Electromagnetic dynamic self-piercing riveting(ED-SPR):A novel approach for enhanced dissimilar material joiningOA

This study introduces electromagnetic dynamic self-piercing riveting(ED-SPR),an innovative technique that integrates electromagnetic riveting principles with static self-piercing riveting(S-SPR)for highperformance structural joints.A dedicated methodology and experimental apparatus for ED-SPR were systematically designed and validated.Quantitative comparative analyses between ED-SPR and S-SPR were conducted on three critical material combinations:CFRP/Al,low-strength steel HC340 LA/Al,and high-strength steel DP590/Al.Key findings demonstrate that the electromagnetic-driven process reduces installation resistance by 60%and achieves a 30%larger interlock distance at the joint base compared to S-SPR.These quantitative advantages directly contribute to an approximately 30%increase in load-bearing capacity and superior damage tolerance in ED-SPR joints,as evidenced by tensile-shear testing of single-lap joints.Furthermore,distinct failure modes were observed:ED-SPR joints exhibited top plate pull-out failure in CFRP/Al and DP590/Al configurations,contrasting with the predominant rivet pull-out failure in S-SPR counterparts.Surface morphology and damage evolution were characterized via scanning electron microscopy(SEM)on post-assembly and tensile-failed specimens.The study establishes a foundation for optimizing electromagnetic-driven riveting parameters to mitigate CFRP delamination and further enhance joint reliability in vehicle body and aircraft fuselage structures.