Optimization of laser-assisted clinching process for 5182 aluminum alloy

As a productive rivet-free joining process, clinching forms mechanical interlocks but often suffers from limited process windows and poor interlock quality in aluminum alloys, compromising joint performance. This study proposes a laser-assisted clinching approach for 5182 aluminum alloy and compares three processing conditions: conventional clinching(C), laser-etched pre-processing clinching (LC), and laser-fusion post-treatment clinching(CL). Finite element modelling is used as a process-analysis tool to interpret deformation and interlock evolution, and tensile-shear testing is conducted to quantify the process outcome. Laser-etched pre-processing markedly improves joint performance, with average failure load and energy absorption increased by 101% and 247% relative to conventional clinching, whereas laser-fusion post-treatment provides improvements of 15.6% and 47% only within an appropriate thermal-input window. The dominant failure mode is neck fracture. Results show that pre-clinching interface texturing effectively enhances 5182 aluminum interlocks, while post-fusion requires precise thermal management to avoid adverse effects.