Abstract:A finite element model of self-piercing riveting of semi-tubular rivets was established by using the finite element software Deform-2D. The process of self-piercing riveted dissimilar metals of aluminum and steel was simulated and analyzed, and the stress distribution on rivets and metal sheets was analyzed. The self-piercing riveted tests and static tensile tests of AA5052 aluminum alloy and SPFC440 high strength steel dissimilar metals were carried out. The self-piercing riveted experiment of semi-tubular rivets for aluminum/steel dissimilar metals was performed. Tensile test and fatigue test were carried out to analyze mechanical properties of self-piercing riveted joint. The failure forms of the riveted joint are analyzed. The results show that the rivet head has good contact with the upper sheet, and the rivet shank spares evenly and smoothly in the lower sheet without crack or buckling. The stress of the rivet concentrates on the rivet shank, and the stress of the bottom sheet concentrates on the contact area between the rivet foot and the lower sheet. The results of numerical simulation and self -piercing riveted test are in good agreement. The relative error between simulation and test values is less than 13% , which meets the requirement of engineering design accuracy. The self-piercing riveted joint has good static tensile property and fatigue property. The maximum load of static tensile test is about 7.6 kN. The upper sheet warps and the rivet foot is pulled out from the lower sheet under the tensile load. The fatigue limit is about 2.3 kN under experimental conditions. In the process of fatigue loading, the aluminum alloy suffered fatigue failure under the combined action of fretting wear and tensile stress.