Abstract: Four groups of self-piercing riveting (SPR) of lightweight alloys were chose to perform a fatigue test.Scanning electron microscope (SEM) and energy dispersive X-ray spectrum (EDX) were adopted to observe the fracture surface and analyze the fretting wear mechanism further.The impact factors of fatigue life and fatigue failure mode of the joints were also analyzed systematically. Results exhibited that bottom substrate fracture along the button and rivet fracture were mainly caused by fretting wear occurred in an interface between bottom substrate and rivet leg, upper substrate fracture close to rivet head was primarily caused by the fretting wear occurred in a riveting interface between two sheets. The main composition of fretting debris was the oxide of metal substrate, and the debris had buffering effect in fretting wear process. Increase substrate thickness could enhance fatigue life, especially when fatigue load was high. Augment substrate strength was able to improve fatigue life, and the increase of fatigue life was influen-ced barely by fatigue load. The fatigue failure mode changed from upper substrate to bottom substrate owing to increase of substrate thickness, fatigue failure mode transformed from substrate fracture to rivet fracture due to augment of substrate strength.
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2017, Vol. 31 
