Joining by Plastic Deformation

Abstract

This paper draws from the existing processes and applications of joining by plastic deformation to a comprehensive overview of a new set of processes that have been recently developed by the authors. The presentation includes solutions for connecting tubes, sheets and tubes to sheets and provides information on the tooling systems, operating variables, deformation mechanics and workability limits. Results from analytical modelling, finite element analysis and experimentation give support to the presentation and prove the feasibility of the new joining by plastic deformation processes for connecting tubes, sheets and tubes to sheets made from dissimilar materials, at room temperature, without having to use addition materials or adhesives. The resulting joints are easy to disassembly at the end of live, thereby allowing recyclability of the individual parts.