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What Rivets to Use on Galvanized Steel?

Table of Contents

When dealing with galvanized steel, many people encounter a common problem: what rivets to use on galvanized steel. This is not a simple choice. If there is an electrochemical reaction between the rivets and the base material, it may lead to accelerated corrosion and affect the service life of the structure. Galvanized steel itself has good anti-rust performance, but if the rivet material does not match, it will destroy this layer of protection. Choosing the right rivets is not only about anti-corrosion, but also directly affects the strength and stability of the connection.

In engineering applications, the selection of rivets often requires a comprehensive consideration of corrosion resistance, structural strength, safety and cost. For instance, in outdoor or humid environments, if rivets undergo galvanic corrosion, the cost of maintenance and replacement far exceeds the initial material selection cost. The correct choice of rivets not only enhances the product’s lifespan but also reduces maintenance expenses over the long term.

Understanding Galvanized Steel and Its Challenges

Galvanized steel is a common structural and manufacturing material. Its surface is covered with a layer of zinc coating, which mainly serves to prevent the steel from direct contact with air or moisture, thereby delaying corrosion. Due to its durability and economy, galvanized steel is widely used in construction, transportation, energy, and outdoor facilities.

Galvanized Steel

However, in the connection and fastening process, galvanized steel faces a particular challenge: galvanic corrosion. This is an electrochemical reaction that occurs when different metals come into contact and are exposed to an electrolyte, such as rainwater or moisture. The metal with a greater potential difference is preferentially corroded.

For example:

  • If incompatible rivets (such as stainless steel or copper) are used on galvanized steel, it may accelerate the consumption of the zinc coating.
  • Once the zinc coating is damaged, the steel substrate will oxidize rapidly, eventually leading to structural failure.

This risk is particularly prominent in outdoor applications, humid environments or industrial settings. According to data from the National Association of Corrosion Engineers (NACE), the global economic loss caused by corrosion accounts for approximately 3-4% of the GDP each year. Among them, electrochemical corrosion is one of the common causes.

Therefore, in the application of galvanized steel, choosing the appropriate material for rivets is of vital importance. This not only affects the firmness of the connection but also directly determines the overall service life and maintenance costs.

Why Rivet Material Matters: Galvanic Corrosion Explained

In fastening applications, electrochemical corrosion is the most common yet often overlooked issue. Its formation conditions are quite simple:

  • Direct contact between different metals.
  • Presence of an electrolyte environment, such as rainwater, moisture or salt fog.
  • Existence of a potential difference between the metals.

When these three conditions are met, the metal with a lower potential will act as the “anode” and be corroded first. While the metal with a higher potential will serve as the “cathode” and remain relatively stable.

electrochemical corrosion
Galvanic Corrosion

Illustrative Examples

  • Use aluminum rivets on galvanized steel. Due to the significant potential difference between aluminum and zinc, in a humid environment, aluminum will accelerate oxidation, causing the strength of the rivets to rapidly decline.
  • If stainless steel rivets are used, the situation will be reversed. At this time, the zinc coating will sacrifice first, resulting in the failure of the protection of the galvanized steel, exposing the steel substrate and causing rusting.

Table: Comparison of Electrode Potentials of Common Metals

(The values are the standard electrode potentials, in relative terms, with the unit: V)

Metal / CoatingElectrode Potential (Approx. Value, V)Corrosion Risk Relation
Zinc Coating (Zn)-0.76 VMost likely to sacrifice, protects the steel substrate
Aluminum (Al)-0.68 VClose to zinc, but still carries corrosion risk
Carbon Steel (Fe)-0.44 VRelatively stable, but corrodes rapidly once zinc protection is lost
Stainless Steel (304/316)-0.10 ~ +0.05 VMuch higher potential, accelerates zinc corrosion

As can be seen from the table, the potential difference between the galvanized layer and stainless steel is the greatest, and thus the risk is the highest. The galvanized layer is relatively close to aluminum, but there are still potential risks. Suggestion:

  • On galvanized steel, it is preferable to use rivets of the same material or with similar potential. For example: galvanized steel rivets or special anti-corrosion coated rivets.
  • If stainless steel rivets must be used, measures such as isolation gaskets and insulating coatings should be employed to reduce direct metal contact.
  • In outdoor, marine or chemical environments, it is recommended to use rivet systems with higher anti-corrosion grades rather than relying on a single material.

