The small-size laser shock clinch-bonded hybrid joining of Al foils

In this paper, an original process that making small-sized clinch-bonded hybrid joints by laser shock forming is put forward and developed, two metal foils, one adhesive layer and one perforated stainless steel sheet are joined together under continuous laser shocks. Finite element models are established to simulate the forming process and the shearing behavior of the hybrid joints. The effect of the adhesive on the manufacturing process is emphatically discussed. The shearing and peeling tests of the hybrid joints are compared with that of single clinched and pure bonded joints. The failure mode of the hybrid joint under loading is analyzed along with numerical simulation taking a shearing test for instance. The experimental results show that the cured adhesive with thin thickness is beneficial to the subsequent clinching process; the application of adhesive can greatly improve the mechanical strength of the single mechanical clinched joints; the failure process of the hybrid joints is that the adhesive fails first and then the interlock. The laser shock forming has enabled the precision manufacturing of small-sized clinch-bonded hybrid joints, which can play a significant role in electronic component processing and other special working conditions.