[{"abstract":[{"lang":"eng","text":"One of the major topics in the modern automotive industry is reducing emissions and increasing the mileage\r\nrange. To tackle this challenge, on the one hand, modifying the powertrain system is a possibility, and on the\r\nother hand, lightweight design offers various possibilities. Multi-Material Design (MMD) involves designing car\r\nbodies that combine different materials that require joining. Given the variety of materials, mechanical joining\r\nprocesses are preferred. Especially the current development of the Giga/Mega-casting process concerning\r\naluminium casting and the subsequent mechanical joining illustrates the challenges of this material group. In car\r\nproduction, aluminium castings are mainly made from aluminium-silicon (AlSi) alloys. Ultimately, the alloy\r\nsystem's insufficient ductility leads to crack initiation during mechanical joining. Cast parts are therefore often\r\nused in areas of the car body that are exposed to high-pressure loads. For example, self-piercing riveting (SPR) is\r\nused due to its high load-bearing capacity. In this study, improved joinability is demonstrated by influencing the\r\nmicrostructure through tailored solidification rates and a developed heat-treatment chain strategy adapted for\r\nhypoeutectic AlSi systems. Data on microstructure, mechanical, and joining properties are used to develop a\r\nsolidification-joining correlation for the SPR process across a range of Si contents and solidification rates. The\r\npurpose is to develop the ability to produce suitable aluminium castings with sufficient joinability, thereby\r\nimproving versatility."}],"publication":"Journal of Manufacturing Processes","language":[{"iso":"eng"}],"keyword":["Mechanical joining","Aluminium","Self-piercing riveting","Casting","Microstructure","Joinability AlSi-alloys"],"year":"2026","quality_controlled":"1","title":"Solidification-joinability correlation of hypoeutectic aluminium casting alloys for self-piercing riveting (SPR)","date_created":"2026-02-26T11:21:24Z","publisher":"Elsevier","status":"public","type":"journal_article","funded_apc":"1","article_type":"original","user_id":"32340","department":[{"_id":"43"},{"_id":"158"},{"_id":"157"},{"_id":"321"}],"project":[{"_id":"131","name":"TRR 285 - Project Area A"},{"_id":"133","name":"TRR 285 - Project Area C"},{"name":"TRR 285 - Subproject A02","_id":"136"},{"_id":"146","name":"TRR 285 - Subproject C02"},{"name":"TRR 285:  Methodenentwicklung zur mechanischen Fügbarkeit in wandlungsfähigen Prozessketten","_id":"130"}],"_id":"64678","citation":{"ieee":"M. Neuser <i>et al.</i>, “Solidification-joinability correlation of hypoeutectic aluminium casting alloys for self-piercing riveting (SPR),” <i>Journal of Manufacturing Processes</i>, vol. 164, 2026, doi: <a href=\"https://doi.org/10.1016/j.jmapro.2026.02.040\">https://doi.org/10.1016/j.jmapro.2026.02.040</a>.","chicago":"Neuser, Moritz, Pia Katharina Kaimann, Ina Stratmann, Mathias Bobbert, Johann Moritz Benedikt Klöckner, Moritz Mann, Kay-Peter Hoyer, Gerson Meschut, and Mirko Schaper. “Solidification-Joinability Correlation of Hypoeutectic Aluminium Casting Alloys for Self-Piercing Riveting (SPR).” <i>Journal of Manufacturing Processes</i> 164 (2026). <a href=\"https://doi.org/10.1016/j.jmapro.2026.02.040\">https://doi.org/10.1016/j.jmapro.2026.02.040</a>.","mla":"Neuser, Moritz, et al. “Solidification-Joinability Correlation of Hypoeutectic Aluminium Casting Alloys for Self-Piercing Riveting (SPR).” <i>Journal of Manufacturing Processes</i>, vol. 164, Elsevier, 2026, doi:<a href=\"https://doi.org/10.1016/j.jmapro.2026.02.040\">https://doi.org/10.1016/j.jmapro.2026.02.040</a>.","bibtex":"@article{Neuser_Kaimann_Stratmann_Bobbert_Klöckner_Mann_Hoyer_Meschut_Schaper_2026, title={Solidification-joinability correlation of hypoeutectic aluminium casting alloys for self-piercing riveting (SPR)}, volume={164}, DOI={<a href=\"https://doi.org/10.1016/j.jmapro.2026.02.040\">https://doi.org/10.1016/j.jmapro.2026.02.040</a>}, journal={Journal of Manufacturing Processes}, publisher={Elsevier}, author={Neuser, Moritz and Kaimann, Pia Katharina and Stratmann, Ina and Bobbert, Mathias and Klöckner, Johann Moritz Benedikt and Mann, Moritz and Hoyer, Kay-Peter and Meschut, Gerson and Schaper, Mirko}, year={2026} }","short":"M. Neuser, P.K. Kaimann, I. Stratmann, M. Bobbert, J.M.B. Klöckner, M. Mann, K.