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<p>Expanding the use of lightweight materials such as aluminum alloys, magnesium alloys, and composites in automotive lightweighting has become an urgent necessity for manufacturers aiming to enhance product competitiveness. Self-piercing riveting (SPR) is a widely utilized joining technique for joining dissimilar materials and has been extensively applied in steel–aluminum automotive body structures. The author accurately predicts the performance of aluminum–magnesium SPR joints through precise modeling and simulation. A detailed analysis of crack formation in magnesium–aluminum SPR joints was conducted by integrating numerical simulation with experimental investigation. Cracks are prone to initiate at the rivet leg. Magnesium alloy tends to accumulate high strain in regions, where deformation rate varies and flow direction changes, promoting further crack propagation in these areas. A novel data expansion approach was employed to predict the geometric parameters of SPR joints. Compared with conventional prediction methods, the augmented data set significantly improved the model’s fitting accuracy. Moreover, this method offers substantial time savings compared to numerical simulation, thereby enhancing the efficiency of SPR joint performance prediction.</p>

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Forming mechanism and strength evaluation on self-piercing riveting of aluminum alloy and die-casting magnesium

  • 期刊论文

  • 发表日期：

    2025年8月21日

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  • Bo Liu,
  • Ke Zhang,
  • Hai Zhou,
  • Ronghao Zhu,
  • Jiangfeng Song,
  • Wei Ren,
  • Yang Yang,
  • Youliang Zeng

摘要

Expanding the use of lightweight materials such as aluminum alloys, magnesium alloys, and composites in automotive lightweighting has become an urgent necessity for manufacturers aiming to enhance product competitiveness. Self-piercing riveting (SPR) is a widely utilized joining technique for joining dissimilar materials and has been extensively applied in steel–aluminum automotive body structures. The author accurately predicts the performance of aluminum–magnesium SPR joints through precise modeling and simulation. A detailed analysis of crack formation in magnesium–aluminum SPR joints was conducted by integrating numerical simulation with experimental investigation. Cracks are prone to initiate at the rivet leg. Magnesium alloy tends to accumulate high strain in regions, where deformation rate varies and flow direction changes, promoting further crack propagation in these areas. A novel data expansion approach was employed to predict the geometric parameters of SPR joints. Compared with conventional prediction methods, the augmented data set significantly improved the model’s fitting accuracy. Moreover, this method offers substantial time savings compared to numerical simulation, thereby enhancing the efficiency of SPR joint performance prediction.