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<p>This paper presents a systematic experimental and mechanical analysis of self-piercing riveting (SPR) joints between hot-stamped steel BR1200HS and aluminum alloy AA6082-T6 thin sheets. The influence of key process parameters—including die type, rivet hardness, sheet stacking sequence, and rivet geometry—on joint formation quality (evaluated in terms of rivet foot expansion and macroscopic cracking) and quasi-static mechanical performance (characterized by peak load and energy absorption) was investigated. The results demonstrate that using a convex die with AA6082-T6 as the lower sheet is necessary to produce joints free of visible macro-cracks. Within the studied parameter range, joints fabricated with rivets of hardness grade H5 and a length of 6.5&#xa0;mm exhibited optimal forming quality, achieving a maximum rivet foot spread diameter of 9.4&#xa0;mm. These joints also showed the highest tensile peak load and energy absorption during failure. Failure analysis indicates that the dominant failure mode under quasi-static tensile loading is rivet pullout from the lower sheet, with the upper sheet remaining intact. Scanning electron microscopy (SEM) examination of the fracture surfaces revealed that the interlock region of the lower sheet exhibits typical ductile fracture features, including dimples and tearing ridges, indicative of shear-dominated ductile tearing as the primary microscopic failure mechanism.</p>

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Formability and Failure Mechanisms of Thin-Sheet Hot-Stamped Steel and Thin-Sheet Aluminum Alloy Joints

  • 期刊论文

  • 发表日期：

    2026年4月4日

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  • Ying-Lian Jia,
  • Shi-Song He,
  • Xiao-Yang Li

摘要

This paper presents a systematic experimental and mechanical analysis of self-piercing riveting (SPR) joints between hot-stamped steel BR1200HS and aluminum alloy AA6082-T6 thin sheets. The influence of key process parameters—including die type, rivet hardness, sheet stacking sequence, and rivet geometry—on joint formation quality (evaluated in terms of rivet foot expansion and macroscopic cracking) and quasi-static mechanical performance (characterized by peak load and energy absorption) was investigated. The results demonstrate that using a convex die with AA6082-T6 as the lower sheet is necessary to produce joints free of visible macro-cracks. Within the studied parameter range, joints fabricated with rivets of hardness grade H5 and a length of 6.5 mm exhibited optimal forming quality, achieving a maximum rivet foot spread diameter of 9.4 mm. These joints also showed the highest tensile peak load and energy absorption during failure. Failure analysis indicates that the dominant failure mode under quasi-static tensile loading is rivet pullout from the lower sheet, with the upper sheet remaining intact. Scanning electron microscopy (SEM) examination of the fracture surfaces revealed that the interlock region of the lower sheet exhibits typical ductile fracture features, including dimples and tearing ridges, indicative of shear-dominated ductile tearing as the primary microscopic failure mechanism.