Method for forming a joint in a stack of light metal alloy sheets

A method for forming a joint in a stack of at least two sheets of light metal alloy, the stack having a thickness of at least 6.0 mm, using a self-piercing rivet comprising the steps of:

• positioning the stack over a die;
• providing a self-piercing rivet having a head and a substantially cylindrical shank that is at least partially hollow so as to define a bore that extends along at least part of the length of the rivet;
• positioning the rivet over the sheet stack at a position opposite the die;
• using a punch to set the rivet and force the rivet into the sheet stack such that the rivet pierces an upper surface of the stack and such that the shank deforms outwardly to interlock with the stack but without penetration to a die side of the stack;
• wherein an outside diameter of the shank is at least 6 mm, an effective length of the rivet is at least 1.3 times the diameter of the shank and the bore has a volume that is at least 38% of an effective solid volume of the rivet.