Advances in Forming and Joining Processes of Lightweight High-strength Thin-walled Vehicle Structures

doi:10.3901/JME.2023.20.001

Abstract

Abstract: The load-bearing structures of aircrafts, carrier rockets, high-speed trains, automobiles, and other transportation tools are featured with thin-walled structures, and manufactured with lightweight and high-strength materials. The forming process needs to meet the requirements of high strength of the final components, good formability, low-cost, and short process. At the same time, thin-walled structures are increasingly using a mixture of multi-materials and multi-structures, which not only improves the lightweighting effect and design flexibility, but also poses a huge challenge to traditional joining processes. This article reviews the research advances of hot stamping technology for lightweight and high-strength sheet metals, as well as riveting and resistance spot welding technologies for thin-walled components. The technological changes brought by new materials and structures to the forming and joining processes are analyzed systematically. The technical challenges and future development directions of these processes are pointed out, aiming to provide guidance and reference for the manufacturing of lightweight, high-strength, and thin-walled components.

Key words: lightweight and high-strength material, thin-walled structure, hot stamping, resistance spot welding, riveting

CLC Number:

TG38
TG44

LIN Zhongqin, MA Yunwu, XIA Yujun, LI Yongfeng, LI Shuhui, LI Yongbing. Advances in Forming and Joining Processes of Lightweight High-strength Thin-walled Vehicle Structures[J]. Journal of Mechanical Engineering, 2023, 59(20): 1-17.

