Injection Lap Riveting of Aluminum Busbars—A Thermo-Electro-Mechanical Investigation
Abstract
:1. Introduction
2. Materials and Methods
2.1. Fabrication of the Joints
2.2. Thermo-Electrical Characterization of the Materials and Joints
2.3. Numerical Modelling
3. Results and Discussion
3.1. Injection Lap Riveting
3.2. Thermo-Electro Characterization of the Joints
3.3. Future Research Directions
4. Conclusions
- Injection lap riveted joints require much less space for assembly than alternative solutions based on conventional bolting or riveting due to the absence of material protrusions above and below the joint surfaces.
- Semi-tubular rivet heads must have counterbored geometries and appropriate shank lengths to ensure complete filling with good mechanical interlocking and appropriate contact pressures on the overlapping areas between the two busbar strip conductors.
- Injection lap riveted joints built upon semi-tubular counterbored head rivets provide electrical resistances more than 3 times smaller than those of bolted joints due to the replacement of the steel bolts by aluminum rivets, causing smaller electric current disturbances.
- The sensitivity of the electrical resistance to temperature variations is also smaller for the injection lap riveted joints, which experience an increase of just 6 μΩ when the temperature is raised from 20 °C to 105 °C.
- Future developments must account for the differences between the in situ and the factory assembly of busbar systems because in the case of the latter, the new solution based on joining by sheet-bulk compression can provide electrical resistances 35% smaller than those obtained by the newly proposed injection lap riveting process.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
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Strips | | ||||||||
AA1050-H111 aluminum | 100 × 50 × 5 (mm3) | ||||||||
Surface preparation | As supplied | ||||||||
Injection lap riveted joints | | ||||||||
Counterbored rivet | Countersunk rivet | Dovetail hole | |||||||
Process parameters | (mm) | (mm) | (mm) | (mm) | (mm) | (mm) | (°) | (mm) | (mm) |
2.1 ± 0.1 | 6.6 ± 0.1 | 11.3, 11.8 | 2 | 3 | 4.3–7.9 | 15, 30 | 3, 4 | 2.3 ± 0.1 | |
Bolted joints | | ||||||||
Process parameters | Material | Size | Tightening torque (Nm) | ||||||
Medium carbon steel (class 8.8) | M8 | 20 |
AA1050-H111 | AA1050-O | Steel (Class 8.8) | |
---|---|---|---|
Elastic modulus (GPa) | 69 | 69 | 205 |
Poisson ratio | 0.33 | 0.33 | 0.29 |
Yield strength (MPa) | 34 | 28 | 640 |
Ultimate tensile strength (MPa) | 83 | 76 | 800 |
Stress-strain curve (MPa) | - |
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Pragana, J.P.M.; Sampaio, R.F.V.; Bragança, I.M.F.; Silva, C.M.A.; Martins, P.A.F. Injection Lap Riveting of Aluminum Busbars—A Thermo-Electro-Mechanical Investigation. J. Manuf. Mater. Process. 2022, 6, 74. https://doi.org/10.3390/jmmp6040074
Pragana JPM, Sampaio RFV, Bragança IMF, Silva CMA, Martins PAF. Injection Lap Riveting of Aluminum Busbars—A Thermo-Electro-Mechanical Investigation. Journal of Manufacturing and Materials Processing. 2022; 6(4):74. https://doi.org/10.3390/jmmp6040074
Chicago/Turabian StylePragana, João P. M., Rui F. V. Sampaio, Ivo M. F. Bragança, Carlos M. A. Silva, and Paulo A. F. Martins. 2022. "Injection Lap Riveting of Aluminum Busbars—A Thermo-Electro-Mechanical Investigation" Journal of Manufacturing and Materials Processing 6, no. 4: 74. https://doi.org/10.3390/jmmp6040074