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Friction stir blind riveting (FSBR) is a new joining method which eliminates the need to predrill a hole for rivet insertion. A new one-sided mechanical joining process, friction stir blind riveting (FSBR) was developed to form lap-shear joints for similar and dissimilar alloy sheets in different combinations. The similar and dissimilar joints are made from copper, Al 5052-H32, Al 6061-T6 metals. The process window was investigated of CNC machines using only three spindle speeds: 1110, 1750 and 2750 rpm. FSBR joints were observed and discussed during tensile testing. All the similar and dissimilar joints are well fabricated at 1750 rpm. Tensile testing results show that any material with copper combinations (copper used as a top plate) at 1750 rpm as riveting speed gives the appreciable ultimate tensile strength. Further study revealed micro structure of the joint interfaces, when compared with different combinations.

Experimental investigation of friction stir blind riveting process for similar and dissimilar alloy sheets