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Low-speed friction riveting, a novel method of joining hybrid structures, is a promising technology for joining polymer with metallic structures in automotive and aerospace industries. It offers unique advantages such as weight reduction, reduced consumption of fuel and its cost without compromising the required mechanical properties. The present work deals with riveting of polymethyl methacrylate (PMMA) to aluminium (AA 1100) rivets using low-speed friction riveting technique. It reports the possibility of friction riveting at lower speed and its influence on the integrity of the hybrid joints. The performance evaluation of the low-speed-friction-riveted components is done by carrying out a series of mechanical tests. Microstructural investigation reveals the formation of distinct zones on the riveted components and modes of failure identified during the tensile and bending tests. Besides, numerical simulation of the low-speed friction riveting process has been carried out using ABAQUS 6.14-1 for better understanding of the process. The developed numerical model could be used as a tool to predict the temperature distribution. Validation shows that there is a good agreement between experimental and numerical results.

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