What is a Rivet: Types, Uses, Working Process, and Applications

Rivets are mechanical fasteners used to permanently join two or more materials together. They are widely utilized in various industries due to their reliability, durability, and ability to withstand significant loads. This article explores the types of rivets, their uses, working processes, and applications across different fields.

What is a Rivet?

A rivet is a mechanical fastener used to permanently join two or more materials together. It consists of a cylindrical shaft (usually with a head on one end) that is inserted into pre-drilled holes in the materials to be joined. The rivet is then deformed or expanded to create a second head, securing the materials in place.

How Do Rivets Work?

The process begins with drilling or punching holes in the materials. The rivet, typically a cylindrical shaft with a head on one end, is inserted into these aligned holes. The tail end of the rivet is then upset or bucked using mechanical force, such as a rivet gun or hammer.

During upset, the tail expands to approximately 1.5 times the original diameter of the shaft, securing the rivet firmly between the materials. This deformation flattens the tail, forming what is known as a dumbbell-shaped rivet. The original head of the rivet is called the ‘factory head,’ while the deformed end is termed the ‘buck-tail.’ Rivets create strong joints capable of supporting tension on each end of the structure. The permanently formed heads at both ends prevent the rivet from detaching from the drilled hole.

Compared to welded connections, rivets offer superior resistance to vibrations and provide secure joints. They are designed for permanent joints, akin to welding or structural adhesives, making them essential in industries requiring strong, reliable fastening solutions.

Different Types of Rivets

Rivets are essential fasteners, each type designed for specific applications based on materials and accessibility requirements. Here’s a breakdown of some key types:

Image Example	Type	Description	Applications
	Solid Rivet	Consists of a solid shaft with a head at one end. Installed by deforming the tail with a rivet gun or hammer.	Aerospace, heavy machinery.
	Split Rivet	Features a split shaft to increase surface area after installation, preventing pull-through in soft materials like leather and wood.	Basic repairs, non-critical applications.
	Blind Rivet (Pop Rivet)	nstalled from one side where the joint isn’t accessible. Uses a mandrel to deform the rivet body, snapping off at a weak point.	Automotive, construction.
	Friction Lock Rivet	Also known as self-plugging rivets, uses internal pressure to expand the shaft and plug the hole.	Structural assemblies, sealed joints.
	Self-Piercing Rivet (SPR)	Cold-forged without the need for pre-punched holes, creates a gas or water-tight joint.	Automotive body panels, appliances.
	Threaded Rivet	Blind rivet with internally threaded shafts, offering enhanced grip through threading onto a mandrel.	Furniture assembly, electronics.
	Semi-Tubular Rivet	Similar to solid rivets but with a semi-tubular end that rolls outward upon installation, requiring less force.	Textile machinery, assembly lines.
	Oscar Rivet	Functions like a blind rivet but with a split shaft that folds out during installation, ideal for high vibration environments.	Aerospace, marine applications.

Each type of rivet offers unique advantages tailored to specific engineering needs, ensuring secure and reliable joints across various industries.

What is the Difference Between a Blind Rivet and a Pop Rivet?

While both blind and POP™ rivets serve similar purposes in fastening materials, POP™ rivets are specifically designed for one-sided accessibility, making them convenient for applications where only one side of the work is accessible for installation.

How Do Pop Rivets Work?

Pop rivets, categorized as blind rivets, are designed to join materials from one side, making them ideal for situations where access to the opposite side is limited. The process begins by preparing the surfaces with drilled or punched pilot holes through both materials that need to be joined.

Next, the mandrel of the rivet is placed into the nose piece of a rivet gun, and the shaft is inserted through the prepped holes. Squeezing the trigger of the rivet gun pulls the mandrel through the hollow shaft of the rivet. This action compresses the rivet’s body, creating a secure joint between the materials.

Once the rivet is fully compressed to the appropriate depth, the mandrel snaps off cleanly at a weakened “necked” point, ensuring a tidy and flush finish. This process can be repeated as needed for additional rivets, effectively securing the materials together.

How to Calculate Rivet Size?

