<p>To investigate the corrosion behavior and failure mechanisms of steel/aluminum adhesively bonded self-piercing riveted (SPR) joints in a synergistic Cl- and HSO3- environment, this study fabricated SPR joints without adhesive (DA) and with an epoxy adhesive (3&#xa0;M-DA) using DP590 steel and AA5052 aluminum alloy as substrates. Cyclic immersion corrosion tests were conducted in a solution of 0.6&#xa0;mol/L NaCl + 0.02&#xa0;mol/L NaHSO3. The results from macroscopic observation, scanning electron microscopy, static tensile tests, and load–displacement curve analysis revealed that the adhesive layer effectively blocked the penetration of the corrosive medium, significantly retarding the corrosion process of the joints. Post-corrosion, the 3&#xa0;M-DA group primarily exhibited rivet self-locking failure, whereas the DA group progressively developed severe failure modes such as sheet tearing. The presence of the adhesive layer resulted in a smaller reduction in joint strength and more stable changes in the load–displacement curves, indicating that the adhesive enhances the durability and mechanical stability of the joints in corrosive environments.</p>

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Study on the Corrosion Failure of Steel/Aluminum Adhesively Bonded Self-Piercing Riveted Joints in a Synergistic Cl- and HSO3- Environment

  • Jihang Liu,
  • Baoying Xing,
  • Lifei Xu,
  • Kai Zeng,
  • Guiqiu Yang

摘要

To investigate the corrosion behavior and failure mechanisms of steel/aluminum adhesively bonded self-piercing riveted (SPR) joints in a synergistic Cl- and HSO3- environment, this study fabricated SPR joints without adhesive (DA) and with an epoxy adhesive (3 M-DA) using DP590 steel and AA5052 aluminum alloy as substrates. Cyclic immersion corrosion tests were conducted in a solution of 0.6 mol/L NaCl + 0.02 mol/L NaHSO3. The results from macroscopic observation, scanning electron microscopy, static tensile tests, and load–displacement curve analysis revealed that the adhesive layer effectively blocked the penetration of the corrosive medium, significantly retarding the corrosion process of the joints. Post-corrosion, the 3 M-DA group primarily exhibited rivet self-locking failure, whereas the DA group progressively developed severe failure modes such as sheet tearing. The presence of the adhesive layer resulted in a smaller reduction in joint strength and more stable changes in the load–displacement curves, indicating that the adhesive enhances the durability and mechanical stability of the joints in corrosive environments.