Joinability of different thermoplastic polymers with aluminium sheets by mechanical clinching

The joinability of different rigid thermoplastic polymers with aluminium AA6082-T6 alloy sheets by mechanical clinching is investigated. The polymers were heated using a convective source prior of clinching. Experimental tests were conducted by varying die geometry and pre-heating time. The joinability window for different thermoplastic polymers including polystyrene (PS), polycarbonate (PC) and poly(methyl methacrylate) (PMMA) was determined. The mechanical behaviours of clinched connections were assessed by means of single lap shear tests. To understand the effect of process parameters on the mechanical behaviours of clinched joints, dimensional analysis was also carried out. It was turned out that mechanical clinching could be successfully employed for joining thermoplastic polymer sheets with aluminium sheets being characterized by a very short processing time and producing high strength joints as compared to competitive technologies. The formability of the aluminium alloy and the toughness of the polymer component are crucial for the success of the process. However, even materials with reduced formability were joined by modifying conveniently the pre-heating time and die geometry.