Lightweight materials, manufacturing technology and the car body structure optimization are the three main approaches to achieve the lightweight constructions. The lightweight materials, such as aluminum or magnesium alloys, are widely utilized in the automotive industry for the weight reduction. Mechanical clinching is used to connect the lightweight materials. In this study, the sheets were joined by the extensible die clinching and flat-clinching. The tensile strength and shear strength of the aluminum alloy 5052 were investigated by the two different tools. Compared with the extensible die clinching, both the tensile strength and shear strength of the clinched joint produced with flat-clinching is higher. And the tensile strength of the clinched joint is up to 54% higher than that of the extensible die clinching.

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