-P. Hoyer, G. Meschut, M. Schaper, Journal of Manufacturing Processes 164 (2026).","ama":"Neuser M, Kaimann PK, Stratmann I, et al. Solidification-joinability correlation of hypoeutectic aluminium casting alloys for self-piercing riveting (SPR). <i>Journal of Manufacturing Processes</i>. 2026;164. doi:<a href=\"https://doi.org/10.1016/j.jmapro.2026.02.040\">https://doi.org/10.1016/j.jmapro.2026.02.040</a>","apa":"Neuser, M., Kaimann, P. K., Stratmann, I., Bobbert, M., Klöckner, J. M. B., Mann, M., Hoyer, K.-P., Meschut, G., &#38; Schaper, M. (2026). Solidification-joinability correlation of hypoeutectic aluminium casting alloys for self-piercing riveting (SPR). <i>Journal of Manufacturing Processes</i>, <i>164</i>. <a href=\"https://doi.org/10.1016/j.jmapro.2026.02.040\">https://doi.org/10.1016/j.jmapro.2026.02.040</a>"},"intvolume":"       164","publication_status":"published","doi":"https://doi.org/10.1016/j.jmapro.2026.02.040","author":[{"first_name":"Moritz","full_name":"Neuser, Moritz","id":"32340","last_name":"Neuser"},{"id":"44935","full_name":"Kaimann, Pia Katharina","last_name":"Kaimann","first_name":"Pia Katharina"},{"full_name":"Stratmann, Ina","last_name":"Stratmann","first_name":"Ina"},{"first_name":"Mathias","id":"7850","full_name":"Bobbert, Mathias","last_name":"Bobbert"},{"last_name":"Klöckner","full_name":"Klöckner, Johann Moritz Benedikt","first_name":"Johann Moritz Benedikt"},{"first_name":"Moritz","last_name":"Mann","full_name":"Mann, Moritz"},{"first_name":"Kay-Peter","last_name":"Hoyer","full_name":"Hoyer, Kay-Peter","id":"48411"},{"first_name":"Gerson","full_name":"Meschut, Gerson","id":"32056","last_name":"Meschut","orcid":"0000-0002-2763-1246"},{"first_name":"Mirko","id":"43720","full_name":"Schaper, Mirko","last_name":"Schaper"}],"volume":164,"date_updated":"2026-02-26T11:22:03Z"},{"title":"Mechanical properties and joinability of the near-eutectic aluminium casting alloy AlSi12","date_created":"2025-02-24T10:25:31Z","publisher":"Sage Publications","year":"2025","quality_controlled":"1","language":[{"iso":"eng"}],"keyword":["aluminium","casting","microstructure","joinability","self-piercing riveting"],"abstract":[{"text":"One of the most important strategies for reducing CO2 emissions in the mobility sector is lightweight construction. In particular, the car body offers several opportunities for weight reduction. Multi-material designs are increasingly being applied to select the most suitable material for the respective load and ultimately achieve synergy effects. For example, aluminium castings are used at the nodes of a spaceframe body. Subsequently, these are joined with profiles to form the bodyshell. To join different materials mechanical joining techniques, such as semi-tubular self-piercing riveting, are deployed. According to the current state of the art, cracks occur in the aluminium castings during the mechanical joining process as a result of the high degree of deformation. Although the aluminium casting alloys of the AlSi-system exhibit low ductility, these alloys reveal excellent castability. In particular, the ability to cast thin structural parts is enabled by the low liquidus point of the near eutectic aluminium casting alloys.\r\nThis study addresses the mechanical joining properties of the near eutectic aluminium casting alloy AlSi12, depending on different microstructures. These are achieved by annealing processes and modifying agents. Through an adapted heat treatment, the previously lamellar morphology can be transformed into a globular morphology, which leads to increased ductility and prevents the formation of cracks during the self-piercing riveting (SPR). The joinability is investigated using different die geometries, whereas the joint formation is analysed regarding crack initiation. To evaluate the increased ductility, microstructural and mechanical tests are performed and finally, a