Upset protrusion riveting method was used to join castings. The performance of joint obtained by the method upsetting-extrusion was analyzed based on the failure modes and strength. The various testing schemes were obtained through orthogonal test method by changing diameters and depths of the punch. Furthermore, based on the principle of constant volume, rivet heights under different test schemes were calculated, and the upset protrusion riveting tests were carried out. Then, it was conducted the shearing and tensile tests of parts. According to the results, the failure modes were analyzed and the failure limit diagram of joints was obtained. At last, the effects of the geometrical dimensions of the punch on the shear strength and tensile strength of joints were studied. The results show that the tensile strength of joints is lower than the shear strength; joints occur to shearing failure on tail under the shear loading. However, joints occur to head peeling, head shearing and joint pulling failure on tail under the tensile loading.