References

[1] 郭斌，郎利辉. 锻压手册(第2卷):冲压[M]. 4版. 北京:机械工业出版社，2021. GUO Bin，LANG Lihui. Forging handbook (Volume 2):Stamping[M] 4th ed. Beijing:China Machine Press，2021.
[2] WANG L L，DEAN T，LIN J G. Innovation，development and implementation of the HFQ process[C]//The 3rd International Conference on Advanced High Strength Steel and Press Hardening (ICHSU2016)，Aug. 25-27，2016，Xi’an，China. 2016:289-300.
[3] WANG L，STRANGWOOD M，BALINT D，et al. Formability and failure mechanisms of AA2024 under hot forming conditions[J]. Mat. Sci. Eng. a-Struct.，2011，528(6):2648-2656.
[4] GAO H X，WENG T X，LIU J，et al. Hot stamping of an Al-Li alloy:A feasibility study [J]. Matec. Web Conf.，2015，21:05007.
[5] ZHENG K，ZHU L，LIN J，et al. An experimental investigation of the drawability of AA6082 sheet under different elevated temperature forming processes [J]. Journal of Materials Processing Technology，2019，273:116225.
[6] 岳毓挺，冯伟骏，杨兵，等. AA7055高强铝合金板预冷热冲压成形研究[J]. 航空制造技术，2021，64(17):61-68. YUE Yuting，FENG Weijun，YANG Bing，et al. Hot stamping with pre-cooling treatment for AA7055 high-strength aluminum alloy sheets[J]. Aeronautical Manufacturing Technology，2021，64(17):61-68.
[7] AP&T. Forming of high-strength aluminum[EB/OL]. [2017-10-22].https://aptgroup.com/solutions/automotive/forming-high-strength-aluminum.
[8] TECHNOLOGIES I. Services and products[EB/OL]. [2021-06-16].https://impression-technologies.com/services-and-products.
[9] HUA L，HU Z，ZHANG W，et al. Hot-stamping forming method for lightweight aluminum alloy vehicle body component:WO2019205768A1[P]. 2019-10-31.
[10] ZHANG W P，LI H H，HU Z L，et al. Investigation on the deformation behavior and post-formed microstructure/properties of AA7075-T6 alloy under pre-hardened hot forming process[J]. Mat. Sci. Eng. a-Struct.，2020，792(5):139749.
[11] 张云光. 7075高强铝合金车身薄壁构件短流程热冲压工艺研究[D]. 上海:上海交通大学，2021. ZHANG Yunguang. Research on short-process hot stamping of thin-walled structural components in 7075 high-strength aluminum alloy automotive bodies[D]. Shanghai:Shanghai Jiao Tong University，2021.
[12] ZHENG K L，LI Y，YANG S，et al. Investigation and modeling of the preheating effects on precipitation and hot flow behavior for forming high strength AA7075 at elevated temperatures [J]. J. Manuf. Mater. Proc.，2020，4(3):76.
[13] 李淑慧，李永丰，张云光，等. 铝合金薄壁构件及其高效热冲压成形方法和应用:中国，CN112775310B [P]. 2021-11-09. LI Shuhui，LI Yongfeng，ZHANG Yunguang，et al. Thin-walled aluminum alloy components and their efficient hot stamping forming method and application:China，CN112775310B [P]. 2021-11-09.
[14] 岳毓挺. 7系铝合金车身构件级进式预强化热冲压工艺实验研究[D]. 上海:上海交通大学，2023. YUE Yuting. Experimental study on progressive pre-strengthening hot stamping process for 7-Series Aluminum alloy automotive body components[D]. Shanghai:Shanghai Jiao Tong University，2023.
[15] MAENO T，YAMASHITA Y，MORI K-I. Hot stamping of titanium alloy sheets into U shape with concave bottom and joggle using resistance heating[J]. Key Engineering Materials，2016，716:915-922.
[16] KOPEC M，WANG K H，POLITIS D J，et al. Formability and microstructure evolution mechanisms of Ti6Al4V alloy during a novel hot stamping process [J]. Mat. Sci. Eng. a-Struct.，2018，719:72-81.
[17] CHEN Y，HAN G F，LI S H，et al. Time-dependent springback prediction with stress relaxation effect for non-isothermal hot stamping of titanium alloy sheets[J]. Int. J. Adv. Manuf. Tech.，2021，115(1-2):637-653.
[18] CHEN Y，LI S H，LI Y F，et al. Constitutive modeling of TA15 alloy sheet coupling phase transformation in non-isothermal hot stamping process[J]. J. Mater. Res. Technol.，2021，12:629-642.
[19] ODENBERGER E L. Concepts for hot sheet metal forming of titanium alloys[D]. Luleå:Luleå University of Technology，2009.
[20] ODENBERGER E L，SCHILL M，OLDENBURG M. Thermo-mechanical sheet metal forming of aero engine components in Ti-6Al-4V-PART 2:Constitutive modelling and validation[J]. Int. J. Mater. Form.，2013，6(3):403-416.
[21] ODENBERGER E L，PEDERSON R，OLDENBURG M. Finite element modeling and validation of springback and stress relaxation in the thermo-mechanical forming of thin Ti-6Al-4V sheets[J]. Int. J. Adv. Manuf. Tech.，2019，104(9-12):3439-3455.
[22] ODENBERGER E L，PEDERSON R，OLDENBURG M. Thermo-mechanical material response and hot sheet metal forming of Ti-6242[J]. Mat. Sci. Eng. a-Struct.，2008，489(1-2):158-168.
[23] LI Z Q，QU H T，CHEN F L，et al. Deformation behavior and microstructural evolution during hot stamping of TA15 sheets:Experimentation and modelling[J]. Materials，2019，12(2):223.
