Numerical modeling and simulation of the flow drill screw process for joining A365 and A6N01 multi-material joints

Abstract

Abstract Multi-material joints are becoming more prevalent in various manufacturing processes due to their excellent mechanical characteristics and lightweight design. In particular, joining metals of dissimilar materials, such as heterogeneous aluminum alloy, is challenging due to the mismatch of material properties and processing characteristics. Flow drill screw (FDS) technology has emerged as a promising method for achieving a reliable and durable joint between dissimilar materials. This work extensively simulates and examines the flow drill screw process for a multi-material joint of aluminum alloys A365 and A6N01. The Deform-3D software and the finite element method (FEM) were employed to generate the numerical simulation model. The thermomechanical behavior of the joint during the FDS process was considered in the model, including material flow, deformation, and temperature distribution. The simulation results indicate that the large amounts of frictional heat generated by the materials and screw cause the temperature distribution around the joint area to grow considerably non-uniform. The model shows that the screw's rotation speed, screw penetration depth, and material deformation behavior significantly affect joint strength. Higher rotation speeds generate more heat and greater tool deformation, thus reducing joint strength. The simulated results are compared with the experimental results. They are found to be in good agreement, demonstrating that the model can serve as a valuable tool for optimizing the FDS process for multi-material joining applications.