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<p>This study investigates the corrosion-induced fatigue performance degradation of two dissimilar aluminum-steel self-piercing riveted (SPR) joints, DP780-Al6061 and 1180MS-Al6061, under neutral salt spray exposure. The effects of accelerated corrosion on static strength, fatigue behavior, crack evolution, and failure mechanisms are systematically evaluated through tensile testing, fatigue testing, and scanning electron microscopy (SEM) fractography. Performance degradation trends are quantified as a function of corrosion duration and interpreted using reliability analysis, incorporating a simplified Markov chain-based degradation model to describe probabilistic transitions between fatigue performance states. In addition, a simplified life cycle assessment (LCA) perspective is adopted to discuss the implications of degradation-driven durability on environmental performance. The results show that the 1180MS-Al6061 joints exhibit higher initial shear capacity and superior early stage corrosion resistance compared to DP780-Al6061 joints. However, both joint configurations experience progressive performance deterioration under salt spray exposure, with reductions of 51.42% for 1180MS-Al6061 and 44.97% for DP780-Al6061 after 49&#xa0;days. Fatigue failure modes evolve from lower sheet fractures to rivet-dominated failures as corrosion progresses, driven by crack initiation at the rivet-sheet interface and subsequent propagation toward the sheet edges. The Markov-based reliability analysis captures distinct degradation pathways for the two joints and provides additional insight into their relative stability under corrosive environments. Overall, the findings emphasize the critical role of material selection in balancing fatigue performance, degradation resistance, and long-term sustainability of SPR joints for demanding service conditions.</p>

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Corrosion-Induced Fatigue Performance Degradation and Reliability Assessment of Self-Piercing Riveted Aluminum-Steel Joints

  • 期刊论文

  • 发表日期：

    2026年6月22日

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  • Intan Mardiono,
  • Imang Eko Saputro,
  • Po-Chin Hsu,
  • Yu-Chieh Wang,
  • Teng Shih Shih,
  • Yiin-Kuen Fuh

摘要

This study investigates the corrosion-induced fatigue performance degradation of two dissimilar aluminum-steel self-piercing riveted (SPR) joints, DP780-Al6061 and 1180MS-Al6061, under neutral salt spray exposure. The effects of accelerated corrosion on static strength, fatigue behavior, crack evolution, and failure mechanisms are systematically evaluated through tensile testing, fatigue testing, and scanning electron microscopy (SEM) fractography. Performance degradation trends are quantified as a function of corrosion duration and interpreted using reliability analysis, incorporating a simplified Markov chain-based degradation model to describe probabilistic transitions between fatigue performance states. In addition, a simplified life cycle assessment (LCA) perspective is adopted to discuss the implications of degradation-driven durability on environmental performance. The results show that the 1180MS-Al6061 joints exhibit higher initial shear capacity and superior early stage corrosion resistance compared to DP780-Al6061 joints. However, both joint configurations experience progressive performance deterioration under salt spray exposure, with reductions of 51.42% for 1180MS-Al6061 and 44.97% for DP780-Al6061 after 49 days. Fatigue failure modes evolve from lower sheet fractures to rivet-dominated failures as corrosion progresses, driven by crack initiation at the rivet-sheet interface and subsequent propagation toward the sheet edges. The Markov-based reliability analysis captures distinct degradation pathways for the two joints and provides additional insight into their relative stability under corrosive environments. Overall, the findings emphasize the critical role of material selection in balancing fatigue performance, degradation resistance, and long-term sustainability of SPR joints for demanding service conditions.