Influence of processing parameters on damage evolution and interface contact behavior in CFRP/aluminum alloy riveting

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ABSTRACT Riveting of carbon fibre reinforced polymer (CFRP) and aluminum alloy is widely used in the aerospace industry. However, the deformation and damage control mechanisms at the contact interface of dissimilar materials remain unclear, limiting precise control of riveting quality. To reveal the influence mechanism of processing parameters on deformation and damage at dissimilar interfaces, this study builds upon an established progressive damage mechanics framework, integrating the Hashin fibre criterion and the Puck matrix fracture criterion to predict damage evolution in CFRP, with model accuracy verified through open hole tensile tests. A finite element model of CFRP and aluminum alloy riveting was established to systematically analyze material flow, damage evolution, and interface deformation characteristics of different layup structures during the riveting process. Using matrix compression damage distribution, polar coordinate deformation values, and interface matching degree as evaluation indices, the influence of process parameters on damage evolution and interface mechanical behavior of laminated structures was revealed. Results indicate that matrix compression damage is the dominant failure mode in CFRP riveting, and [0/45/90/-45] 2s laminates exhibit superior damage resistance through fibre synergistic load bearing. Process parameter investigation found that increasing riveting speed and forming height both reduce damage area, but excessive speed leads to decreased interface matching degree due to strain rate differences. Appropriately increasing forming height improves interface deformation coordination between CFRP and aluminum alloy, with [0/45/90/-45] 2s laminates demonstrating more stable interface contact behavior. This study provides theoretical basis for riveting process optimization and layup design of CFRP and aluminum alloy dissimilar structures.

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