Scholarlink

<p>Joining aluminum alloys and high-strength steels remains a significant challenge in lightweight multi-material structures owing to their distinguished properties. In this study, a hybrid laser spot welding and self-piercing riveting (LSW-SPR) process was proposed to join AA6061 aluminum alloy and DP590 steel by combining metallurgical bonding with mechanical interlocking. The effects of laser power on joint formation, microstructural evolution, mechanical performance, and failure behavior were systematically investigated at 700W, 800W, and 900W. The results demonstrated the feasibility of the proposed hybrid joining approach and proved a strong dependence of joint quality on laser power. An optimal laser power of 800W provided the most favorable balance between fusion quality and joint integrity. In contrast, insufficient heat input at 700W limited metallurgical bonding, whereas excessive heat input at 900W promoted segregation, interfacial defects, and thermal degradation, leading to reduced joint performance. Microstructural characterization showed the formation of Fe–Al intermetallic compounds at the steel–aluminum interface, and a mixed ductile–brittle failure mechanism was detected. These findings demonstrate that the proposed LSW-SPR process is a promising joining solution for lightweight aluminum–steel structures and provides a foundation for the development of high-performance multi-material assemblies.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Mechanical performance and failure analysis of AA6061/DP590 dissimilar hybrid laser-riveted joints

  • 期刊论文

  • 发表日期：

    2026年7月1日

查看全文
  • Zhen Zhang,
  • Amr Monier,
  • Lun Zhao,
  • Fan Xu,
  • Lan Zhang,
  • Haohan Zhang,
  • Xuanlin Ye,
  • Jianxiong Zhu,
  • Zeshan Abbas,
  • Mahmoud Khedr

摘要

Joining aluminum alloys and high-strength steels remains a significant challenge in lightweight multi-material structures owing to their distinguished properties. In this study, a hybrid laser spot welding and self-piercing riveting (LSW-SPR) process was proposed to join AA6061 aluminum alloy and DP590 steel by combining metallurgical bonding with mechanical interlocking. The effects of laser power on joint formation, microstructural evolution, mechanical performance, and failure behavior were systematically investigated at 700W, 800W, and 900W. The results demonstrated the feasibility of the proposed hybrid joining approach and proved a strong dependence of joint quality on laser power. An optimal laser power of 800W provided the most favorable balance between fusion quality and joint integrity. In contrast, insufficient heat input at 700W limited metallurgical bonding, whereas excessive heat input at 900W promoted segregation, interfacial defects, and thermal degradation, leading to reduced joint performance. Microstructural characterization showed the formation of Fe–Al intermetallic compounds at the steel–aluminum interface, and a mixed ductile–brittle failure mechanism was detected. These findings demonstrate that the proposed LSW-SPR process is a promising joining solution for lightweight aluminum–steel structures and provides a foundation for the development of high-performance multi-material assemblies.