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Mechanical properties and failure modes analysis of UVPC joints under different ultrasonic amplitudes.

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Title: Mechanical properties and failure modes analysis of UVPC joints under different ultrasonic amplitudes.
Authors: Mei, Miaoyuan1 (AUTHOR), Zhang, Xingang2 (AUTHOR), He, Qinghui1 (AUTHOR), Ma, Ji1 (AUTHOR), Chen, Chao1,3,4 (AUTHOR) profchenchao@csu.edu.cn
Source: Archives of Civil & Mechanical Engineering (Elsevier Science). Jul2026, Vol. 26 Issue 4, p1-27. 27p.
Subjects: Joints (Engineering), Joining processes, Ultrasonic waves, Aluminum construction, Lightweight construction, Failure analysis, Mechanical behavior of materials, Automobile industry
Abstract: In the automotive industry, reducing vehicle weight while maintaining high strength and corrosion resistance has become a critical challenge. Steel-aluminum hybrid structures are increasingly used in automotive bodies due to their combination of light weight, high strength, and good corrosion resistance. To achieve lightweight joining between high-strength steel and aluminum alloy, this study proposed an ultrasonic vibration-assisted punch-shear clinching process and systematically investigated the effects of different vibration amplitudes on the forming quality, mechanical properties, failure modes and micro-hardness of the joints. The results indicated that as the vibration amplitude increased from 0 to 7.11 μm, the forming forces during the shear and forming phases decreased by 6.42% and 15.61%, respectively. The bottom thickness, interlock value, and neck thickness increased by 8.79%, 5.41%, and 4.49%, respectively, while the tensile and shear loads increased by 6.60% and 21.22%, and the energy absorption of the joints increased by more than 22%. All joints exhibited ductile fracture characteristics, with the average diameter and area of dimples in the failure regions significantly reduced. In addition, the residual effects of ultrasonic vibration decreased the hardness of the upper sheet and increased that of the lower sheet without compromising joint reliability. This technique provides an effective solution for reliable joining of high-strength steel and aluminum alloy, offering significant engineering potential for lightweight automotive manufacturing. [ABSTRACT FROM AUTHOR]
Copyright of Archives of Civil & Mechanical Engineering (Elsevier Science) is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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Header DbId: egs
DbLabel: Engineering Source
An: 194640516
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
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  Data: Mechanical properties and failure modes analysis of UVPC joints under different ultrasonic amplitudes.
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  Data: <searchLink fieldCode="AR" term="%22Mei%2C+Miaoyuan%22">Mei, Miaoyuan</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Zhang%2C+Xingang%22">Zhang, Xingang</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22He%2C+Qinghui%22">He, Qinghui</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Ma%2C+Ji%22">Ma, Ji</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Chen%2C+Chao%22">Chen, Chao</searchLink><relatesTo>1,3,4</relatesTo> (AUTHOR)<i> profchenchao@csu.edu.cn</i>
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  Data: <searchLink fieldCode="DE" term="%22Joints+%28Engineering%29%22">Joints (Engineering)</searchLink><br /><searchLink fieldCode="DE" term="%22Joining+processes%22">Joining processes</searchLink><br /><searchLink fieldCode="DE" term="%22Ultrasonic+waves%22">Ultrasonic waves</searchLink><br /><searchLink fieldCode="DE" term="%22Aluminum+construction%22">Aluminum construction</searchLink><br /><searchLink fieldCode="DE" term="%22Lightweight+construction%22">Lightweight construction</searchLink><br /><searchLink fieldCode="DE" term="%22Failure+analysis%22">Failure analysis</searchLink><br /><searchLink fieldCode="DE" term="%22Mechanical+behavior+of+materials%22">Mechanical behavior of materials</searchLink><br /><searchLink fieldCode="DE" term="%22Automobile+industry%22">Automobile industry</searchLink>
– Name: Abstract
  Label: Abstract
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  Data: In the automotive industry, reducing vehicle weight while maintaining high strength and corrosion resistance has become a critical challenge. Steel-aluminum hybrid structures are increasingly used in automotive bodies due to their combination of light weight, high strength, and good corrosion resistance. To achieve lightweight joining between high-strength steel and aluminum alloy, this study proposed an ultrasonic vibration-assisted punch-shear clinching process and systematically investigated the effects of different vibration amplitudes on the forming quality, mechanical properties, failure modes and micro-hardness of the joints. The results indicated that as the vibration amplitude increased from 0 to 7.11 μm, the forming forces during the shear and forming phases decreased by 6.42% and 15.61%, respectively. The bottom thickness, interlock value, and neck thickness increased by 8.79%, 5.41%, and 4.49%, respectively, while the tensile and shear loads increased by 6.60% and 21.22%, and the energy absorption of the joints increased by more than 22%. All joints exhibited ductile fracture characteristics, with the average diameter and area of dimples in the failure regions significantly reduced. In addition, the residual effects of ultrasonic vibration decreased the hardness of the upper sheet and increased that of the lower sheet without compromising joint reliability. This technique provides an effective solution for reliable joining of high-strength steel and aluminum alloy, offering significant engineering potential for lightweight automotive manufacturing. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Archives of Civil & Mechanical Engineering (Elsevier Science) is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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RecordInfo BibRecord:
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      – Type: doi
        Value: 10.1007/s43452-026-01560-z
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      – Code: eng
        Text: English
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      Pagination:
        PageCount: 27
        StartPage: 1
    Subjects:
      – SubjectFull: Joints (Engineering)
        Type: general
      – SubjectFull: Joining processes
        Type: general
      – SubjectFull: Ultrasonic waves
        Type: general
      – SubjectFull: Aluminum construction
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      – SubjectFull: Lightweight construction
        Type: general
      – SubjectFull: Failure analysis
        Type: general
      – SubjectFull: Mechanical behavior of materials
        Type: general
      – SubjectFull: Automobile industry
        Type: general
    Titles:
      – TitleFull: Mechanical properties and failure modes analysis of UVPC joints under different ultrasonic amplitudes.
        Type: main
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            NameFull: Mei, Miaoyuan
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            NameFull: Zhang, Xingang
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            NameFull: He, Qinghui
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            NameFull: Ma, Ji
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            – D: 01
              M: 07
              Text: Jul2026
              Type: published
              Y: 2026
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