Joining by forming—A review on joint mechanisms, applications and future trends

Abstract Public demand for an efficient and sustainable use of energy and resources has led to new design criteria for technical products. An even more consequent use of light-weight construction and so-called smart structures are two examples of this. Both approaches lead to hybrid components consisting of dissimilar materials. Joining processes based on plastic deformation of at least one joining partner promise great potential regarding the production of multi material joints. This paper first examines in detail the basic plastic joining principles for force- and form-closed joints as well as for solid state welds and presents a systematic classification. Subsequently, the joining processes based on these principles are discussed along with their specific potentials and limitations. Additionally, industrial applications of these processes are presented. Future trends in joining by forming based upon current research developments are finally highlighted. Despite these extensive research activities the outlook shows that gaps of knowledge still exist and hinder a broad industrial application so far.