Best Rivet Materials for Galvanized Steel

When choosing galvanized steel rivets, material compatibility is crucial. The correct selection not only ensures a strong connection but also extends the service life and reduces maintenance costs. The following are the advantages and disadvantages of several common rivet materials:

a. Galvanized steel rivets (Steel Rivets, Zinc-Plated)

  • Advantages: Consistent with galvanized steel material, with the best electrochemical compatibility. Wide range of supply, low cost.
  • Disadvantages: The exposed parts are prone to rust. Usually, additional protection is required, such as anti-rust paint or sealant.
  • Application scenarios: Construction, machinery, interior and general industrial use.

b. Stainless Steel Rivets

  • Advantages: High strength, excellent corrosion resistance, particularly suitable for outdoor environments.
  • Disadvantages: There is a significant potential difference with the galvanized layer, which may accelerate the corrosion of the zinc layer. Isolation measures are required, such as insulating gaskets, coatings or sealants.
  • Application scenarios: Outdoor facilities, transportation, humid or highly corrosive environments.

Stainless Steel Open type blind pop rivet

c. Monel rivets (nickel-copper alloy) or other special anti-corrosion rivets

Monel Solid Rivets - Wholesale Monel Rivets from Manufacturer
  • Advantages: Performs best in marine or extremely corrosive environments, resistant to salt fog and chemical corrosion.
  • Disadvantages: Expensive, not suitable for large-scale use.
  • Application scenarios: High-end applications such as ships, marine engineering, and chemical equipment.

d. Aluminum rivets (Not recommended)

  • Disadvantage: It is prone to electrochemical corrosion when in contact with galvanized steel, resulting in a short service life.
  • Application Limitations: It is only suitable for indoor use, low-strength applications, and temporary connections.
  • Expert Recommendation: Try to avoid using aluminum rivets on galvanized steel.

Summary:

Economy option: Galvanized steel rivets.
Outdoor or industrial applications: Stainless steel rivets (with isolation measures required).
Extreme environments: Monel or specially anti-corrosion rivets.
Avoid using: Aluminum rivets.

Application-Based Recommendations

applications of black anodized pop rivets

The selection of rivets is not only dependent on the material, but also closely related to the application environment. The corrosive media, load requirements and maintenance costs vary in different environments. The following table summarizes the best rivet choices for typical scenarios:

Application ScenarioRecommended Rivet MaterialDescription
Outdoor ConstructionStainless Steel Rivets + SealantResistant to rain, moisture, and temperature variations. Sealant helps reduce galvanic corrosion risk.
Indoor FixturesZinc-Plated Steel RivetsLow cost, good compatibility. Suitable for low-humidity and low-corrosion environments.
Automotive / Rail / HVACStainless Steel RivetsHigh strength and vibration resistance. Suitable for automotive body, rail transport, and HVAC systems.
Marine / CoastalMonel or Special Corrosion-Resistant Alloy RivetsExcellent corrosion resistance. Ideal for ships, port facilities, and high-salinity environments.

  • In outdoor or high-humidity environments, stainless steel rivets should be used in conjunction with isolation measures.
  • In extremely corrosive environments, although Monel is more expensive, its long-term maintenance cost is lower.
  • Indoor low-risk environments, galvanized steel rivets are the most cost-effective choice.

