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<p>This study investigates the effects of rivet length and die type on the quality and joint strength of self-piercing riveting (SPR) joints between Glass Fiber-Reinforced Polymer (GFRP) composite and AA50052-H32 sheets. SPR joints were produced using pip and flat die configurations with different rivet lengths, and their performance was evaluated through lap shear tests and cross sectional analysis. Key geometric measurements, including interlock distance, rivet flaring, and remaining bottom thickness, were recorded. The results show that increasing rivet length enhances the lap shear fracture load for both die types, up to 26.76% for the pip die and 19% for the flat die, along with increased interlock distance and rivet flaring. Flat die joints exhibit up to 20.8% higher lap shear strength, while pip die joints require greater maximum riveting force. The combined effect of longer rivets and lower rivet hardness further improves lap shear strength, although excessive bottom sheet thinning was observed in some cases. These findings help select the appropriate rivet and die combinations to produce strong SPR joints in GFRP composite Aluminum sheet assemblies.</p>

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Investigation on Self-piercing Riveting of Glass Fiber-Reinforced Polymer Composite and Aluminum Sheets

  • 期刊论文

  • 发表日期：

    2026年6月23日

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  • Shailesh Kumar,
  • R. Ganesh Narayanan,
  • Brajesh Asati

摘要

This study investigates the effects of rivet length and die type on the quality and joint strength of self-piercing riveting (SPR) joints between Glass Fiber-Reinforced Polymer (GFRP) composite and AA50052-H32 sheets. SPR joints were produced using pip and flat die configurations with different rivet lengths, and their performance was evaluated through lap shear tests and cross sectional analysis. Key geometric measurements, including interlock distance, rivet flaring, and remaining bottom thickness, were recorded. The results show that increasing rivet length enhances the lap shear fracture load for both die types, up to 26.76% for the pip die and 19% for the flat die, along with increased interlock distance and rivet flaring. Flat die joints exhibit up to 20.8% higher lap shear strength, while pip die joints require greater maximum riveting force. The combined effect of longer rivets and lower rivet hardness further improves lap shear strength, although excessive bottom sheet thinning was observed in some cases. These findings help select the appropriate rivet and die combinations to produce strong SPR joints in GFRP composite Aluminum sheet assemblies.