Rivets play a crucial role in fastening materials securely, and choosing the right size is essential for ensuring structural integrity. Here’s a straightforward method to calculate rivet size:

To determine the length of the rivet:

• Start by adding together the thickness of all materials that will be riveted together.
• Add 1.5 times the diameter of the rivet to this total thickness. This ensures that the rivet will penetrate all materials sufficiently without pulling through.

For the diameter of the rivet:

• Identify the thickness of the thickest piece of material being joined.
• Multiply this thickness by three. This calculation provides the minimum diameter required for the rivet to withstand lateral and vertical forces effectively.

Example Calculation:

• If you are joining two metal sheets, each 2 mm thick:
  • Diameter of the rivet = 3 times 2 mm = 6 mm.
  • Therefore, a 6.35 mm (one-quarter inch) rivet is appropriate.
  • Minimum length of the rivet = Total thickness (4 mm) + 1.5 times diameter (1.5 × 6.35 mm ≈ 9.5 mm) = 13.5 mm.

Why Use Rivets Instead of Bolts?

Rivets offer distinct advantages over threaded bolts in certain applications. They excel in environments prone to vibration, as they remain secure without loosening over time. Rivets also provide strong joints with minimal clamp length required.

However, compared to threaded bolts, rivets can be more labor-intensive to install and remove, requiring specialized tools and techniques. Additionally, they may offer limited clamp load capability depending on the application requirements.

Are Steel Rivets Stronger than Aluminum?

Steel rivets generally offer greater strength compared to aluminum rivets, making them suitable for applications requiring higher load-bearing capabilities. However, aluminum rivets and stainless-steel solid rivets excel in corrosion resistance, which is crucial in environments prone to rust and degradation. It’s essential to match the mechanical properties of your rivets with the components being joined to ensure optimal performance and longevity.

How Much Weight Can a Rivet Hold?

The strength of a rivet varies depending on its material and size. Here are approximate minimum shear strengths for different types of rivets:

• Aluminum Rivet/Steel Body:
  • 1/8 inch: 170 lbs
  • 5/32 inch: 260 lbs
  • 3/16 inch: 380 lbs
• Steel Rivet/Steel Body:
  • 1/8 inch: 260 lbs
  • 5/32 inch: 370 lbs
  • 3/16 inch: 540 lbs
• Stainless Rivet/Steel Body:
  • 1/8 inch: 420 lbs
  • 5/32 inch: 650 lbs
  • 3/16 inch: 950 lbs

These values represent the minimum shear strength, indicating the amount of force required to shear the rivet under load. Choosing the right rivet size and material is crucial to ensure it can withstand the intended weight and conditions of the application.

Riveting vs. Welding

Why Use Rivets Instead of Welding?

Riveting emerges as the ideal solution when joining two different types of materials together. Unlike welding, which may not be suitable or feasible for dissimilar materials such as metal and plastic, rivets offer an effective alternative. They provide a secure, durable joint without the need for specialized equipment or extensive preparation, making them versatile in various manufacturing and repair applications.

Which is Stronger, Riveting or Welding?

Welding leads to a permanent and rigid joint that surpasses the strength of riveted joints. Welded joints are known for their exceptional strength, durability, and ability to create rigid frames. Therefore, welding is often the preferred method for manufacturing products that require superior strength and rigidity. It is particularly advantageous when working with materials of different shapes, as welding can seamlessly join dissimilar components into a cohesive unit.

Advantages and Disadvantages of Rivets

Rivets are widely used fasteners known for their reliability and strength in joining materials. However, like any mechanical fastening method, they come with both advantages and disadvantages:

Advantages:

1. Strength and Durability: Rivets create strong, permanent joints that can withstand high loads and vibrations, making them ideal for structural applications in aerospace, automotive, and construction industries.
2. No Specialized Tools Required: Basic riveting tools like rivet guns and hammers are sufficient for installation, reducing dependency on complex equipment.
3. Cost-Effective: Rivets are generally inexpensive compared to other fastening methods, providing economical solutions for large-scale manufacturing and assembly.
4. Versatility: Available in various materials (aluminum, steel, copper, etc.) and types (solid, blind, tubular), rivets offer versatility to suit different material types and thicknesses.
5. Tamper Resistance: Once installed, rivets are difficult to remove without damaging the materials, enhancing security and preventing unauthorized disassembly.

