TALAT Lecture 4105

Combination of Joining Methods

16 pages, 19 figures

Basic Level

prepared by Lothar Budde, Universität-Gesamthochschule Paderborn

Objectives:

− to describe the combination of mechanical joining with adhesive bonding with

respect to application criteria, productions considerations and resultant properties

Prerequisites:

− General mechanical engineering background

− TALAT lectures 4101 - 4104

Date of Issue: 1994

 EAA - European Aluminium Association
4105 Combination of Joining Methods

Table of Contents

4105 Combination of Joining Methods ..............................................................2

4105.01 Application Criteria.................................................................................. 3
Comparison of Functional Characteristics of Different Fastening Technologies ....3
Classification Index of Joints...................................................................................4
Advantages of Combined Joint Types .....................................................................4
Properties of Elementary Joints ...............................................................................5
Main Advantages and Disadvantages of Adhesive Joining .....................................5
Fold-Adhesive Joints ...............................................................................................6
Examples of Combined Joints Used in the Aircraft Industry ..................................6
Combination of Material Locking and Form Locking Joints...................................7
Fractured Surfaces of Combined Joints after Shear Testing....................................8
4105.02 Production Considerations...................................................................... 8
Production of Combined Joints................................................................................8
Production Variants for Combined Joints................................................................9
Technical Operations in the Production of an Adhesive-Clinch Joint Combination
...............................................................................................................................10
Methods of Producing Adhesively Joint and Clinched Fastenings........................10
Form of Clinched Joints With and Without Adhesives .........................................11
4105.03 Properties of Combination Joints.......................................................... 12
Criteria for the Use of Combined Joining Technologies .......................................12
Results of Fatigue Tests with Adhesive Joints ......................................................13
Impact Strength of Different Joints........................................................................13
Shear Strength of Different Joints With and Without Ageing...............................14
Comparison of Properties of Different Joining Technologies ...............................15
4105.04 Literature/References ............................................................................ 15
4105.05 List of Figures............................................................................................ 16

TALAT 4105 2
4105.01 Application Criteria

• Comparison of functional characteristics of different fastening

technologies
• Classification index of joints
• Advantages of combined joint types
• Properties of elementary joints
• Main advantages and disadvantages of adhesive joining
• Fold-adhesive joints
• Examples of combined joints used in the aircraft industry
• Combination of material locking and form locking joints
• Fractured surfaces of combined joints after shear testing

Comparison of Functional Characteristics of Different Fastening Technologies

The functional characteristics of the different fastening technologies is important, since

this enables us to choose the most appropriate joining technology for light constructions
which are being developed and used increasingly.

A large number of the so-called "classical" fastening technologies currently in use fulfil
these requirements only partly, making it necessary to use solutions which are a
compromise (Figure 4105.01.01).

Joining
Technology Adhesive
Spot Welding Clinching Riveting
Joining
Characteristics

Functional Load-Carrying Load-Carrying Load-Carrying Load-Carrying

Characteristics
Fixing Fixing Fixing Fixing

Sealing Elec. Conduct. Elec. Conduct. Elec. Conduct.

Isolating Relatively Low Relatively Low Relatively Low

Fatigue Strenght Fatigue Strenght Fatigue Strenght
Damping

Equalising

Good Fatigue
Strength

Source: Budde
Comparison of Functional Characteristics
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of Different Fastening Technologies
4105.01.01
Training in A luminium Application Technologies

TALAT 4105 3
Classification Index of Joints

The joining technology used in light constructions should be such that the classification
index of the joint, a value for the functional characteristics relative to the corresponding
base material of the corresponding material combination, optimally approaches the
limiting value of 1 (Figure 4105.01.02).At increased stresses, the principles of force
actions, the reduction of disadvantageous notch effects, the constancy of the material
properties and the joint reliability become increasingly important.

A consequence of the above mentioned is that there is an increasing tendency to use

aluminium for highly stressed constructions.

Functional Properties
of the Joint

Functional Properties
of the Base Material
1

Increasing Stress Levels

Source: Wittke, Füssel

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Classification Index of Joints 4105.01.02
Training in Aluminium Application Technologies

Advantages of Combined Joint Types

A combination of joint types can be used, among others, to take advantage of the
specific material properties of aluminium, thus making it possible to optimise the joint
quality, allow certain materials and material combinations to be joint and/or to simplify
the fastening process. A combination of different joint types can be used either to
improve the statical and dynamical properties of the joint or to guarantee leakproof
joints (Figure 4105.01.03).

