Adaptation of a solid self-piercing rivet made of aluminum using numerical simulation to extend the application limits

Increasing resource efficiency, for example through the consistent application and further development of lightweight construction concepts, plays an important role in the development of the mobility sector. This requires a steadily increasing use of high-strength aluminum alloys in primary vehicle structures. A suitable and efficient process for joining high-strength aluminum alloys is solid self-piercing riveting (SSPR). A major advantage of this process is the elimination of time-consuming preparatory work such as pre-drilling, deburring and positioning of the components to be joined, as the rivet punches through these during the installation process. Due to the high stresses on the rivet during the installation process and the lack of knowledge on the use of ultra-high-strength aluminum alloys as the rivet material, solid self-piercing rivets (SSP-rivets) made of steel are generally used. However, against the background of recyclability, thermal expansion and corrosion protection, the use of aluminum SSP-rivets would be desirable.