Extent of interlocking and metallurgical bonding in friction riveting of aluminum alloy to steel

In this study, the joining of 6061-T6 aluminum alloy and DP590 steel using a M42 rivet via friction riveting technique is investigated. The surface morphology microstructure characterization reveal formation an anchor zone that imparts mechanical interlock as well metallurgical bonds at interface steel. A combination interlocking bonding results in achievement high load-carrying capacity 5.7 kN during lap shear testing room temperature. finite element-based computational model was developed which accurately predicted response joint. revealed bond formed fric-riveting adds 39% peak load strength to An extensive microstructural investigation, post-lap-shear fractography, modeling results, together provided insights on joint failure mechanism. This study highlights promising method for aluminum-to-steel dissimilar joining, important lighweighing automotive vehicles energy efficiency.