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The increased use of polymer-based material in the manufacturing of vehicles structures makes critical the management of multi-material interfaces, and hence the issue of polymer-metal joining. It has been demonstrated in the literature that for large-scale manufacturing, self-piercing riveting (SPR) represents a reliable alternative technique to conventional resistance spot welding (RSW). However, the riveting operation induces, by nature, damages to the joint composite layer due to the steel rivet crossing it. In this study, the damage of the SMC thermoset material during SPR process has been experimentally investigated. Moreover, the influence of the riveting velocity as a major SPR process parameter on the composite layer damage has been identified. Eventually, the failure mechanisms of the polymer-metal joint resulting from failure under lap-shear and pure tension loadings were studied with the support of the numerical simulation tool.

Experimental Investigation of Damage and Failure Mechanisms of Polymer-Metal Joints assembled by Self-Piercing Riveting