[24] WANG K H，KOPEC M，CHANG S P，et al. Enhanced formability and forming efficiency for two-phase titanium alloys by fast light alloys stamping technology (FAST) [J]. Materials & Design，2020，194:108948.
[25] 陈源，李淑慧，李永丰，等. TA15钛合金应力松弛行为宏微耦合本构建模[J]. 机械工程学报，2022，58(12):64-74. CHEN Yuan，LI Shuhui，LI Yongfeng，et al. Macro-micro coupled constitutive modeling for stress relaxation behavior of TA15 alloy sheet[J]. Journal of Mechanical Engineering，2022，58(12):64-74.
[26] 陈源. TA15钛合金薄板热变形本构建模及热冲压回弹预测研究[D]. 上海:上海交通大学，2021. CHEN Yuan. A study on the constitutive modeling of hot deformation and springback prediction of hot stamping in TA15 Titanium alloy thin sheets[D]. Shanghai:Shanghai Jiao Tong University，2021.
[27] SIGLER D R，CARLSON B E，JANIAK P. Aluminum resistance spot welding electrode degradation[C/CD]//AWS Sheet Metal Welding Conference XV，Oct.，Livonia，MI. 2012.
[28] CHEN N，WANG H P，WANG M，et al. Schedule and electrode design for resistance spot weld bonding Al to steels[J]. J. Mater. Process Technol.，2019，265:158-172.
[29] REN D X，ZHAO D W，LIU L M，et al. Clinch-resistance spot welding of galvanized mild steel to 5083 Al alloy[J]. Int. J. Adv. Manuf. Tech.，2019，101(1-4):511-521.
[30] QI L，ZHANG Q X，NIU S Z，et al. Influencing mechanism of an external magnetic field on fluid flow，heat transfer and microstructure in aluminum resistance spot welding[J]. Eng. Appl. Comp. Fluid，2021，15(1):985-1001.
[31] 李永兵，马运五，楼铭，等. 轻量化薄壁结构点连接技术研究进展[J]. 机械工程学报，2020，56(6):125-146. LI Yongbing，MA Yunwu，LOU Ming，et al. Advances in spot joining technologies of lightweight thin-walled structures[J]. Journal of Mechanical Engineering，2020，56(6):125-146.
[32] SHAH U，LIU X. Effects of ultrasonic vibration on resistance spot welding of transformation induced plasticity steel 780 to aluminum alloy AA6061[J]. Materials & Design，2019，182:108053.
[33] MSANORI Y，KAZUHIRO O，TAKAO T. Spot welding of aluminum and steel sheet (I). Spot welding of aluminum and steel sheet with insert of aluminum clad steel sheet[J]. Quarterly Journal of the Japan Welding Society，1996，14(2):314-320.
[34] LING Z，LI Y，LUO Z，et al. Resistance element welding of 6061 aluminum alloy to uncoated 22MnMoB boron steel[J]. Materials and Manufacturing Processes，2016，31(16):2174-2180.
[35] ZHANG G，ZHAO H，XU X，et al. Metallic bump assisted resistance spot welding (MBaRSW) of AA6061-T6 and Bare DP590:Part II-joining mechanism and joint property[J]. J. Manuf. Process，2019，44:19-27.
[36] SU Zewei，Xia Yujun，Shen Yan，et al. A novel real-time measurement method for dynamic resistance signal in medium-frequency DC resistance spot welding[J]. Measurement Science and Technology，2020，31(5):055011.
[37] 夏裕俊，李永兵，楼铭，等. 电阻点焊质量监控技术研究进展与分析[J]. 中国机械工程，2020，31(1):100-125. XIA Yujun，LI Yongbing，LOU Ming，et al. Recent advances and analysis of quality monitoring and control technologies for RSW[J]. China Mechanical Engineering，2020，31(1):100-125.
[38] Shen Yan，Xia Yujun，Li Huan，et al. A novel expulsion control strategy with abnormal condition adaptability for resistance spot welding[J]. Journal of Manufacturing Science and Engineering，2021，143(11):111009-12.
[39] Dai Wei，Li Dayong，Tang Ding，et al. Deep learning assisted vision inspection of resistance spot welds[J]. Journal of Manufacturing Processes，2021，62:262-274.
[40] Fethi D，Slah Y，Mahjoub E M，et al. On the nondestructive testing and monitoring of cracks in resistance spot welds:Recent gained experience[J]. Welding in the World，2022，66:629-641.
[41] Ingo B，Uwe F，Christoph G，et al. Data mining in resistance spot welding:A non-destructive method to predict the welding spot diameter by monitoring process parameters[J]. The International Journal of Advanced Manufacturing Technology，2018，99:1085-1099.
[42] Xia Yujun，Su Zewei，Li Yongbing，et al. Online quantitative evaluation of expulsion in resistance spot welding[J]. Journal of Manufacturing Processes，2019，46:34-43.
[43] Guo Shenghan，Wang Dali，Chen Jian，et al. Predicting nugget size of resistance spot welds using infrared thermal videos with image segmentation and convolutional neural network[J]. Journal of Manufacturing Science and Engineering，2022，144(2):021009.
[44] Xia Yujun，Su Zewei，Lou Ming，et al. Online precision measurement of weld indentation in resistance spot welding using servo gun[J]. IEEE Transactions on Instrumentation and Measurement，2020，69(7):4465-4475.
[45] Zhou Lang，Xia Yujun，Shen Yan，et al. Comparative study on resistance and displacement based adaptive output tracking control strategies for resistance spot welding[J]. Journal of Manufacturing Processes，2021，63:98-108.
