Self-Piercing Riveted Joints and Resistance Spot Welded Joints in Steel and Aluminium

Self-piercing riveting and resistance spot welding are competing processes for joining sheet materials, typically 1 to 2mm thick, for the automotive industry. However, for these processes to be used with confidence, detailed performance data are required on which to base design guidelines.

This paper describes mechanical tests carried out on joints made in steel (both Zn coated and uncoated), and in aluminium alloys. In addition, hybrid joints (self piercing riveting/adhesive bonding and resistance welding/adhesive bonding) were also investigated. Properties determined were lap shear strength, T-peel strength and fatigue strength.

The main conclusions were that satisfactory joints could achieved; the static strength of resistance welded joints was greater than that of the riveted joints; the fatigue strength of the riveted joints was superior to resistance welded joints and that hybrid joints exhibited enhanced static and fatigue properties compared with simple joints.