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In this study, electromagnetic riveting (EMR) was proposed to connect CFRP/Al structures due to its little damage on composite. The joining process and failure behaviors of CFRP/Al joints were studied. Specifically, the finite element model was established to analyze the joining process. The riveted joints were tested under various loading velocities to obtain the failure behaviors. The simulation results showed that hole wall of the CFRP and Al sheets had uniform residual stresses, and no damage of the CFRP sheet was observed around the hole after EMR, indicating that the joint had superior performance. The tensile test results showed that the loading speed had a great influence on the performance of the joint. The maximum shear force at lower loading speeds was less than that at higher loading speeds, while the trend of energy absorption was opposite. The main failure position was in CFRP with a mix mode of bearing and shear out. Based on the failure analysis, a simplified analytical model for the maximum shear load was presented.

Numerical and experiment investigation on joining process and failure behaviors of CFRP/Al electromagnetic riveted joint