Combined Joints

Improving the Static and Dynamic Properties of Joints!

Guaranteeing the Joint Gas and Fluid Tightness!

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Advantages of Combined Joint Types 4105.01.03
Training in Aluminium Application Technologies

TALAT 4105 4
Properties of Elementary Joints

Depending on the load carrying capacity and the design of the light construction, the
types of joints used may be of the material locking kind or of the force or shape locking
type (Figure 4105.01.04). The choice of the elementary joints to be used in combination
is based on the principle of elimination. According to this principle, those particular
combinations of joints which do not fulfil any one out of a required list of criteria, are
eliminated.

Elementary Joints

Form Locking Force Locking Material Locking

Strength
Temperature
Stability
Sealing Props.
Safety against
Loosening
Detachability
Corrosion
Resistance
Electrical /Tthermal
Conductivity

Function Fulfilled
Function not Fulfilled

Source: Wittke, Füssel

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Properties of Elementary Joints 4105.01.04
Training in Aluminium Application Technologies

Main Advantages and Disadvantages of Adhesive Joining

Adhesive joining plays an important role in the design of ultralight constructions. The
main advantages of adhesive joints are the transmission of forces over large areas and
the possibility of joining different and non-metallic materials as well as material
combinations. The disadvantage of adhesive joining is the fact that, as a rule, the
components have to be held rigidly in a fixture during the hardening process. In addition
to this, adhesive joints have a limited high-temperature strength (Figure 4105.01.05).

One-Sided Overlapped Adhesive Joints

Advantages: Disadvantages:

- Force Transmission over - Sensitive to Peeling Forces

Large Areas
- No Thermal Influence of - Aging Problems
Material Microstructure
- Suitable for Different Types - Limited Warm Strength
of Materials and for Non-Metals

Source: Budde
Main Advantages and Disadvantages
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4105.01.05
Training in Aluminium Application Technologies of Adhesive Joining

The specific disadvantages of adhesive joining can be compensated for by using a

TALAT 4105 5
combination of this material locking joint type with force and shape locking types of
joints. Examples of such combined joints can be found in the automotive (mass
production) and aircraft (small series production) industries.

Fold-Adhesive Joints

In the automotive industry, the combination of adhesive joining and folding can be used
for fastening car-body parts. If applied properly, the folded and adhesively joint parts
possess the combined advantages of both fastening technologies (Figure 4105.01.06).

The main advantage of folded joints is that these can be loaded immediately, i.e., a
rational production is possible. The surfaces of the folded joints produced remain
smooth and clean. The additional use of adhesives in the fold leads to leakproof joints.
At the same time, the adhesive used improves the damping characteristics of the whole
aluminium construction.

Folding and Adhesive Joining in Body Building

Adhesive Joint

Function: Sealing

Interior Part
Exterior Part

Folding Joint
Aluminium Sheet
Function: Strength
Soucre: Hoesch Company Document

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Fold-Adhesive Joints 4105.01.06
Training in Aluminium Application Technologies

Examples of Combined Joints Used in the Aircraft Industry

Some adhesive and sealed joints are prone to a deleterious ageing, especially if exposed
to industrial atmosphere, water, solvents or aggressive chemicals.

Examples of combined adhesive and sealed joints used in aircraft construction illustrate
how this deleterious effect can be reduced by the judicious choice of adhesive and
sealant, the long-time testing of the joints, a specific design as well as the application of
protective layers on the surface of the adhesive and sealed joints (Figure 4105.01.07).

TALAT 4105 6
 Adhesively Fastened Longitudinal Stiffener

Adhesive
Sealant Coating

Reinforced Rivet-Adhesive Joint

Surface Sealant
Adhesive
Sealant Coating
Sealed Riveted Joints

Sealant

Adhesive
Sour ce: Endlich

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Training in Aluminium Application Technologies

Combination Joints Used in the Aircraft Industry 4105.01.07

Combination of Material Locking and Form Locking Joints

Joints, consisting of a combination of both adhesive joining and locally active fastening
methods, mostly use spot welding or mechanical joining methods like riveting and
clinching. In the automotive industry, spot welding is used mainly to shorten production
times in spite of the long hardening times of the adhesives. The combination of adhesive
and riveted joints is used primarily in the aircraft industry for parts subject to dynamic
loading (Figure 4105.01.08).