Rivmate Expertise & Standards

As a professional supplier in the fastener industry, Rivmate has always emphasized the compatibility of its products with galvanized steel in the design and selection process. We are well aware that the matching of the rivet material and the base material directly determines the reliability and durability of the connection.

Material Compatibility Guarantee

  • Rivmate offers a variety of material options, including galvanized steel, stainless steel, Monel, etc.
  • Each batch of products undergoes electrochemical compatibility testing to ensure safe use in different environments.
  • For the application of galvanized steel, Rivmate will preferentially recommend galvanized steel rivets or isolated stainless steel rivets to reduce the risk of electrochemical corrosion.

Adhered International Standards

IATF 16949 Certificate - Rivmate Certificate
IATF 16949

Rivmate’s products comply with and implement multiple international standards, ensuring performance and quality:

  • IFI (Industrial Fasteners Institute) — North American fastener standards.
  • ISO (International Organization for Standardization) — International unified standards.
  • DIN (Deutsches Institut fur Normung) — German industrial standards, commonly used in mechanical manufacturing.
  • ASTM (American Society for Testing and Materials) — Involves tests on material properties, corrosion resistance, etc.

The strict implementation of these standards has enabled Rivmate’s rivets to meet the requirements of industrial applications in terms of strength, corrosion resistance and consistency.

Rivmate's Selection Chart

To facilitate customers’ quick selection, Rivmate offers an intuitive selection tool.

Rivet TypeRecommended MaterialApplicable Grip RangeApplication Environment
Standard Open RivetZinc-Plated Steel1.5 – 6.0 mmIndoor structures, light installations
Sealed RivetStainless Steel2.0 – 8.0 mmOutdoor facilities, humid environments
High-Strength RivetStainless Steel / Monel3.0 – 12.0 mmTransportation, heavy-duty equipment
Special Corrosion-Resistant RivetMonel / Alloy Coated2.5 – 10.0 mmMarine, chemical, high-salt environments

The advantages of Rivmate lie in compatibility testing + international standard implementation + application scenario selection table. This not only helps customers enhance the reliability of their projects, but also reduces the maintenance costs in the later stage.

FAQ

Can aluminum rivets be used on galvanized steel?

Answer: Not recommended. There is a potential difference between aluminum and zinc. In humid or salt spray environments, it will corrode rapidly, causing the rivets to fail. Only consider this option for indoor or temporary applications.

Will stainless steel and galvanized steel corrode?

Answer: There will be risks. The potential difference between stainless steel and the galvanized layer is significant, which may accelerate the consumption of the zinc layer. However, by using sealant, insulating gaskets or surface coatings, the risk of corrosion can be significantly reduced.

What is the most cost-effective choice of rivets for galvanized steel?

Answer: The galvanized steel rivets themselves. They have the best compatibility with the base material, are inexpensive, and are widely available. For most indoor and light structures, this is the most cost-effective solution.

Is it necessary to apply a coating or sealant during the installation process?

Answer: It is strongly recommended to use it in an outdoor environment. Sealants or coatings can prevent moisture and electrolytes from penetrating, thereby extending the service life. This step is particularly crucial for applications that are exposed to rain, salt fog, or chemical environments for an extended period.

Protect Against Corrosion — Choose Rivmate Rivets Today

In the application of galvanized steel, the correct selection of rivets is of utmost importance. It not only effectively prevents electrochemical corrosion but also significantly extends the service life of the structure and reduces the cost of later maintenance. Incorrect selection often leads to premature failure and additional expenses.

From a practical application perspective:

  • Indoor environment → Choose galvanized steel rivets, which are economical and efficient.
  • Outdoor or humid environment → Use stainless steel rivets and combine with sealing measures.
  • Extremely corrosive environment → Use Monel or special anti-corrosion rivets.

Rivmate - russia(Moscow) International Fastener exhibition 2025

Rivmate offers a complete range of galvanized steel special rivet solutions, covering various materials, specifications and application scenarios. Moreover, all products comply with international standards (IFI, ISO, DIN, ASTM) and have undergone rigorous testing to ensure reliability in different environments.

