Evaluating the joinability of aluminum 2024 T351 for aerospace structures using aluminum solid self-piercing rivets

Abstract. The load-bearing capacity of material equivalent aluminum joints with a developed solid self-piercing rivet (SSPR) was investigated. In particular, the effect of the rivet material on the joint strength under quasi-static and fatigue loading was analyzed systematically in order to evaluate the joinability. To demonstrate the load-bearing capacity of the Al-SSPR, it was also compared to a conventional cold-formed solid aluminum rivet (Al-SR). Under a quasi-static load, the load-bearing capacity of the developed aluminum SSPR is 10% lower than that of a geometrically identical SSPR made of steel (St-SSPR) and is approximately 27% lower than that of the Al-SR. However, the fatigue strength was found to be equivalent. Thus, the joinability of the aluminum alloy 2024 T351 up to a total sheet thickness of at least 3.0 mm using the developed Al-SSPR was demonstrated.