Disadvantages:

1. Permanent Fastening: Unlike bolts or screws, rivets cannot be easily removed or adjusted once installed, requiring drilling out for disassembly, which can damage the materials.
2. Limited Joining Thickness: Rivets are most effective within a certain range of material thicknesses. For extremely thin or thick materials, alternative fastening methods may be more suitable.
3. Requires Access to Both Sides: Some types of rivets, like blind rivets, require access to both sides of the materials being joined for installation, which can be challenging in certain applications.
4. Potential for Corrosion: Depending on the material used, rivets may be susceptible to corrosion over time, especially in environments with high moisture or chemical exposure.
5. Skill and Precision Required: Proper installation of rivets requires skill and precision to ensure the rivet forms a secure joint without damaging the materials or compromising structural integrity.

While rivets offer significant advantages in terms of strength, cost-effectiveness, and versatility, they also come with limitations related to permanent fastening and installation requirements.

What is a Rivet Used For?

A rivet is primarily used as a fastener to permanently join two or more materials together. It achieves this by creating a strong, secure connection that can withstand various forces such as tension, shear, and vibration. Here are some specific uses of rivets:

Applications of Rivets

Rivets find applications across diverse industries:

• Structural components
• Enclosures and casing
• Chassis and frames
• Mounting brackets
• Automotive fasteners
• Sealed joints
• Casing panels
• Internal support structures
• Wearable technology

Materials Used for Rivets

Rivets are crafted from a variety of materials tailored to specific applications:

• Aluminum: Lightweight with good corrosion resistance, ideal for hand-operated installation in applications requiring ease of deformation.
• Stainless Steel: Offers excellent corrosion resistance but requires pneumatic tools for installation due to its hardness.
• Copper: Known for its excellent electrical conductivity and ease of forming.
• Steel: Available in solid or hollow shank forms, requires pneumatic or hydraulic equipment for installation; low-carbon steel preferred for its ductility.
• Brass: Combines corrosion resistance with strength and non-sparking properties, favored in industries like oil and gas for its reliability and aesthetic appeal.

Careful selection of rivet materials is crucial to avoid galvanic corrosion, ensuring compatibility with the materials being fastened.

What are Alternatives to Rivets?

While rivets are affordable and reliable, they can be time-consuming to install and are permanent, making them challenging to remove without damaging the workpiece.

In DIY projects, pop rivets are popular due to their one-sided accessibility, but their permanence can be a drawback unless you’re willing to drill out the rivet later. Another alternative is self-clinching studs, which, like press fit nuts, require access to only one side and offer the advantage of fixed rotation.

Do I Need a Rivet or a Rivet Nut?

If you anticipate needing to disassemble the assembly for storage or relocation, hardware insertion, such as a rivet nut, is recommended. Rivet nuts allow for repeated assembly and disassembly without compromising joint integrity.

On the other hand, if your priority is achieving the lightest weight and best vibration resistance, solid shaft rivets are ideal. They provide a secure, permanent joint that is resilient to vibrations, making them suitable for applications where durability and stability are crucial.

Conclusion

Rivets are essential fasteners known for their strength and permanence in joining materials. Understanding the types, uses, working processes, and applications of rivets is crucial for selecting the right fastening solution in various industrial and manufacturing contexts.

By leveraging the appropriate rivet type for specific applications, industries can achieve robust and reliable joints that withstand the demands of their operational environments, ensuring safety, longevity, and performance in their products and structures.

Take advantage of BOYI custom CNC machining services to complete your Rivets project and get a free quote now.

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Fuquan Chen

This article was written by engineers from the BOYI team. Fuquan Chen is a professional engineer and technical expert with 20 years of experience in rapid prototyping, mold manufacturing, and plastic injection molding.