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This paper studied the process development of dissimilar clinch joints in cross-tension specimens of aluminum alloy 5052-H32 (AA5052-H32)/thermoplastic carbon fiber reinforced plastic (TP-CFRP) sheets. The AA5052-H32 and TP-CFRP sheets with a thickness of 1.6 mm were used. The important processing parameters for AA5052/TP-CFRP clinch joints, such as the punching load, heating mode, heating temperature, and die depth, were considered. The failure loads, failure modes, and metallographic micrographs of AA5052/TP-CFRP clinch joints were analyzed to determine an available processing parameter set for fatigue tests. Finally, the fatigue performance and failure mode of AA5052/TP-CFRP clinch joints were obtained.

This research work presented the process development for dissimilar clinch joints in aluminum alloy 5052-H32 (AA5052-H32 or Al) and thermoplastic carbon fiber reinforced plastic (TP-CFRP or CFRP) sheets. For process analysis, AA5052-H32 and TP-CFRP sheets with a thickness of 1.6 mm were taken. The design of the punch and die were examined by tensile tests and metallographic micrographs. The influence of punching force on the process was studied as well. One appropriate process setup of the punch, die and punching force was determined. Finally, the feasibility of the Al/CFRP clinching process was confirmed.