About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Forming and Joining of Advanced Sheet Metal Materials
|
| Presentation Title |
Process Development of Dissimilar Steel–Aluminum Friction Self-Piercing Riveting via Regression Analysis |
| Author(s) |
Tianzhao Wang, Wei Zhang, Yong Chae Lim, Zhili Feng |
| On-Site Speaker (Planned) |
Tianzhao Wang |
| Abstract Scope |
The demand for improved energy efficiency in the automotive industry has driven the adoption of high-strength wrought and cast aluminum (Al) alloys in body-in-white (BIW) structures, requiring reliable dissimilar steel-Al alloy joints. However, the low ductility of high-strength 7xxx Al sheet and cast Al at room temperature presents challenges for conventional mechanical and fusion joining techniques. To address this, we proposed a friction self-piercing riveting (F-SPR) process, wherein a rotating rivet is driven into the stacked materials to form mechanical interlocks and solid-state joining. Frictional heat locally softens the material and mitigates cracking. We investigated the effect of rivet hardness and process parameters on joint formation and mechanical performance in joints with mild or dual phase steel on top to high strength or casting Al on bottom. Regression analysis was used to correlate process variables with joint characteristics, providing a framework for optimizing F-SPR process parameters to enhance joint strength. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Joining, Aluminum, Iron and Steel |