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<p>The incorporation of structural adhesive in self-piercing riveted bonded (SPR-bonded) joints yields conflicting results between enhanced strength performance and practical loading conditions in real-world applications. During the joining process, the large material deformation causes non-uniform adhesive distribution within the joint, significantly influencing the cross-sectional geometry and consequently affecting both the strength performance and failure behavior of the joint. In this study, the adhesive flow behavior during the riveting process was investigated via numerical simulation. Six simulation models with different bonding areas (called hybrid 1x–5x and hybrid-full) of the riveting process were established and experimentally verified. In addition, the strength performance and failure behavior of the SPR joints under lap shear and pull-out conditions were comparatively analyzed. Both simulation and experimental results showed that the interlocking values of the SPR joint were greater than those of SPR-bonded hybrid joints, as the presence of adhesive impeded the insertion of the rivet mechanical interlock formation. The experimental results demonstrated a strong positive correlation between bonding area and joint strength under lap-shear loading, with the hybrid-full joint exhibiting a 117.7% increase in peak force compared to the hybrid-1x joint. However, under pull-out loading conditions, the peak force of the hybrid-full joint was 13.5% and 19.3% lower than those of the hybrid-1x and SPR joint, respectively. These findings indicate that while increasing the bonding area significantly enhances the lap-shear strength of SPR-bonded joints, it adversely affects their pull-out performance. This study provides crucial guidelines for engineers to consider loading conditions when designing SPR-bonded joints.</p>

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Influence of bonding area on the formability and strength of self-piercing riveted bonded joints under different loading conditions

  • 期刊论文

  • 发表日期：

    2025年6月30日

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  • Jianpeng Liu,
  • Pingpo Fu,
  • Congchang Xu,
  • Zhigang Xue,
  • Liang Xu,
  • Luoxing Li

摘要

The incorporation of structural adhesive in self-piercing riveted bonded (SPR-bonded) joints yields conflicting results between enhanced strength performance and practical loading conditions in real-world applications. During the joining process, the large material deformation causes non-uniform adhesive distribution within the joint, significantly influencing the cross-sectional geometry and consequently affecting both the strength performance and failure behavior of the joint. In this study, the adhesive flow behavior during the riveting process was investigated via numerical simulation. Six simulation models with different bonding areas (called hybrid 1x–5x and hybrid-full) of the riveting process were established and experimentally verified. In addition, the strength performance and failure behavior of the SPR joints under lap shear and pull-out conditions were comparatively analyzed. Both simulation and experimental results showed that the interlocking values of the SPR joint were greater than those of SPR-bonded hybrid joints, as the presence of adhesive impeded the insertion of the rivet mechanical interlock formation. The experimental results demonstrated a strong positive correlation between bonding area and joint strength under lap-shear loading, with the hybrid-full joint exhibiting a 117.7% increase in peak force compared to the hybrid-1x joint. However, under pull-out loading conditions, the peak force of the hybrid-full joint was 13.5% and 19.3% lower than those of the hybrid-1x and SPR joint, respectively. These findings indicate that while increasing the bonding area significantly enhances the lap-shear strength of SPR-bonded joints, it adversely affects their pull-out performance. This study provides crucial guidelines for engineers to consider loading conditions when designing SPR-bonded joints.