Influence of HPDC Aluminum Microstructure on Forming and Mechanical Properties of Self-piercing Riveting

doi:10.3901/JME.260566

Abstract

Abstract: Radial cracks can be formed at rivet joint during Self-Piercing Riveting(SPR) when HPDC aluminum chosen as bottom layer. Regard to the low elongation of HPDC aluminum caused cracks, the effect of microstructure of cast alloy need to take consideration during SPR rivet forming process. Three types of HPDC Al-Si alloy with different cast parameters are prepared and riveted with same riveting parameters. The riveting appearance, section geometry and static mechanical properties were compared. By the change of microstructure before and after riveting, the relationship between microstructure, mechanical properties and riveting properties are investigated. Radial cracks of riveting occur on the surface of HPDC alloy, and the eutectic Si segregation in the surface layer will increase the risk of crack during HPDC riveting. The mechanical properties of HPDC Al-Si alloy are controled by microstructure, which effected by chemical composition and casting parameters during fabrication. The section size of rivet joint is affected by mechanical properties of alloy during rivet forming. During rivet piercing, alloy with low mechanical properties provide less resistance to rivet. Therefore, rivet can form higher interlock value and effevtive thickness with low mechanical property alloy chosen as bottom layer during riveting. The static shear property of rivet joint is affected by mechanical properties of alloy and section geometry, low mechanical property material with high rivet section geometry can reach to same static shear strength as material with high mechanical properties. This study investigates the causes of riveting cracks at the microstructural level of alloys, and proposes novel approaches to enhance riveting formability and performance through optimized alloy composition design and casting process modifications.

Key words: HPDC aluminum, self-piercing riveting, cracks, microstructure, mechanical propertie

CLC Number:

TG938
TG146

WANG Shuai, SONG Jia, ZHU Wei, LI Jun, QIN Jian, ZHANG Hai. Influence of HPDC Aluminum Microstructure on Forming and Mechanical Properties of Self-piercing Riveting[J]. Journal of Mechanical Engineering, 2026, 62(12): 273-284.

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URL: http://www.cjmenet.com.cn/EN/10.3901/JME.260566

http://www.cjmenet.com.cn/EN/Y2026/V62/I12/273

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