article published yes Pia Katharina Kaimann author 44935 J Sarris author Robert Beck author 382790000-0001-9056-4528 Mathias Bobbert author 7850 M Lechner author Gerson Meschut author 320560000-0002-2763-1246 43 department 157 department TRR 285: Methodenentwicklung zur mechanischen Fügbarkeit in wandlungsfähigen Prozessketten project TRR 285 - Project Area C project TRR 285 - Subproject C02 project <jats:p> The increasing use of aluminium alloys and ultra-high-strength steels, such as CP1000, in automotive lightweight design imposes stringent requirements on mechanical joining technologies. Self-piercing riveting (SPR) is widely used in multi-material structures; however, conventional rivet systems are limited ranges of material and sheet thickness. To address this limitation, Kappe et al. introduced versatile self-piercing riveting (V-SPR), which combines an extended punch actuator with a multi-range-capable rivet to enable joining of materials with tensile strengths up to 600 MPa without tool changes. <jats:sup> <jats:xref ref-type="bibr">1</jats:xref> </jats:sup> This study presents a comparative investigation of a multi-range-capable rivet for V-SPR and conventional standard rivets in CP1000–aluminium and aluminium–aluminium joints. The analysis focuses on joint formation and mechanical performance under shear-tensile and cross-tensile loading. Metallographic cross-sections are used to characterise interlock formation, minimum die-side material thickness, and failure modes. Mechanical performance is evaluated using quasi-static tests, with emphasis on maximum load and failure mode. The experiments establish a demonstrated joinability matrix for the investigated sheet-thickness combinations using adapted punch and die motions. The results demonstrate the applicability of V-SPR to ultra-high-strength steel–aluminium and aluminium–aluminium joints. For the most industrially relevant combination investigated, St1.5–Al2.0 (CP1000–EN AW-6014), V-SPR achieves mechanical performance comparable to or higher than that of standard SPR while substantially reducing tool complexity through a single multi-range-capable rivet, a reduced die configuration, and fewer stack-specific changeovers. However, the independently driven inner and outer punches and active die increase actuator and control-system complexity. </jats:p> SAGE Publications2026 eng 1464-4207 2041-307610.1177/14644207261497691 Kaimann, P. K., Sarris, J., Beck, R., Bobbert, M., Lechner, M., &#38; Meschut, G. (2026). Comparative study of multi-range-capable rivet and standard self-piercing rivets in aluminium-aluminium and ultra-high-strength steel-aluminium assemblies. <i>Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications</i>, Article 14644207261497692. <a href="https://doi.org/10.1177/14644207261497691">https://doi.org/10.1177/14644207261497691</a> P. K. Kaimann, J. Sarris, R. Beck, M. Bobbert, M. Lechner, and G. Meschut, “Comparative study of multi-range-capable rivet and standard self-piercing rivets in aluminium-aluminium and ultra-high-strength steel-aluminium assemblies,” <i>Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications</i>, Art. no. 14644207261497692, 2026, doi: <a href="https://doi.org/10.1177/14644207261497691">10.1177/14644207261497691</a>. Kaimann, Pia Katharina, J Sarris, Robert Beck, Mathias Bobbert, M Lechner, and Gerson Meschut. “Comparative Study of Multi-Range-Capable Rivet and Standard Self-Piercing Rivets in Aluminium-Aluminium and Ultra-High-Strength Steel-Aluminium Assemblies.” <i>Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications</i>, 2026. <a href="https://doi.org/10.1177/14644207261497691">https://doi.org/10.1177/14644207261497691</a>. P.K. Kaimann, J. Sarris, R. Beck, M. Bobbert, M. Lechner, G. Meschut, Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications (2026). Kaimann, Pia Katharina, et al. “Comparative Study of Multi-Range-Capable Rivet and Standard Self-Piercing Rivets in Aluminium-Aluminium and Ultra-High-Strength Steel-Aluminium Assemblies.” <i>Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications</i>, 14644207261497692, SAGE Publications, 2026, doi:<a href="https://doi.org/10.1177/14644207261497691">10.1177/14644207261497691</a>. Kaimann PK, Sarris J, Beck R, Bobbert M, Lechner M, Meschut G. Comparative study of multi-range-capable rivet and standard self-piercing rivets in aluminium-aluminium and ultra-high-strength steel-aluminium assemblies. <i>Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications</i>. Published online 2026. doi:<a href="https://doi.org/10.1177/14644207261497691">10.1177/14644207261497691</a> @article{Kaimann_Sarris_Beck_Bobbert_Lechner_Meschut_2026, title={Comparative study of multi-range-capable rivet and standard self-piercing rivets in aluminium-aluminium and ultra-high-strength steel-aluminium assemblies}, DOI={<a href="https://doi.org/10.1177/14644207261497691">10.1177/14644207261497691</a>}, number={14644207261497692}, journal={Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications}, publisher={SAGE Publications}, author={Kaimann, Pia Katharina and Sarris, J and Beck, Robert and Bobbert, Mathias and Lechner, M and Meschut, Gerson}, year={2026} } 675692026-10-16T11:33:10Z2026-10-16T11:47:04Z