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Effects of processing parameters on preheated (heat-assisted) clinching process to join aluminum alloy 5052-H32 (AA5052) and thermoplastic carbon-fiber-reinforced-plastic (TP-CFRP) sheets for cross-tension (CT) specimens were first studied. Preheating was critical since brittle TP-CFRP could be softened to avoid fracturing or cracking during clinching process. Four processing parameters, including punching force, die depth, heating mode, and heating temperature, were considered. Quasi-static tests and microscope observations were taken to evaluate AA5052/TP-CFRP clinch joints in CT specimens and determine appropriate processing parameters for fatigue tests. Finally, fatigue data and failure mode of clinch joints in CT specimens were obtained and discussed.

Preheated (Heat-Assisted) Clinching Process for Al/CFRP Cross-Tension Specimens