In this study, clinching characteristics of aluminum and galvanized steels were investigated for the application of clinching as a joining technique to aluminum wheelhouse assembly. A6451 aluminium alloy and galvanized steel sheets were joined by hybrid joining(clinching + adhesive bonding). Tensile-shear load and fracture mode of hybrid joints were investigated. Maximum tensile-shear load of hybrid joints was about six times higher than that of clinched joints without adhesive. Energy absorption values of hybrid joints were higher than those of clinched joints without adhesive as well as resistance spot welded steel joints. Developed aluminum wheelhouse assembly showed higher static stiffness than the existing steel parts. Aluminum wheelhouse inner panel unit was 44% lighter than the steel unit, and the final assembled aluminum wheelhouse was 14.6% lighter than the existing steel parts.

Multiple galvanized steel and aluminium alloy sheets were joined by self-piercing rivet(SPR) and hybrid joining(SPR + adhesive bonding). In this study, tensile-shear load and fatigue properties of multi-layer SPR and hybrid joints were investigated. Moreover, tensile-shear deformation behavior of the joints under different specimen configurations was investigated. Depending on the specimen configurations either top sheet tearing failure mode or rivet tail pull-out failure mode was observed during the tensile-shear tests. The top sheet tearing failure mode resulted in low maximum tensile-shear load, but it led to larger displacement value as compared to that in the tail pull-out failure mode. Maximum tensile-shear load of hybrid joints was about four times higher than that of SPR joints. Also, fatigue limit of hybrid joints was about two times higher than that of SPR joints.