The joints of four aluminum alloy (7075, 5754, 6061, 1060) sheets were prepared using the clinching process with different die assemblies, and the forming and mechanical properties of the produced joints were evaluated using different testing procedures. The neck thickness, undercut values, bottom thickness, and joint dimensions of the joints were measured to investigate the joinability. The forming quality parameters, strength, failure displacement, failure mode, and energy absorption of the joints were investigated using the tensile shear test and peeling test. It was revealed that all four aluminum alloy sheets could form clinched joints with a suitable undercut, neck thickness and different die fits. A combination of SR5202 and SR703.12 dies resulted in an optimum joint quality for different sheets. Both neck thickness and the undercut amount played a major role in the determination of the strength of the joints. The best mechanical properties of the single-lap and cross joints were found for the sheets made from aluminum alloys 7075 and 6061. The aluminum alloy 5754 clinched joints exhibited slightly deteriorated mechanical properties but had the highest energy absorption capacity of the joints. However, the lower yield strength of aluminum alloy 1060 led to poor mechanical properties of these joints. All the single lap joints showed a tensile-shear failure mode of the upper sheet material, whereas the peel failure modes of the cross joints showed neck pull-off failure, neck fracture failure, and neck mixed failure.

使用不同模具组件的铆接工艺制备了四种铝合金（7075、5754、6061、1060）板的接头，并使用不同的测试程序评估了所生产接头的成形和机械性能。测量接头的颈部厚度、底切值、底部厚度和接头尺寸以研究可接合性。采用拉伸剪切试验和剥离试验研究了接头的成形质量参数、强度、破坏位移、破坏模式和能量吸收。结果表明，所有四种铝合金板都可以形成具有合适底切、颈部厚度和不同模具配合的铆接接头。SR5202 和 SR703.12 模具的组合为不同的板材带来了最佳的接合质量。颈部厚度和咬边量在确定关节强度方面起着重要作用。7075 和 6061 铝合金板材的单搭接和交叉接头的机械性能最好。5754 铝合金铆接接头的机械性能略有下降，但接头的能量吸收能力最高。然而，1060 铝合金较低的屈服强度导致这些接头的机械性能较差。所有的单搭接接头都表现出上片材料的拉伸-剪切破坏模式，而交叉接头的剥离破坏模式则表现出颈部拉脱破坏、颈部断裂破坏和颈部混合破坏。7075 和 6061 铝合金板材的单搭接和交叉接头的机械性能最好。5754 铝合金铆接接头的机械性能略有下降，但接头的能量吸收能力最高。然而，1060 铝合金较低的屈服强度导致这些接头的机械性能较差。所有的单搭接接头都表现出上片材料的拉伸-剪切破坏模式，而交叉接头的剥离破坏模式则表现出颈部拉脱破坏、颈部断裂破坏和颈部混合破坏。7075 和 6061 铝合金板材的单搭接和交叉接头的机械性能最好。5754 铝合金铆接接头的机械性能略有下降，但接头的能量吸收能力最高。然而，1060 铝合金较低的屈服强度导致这些接头的机械性能较差。所有的单搭接接头都表现出上片材料的拉伸-剪切破坏模式，而交叉接头的剥离破坏模式则表现出颈部拉脱破坏、颈部断裂破坏和颈部混合破坏。1060 铝合金较低的屈服强度导致这些接头的机械性能较差。所有的单搭接接头都表现出上片材料的拉伸-剪切破坏模式，而交叉接头的剥离破坏模式则表现出颈部拉脱破坏、颈部断裂破坏和颈部混合破坏。1060 铝合金较低的屈服强度导致这些接头的机械性能较差。所有的单搭接接头都表现出上片材料的拉伸-剪切破坏模式，而交叉接头的剥离破坏模式则表现出颈部拉脱破坏、颈部断裂破坏和颈部混合破坏。