Paper Titles
Preface
Enhancing the Bonding of Insulated Homogeneous Interfaces in Factory Joints via Ultrasonic Vibration
p.1
Development of a Novel Rivet-Based Joining-By-Forming Process Using Flat Dies
p.9
Influence of Tumbling-Induced Geometric Anisotropy on the Mechanical Performance of Self-Piercing Rivet Joints
p.19
Experimental and Numerical Evaluation of L-PBF Printed Tool for Friction Stir Welding
p.29
Micro Friction Stir Spot Welding for Copper Current Collector Applications - An Experimental Study
p.41
Influences of the Rolling Parameters on Multi-Material Copper-Aluminum Composites via Compound Casting
p.55
A Hybrid Joining Strategy for Al–Cu Bimetallic Sheets Produced by Friction Stir Welding
p.69
Potentials of Heat Superimposed Rotary Friction Welding for Steel-Aluminium Joints
p.77

Development of a Novel Rivet-Based Joining-By-Forming Process Using Flat Dies

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Abstract:

The direct reuse of End-of-Life (EoL) automotive sheet metal offers significant environmental benefits, particularly when panels are flattened rather than remelted. However, the geometric irregularity and variable formability of reclaimed sheets require joining solutions that operate with minimal tooling and are compatible with flat-die pressing. This work introduces a novel rivet-based joining-by-forming process designed to create a mechanical interlock using only flat tools, enabling integration into the same hydraulic press used for EoL panel flattening.Finite element simulations were performed to optimize rivet geometry and study flange formation, stress distribution, and failure mechanisms. The optimized rivet design achieves stable outward flaring under axial compression, producing a functional joint without shaped dies. Experimental tests on reclaimed automotive sheets validated the joining concept and confirmed the deformation behaviour predicted numerically.The proposed method provides a low-cost, low-energy joining strategy suitable for reclaimed steels of uncertain formability and supports the development of circular manufacturing routes based on the direct reuse of automotive sheet metal.

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Periodical:

Materials Science Forum (Volume 1185)

Pages:

9-17

DOI:

https://doi.org/10.4028/p-5r6ON6

Citation:

Cite this paper

Online since:

April 2026

Authors:

Daniel Yeniss Unni*, Matteo Strano

Keywords:

Cold Joining, End Of Life (EoL) Vehicles, Joining by Forming, Low Cost Tooling, Rivet Design, Sheet Metal Joining, Sustainable Manufacturing

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Creative Commons CC BY 4.0

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* - Corresponding Author

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