Due to the increased use of lightweight sheet materials, there has been a significant increase in the use of self-pierce riveting. This paper deals with the strength and fracture mechanism of single-lap self-pierce riveted joints. The online window technique was introduced in the single-lap self-pierce riveting processes for evaluating the quality of joints. Signals obtained from sensors were amplified and transferred to the data acquisition system which measures, processes and saves the signals. Monotonic tensile tests were carried out to measure the ultimate tensile strengths for the single-lap self-pierce riveted joints. For investigating the fracture mechanism of the single-lap self-pierce riveted joints, the electrolytic polishing and anode film coating were used for dealing with the cross-section. The differential interference contrast method was used for observing the micro-structure of the cross-section of the joints. The distribution of the hardness in the cross-section of the single-lap self-pierce riveted joints was also studied. The normal hypothesis tests were performed to examine the rationality of the test data.
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