Fatigue evolution behavior of flat electromagnetic self-pierce riveted CFRP/aluminum structures

IF 6.8 2区材料科学 Q1 ENGINEERING, MECHANICAL

International Journal of Fatigue Pub Date : 2025-09-06 DOI:10.1016/j.ijfatigue.2025.109261

Jiageng Jin , Yuanna Xu , Peng Wang , Qing Wang , Guangyao Li , Junjia Cui , Hao Jiang

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引用次数: 0

Abstract

Flat electromagnetic self-pierce riveting (FE-SPR) can connect carbon fiber-reinforced plastics (CFRP) and aluminum alloys with low damage and high efficiency in the automobile field. However, the lack of quantitative understanding of the fatigue performance of FE-SPR joints and the evolution of CFRP damage is hindering their engineering application. Therefore, the optimal process parameter, and the corresponding joint fatigue crack propagation, CFRP damage, and joint fatigue evolution are systematically investigated. The results showed that the optimal performance was achieved with the discharge voltage of 300 V, resulting in CFRP damage areas of 8.73 mm² and a peak load of 6.28 kN. Three fatigue failure modes were achieved: complete fracture of the aluminum plate; local tearing of the aluminum plate; and tensile shear failure. The fracture of the aluminum plate for the low load level was attributed to fretting on the faying surface between the rivet and aluminum plate. This caused stress concentration, leading to crack initiation and propagation, resulting in eventual fracture. The ultrasonic nondestructive testing was conducted to evaluate the area of the CFRP damage under different fatigue life. It was found that, when the rivet leg was partially pulled out, the areas of CFRP damage increased slightly during the stage of stable cycle loading. Instead, it was more the initiation and propagation of cracks inside the aluminum plate. This result can provide a reference for practical applications.

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平板电磁自刺铆接CFRP/铝结构疲劳演化行为

平面电磁自孔铆接（FE-SPR）是汽车领域中碳纤维增强塑料（CFRP）与铝合金之间的一种低损伤、高效率的连接方法。然而，缺乏对FE-SPR接头疲劳性能和CFRP损伤演变的定量认识，阻碍了其工程应用。因此，系统地研究了最佳工艺参数，以及相应的接头疲劳裂纹扩展、CFRP损伤和接头疲劳演化。结果表明，在放电电压为300 V时，CFRP损伤面积为8.73 mm2，峰值载荷为6.28 kN，性能最佳。实现了三种疲劳破坏模式：铝板完全断裂；铝板局部撕裂；和拉伸剪切破坏。低载荷水平下铝板断裂的原因是铆钉与铝板之间的接合面发生微动。这导致应力集中，导致裂纹萌生和扩展，最终导致断裂。对碳纤维布在不同疲劳寿命下的损伤面积进行了超声无损检测。结果表明：在稳定循环加载阶段，当铆钉腿部分拔出时，CFRP损伤面积略有增加；相反，更多的是铝板内部裂纹的萌生和扩展。该结果可为实际应用提供参考。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

International Journal of Fatigue 工程技术-材料科学：综合

CiteScore

10.70

自引率

21.70%

发文量

619

审稿时长

58 days

期刊介绍： Typical subjects discussed in International Journal of Fatigue address: Novel fatigue testing and characterization methods (new kinds of fatigue tests, critical evaluation of existing methods, in situ measurement of fatigue degradation, non-contact field measurements) Multiaxial fatigue and complex loading effects of materials and structures, exploring state-of-the-art concepts in degradation under cyclic loading Fatigue in the very high cycle regime, including failure mode transitions from surface to subsurface, effects of surface treatment, processing, and loading conditions Modeling (including degradation processes and related driving forces, multiscale/multi-resolution methods, computational hierarchical and concurrent methods for coupled component and material responses, novel methods for notch root analysis, fracture mechanics, damage mechanics, crack growth kinetics, life prediction and durability, and prediction of stochastic fatigue behavior reflecting microstructure and service conditions) Models for early stages of fatigue crack formation and growth that explicitly consider microstructure and relevant materials science aspects Understanding the influence or manufacturing and processing route on fatigue degradation, and embedding this understanding in more predictive schemes for mitigation and design against fatigue Prognosis and damage state awareness (including sensors, monitoring, methodology, interactive control, accelerated methods, data interpretation) Applications of technologies associated with fatigue and their implications for structural integrity and reliability. This includes issues related to design, operation and maintenance, i.e., life cycle engineering Smart materials and structures that can sense and mitigate fatigue degradation Fatigue of devices and structures at small scales, including effects of process route and surfaces/interfaces.