{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,3,8]],"date-time":"2026-03-08T02:33:26Z","timestamp":1772937206463,"version":"3.50.1"},"reference-count":28,"publisher":"MDPI AG","issue":"5","license":[{"start":{"date-parts":[[2025,5,5]],"date-time":"2025-05-05T00:00:00Z","timestamp":1746403200000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"name":"Funda\u00e7\u00e3o para a Ci\u00eancia e a Tecnologia of Portugal (FCT) and IDMEC","award":["10.54499\/UIDB\/50022\/2020"],"award-info":[{"award-number":["10.54499\/UIDB\/50022\/2020"]}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Metals"],"abstract":"<jats:p>This paper explores a novel double-flush riveting process for assembling hybrid busbars made from aluminum and copper sheets. The process involves drilling and forging countersunk holes with controlled geometry in both materials followed by compression of cylindrical rivets into the holes to create strong, form- and force-closed mechanical joints. Experimental and numerical analyses are combined to examine material flow, quantify the required forces, and assess the structural integrity of the joints through destructive testing. Additionally, the electrical resistance of these novel joints is evaluated and compared with that of ideal and conventional fastened hybrid busbar joints in order to assess their performance and reliability in real-world electrical service conditions. The results indicate that the novel double-flush riveting process is a viable alternative to other conventional joining processes, such as fastening, delivering good structural integrity and enhanced electrical conductivity for hybrid busbar applications.<\/jats:p>","DOI":"10.3390\/met15050521","type":"journal-article","created":{"date-parts":[[2025,5,5]],"date-time":"2025-05-05T21:42:09Z","timestamp":1746481329000},"page":"521","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":2,"title":["Double-Flush Riveting for Hybrid Busbar Assembly"],"prefix":"10.3390","volume":"15","author":[{"ORCID":"https:\/\/orcid.org\/0000-0002-4067-0389","authenticated-orcid":false,"given":"Rui F. V.","family":"Sampaio","sequence":"first","affiliation":[{"name":"IDMEC, Instituto Superior T\u00e9cnico, Universidade de Lisboa, 1049-001 Lisboa, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-3599-7053","authenticated-orcid":false,"given":"Jo\u00e3o P. M.","family":"Pragana","sequence":"additional","affiliation":[{"name":"IDMEC, Instituto Superior T\u00e9cnico, Universidade de Lisboa, 1049-001 Lisboa, Portugal"}]},{"given":"Miguel P.","family":"Figueiredo","sequence":"additional","affiliation":[{"name":"IDMEC, Instituto Superior T\u00e9cnico, Universidade de Lisboa, 1049-001 Lisboa, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-5409-619X","authenticated-orcid":false,"given":"Ivo M. F.","family":"Bragan\u00e7a","sequence":"additional","affiliation":[{"name":"CIMOSM, Instituto Superior de Engenharia de Lisboa, Instituto Polit\u00e9cnico de Lisboa, 1549-020 Lisboa, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-3837-5185","authenticated-orcid":false,"given":"Carlos M. A.","family":"Silva","sequence":"additional","affiliation":[{"name":"IDMEC, Instituto Superior T\u00e9cnico, Universidade de Lisboa, 1049-001 Lisboa, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-2630-4593","authenticated-orcid":false,"given":"Paulo A. F.","family":"Martins","sequence":"additional","affiliation":[{"name":"IDMEC, Instituto Superior T\u00e9cnico, Universidade de Lisboa, 1049-001 Lisboa, Portugal"}]}],"member":"1968","published-online":{"date-parts":[[2025,5,5]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"2104","DOI":"10.1016\/j.proeng.2014.10.293","article-title":"Joining Technologies for Future Automobile Multi-Material Modules","volume":"81","author":"Chastel","year":"2014","journal-title":"Procedia Eng."},{"key":"ref_2","doi-asserted-by":"crossref","unstructured":"Casalino, G. (2017). Advances in Welding Metal Alloys, Dissimilar Metals and Additively Manufactured Parts. Metals, 7.","DOI":"10.3390\/met7020032"},{"key":"ref_3","doi-asserted-by":"crossref","unstructured":"Cavezza, F., Boehm, M., Terryn, H., and Hauffman, T. (2020). A Review on Adhesively Bonded Aluminium Joints in the Automotive Industry. 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