riveted Joints." Materials 10, no. 2: 184.