Clinching with or without local incisions is an interesting technology which could be

used for combined joints and shall, therefore, be illustrated for combinations with
adhesive joining. The following remarks generally apply also to other mechanical
fastenings.

Adhesive Joining
(Material Locking)

+ Spot Welding + Conventional Riveting + Clinching

(Material Locking) (Quasi Form Locking) (Quasi Form Locking)
Source: Budde

Combination of Material Locking and

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4105.01.08
Training in Aluminium Application Technologies Form Locking Joints

TALAT 4105 7
Fractured Surfaces of Combined Joints after Shear Testing

During the clinching process, aluminium shaped sheet components and profiles are joint
together according to the quasi form locking principle simply through the action of local
plastic material deformation without using auxiliary parts or thermally influencing the
microstructure.

Material spray, which occurs as a joint defect due to the high material pressure in the
spot welded region, thereby reducing the joint strength, is absent in joint combinations
of clinching and adhesive joining (Figure 4105.01.09).

35 mm
Spot Welding and
Adhesive Joining

Clinching and
Adhesive Joining
Source: Budde

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Fractured Surface of Combined Joints after Shear Testing 4105.01.09
Training in Aluminium Application Technologies

4105.02 Production Considerations

• Production of combined joints

• Production variants for combined joints
• Technical operations in the production of an adhesive-clinch joint
combination
• Methods of producing adhesively joint and clinched fastenings
• Form of clinched joints with and without adhesives

Production of Combined Joints

Joint combinations consisting of more than one elementary joint can be fabricated by
producing the individual joints either simultaneously or one after the other (see Figure
4105.02.01). This chronological order can influence the properties of the joint.

TALAT 4105 8
 Fabricating
Combined Joints

No. of
Processes One Process Multiple Processes

Chronological
Order of Process Simultaneously Consecutively

Moment of
Reaching the Prior Prior Prior
During During During
Required to to to
Use Use Use
Properties Use Use Use

Source: Füssel

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Production of Combined Joints 4105.02.01
Training in Aluminium Application Technologies

Production Variants for Combined Joints

In principle, three variants are possible for the consecutive production of adhesive
joining and mechanical joining (see Figure 4105.02.02).

(4.) (4.) (3.)

(3.)
=RT..200°C =RT..200° =RT..200° (4.)
(2.)
(2.) (1.) (2.)
(1.) (1.)

(3.)
"Capillary Method"

Variant 1 Variant 2 Variant 3

1. apply adhesive 1. place parts together 1. apply adhesive

2. place parts together 2. mechanical joining 2. place parts together
3. mechanical joining 3. apply adhesive 3. curing adhesive
4. curing adhesive 4. curing adhesive 4. mechanical joining

Source: Stepanski

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Production Variants for Combined Joints 4105.02.02
Training in Aluminium Application Technologies

In the so-called "capillary" method, a mechanical joint is first prepared and then an
adhesive of low viscosity is brought into the joint crevice. In this variation - which is
characterised by a clear separation of the parts to be joint - the adhesive serves generally
as a sealant and/or as an inhibitor for corrosion.

The adhesive joining of sheet and profile parts followed by a mechanical fastening
process, the latter being used to improve the peeling strength of the joint, has till now
played only a secondary role.
Another fastening process has been found to be industrially most suitable for making
combined joints, especially for mass production. In this process, the adhesive is first

TALAT 4105 9
applied to the parts and then, before the adhesive hardens, followed by a mechanical
joining process which goes through the unhardened adhesive. The hardening then
follows as usual, depending on the type of adhesive used.

Technical Operations in the Production of an Adhesive-Clinch Joint Combination

A closer look at the individual process steps involved in the production of the combined
adhesive-clinch joint shows that the combined adhesive-mechanical joining process can
be easily integrated in the mass production of thin sheet constructions (Figure
4105.02.03).

Surface Adhesive Finished Part

Raw Parts Handle
Element Application
Fix

Join

Setting

Source: Budde

Operations in the Production

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of an Adhesive-Clinch Joint Combination 4105.02.03

Training in Aluminium Application Technologies

Methods of Producing Adhesively Joint and Clinched Fastenings

The advantage of using clinching instead of spot welding in combination with adhesive
joining is that the former allows the use of not only fluid and pasty adhesives but also of
adhesive foils and bands (Figure 4105.02.04).

