Effect of Process Parameters on CFRP/Steel Joints Using Self-Piercing Rivets

Self- piercing riveting (SPR) is an advanced process of the mechanical joining of two or more sheet metals by piercing a rivet into the sheets. SPR has been widely applied to join dissimilar materials that are difficult to join, such as aluminum alloys and steels, especially in automobile industries. In the present work, the Carbon Fiber Reinforced Plastics (CFRP) with thickness of 1.3 mm to SPFC 590DP steel with thickness of 1.2 mm was mechanical joined in lap configuration by the SPR process, and the effect of process parameters of force and shape of rivets on joints were investigated. The integrity of the joints was estimated by quality criteria in terms of the gap between the rivet head and the upper plate, remaining thickness of bottom plate and the length of interlock between the rivet and bottom plate. Furthermore, the tensile shear load, fatigue load and the fracture mode characteristics were investigated. From the result, maximum tensile-shear load of 1.94 kN was obtained at a force of 29 kN, which showed separation of CFRP due to fiber split phenomenon on interface of CFRP side in joints.