Fatigue failure mechanism and estimation of aluminum alloy self-piercing riveting at different load levels

•Influence of varying aluminum alloys on mechanical characteristics of self-piercing riveting joints.•The microstructure, fracture behavior and failure mechanism of the joints was analyzed from macro and micro perspectives.•The mechanical properties of low ductility material Al7075 self-piercing riveting joint were studied.•The fatigue failure mechanism of 7075 self-piercing riveting joint under different load levels was investigated.•The fatigue life of 7075 self-piercing rivet joints was estimated using Paris law.