Solid adhesives have special advantages, both as far as process technology as well as
health aspects are concerned.

TALAT 4105 10
 Clinching and Adhesive Joining

Adhesive Fluid Pasty Solid

Combined With

Without Local With Local

Clinching
Incision Incision

Source: Budde
Methods of Producing Adhesively Joint and
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4105.02.04
Training in Aluminium Application Technologies Clinched Fastenings

Form of Clinched Joints With and Without Adhesives

Clinching without local incision can be used as the mechanical fastening partner for
adhesive joining using pasty adhesives. On the other hand, clinching with local incision
is used together with adhesive foils and bands.

The geometry of the joint element of combined clinched fastenings illustrates that in
spite of the presence of adhesives, an optimal form of the clinch joint is created,
assuming of course that an appropriate process technology is applied (Figure
4105.02.05).

Clinching with Without Adhesive With Adhesive Film

Local Incision

Clinching without
Local Incision Without Adhesive With Pasty Adhesive

Source: Budde

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Form of Clinched Joints with and without Adhesives 4105.02.05
Training in Aluminium Application Technologies

TALAT 4105 11
4105.03 Properties of Combination Joints

• Criteria for the use of combined joining technologies

• Results of fatigue tests with adhesive joints
• Impact strength of different joints
• Shear strength of different joints with and without ageing
• Comparison of properties of different joining technologies

Criteria for the Use of Combined Joining Technologies

In principle, the choice of the combined technology, mechanical fastening and adhesive
joining, which may be used for joining in light constructions depends mainly on two
application criteria.

In mechanical fastenings combined with adhesive joining, the former is the main joining
process. The adhesive used serves primarily as a sealant, corrosion inhibitor and/or as a
damping material.

In adhesive joints combined with mechanical joining, the former is the main joining
process. The mechanical joining serves as a positioning (fixing) help and helps the
adhesive joint to withstand peeling forces and long-time static forces (Figure
4105.03.01).

Mechanical Joining Combined with Adhesive Joining

Clinching is the main joining process. The applied adhesive serves

primarily as sealant, corrosion protection and/ or damping material
and relieves the joint in regions where the force lines lie outside the
joining point.

Adhesive joining Combined with Mechanical Fastening

Adhesive joining is the main joining process. The mechanical joint

serves as a help in fixing and relieves the adhesive layer during
fabrication or peeling loads or long-time static loads.

Source: Budde

alu Criteria for the Use of Combined

Training in Aluminium Application Technologies Joining Technologies 4105.03.01

TALAT 4105 12
Results of Fatigue Tests with Adhesive Joints

The properties of the adhesive used are the main deciding criteria for the application.
Under quasi static, dynamic and impact loading, the load carrying capacity of, for
example, clinched adhesive joints compares well with that of spot welded joints (see
Figure 4105.03.02). Under the action of dynamic loads, the geometric notch effect of
the "point formed" joint element has a deleterious effect on the load carrying capacity of
the combined joint.

A Adhesive Joint B Spot Welded C Clinched-

Adhesive Joint Adhesive Joint

Pasty Epoxy
Resin Adhesive
N / mm2
f = 80 Hz / R =0,0
6,0

5,0
Force Amplitude

F 35
45
F
4,0
A
1,0

B 1,0
105

3,0
C
Al Mg 5 Mn

2,0

3 4 5 6 7 8
10 10 10 10 10 10
Source: Budde No. of Cycles
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Training in Aluminium Application Technologies

Results of Fatigue Tests with Adhesive Joints 4105.03.02

Impact Strength of Different Joints

Joints made with ductile adhesives having a high deformability and low strength behave
differently. Here again, depending on the loading, the joint strength is determined
mainly by the clinch joint (Figure 4105.03.03). By giving proper consideration to
factors like property profile and processing properties of the adhesive, it is basically
possible to design combined joints with properties which are a combination of the
individual properties of the joints.

