Friction riveting as an alternative mechanical fastening to join engineering plastics

Friction Rivecting is a quite new joining process to connect multi-material structures. In brief, a metallic rivet is dipped rotating inside matrixes, usually made of plastics, increasing its original diameter. The use of high-performance plastics is more suitable being their higher mechanical and thermal properties important to avoid material degradation and to allow strong part connections. High-speed friction welding system has been usually used to perform the process. In the work here proposed, the joints have been achieved by means of a traditional milling machine and the attention has been focused on a widely used engineering plastic, i.e. polyamide 6 (PA6) with and without glass fiber reinforcement. A specific speed multiplier has been attached into the mandrel of the used machine to increase the reachable rotational speed. Moreover, rivets made of Titanium Grade 2 and of an Aluminum Alloy, the AA-6060, are utilized. The influence that the heating and the forging length can have on the quality of the obtained junctions, considering a fixed joining depth, has been tested and investigated. The performed connections have been judged by tensile tests, which were set to quantify the maximum strength of the joints for a transverse speed of 1,0 mm/min. Barreling effect can be observed close to the tip, which loses the initial shape of a cylinder characterized by straight vertical walls. Finally, the possible degradation of the polymer, due to temperature increment, has been also evaluated close to the working zone. According to that, it has to be highlighted that the process needs a heating balance, which is necessary to get sound joints. The compromise has, on one side, to allow the rivet penetration and deformation, and on the other side, to avoid the degradation of the polymer, which would affect its properties and a proper rivet deformation.