Process Development of Dissimilar Clinch Joints in Aluminum 5052-H32 and Thermoplastic-CFRP Sheets

This research work presented the process development for dissimilar clinch joints in aluminum alloy 5052-H32 (AA5052-H32 or Al) and thermoplastic carbon fiber reinforced plastic (TP-CFRP or CFRP) sheets. For process analysis, AA5052-H32 and TP-CFRP sheets with a thickness of 1.6 mm were taken. The design of the punch and die were examined by tensile tests and metallographic micrographs. The influence of punching force on the process was studied as well. One appropriate process setup of the punch, die and punching force was determined. Finally, the feasibility of the Al/CFRP clinching process was confirmed.