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The joining of three-layer AL5052-H32 sheets with the square and round clinching process was studied by experimental means. Two 1.5 mm thick and one 2 mm thick AL5052-H32 sheets with three sheet sequences were joined by the square and round clinching process, respectively. The results showed that the square tools can successfully join three sheets in all three sheet orders, while the round tools can effectively connect three sheets only when the thick sheet is at the bottom. Moreover, the strength of the round joints is generally lower than that of the square joints. The square three-layer joint with the thick top sheet achieves high strength at both two mechanical interlocks.

Joining three aluminium alloy sheets by square clinching process