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- A self-clinching fastener for hidden lap jointsPublication . Sampaio, Rui F. V.; Pragana, João; Bragança, Ivo M. F; Silva, Carlos M. A.; Martins, P. A. F.This paper presents a new self-clinching fastener to connect two sheets (or plates), made from similar or dissimilar materials, placed over one another by means of a mechanical form-closed joint that is hidden inside the sheets. The development of the fastener, the definition of its main design variables and the identification of its workability limits are carried out by means of a combined experimental and numerical simulation work based on finite elements. It is shown that self-clinching by pressing the two overlapped sheets against each other to displace material around the annular groove of the fastener shank and create undercuts in both sheets requires an appropriate choice of the design variables. Wrong values of the design variables resulting in lack or excess of material displaced by plastic flow gives rise to inappropriate lap joints that cannot be used in production. The new proposed fastener allows, for the first time ever, joining by forming with the use of auxiliary elements that are harder than the sheet materials to fabricate invisible joints with no material protrusions in applications requiring minimum installation space
- Hybrid metal additive manufacturing: A state–of–the-art reviewPublication . Pragana, J. P. M.; Sampaio, Rui F. V.; Bragança, Ivo; Silva, C. M. A.; Martins, P. A. F.This paper starts from the early developments and working principles of the additive manufacturing of polymers, continues with a glimpse on the extension to metals with identification and characterization of the two most widespread technologies, and ends with an overview of the recent developments in hybrid metal additive manufacturing. Earlier classifications of hybrid manufacturing with roots on the utilization of primarily processed raw materials in the form of ingots, sheets, rods, tubes, profiles, powders and pellets are revisited in the light of the emergence of a new type of hybridization resulting from the combination of additive manufacturing with traditional manufacturing processes. Special emphasis is given to the combination of additive manufacturing with forming processes with the two-fold objective of (i) increasing the applicability domain of metal additive manufacturing and overcoming its limitations related to low productivity, metallurgical defects, rough surface quality and lack of dimensional precision, and (ii) adding flexibility and fostering new applications of traditional forming processes.
- Injection lap riveting of aluminum busbars — a thermo-electro-mechanical investigationPublication . Pragana, J.P.M; Sampaio, Rui F. V.; Bragança, Ivo; Martins, P. A. F.This paper presents a new mechanical joining process to assemble aluminum busbars in energy distribution systems. The process is based on the extension of injection lap riveting to the connection of busbars made from the same material as the rivets and requires redesigning the joints to ensure complete filling with good mechanical interlocking and appropriate contact pressures on the overlapping area. The experimental work was carried out in unit cells and involved the fabrication of the riveted joints and the evaluation of their electrical resistance at different service temperatures. Comparisons with the bolted joints that were fabricated and tested for reference purposes show that injection riveted joints provide lower values of electrical resistance and require much less space for assembly due to the absence of material protrusions above and below their surfaces. Numerical simulation with finite elements allows the relating of the reduction in electrical resistance with the changes in the electric current flow when the bolts are replaced by the new type of rivets. The experimental and numerical predictions revealed that the new type of rivets experience an increase in electrical resistance of up to 6 μΩ (30%) when the service temperature approaches 105 °C. Still, the resistance at this temperature (26.2 μΩ) is more than 3 times smaller than that of the bolted joints (80.5 μΩ).