[46] MORI K，ABE Y. A review on mechanical joining of aluminum and high strength steel sheets by plastic deformation[J]. International Journal of Lightweight Materials and Manufacture，2018，1(1):1-11.
[47] WANG Tianhao，WHALEN S，MA Xiaolong，et al. Friction-based riveting technique for AZ31 magnesium alloy[J]. Journal of Magnesium and Alloys，2022，10:110-118.
[48] WANG Tianhao，GWALANI B，SONG Miao，et al. Extreme shear deformation enables ultra-fast riveting of high strength aluminum alloys[J]. Journal of Manufacturing Processes，2022，75:814-825.
[49] MA Yunwu，LI Yongbing，LIN Zhongqin. Joint formation and mechanical performance of friction self-piercing riveted aluminum alloy AA7075-T6 joints[J]. Transactions of the ASME:Journal of Manufacturing Science and Engineering，2019，141(4):041005.
[50] YANG B，MA Y，SHAN H，et al. A comparative study of self-piercing riveting and friction self-piercing riveting of cast aluminum alloy Al-Si7Mg[J]. ASME. J. Manuf. Sci. Eng.，2023，145(1):011003.
[51] YANG Bingxin，MA Yunwu，SHAN He，et al. Friction self-piercing riveting (F-SPR) of aluminum alloy to magnesium alloy using a flat die[J]. Journal of Magnesium and Alloys，2022，10(5):1207-1219.
[52] SHAN He，YANG Bingxin，MA Yunwu，et al. Friction stud riveting (FSR) of thick high strength aluminum alloy structure[J]. International Journal of Machine Tools and Manufacture，2022，177:103889.
[53] MARTINSEN K，HU S J，CARLSON B E. Joining of dissimilar materials[J]. CIRP Annals，2015，64(2):679-699.
[54] MORODOMI H，NISHIHARA Y，MATSUBARA S，A study of high-speed joining method using spiral nails[J]. Journal of Manufacturing Processes，2020，59:500-508.
[55] UFFERMAN B A，BARKER T，VIVEK M，et al. Mechanical properties of joints in 5052 aluminum made with adhesive bonding and mechanical fasteners[J]. International Journal of Adhesion & Adhesives，2018，83:96-102.
[56] MESCHUT G，JANZEN V，OLFERMANN T，Innovative and highly productive joining technologies for multi-Material lightweight car body structures[J]. Journal of Materials Engineering and Performance，2014，23:1515-1523.
[57] SKOVRON J D，ROHAN PRASAD R，ULUTAN D，et al. Effect of thermal assistance on the joint quality of Al6063-T5A during flow drill screwdriving[J]. Journal of Manufacturing Science and Engineering:Transactions of the ASME，2015，137(5):051019.
[58] HUANG C P，CHEN W N，SUNG S J，et al. Mechanical strength and failure mode of flow drill screw joints in coach-peel specimens of aluminum 6082-T6 sheets of different thicknesses and processing conditions[C]//Wcx World Congress Experience，2018.
[59] GAO D，ERSOY U，STEVENSON R. A new one-sided joining process for aluminum alloys:Friction stir blind riveting[J]. Journal of Manufacturing Science and Engineering:Transactions of the ASME，2009(6):131.
[60] YANG B，SHAN H，HAN X，et al. Single-sided friction riveting process of aluminum sheet to profile structure without prefabricated hole[J]. Journal of Materials Processing Technology，2022，307:117663.
[61] MESCHUT G，HAHN O，JANZEN V，et al. Innovative joining technologies for multi-material structures[J]. Weld. World，2014，58:65-75.
[62] GÜNTER H，MESCHUT G. Joining of ultra-high-strength steels using resistance element welding on conventional resistance spot welding guns[J]. Weld. World，2021，65:1899-1914.
[63] NIU S，MA Y，LOU M，et al. Joint formation mechanism and performance of resistance rivet welding (RRW) for aluminum alloy and press hardened steel[J]. J. Mater. Process. Technol.，2020，286:116830.
[64] MESCHUT G，JANZEN V，OLFERMANN T. Innovative and highly productive joining technologies for multi-material lightweight car body structures[J]. J. Mater. Eng. Perform.，2014，23:1515-1523.
[65] SHAN H，MA Y，NIU S，et al. Friction stir riveting (FSR) of AA6061-T6 aluminum alloy and DP600 steel[J]. J. Mater. Process. Tech.，2021，295:117156.
[66] OUYANG Y，CHEN C. Research advances in the mechanical joining process for fiber reinforced plastic composites [J]. Composite Structures，2022，296:115906.
[67] ZHANG X，HE X，XING B，et al. Pre-holed self-piercing riveting of carbon fibre reinforced polymer laminates and commercially pure titanium sheets[J]. J. Mater. Process Technol，2020，279:116550.
[68] ZHUANG W，CHEN S，LIU Y. Influence of joining temperature on damage of warm self-piercing riveted joints in carbon fiber reinforced polymer and aluminum alloy sheets[J]. Journal of Manufacturing Processes，2023，89:77-91.
[69] LIANG J，JIANG H，ZHANG J，et al. Investigations on mechanical properties and microtopography of electromagnetic self-piercing riveted joints with carbon fiber reinforced plastics/aluminum alloy 5052[J]. Archives of Civil and Mechanical Engineering，2019，19(1):240-250.