On the applicability of high strength self-tapping aluminium bolts in magnesium nut materials for automotive applications

High strength aluminium bolts made of AW 6056 T6, AW 7075 T6 and T79 have been investigated regarding the applicability in magnesium nut materials for automotive applications. With respect to galvanic corrosion all combinations of aluminium bolts with magnesium parts show superior corrosion properties when compared to galvanised steel bolts connected to magnesium. With respect to stress corrosion cracking (SCC) no aluminium bolt in contact with magnesium failed due to SCC. This is because of cathodic protection of aluminium alloy through magnesium. Even peak‐tempered highest strengthened T6 7xxx aluminium bolts can be used for automotive applications when compressive residual stresses are present in the thread root of the bolts.