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Study on Crack Propagation Behavior and Process Optimization in Die-Cast Aluminum Alloy Self-Piercing Riveted Joints
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Zhiqiang Sun, Jingyuan Qi, Xupeng Li, Zhuoyi Li, Xiang Wang, Yichang Chen
Automobile Technology & Material | 2026, (8) : 44 - 57
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Automobile Technology & Material | 2026, (8): 44-57
Study on Crack Propagation Behavior and Process Optimization in Die-Cast Aluminum Alloy Self-Piercing Riveted Joints
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Zhiqiang Sun, Jingyuan Qi, Xupeng Li, Zhuoyi Li, Xiang Wang, Yichang Chen
Affiliations
  • BYD Industries Co., Ltd., Shenzhen 518000
Published: 2026-08-20 doi: 10.19710/J.cnki.1003-8817.20250342
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To address the cracking problem during Self-Piercing riveting (SPR) on AlSi10MnMg die-cast aluminum shock towers, a combined experimental and numerical approach is employed to investigate crack initiation and propagation behavior. Optimization is conducted from 3 perspectives: the riveting process, material composition, and die-casting process. The results indicate that riveting cracking is induced by the tensile stress in the lower sheet and the compressive stress in the adjacent region, while the low elongation and porosity defects of the cast aluminum make it prone to crack initiation. A contoured riveting die reduces plastic deformation and tensile stress; Sr modification treatment optimizes the eutectic Si morphology and increases elongation; and optimizing the runner, overflow, and die temperature reduces casting defects, thereby lowering the cracking risk.

AlSi10MnMg cast aluminum alloy  /  Self-Piercing Riveting(SPR)  /  Riveting crack
孙志强, 祁靖媛, 李绪鹏, 李卓裔, 王翔, 陈逸昶. 压铸铝合金自冲铆接接头裂纹扩展行为及工艺优化研究. 汽车工艺与材料, 2026 , (8) : 44 -57 . DOI: 10.19710/J.cnki.1003-8817.20250342
Zhiqiang Sun, Jingyuan Qi, Xupeng Li, Zhuoyi Li, Xiang Wang, Yichang Chen. Study on Crack Propagation Behavior and Process Optimization in Die-Cast Aluminum Alloy Self-Piercing Riveted Joints[J]. Automobile Technology & Material, 2026 , (8) : 44 -57 . DOI: 10.19710/J.cnki.1003-8817.20250342
Year 2026 volume Issue 8
172
34
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doi: 10.19710/J.cnki.1003-8817.20250342
  • Online Date:2026-09-23
  • Published:2026-08-20
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    BYD Industries Co., Ltd., Shenzhen 518000
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表12种不同金属材料的力学参数
科
Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)
属
Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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