Multiscale modelling of joining processes under consideration of the thermo-mechano-chemical behaviour in the interface

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Joining processes, such as the here considered processes of roll bonding and clinching, are characterized by a complex interplay of plastic deformation, thermomechanical cou-pling effects, adhesive and diffusive processes as well as interactions between the mi-crostructures involved in the process. The design of new or improved joining technologies requires a fundamental understanding of the mechanisms which is barely achievable by working solely experimentally. The present project deals therefore with a sound multiscale modelling of the essential effects characterizing joining. In particular, state-ments about the corrosion behaviour, the fatigue behaviour, and the bonding strength and properties of the joint are to be worked out. We distinguish between the modelling at the microscale, which allows the process-independent investigation of the physical and chemical processes taking place during joining, and the macromechanical modelling, which takes the structural characteristics of concrete processes into account. The focus is on the as accurate as possible but scale adequate resolution of the thermomechanical behaviour in the interface, which is to be achieved by a significant extension of the co-hesive zone technique. The macromechanical modelling is to be developed by means of a database that is generated on the basis of detailed parameter studies at the microscale and is complemented by experimental results obtained both within the current project as well as by partner projects. The influence of the micro- and macromechanical process parameters on the joining result is to be precisely captured at each modelling scale. A middle-term objective of the research project is to render the new simulation tool so powerful that it could enable the prediction of results of diverse joining processes, and allow the choice of a suitable joining process in terms of reliability and reproducibility without the need of additional experimental investigations.