Ferrous Rivet Join Structure for Lightweight Metal Corrosion
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Solution Overview
Problem
Existing vehicle member join structures using ferrous metal rivets and lightweight metal members are prone to electrolytic corrosion due to water ingress, which can compromise the structural integrity and durability of vehicle components.
Innovation Solution
A vehicle member join structure that incorporates a ferrous metal rivet with a shaft penetrating a lightweight metal member and a head remaining on the surface, where the rivet shaft is welded to a ferrous metal member, and a waterproof section is applied to prevent water ingress, thereby reducing the risk of electrolytic corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a ferrous metal rivet is used to join a lightweight metal member and a ferrous metal member, then the strength and durability of the joint is improved, but electrolytic corrosion occurs due to water ingress between the dissimilar metals
Solution Approach 1:
An intermediary substance (waterproof material or coating) is introduced between the ferrous rivet and the lightweight metal member to prevent direct contact with water. This intermediary layer blocks the electrolytic corrosion pathway while allowing the rivet to maintain its structural joining function, thus resolving the contradiction between joint strength and corrosion resistance.
Solution Approach 2:
The design accepts the inherent galvanic corrosion risk between dissimilar metals but converts this potential harm into a controlled scenario by applying waterproof materials. The waterproofing treatment transforms the harmful effect of water contact into a protected environment, allowing the ferrous rivet to provide strong joining without suffering from electrolytic corrosion.
2Reliability
If the rivet shaft is welded to the ferrous metal member, then the connection reliability is improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The rivet shaft is pre-formed with welding capability, and the welding to the ferrous metal member is performed as a preliminary action before final assembly. This preliminary welding ensures reliable connection from the outset, and the process complexity is managed by integrating the welding step into the standard manufacturing flow rather than treating it as an additional complex operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed structure effectively suppresses electrolytic corrosion between the ferrous rivet and lightweight metal member, enhancing the durability and reliability of vehicle components while maintaining the strength of the ferrous metal members.
Implementation Method 1
the shaft being welded to the second member so as to connect the first member and the second member together
Implementation Method 2
there is a possibility that electrolytic corrosion (also referred to as galvanic corrosion) due to water ingress might occur at a location where the rivet is provided on the vehicle exterior of a vehicle
Data Source
AI summary
A vehicle member join structure includes a sheet-shaped first member made of a lightweight metal, a sheet-shaped second member made of a ferrous metal, a rivet made of a ferrous metal and including a shaft that penetrates the first member and a head that remains at an outer surface of the first member, the shaft being welded to the second member so as to connect the first member and the second member together, and a waterproof section that prevents water ingress by covering a region where the rivet and the first member contact each other.