Double-Sided Self-Pierce Riveting: Electro-Mechanical Analysis of Dissimilar Al-Cu Half-Lap Butt Joints

Abstract

Double-sided self-pierce riveting (DSSPR) can be utilized as an alternative to self-pierce riveting (SPR) to produce butt joints through half-lap joints in dissimilar materials. The mechanical joining process makes use of tubular rivets with simple geometry that are here employed to join two sheets made from aluminium (Al) and copper (Cu). This research work analyses the influence of the stainless-steel rivet on both the electrical and mechanical performance of the joint. The electrical resistance variation of the joined assembly is measured at different temperatures and compared with conventional fastened joints made from the same material combination. The mechanical performance of the aluminium–copper connections is evaluated by means of shear tests and compared to the original fastened Al-Cu joint. An experimental approach is utilized to analyse the combined influence of different mechanical and electrical parameters to assess the performance of DSSPR in electrical applications.