Friction stir blind riveting for aluminum alloy sheets

Single lap-shear joints of two Al alloy sheets: 2.0 mm AA6111-T4 and 2.0 mm AA6022-T4 were fabricated by applying the friction stir blind riveting (FBSR) process using either a 4.8 mm or 6.4 mm shank diameter blind rivet. The process window was investigated using three spindle speeds: 3000, 6000 and 9000 rpm and three feed rates: 120, 420 and 780 mm min−1. Force and torque FSBR process data was captured and used in part to analyze the mechanical process during frictional penetration of the rivet. Over 95% of the total energy was consumed by the rotational motion during frictional penetration of the rivet. The combination of Al sheet alloy rivet, spindle speed, and feed rate have statistically significant effects upon the peak force, the peak torque, the energy input and the peak power; all of which need to be properly selected for an optimized process