Optimization of friction stir blind riveting process parameters for non-ferrous sheet metal alloys

Friction Stir Blind Riveting (FSBR) is a modern successful solid-state joining method used to join different combinations of dissimilar and similar alloy sheets. The most critical elements that influence the Ultimate Tensile Strength (UTS) of joints produced by the friction stir blind riveting technique were determined using the Design of Experiments (DOE). In this proposed research study, the effect of process parameters such as rivet material, rivet diameter, sheet material 1 (top sheet), sheet material 2 (bottom sheet), and spindle speed was determined using the Taguchi experimental design approach with the L36 orthogonal array. The percentage contribution of each element to the tensile strength of FSBR riveted joints was determined using an ANOVA analysis. The tensile strength of riveted joints increased with an increase in rotational speed from 1150 rpm to 1750 rpm but a further increase in the rotational speed from 1750 rpm to 2750 rpm decreased the tensile strength of the joints. In addition, this study revealed that the most important process parameter on the joint strength is the rivet material followed by rivet diameter, sheet material 2, spindle speed, and sheet material 1.