Alpendre, João M. B.Rosado, Pedro M. S.Sampaio, Rui F. V.Pragana, João P. M.Bragança, IvoSilva, Carlos M. A.Martins, Paulo A. F.2025-07-112025-07-112025-12Alpendre, J. M. B., Rosado, P. M. S., Sampaio, R. F. V., Pragana, J. P. M., Bragança, I. M. F., Silva, C. M. A. & Martins, P. A. F. (2025). Enhancing the performance of double-flush riveted joints through hybridization with adhesive bonding. Journal of Advanced Joining Processes, 12, 1-8. https://doi.org/10.1016/j.jajp.2025.1003242666-3309http://hdl.handle.net/10400.21/21971This paper explores the potential to enhance the mechanical performance of joints created through a new joining-by-forming technique called hybrid double-flush riveting. To achieve this, adhesive bonding is used to form hybrid lap joints with superior mechanical properties. The study focuses on high-strength steel sheets and starts by identifying the appropriate surface conditions necessary for producing strong adhesive-bonded joints. A similar strategy is applied to construct double-flush riveted joints, focusing on the geometric variables involved in the process. Hybrid joints are then created by integrating adhesive bonding with double-flush riveting, with the second carried out before or after curing is completed. The experimental development is supported by finite element analysis conducted with an in-house computer program. The mechanical performance of the hybrid joints is compared to that of purely adhesive-bonded and conventionally double-flush riveted joints through shear and peel destructive testing. Results demonstrate that hybrid joints ultimately provide greater joint strength for both solicitations. This allows showcasing the hybridization of double-flush riveting with adhesive bonding as an effective solution for applications where joint strength and continuity are essential.engJoining by formingDouble-flush rivetingAdhesive bondingHybrid lap jointsFinite element modellingExperimentationresearch articlehttps://doi.org/10.1016/j.jajp.2025.100324