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Self-piercing riveting of dissimilar carbon fiber-reinforced composites and aluminum alloy sheets: state-of-the-art achievements

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Abstract

Lightweight design of the vehicle is critical in reducing carbon emissions and energy consumption. In recent decades, high-performance carbon fiber–reinforced plastic (CFRP) composites, which are the most direct and effective choice for lightweight designs, are broadly applied in the vehicle industry to meet both strength and lightweight requirements. However, among many reasons for car body manufacturing, the higher price of composite is one of the limitations for its application, so the utilization of hybrid composite materials and metallic materials is widely adopted together in guaranteeing the economy of vehicle development and manufacturing. Aiming at the hybrid metal-composite multi-layer joint combination requirement, how to implement a valid connection has become a complex challenge. Currently, the more popular mechanical join approach is using self-piercing riveting (SPR) technology. This paper summarizes the state-of-the-art achievements in the aforementioned research field to connect hybrid composites and metallic materials especially by using SPR methods, which involve the process, the joinability, the mechanical behavior of joints, and the corresponding FE modeling methods. This paper also provides a detailed discussion of self-piercing riveting from a relatively comprehensive point of view to provide perspectives for subsequent in-depth research.

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Funding

This work was supported by the National Natural Science Foundation of China (No.52375310) and Chinese Fundamental Research Funds for the Central University (DUT21JC41).

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Authors and Affiliations

  1. School of Mechanical Engineering, Dalian University of Technology, Linggong Road 2#Liaoning Province, Dalian, 116024, People’s Republic of China

    Liang Ying & Minghua Dai

  2. School of Automotive Engineering, Dalian University of Technology, Dalian, 116024, People’s Republic of China

    Liang Ying, Quanyi Dong, Tianhan Gao & Ping Hu

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Liang Ying: methodology, conceptualization, writing—review and editing, supervision. Quanyi Dong: writing—original draft, investigation. Tianhan Gao: visualization, validation. Minghua Dai: formal analysis, funding acquisition. Ping Hu: project administration.

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Ying, L., Dong, Q., Gao, T. et al. Self-piercing riveting of dissimilar carbon fiber-reinforced composites and aluminum alloy sheets: state-of-the-art achievements. Int J Adv Manuf Technol 130, 1–22 (2024). https://doi.org/10.1007/s00170-023-12596-3

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