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Polyoxymethylene (POM), as an energy‐saving material, is widely applied in the manufacturing field. Yet, research on the rectangular clinching process between metal and POM sheets is still lacking. In this paper, the rectangular clinching process for POM and Al5052‐H32 plates was investigated. The feasibility of the metal–polymer hybrid component had been analyzed in terms of diverse forming forces and diverse joint layout angles, respectively. The mechanical characteristics were appraised by the lap‐shear test. The failure modes of rectangular clinched joints produced under diverse forming conditions had also been analyzed. The results showed that the optimal forming force of rectangular clinched joints was 14 kN, in which the lap‐shear strength was 1090 N. Furthermore, the rectangular clinched joints produced under the joint layout angle of 90° could withstand the maximum lap‐shear load (1415 N) under the optimal forming force. The failure mode was the separation of two plates and the fracture of the bridge structures.

In order to discuss the influence of the stress ratio on the corrosion fatigue life of high‐strength steel wires, a theoretical and experimental investigation was conducted on corroded steel wires at three different stress ratios (R = 0.1, 0.3, and 0.5) under axial tensile fatigue loading. Different S‐N curves of corroded steel wires were regressed from test data. The stress method based on eight mean stress correction models, the strain energy method, and the facture mechanics method considering environmental corrosion and crack closure were proposed to estimate the fatigue life. Preliminary results show that corrosion can reduce the ultimate strength, the yield strength, and the fatigue life. There is a negative correlation between corrosion fatigue life and stress ratio. When R > 0, fatigue life predicted results by using the Morrow and Marin models in the stress method are more efficient and accurate than other models. Likewise, the Zheng model in the fracture mechanics method is in better agreement with test results. The error and scatter of the strain energy method are relatively large. Therefore, the Morrow, Marin, and Zheng models are more suitable to predict the corrosion fatigue life of high‐strength steel wires under different stress ratios.

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