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<p>Automobile manufacturers are increasingly focusing on lightweight structures to improve fuel efficiency, with carbon fiber reinforced plastic (CFRP) and aluminum alloys widely applied. However, joining these dissimilar materials remains challenging due to differences in their physical and mechanical properties, and conventional fusion welding processes often result in defects such as cracks and porosity. To overcome these limitations, self-piercing riveting (SPR) has been widely adopted. However, its limitations have become more apparent with increasing demands for joint performance. Electromagnetic self-piercing riveting (E-SPR), which enables high-velocity piercing through electromagnetic force, has attracted attention for joining CFRP/Al dissimilar materials. During E-SPR, a rapid punch drives the rivet into the upper sheet, forming a mechanical interlock through plastic deformation. Despite these advantages, the effect of charge energy on interlock and failure behavior has not been clearly established. This study evaluates suitable rivet-die geometries and investigates the effects of charge energy on interlock and failure behavior in CFRP/Al E-SPR joints. Using a C-type rivet and FM-type die, cross-sectional dimensions—including head height, interlock distance, and bottom thickness—varied systematically with charge energy, with interlock distance increasing from 0.18 to 0.65&#xa0;mm. A transition in failure mode from rivet pull-out to bearing failure was observed when the interlock distance exceeded approximately 0.42&#xa0;mm. While increasing charge energy enhanced the interlock distance, excessive energy levels (≥ 5.5&#xa0;kJ) induced significant CFRP damage, resulting in a decrease in joint strength from 3.07 kN at 4.5&#xa0;kJ to 2.80 kN at 6.5&#xa0;kJ despite further increase in interlock distance. These results indicate that failure mode is governed by interlock distance, while joint strength is limited by CFRP damage at higher charge energy levels.</p>

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Charge energy-dependent interlock and failure behavior of CFRP/Al E-SPR joints

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月10日

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  • Minseok Kim,
  • Minwoo Park,
  • Junghyun Lee,
  • Changon Park,
  • Byungju Jin,
  • Jiyeon Shim

摘要

Automobile manufacturers are increasingly focusing on lightweight structures to improve fuel efficiency, with carbon fiber reinforced plastic (CFRP) and aluminum alloys widely applied. However, joining these dissimilar materials remains challenging due to differences in their physical and mechanical properties, and conventional fusion welding processes often result in defects such as cracks and porosity. To overcome these limitations, self-piercing riveting (SPR) has been widely adopted. However, its limitations have become more apparent with increasing demands for joint performance. Electromagnetic self-piercing riveting (E-SPR), which enables high-velocity piercing through electromagnetic force, has attracted attention for joining CFRP/Al dissimilar materials. During E-SPR, a rapid punch drives the rivet into the upper sheet, forming a mechanical interlock through plastic deformation. Despite these advantages, the effect of charge energy on interlock and failure behavior has not been clearly established. This study evaluates suitable rivet-die geometries and investigates the effects of charge energy on interlock and failure behavior in CFRP/Al E-SPR joints. Using a C-type rivet and FM-type die, cross-sectional dimensions—including head height, interlock distance, and bottom thickness—varied systematically with charge energy, with interlock distance increasing from 0.18 to 0.65 mm. A transition in failure mode from rivet pull-out to bearing failure was observed when the interlock distance exceeded approximately 0.42 mm. While increasing charge energy enhanced the interlock distance, excessive energy levels (≥ 5.5 kJ) induced significant CFRP damage, resulting in a decrease in joint strength from 3.07 kN at 4.5 kJ to 2.80 kN at 6.5 kJ despite further increase in interlock distance. These results indicate that failure mode is governed by interlock distance, while joint strength is limited by CFRP damage at higher charge energy levels.