Evaluating the Corrosion Performance of Mixed Material Stackups Fastened by Resistance Spot Rivets
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The Ohio State University / OhioLINK
2020
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| Online Access: | http://rave.ohiolink.edu/etdc/view?acc_num=osu1595886807867032 |
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ndltd-OhioLink-oai-etd.ohiolink.edu-osu15958868078670322021-10-15T05:10:51Z Evaluating the Corrosion Performance of Mixed Material Stackups Fastened by Resistance Spot Rivets Krell, Paul David Materials Science Metallurgy Corrosion Rivets Galvanic Corrosion Crevice Corrosion Accelerated Exposure Exposure Testing Flow Drill Screw Flow-Drill Screw FDS Self Piercing Rivet Self-Piercing Rivet SPR Resistance Spot Rivet RSR Fuel economy standards for new passenger vehicles have increased both domestically and internationally over the last 20 years, and vehicle light-weighting is frequently a goal of consumer vehicle manufacturers to improve fuel economy. To meet this goal, Arconic Inc. developed a new riveting technology, resistance spot riveting (RSR), to join aluminum to steel or carbon-fiber reinforced plastic7, 8. Unlike conventional riveting technologies, resistance spot riveting applies a weld between the rivet and the joining surface for improved strength. The objective of this study is to use accelerated environmental exposure to quantify the corrosion resistance of stackups joined by RSR and compare results to stackups joined by the conventional joining technologies self-piercing rivets (SPR) and flowdrill screws (FDS).In order to understand the corrosion behavior of RSR stackups several studies were conducted. In all studies, several samples were cross-sectioned and micrographed post-exposure to directly measure corrosion depth in accessible and occluded regions of the joints. The maximum sustained load and failure mode of other samples were recorded to find the change in mechanical performance with respect to exposure time.In the first study, the strength and corrosion resistance of aluminum – steel stackups joined by RSR stackups were compared to stackups joined by FDS and SPR using the above methods. Stackups joined by the three joining technologies were exposed to salt spray specification ASTM G85-A2 in two different orientations for 1, 3, and 21 days of exposure, after which they were cross-sectioned to measure corrosion depths and mechanically loaded in tension to determine the maximum sustained load. After exposure, RSR stackups outperformed FDS stackups and performed similarly to SPR stackups in strength and corrosion resistance. The orientation of the sample during testing affected the depth of corrosion attack.In the second study, RSR stackups consisting of different materials were exposed to ASTM G85-A29 for 1, 3, 21, and 32 days to quantify the progression of corrosion with time. All stackups in this study were exposed with the rivet facing upwards and the aluminum sheet above the steel sheet. Cross-sectional analysis after exposure showed that changing the aluminum alloy in an aluminum-steel stackup had a large effect on corrosion depth and number of attack sites, while changing the steel alloy in an aluminum-steel stackup did not. The area of deepest attack changed from the aluminum faying surface near the steel leading edge at 21 days of exposure to the aluminum adjacent to the steel rivet after 32 days of exposure. Stackups of different materials were also exposed to ASTM B117 and CCT-1 for 32 days to study the effect of accelerated test methods. Results showed that CCT-1 exposure resulted in deeper corrosion than ASTM G85-A2 or ASTM B117. 2020 English text The Ohio State University / OhioLINK http://rave.ohiolink.edu/etdc/view?acc_num=osu1595886807867032 http://rave.ohiolink.edu/etdc/view?acc_num=osu1595886807867032 unrestricted This thesis or dissertation is protected by copyright: all rights reserved. It may not be copied or redistributed beyond the terms of applicable copyright laws. |
| collection |
NDLTD |
| language |
English |
| sources |
NDLTD |
| topic |
Materials Science Metallurgy Corrosion Rivets Galvanic Corrosion Crevice Corrosion Accelerated Exposure Exposure Testing Flow Drill Screw Flow-Drill Screw FDS Self Piercing Rivet Self-Piercing Rivet SPR Resistance Spot Rivet RSR |
| spellingShingle |
Materials Science Metallurgy Corrosion Rivets Galvanic Corrosion Crevice Corrosion Accelerated Exposure Exposure Testing Flow Drill Screw Flow-Drill Screw FDS Self Piercing Rivet Self-Piercing Rivet SPR Resistance Spot Rivet RSR Krell, Paul David Evaluating the Corrosion Performance of Mixed Material Stackups Fastened by Resistance Spot Rivets |
| author |
Krell, Paul David |
| author_facet |
Krell, Paul David |
| author_sort |
Krell, Paul David |
| title |
Evaluating the Corrosion Performance of Mixed Material Stackups Fastened by Resistance Spot Rivets |
| title_short |
Evaluating the Corrosion Performance of Mixed Material Stackups Fastened by Resistance Spot Rivets |
| title_full |
Evaluating the Corrosion Performance of Mixed Material Stackups Fastened by Resistance Spot Rivets |
| title_fullStr |
Evaluating the Corrosion Performance of Mixed Material Stackups Fastened by Resistance Spot Rivets |
| title_full_unstemmed |
Evaluating the Corrosion Performance of Mixed Material Stackups Fastened by Resistance Spot Rivets |
| title_sort |
evaluating the corrosion performance of mixed material stackups fastened by resistance spot rivets |
| publisher |
The Ohio State University / OhioLINK |
| publishDate |
2020 |
| url |
http://rave.ohiolink.edu/etdc/view?acc_num=osu1595886807867032 |
| work_keys_str_mv |
AT krellpauldavid evaluatingthecorrosionperformanceofmixedmaterialstackupsfastenedbyresistancespotrivets |
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1719489818637893632 |