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<p>In the automotive industry, reducing vehicle weight while maintaining high strength and corrosion resistance has become a critical challenge. Steel-aluminum hybrid structures are increasingly used in automotive bodies due to their combination of light weight, high strength, and good corrosion resistance. To achieve lightweight joining between high-strength steel and aluminum alloy, this study proposed an ultrasonic vibration-assisted punch-shear clinching process and systematically investigated the effects of different vibration amplitudes on the forming quality, mechanical properties, failure modes and micro-hardness of the joints. The results indicated that as the vibration amplitude increased from 0 to 7.11 μm, the forming forces during the shear and forming phases decreased by 6.42% and 15.61%, respectively. The bottom thickness, interlock value, and neck thickness increased by 8.79%, 5.41%, and 4.49%, respectively, while the tensile and shear loads increased by 6.60% and 21.22%, and the energy absorption of the joints increased by more than 22%. All joints exhibited ductile fracture characteristics, with the average diameter and area of dimples in the failure regions significantly reduced. In addition, the residual effects of ultrasonic vibration decreased the hardness of the upper sheet and increased that of the lower sheet without compromising joint reliability. This technique provides an effective solution for reliable joining of high-strength steel and aluminum alloy, offering significant engineering potential for lightweight automotive manufacturing.</p>

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Mechanical properties and failure modes analysis of UVPC joints under different ultrasonic amplitudes

  • 期刊论文

  • 发表日期：

    2026年6月16日

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  • Miaoyuan Mei,
  • Xingang Zhang,
  • Qinghui He,
  • Ji Ma,
  • Chao Chen

摘要

In the automotive industry, reducing vehicle weight while maintaining high strength and corrosion resistance has become a critical challenge. Steel-aluminum hybrid structures are increasingly used in automotive bodies due to their combination of light weight, high strength, and good corrosion resistance. To achieve lightweight joining between high-strength steel and aluminum alloy, this study proposed an ultrasonic vibration-assisted punch-shear clinching process and systematically investigated the effects of different vibration amplitudes on the forming quality, mechanical properties, failure modes and micro-hardness of the joints. The results indicated that as the vibration amplitude increased from 0 to 7.11 μm, the forming forces during the shear and forming phases decreased by 6.42% and 15.61%, respectively. The bottom thickness, interlock value, and neck thickness increased by 8.79%, 5.41%, and 4.49%, respectively, while the tensile and shear loads increased by 6.60% and 21.22%, and the energy absorption of the joints increased by more than 22%. All joints exhibited ductile fracture characteristics, with the average diameter and area of dimples in the failure regions significantly reduced. In addition, the residual effects of ultrasonic vibration decreased the hardness of the upper sheet and increased that of the lower sheet without compromising joint reliability. This technique provides an effective solution for reliable joining of high-strength steel and aluminum alloy, offering significant engineering potential for lightweight automotive manufacturing.