The trend towards lightweight design, driven by increasingly stringent emission targets, poses challenges to conventional joining processes due to the different mechanical properties of the joining partners used to manufacture multi-material systems. For this reason, new versatile joining processes are in demand for joining dissimilar materials. In this regard, pin joining with cold extruded pin structures is a relatively new, two-stage joining process for joining materials such as

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... steel and aluminium as well as steel and fibre-reinforced plastic to multi-material systems, without the need for auxiliary elements. Due to the novelty of the process, there are currently only a few studies on the robustness of this joining process available. Thus, limited statements on the stability of the joining process considering uncertain process conditions, such as varying material properties or friction values, can be provided. Motivated by this, the presented work investigates the influence of different uncertain process parameters on the pin extrusion as well as on the joining process itself, carrying out a systematic robustness analysis. Therefore, the methodical approach covers the complete process chain of pin joining, including the load-bearing capacity of the joint by means of numerical simulation and data-driven methods. Thereby, a deeper understanding of the pin joining process is generated and the versatility of the novel joining process is increased. Additionally, the provision of manufacturing recommendations for the forming of pin joints leads to a significant decrease in the failure probability caused by ploughing or buckling effects.