Corrosion of Al-Fe self-pierce riveting joints with multiphysics-based modeling and experiments

Self-piercing riveting (SPR) is an extensively used joining technique to assemble dissimilar materials. However, this joining of the dissimilar materials can generate galvanic/crevice corrosion, which can drastically impact the mechanical properties and the service life of the joint. In this study, a multiphysics-based hybrid modeling approach is developed for the galvanic corrosion of the Al-Fe SPR joints, which can consider the corrosion initiation and corrosion evaluation jointly. Experimental studies are first performed to extract information regarding the corrosion initiation sites, corrosion evolution and overall corrosion induced material loss in SPR joints. The initiation information is then passed onto the multiphysics FE model thus making it a hybrid model. This model can help understand the influences of metal microstructure on the corrosion propagation while the morphology changes can also be analyzed. Using the developed hybrid modeling approach, thorough parametric studies can be performed to explore the coupled impacts of multiple corrosion factors on the corrosion behavior of the joints. The developed hybrid model is validated on the prediction of galvanic corrosion for the SPR joints by comparing with experimental observations.

Automated summary

In this study, a multiphysics-based hybrid modeling approach is developed to investigate the galvanic corrosion of Al-Fe self-piercing rivet (SPR) joints. Experimental studies are conducted to gather information on the corrosion initiation sites, corrosion evolution, and overall material loss in SPR joints. This information is then used to develop a hybrid model, which integrates the corrosion initiation and evaluation processes. The developed hybrid model allows for parametric studies to analyze the combined effects of multiple corrosion factors on the corrosion behavior of the joints. The model is validated by comparing its predictions with experimental observations.