Clinching is a manufacturing method of mechanical joining two or more materials without the use of heat or additional components. This process relies on high plastic deformation to create a secure bond. Clinching technology is widely used for joining various grades and thickness of materials. Especially in the automotive industry, clinching is an alternative to spot resistance welding. However, the load-bearing capacity of clinched joints is comparatively lower when compared to resistance spot welded joints. This research aimed to enhance the load-carrying capacity of clinched joints. Experimental tests were conducted on clinched joints with locally modified microstructures to optimize their placement within the joint. The microstructure distribution in the clinched joint region was analysed using light and scanning electron microscopy, as well as microhardness measurements. Two material grades, micro-alloyed steels HX420LAD+Z and dual-phase ferritic-martensitic steels HCT600X+Z, were tested. Each grade underwent five groups of ten samples, subject to identical experimental conditions of local heating by resistance spot welding (RSW) and clinching. The application of RSW to the clinched joint area resulted in increase of load-bearing capacity for both joined types of materials.

The multi-material design and the adaptability of a modern process chain require joining connections with specifically adjustable mechanical, thermal, chemical or electrical properties, whereby previous considerations have focused primarily on the mechanical properties. With clinching, the multitude of possible combinations of requirements, materials and component or joint geometry makes it impossible to determine these joint properties empirically. As a result of the established and empirically based procedure, no model exists to date that considers all questions of joinability, i.e. the materials (suitability for joining), the design (joining safety) and the production (joining possibility) and allows a calculation of the achievable properties. It is therefore necessary to describe the physical properties of the joint as a function of the three bonding mechanisms force closure, form closure and material closure in relation to the application. This approach enables the illustration of the relationships along the causal chain "joint requirement - binding mechanism - joining parameters". In this way the adaptability of the mechanical joining technology can be improved. A geometric comparison is made using metallographic cross sections, of clinched joints of the combination of aluminum and steel. The torsional testing of the rotationally symmetric clinching points for detection of the mechanical stress state are qualified as examination method and technological test. By measuring the electrical resistance in the base material, in the clinch joint and during the production cycle (after clinching, before precipitation hardening and after precipitation hardening), this change in the stress state can also be detected.