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<p>Plain-woven basalt fiber-reinforced polymer (BFRP) has become a key material for automotive lightweighting due to its excellent specific strength and environmental friendliness. However, research on its joining technology with light metals remains insufficient, this paper investigates the self-piercing riveting process between BFRP and aluminum alloy. Through experimental and numerical simulation methods, the effects of sheet thickness on joint quality and damage evolution are systematically analyzed, and a process evaluation window for sheet thickness and die is established. Furthermore, the study explores the influence of BFRP thickness and geometric loading conditions on the shear mechanical properties and failure evolution of the joints, and a corresponding finite element model for joint shear tension is developed. The results indicate that increasing sheet thickness significantly weakens interlock strength, while the ED die achieves full thickness range coverage due to its self-adaptive characteristics. When the BFRP thickness increases from 1.6&#xa0;mm to 1.8&#xa0;mm, the load-bearing weak link of the joint shifts from the sheet itself to the mechanical interlock structure, and the failure mode transitions from ductile hole enlargement to brittle pull-out. Although 45° off-axis loading does not alter the peak load due to interlock strength limitations, it effectively extends the failure displacement and enhances energy absorption capacity by inducing local shear collapse of the matrix and fibers around the hole.</p>

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Effect of Ply Number and Tensile Angle on Mechanical Properties and Damage Behavior of BFRP/Al Self-Piercing Riveted Joints

  • 期刊论文

  • 发表日期：

    2026年7月2日

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  • Junjie Duan,
  • Menghan Wang,
  • Shun Liu,
  • Guojun Tang

摘要

Plain-woven basalt fiber-reinforced polymer (BFRP) has become a key material for automotive lightweighting due to its excellent specific strength and environmental friendliness. However, research on its joining technology with light metals remains insufficient, this paper investigates the self-piercing riveting process between BFRP and aluminum alloy. Through experimental and numerical simulation methods, the effects of sheet thickness on joint quality and damage evolution are systematically analyzed, and a process evaluation window for sheet thickness and die is established. Furthermore, the study explores the influence of BFRP thickness and geometric loading conditions on the shear mechanical properties and failure evolution of the joints, and a corresponding finite element model for joint shear tension is developed. The results indicate that increasing sheet thickness significantly weakens interlock strength, while the ED die achieves full thickness range coverage due to its self-adaptive characteristics. When the BFRP thickness increases from 1.6 mm to 1.8 mm, the load-bearing weak link of the joint shifts from the sheet itself to the mechanical interlock structure, and the failure mode transitions from ductile hole enlargement to brittle pull-out. Although 45° off-axis loading does not alter the peak load due to interlock strength limitations, it effectively extends the failure displacement and enhances energy absorption capacity by inducing local shear collapse of the matrix and fibers around the hole.