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| Abstract: |
| The development and application of large die-casting Al alloy (DCAA) parts and thermo-formed steel sheets（TFSS）in body-in-white(BIW) come up with higher requirements on the joining technology of high-strength steel/Al dissimilar materials. As a new technology, FSPR is still in the stage of experiment and small batch equipment verification. This paper focuses on the joining methods of DCAA and TFSS BIW and investigates the joining mechanisms, technical features, and forming principles of FSPR for steel/Al dissimilar material with two-layer or three-layer plate combination. Taking the TL4225/C611/CR5 sheet combination as a subject, the forming mechanism of high-quality joints is studied, and a physical and mathematical model is established to depict the relationship between filling amount of the arc gap and die dimensions, as well as the extrusion amount. This model directly reflects the relationship between the filling amount of flowing metal in the arc gap and important parameters such as die dimensions and feeding amounts, simplifies the process of choosing joining parameters, thus reduces the time and experimental workload associated with parameter selection. This provides a technical foundation for the application of DAAA and TFSS parts in BIW, enables the rapid choice of appropriate joining parameters to meet the requirements for obtaining high-quality joints. The model, under the condition of unchanging other parameters, can be used to study the relationships between key parameters such as arc gap radius, plate thickness, rivet arc radius and nail head radius, groove width, and feeding amount, providing a theoretical basis for the design of FSPR joints and parameters ‘choosing. |
| Key words: FSPR, Joining, die-casting Al alloy, thermo-formed steel sheet, two or three-layer plate. |
| DOI：10.11916/j.issn.1005-9113.24013 |
| Clc Number:TG444 |
| Fund: |
