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<p>Steel–aluminum hybrid materials are employed to achieve both vehicle lightweight and crash safety objectives. The integrity of self-piercing riveting (SPR) joints in such structures is critical to their crashworthiness. This study presents a numerical investigation into the failure behavior of steel–aluminum SPR joints under dynamic loading. The Johnson–Cook (J–C) material model parameters for high-strength steel B280VK and aluminum alloy 6063-T6 are first determined through uniaxial and notch tensile tests at various strain rates. These parameters are then applied in simulations of tensile tests to validate the model. Finally, the dynamic mechanical response and failure mechanism of steel–aluminum SPR joints are analyzed using the calibrated J–C model. Good agreement between experimental and numerical results confirms the model’s accuracy in predicting the dynamic failure of SPR joints. This work provides a reliable numerical framework for assessing the failure behavior of hybrid SPR joints and offers insight into their failure mechanisms under high-speed loading conditions.</p>

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Numerical Investigation on Dynamic Failure Behaviors of Steel–Aluminum Hybrid SPR Joint with Johnson–Cook Model

  • 期刊论文

  • 发表日期：

    2026年3月19日

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  • Zhanpeng Du,
  • Tao Guo,
  • Ziye Tang,
  • Yulong Su

摘要

Steel–aluminum hybrid materials are employed to achieve both vehicle lightweight and crash safety objectives. The integrity of self-piercing riveting (SPR) joints in such structures is critical to their crashworthiness. This study presents a numerical investigation into the failure behavior of steel–aluminum SPR joints under dynamic loading. The Johnson–Cook (J–C) material model parameters for high-strength steel B280VK and aluminum alloy 6063-T6 are first determined through uniaxial and notch tensile tests at various strain rates. These parameters are then applied in simulations of tensile tests to validate the model. Finally, the dynamic mechanical response and failure mechanism of steel–aluminum SPR joints are analyzed using the calibrated J–C model. Good agreement between experimental and numerical results confirms the model’s accuracy in predicting the dynamic failure of SPR joints. This work provides a reliable numerical framework for assessing the failure behavior of hybrid SPR joints and offers insight into their failure mechanisms under high-speed loading conditions.