Steel‑aluminum clinched joints mechanical properties and strength prediction under different geometric parameters

Abstract

With the evolution of modularization and prefabrication in construction, there is a growing adoption of prefabricated thin-wall steel and aluminum structures for lightweight buildings and interior decoration. Clinching emerges as a proficient method for achieving heterogeneous metal connections, offering benefits such as streamlined processes, reduced material usage, environmental friendliness, and potential for automation. This study focuses on high-strength steel DP590 and aluminum alloy AW5754-H22, exploring various process parameters (including punch diameter, punch fillet radius, extensible die diameter, and extensible die depth) tailored for clinching experiments on thin steel and aluminum plates. The research analyzes how these process parameters affect the geometric characteristics of the joints and investigates their mechanical properties through static shear tests. Findings indicate that interlocks exceeding 0.29 mm lead to neck cracks during the clinching process. Additionally, the energy absorption of the specimens in button separation exceeds that in neck fracture by 44 % under comparable maximum failure loads in static shear. Optimal process parameters identified are SR5605-SR60310, achieving a maximum failure load of 4.14kN and an energy absorption value of 12.37 J in static shear tests. Finally, a method is proposed to calculate the shear strength of steel‑aluminum clinched joints based on the transmission dynamics of infectious diseases model (SIR model), accounting for the influence of geometric parameters on the static performance of the joints. This approach accurately describes the load-displacement curve trend and predicts the static shear strength of steel‑aluminum clinched joints effectively.