TALAT 4105 13
 A Spot Welding B Clinching C Adhesive Joining
with Adhesive Band

20 D
Vs= 5 m/s

15
F 35
45
F
Rupture Energy

1,0
10 1,0
105

Al Mg 5 Mn
5

A B C D
0
Source: Budde

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Impact Strength of Different Joints 4105.03.03
Training in Aluminium Application Technologies

Shear Strength of Different Joints With and Without Ageing

In connection with combined fastenings of mechanical and adhesive joints, the aspect of
ageing of the combined joint plays a central role.
It has been found that corrosion increases the strength of riveted and clinched joints of
aluminium sheets (see Figure 4105.03.04). This is due to the fact that the corrosion
products of aluminium occupy a larger volume than the uncorroded aluminium material.
This increases the strain on the joint causing the force locking component to increase.
Although the mechanical fastening process can cause aluminium sheets to be pulled
apart in the joint vicinity, the supporting action of the mechanical joint in the combined
mechanical-adhesive joint greatly reduces the decrease in joint strength caused by
ageing.

Single-Element Samples
kN without Corrosion
AlMg4.5Mn
with Corrosion v=10mm/min
s=1.0mm
10
Elementary Combined
Joint Joint
8
Rupture force

Adhesive Clinching Punch Clinching and Riveting and

Joining Riveting Adhesive Adhesive
Joining Joining
Source: Singh

Shear Strength of Different Joints

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4105.03.04
Training in Aluminium Application Technologies with and without Ageing

TALAT 4105 14
Comparison of Properties of Different Joining Technologies

Mechanical fastening methods, used alone or in combination with adhesive joining,

improve the standard of quality as far as rigidity, damping of noise and vibrations,
pressure tightness and corrosion protection are concerned, making this an interesting
proposal for highly stressed aluminium constructions (Figure 4105.03.05).

Joining
Technology Adhesive
Spot Welding Clinching Riveting
Joining
Characteristics

Joint Large Surface Local Local Local

Plane Surface Uneven Surface Deformed Damaged

Surface Surface

Properties Very Sensitive Conditionally Conditionally Sensitive to

to Environment Sensitive to Sensitive to Environment
Environment Environment

Depend on Depend on Depend on Depend on

Direction Direction Direction Direction

Source: Budde

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Comparison of Properties of Different
Joining Technologies 4105.03.05
Training in Aluminium App licatio n Tech nologies

4105.04 Literature/References

1. Budde, L. Untersuchungen zur Kombination quasi-formschlüssiger und

stoffschlüssiger Verbindungsverfahren. Dissertation Uni-GH-Paderborn, 1989
2. Wittke, K. und Füssel, U. Kombinierte Fügeverbindungen. Wissenschaftliche
Schriftenreihe der TU Chemnitz 13/1986
3. Patrick, E. and Sharp, M.L. Joining methods for aluminium car body structures.
Automotive Technology International (1993), 61-70
4. Füssel, U. Kombinierte Fügeverbindungen. Habilitation TU Chemnitz, 1989
5. Endlich, W. Klebdichten. Angewandte Technik 1 (1988) 4, 4-31
6. Stepanski, H. Punktschweißkleben von Karosserieblechen aus Stahl und
Aluminium. Dissertation TH Aachen, 1980
7. Budde, L. Alternative Lösungen für Fügeprobleme durch
Verbindungskombinationen. Der Konstrukteur 23 (1992) 1/2, 22-25

TALAT 4105 15
4105.05 List of Figures

Figure No. Figure Title (Overhead)

4105.01.01 Comparison of Functional Characteristics of Different Fastening Technologies

4105.01.02 Classification Index of Joints
4105.01.03 Advantages of Combined Joint Types
4105.01.04 Properties of Elementary Joints
4105.01.05 Main Advantages and Disadvantages of Adhesive Joining
4105.01.06 Fold-Adhesive Joints
4105.01.07 Examples of Combined Joints Used in the Aircraft Industry
4105.01.08 Combination of Material Locking and Form Locking Joints
4105.01.09 Fractured Surface of Combined Joints After Shear Testing

4105.02.01 Production of Combined Joints

4105.02.02 Production Variants for Combined Joints
4105.02.03 Operations in the Production of an Adhesive-Clinch Joint Combination
4105.02.04 Methods of Producing Adhesively Joint and Clinched Fastenings
4105.02.05 Form of Clinched Joints with and without Adhesives

4105.03.01 Criteria for the Use of Combined Joining Technologies

4105.03.02 Results of Fatigue Tests with Adhesive Joints
4105.03.03 Impact Strength of Different Joints
4105.03.04 Shear Strength of Different Joints with and without Ageing
4105.03.05 Comparison of Properties of Different Joining Technologies

TALAT 4105 16