microstructure-joinability correlation is established.","lang":"eng"}],"publication":"The Journal of Materials: Design and Applications, Part L","conference":{"name":"5th International Conference on Materials Design and Applications 2024","start_date":"2024-07-04","end_date":"2024-07-05","location":"Porto, Portugal"},"doi":"10.1177/14644207251319922","author":[{"last_name":"Neuser","full_name":"Neuser, Moritz","id":"32340","first_name":"Moritz"},{"first_name":"Pia Katharina","last_name":"Holtkamp","full_name":"Holtkamp, Pia Katharina","id":"44935"},{"first_name":"Kay-Peter","id":"48411","full_name":"Hoyer, Kay-Peter","last_name":"Hoyer"},{"id":"66459","full_name":"Kappe, Fabian","last_name":"Kappe","first_name":"Fabian"},{"first_name":"Safak","full_name":"Yildiz, Safak","last_name":"Yildiz"},{"id":"7850","full_name":"Bobbert, Mathias","last_name":"Bobbert","first_name":"Mathias"},{"last_name":"Meschut","orcid":"0000-0002-2763-1246","full_name":"Meschut, Gerson","id":"32056","first_name":"Gerson"},{"last_name":"Schaper","id":"43720","full_name":"Schaper, Mirko","first_name":"Mirko"}],"date_updated":"2025-02-24T12:25:04Z","citation":{"ama":"Neuser M, Holtkamp PK, Hoyer K-P, et al. Mechanical properties and joinability of the near-eutectic aluminium casting alloy AlSi12. <i>The Journal of Materials: Design and Applications, Part L</i>. Published online 2025. doi:<a href=\"https://doi.org/10.1177/14644207251319922\">10.1177/14644207251319922</a>","chicago":"Neuser, Moritz, Pia Katharina Holtkamp, Kay-Peter Hoyer, Fabian Kappe, Safak Yildiz, Mathias Bobbert, Gerson Meschut, and Mirko Schaper. “Mechanical Properties and Joinability of the Near-Eutectic Aluminium Casting Alloy AlSi12.” <i>The Journal of Materials: Design and Applications, Part L</i>, 2025. <a href=\"https://doi.org/10.1177/14644207251319922\">https://doi.org/10.1177/14644207251319922</a>.","ieee":"M. Neuser <i>et al.</i>, “Mechanical properties and joinability of the near-eutectic aluminium casting alloy AlSi12,” <i>The Journal of Materials: Design and Applications, Part L</i>, 2025, doi: <a href=\"https://doi.org/10.1177/14644207251319922\">10.1177/14644207251319922</a>.","apa":"Neuser, M., Holtkamp, P. K., Hoyer, K.-P., Kappe, F., Yildiz, S., Bobbert, M., Meschut, G., &#38; Schaper, M. (2025). Mechanical properties and joinability of the near-eutectic aluminium casting alloy AlSi12. <i>The Journal of Materials: Design and Applications, Part L</i>. 5th International Conference on Materials Design and Applications 2024, Porto, Portugal. <a href=\"https://doi.org/10.1177/14644207251319922\">https://doi.org/10.1177/14644207251319922</a>","short":"M. Neuser, P.K. Holtkamp, K.-P. Hoyer, F. Kappe, S. Yildiz, M. Bobbert, G. Meschut, M. Schaper, The Journal of Materials: Design and Applications, Part L (2025).","bibtex":"@article{Neuser_Holtkamp_Hoyer_Kappe_Yildiz_Bobbert_Meschut_Schaper_2025, title={Mechanical properties and joinability of the near-eutectic aluminium casting alloy AlSi12}, DOI={<a href=\"https://doi.org/10.1177/14644207251319922\">10.1177/14644207251319922</a>}, journal={The Journal of Materials: Design and Applications, Part L}, publisher={Sage Publications}, author={Neuser, Moritz and Holtkamp, Pia Katharina and Hoyer, Kay-Peter and Kappe, Fabian and Yildiz, Safak and Bobbert, Mathias and Meschut, Gerson and Schaper, Mirko}, year={2025} }","mla":"Neuser, Moritz, et al. “Mechanical Properties and Joinability of the Near-Eutectic Aluminium Casting Alloy AlSi12.” <i>The Journal of Materials: Design and Applications, Part L</i>, Sage Publications, 2025, doi:<a href=\"https://doi.org/10.1177/14644207251319922\">10.1177/14644207251319922</a>."},"publication_status":"published","has_accepted_license":"1","article_type":"original","user_id":"32340","department":[{"_id":"43"},{"_id":"158"},{"_id":"157"},{"_id":"9"},{"_id":"321"}],"project":[{"_id":"131","name":"TRR 285 - A: TRR 285 - Project Area A"},{"name":"TRR 285 – A02: TRR 285 - Subproject A02","_id":"136"},{"_id":"133","name":"TRR 285 - C: TRR 285 - Project Area C"},{"_id":"146","name":"TRR 285 – C02: TRR 285 - Subproject C02"}],"_id":"58807","status":"public","type":"journal_article"}]