If you are looking for reliable galvanized steel rivets, please contact Rivmate. Our engineering team will provide you with professional selection suggestions and highly cost-effective products based on your project requirements.

Reference

What is a rivet? Understanding rivets and the different blind rivet types

Rivets: which material is best for you?

Types of Rivets

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What is the Smallest Allowable Rivet Pitch?

Table of Contents

In structural design and manufacturing, a core issue often arises: what is the smallest allowable rivet pitch. As a connecting component, the pitch design of rivets directly affects the strength and durability of parts. If the pitch is too small, the material will have a reduced effective bearing area due to overly dense holes, and may even lead to tearing or premature failure. If the pitch is too large, the connection area may become loose or crack, thereby affecting the overall structural stability.

Rivet pitch usually refers to the distance between the centers of adjacent rivets in the same row. This parameter, seemingly simple, is closely related to material properties, force distribution, and process standards. This article will combine international standards and manufacturing experience to analyze the design basis, recommended values, and engineering practices of the minimum allowable rivet pitch.

Fundamentals of Rivet Pitch and Related Parameters

In mechanical connections and sheet metal structures, rivets are one of the most common methods of fastening. To ensure the strength and reliability of the structure, several core geometric parameters must be mastered: Pitch (rivet spacing), Edge Distance (margin), Row Spacing (row spacing). These three parameters directly determine the load-bearing capacity, fatigue life and safety of the structure.

1. What is Rivet Pitch?

Pitch refers to the distance between the centers of two adjacent rivets. It is the most fundamental layout parameter. The common recommended range is 2.5D ~ 6D (D represents the diameter of the rivet).

  • If the spacing is too small, it may cause the material to crack or have stress concentration.
  • If the spacing is too large, there may be bulging of the panels or failure of the connections.

How to extend the life of zinc plated rivets？

2. Edge Distance - Edge Distance

Edge Distance refers to the distance from the center of the rivet to the edge of the workpiece. It directly affects whether cracks will occur at the edges of the workpiece. The general requirement is ≥ 2D.

  • If the edge gap is too small, the rivets are prone to tearing the edges when under force.
  • If the edge gap is too large, it wastes materials and is not conducive to lightweighting of the structure.

In actual design, the commonly recommended value is 2D to 2.5D.

3. Row Spacing

Applications of Monobolt Blind Rivets for Commercial Vehicles

“Row Spacing” refers to the distance between adjacent rivet rows. It affects the overall load distribution and fatigue resistance performance. Generally, 2D to 4D is recommended.

  • If the spacing is too small, it will cause local weakening of the sheet material.
  • If the spacing is too large, it will result in insufficient stiffness in the connection area.

4. Why These Three Parameters Are Critical?

Pitch, Edge Distance, and Row Spacing jointly determine the overall performance of the connection:

  1. Load-bearing capacity: Appropriate spacing ensures uniform distribution of the load and avoids local overloading.
  2. Fatigue life: Avoid stress concentration and crack initiation points.
  3. Structural stability: Prevent warping, bulging or loosening of the plates.

In the aviation and automotive industries, riveted components need to undergo fatigue tests. The data shows that an improper Pitch arrangement can reduce the fatigue life by more than 30%.

5. Design Best Practices

  • Always take the diameter D of the rivets as the benchmark and follow the empirical formula.
  • Use Pitch ≥ 3D as the safety lower limit.
  • The edge clearance should be maintained at 2D ~ 2.5D, avoiding the risk of cracks.
  • The pitch should be controlled within 2D ~ 4D, ensuring uniform load distribution.
  • For high-strength materials or thin plates, the spacing should be appropriately increased.

Design Basis for Minimum Rivet Pitch

Purchasing cost of zinc plated blind rivets

The arrangement of rivets is not merely a geometric issue; it is directly related to the structural strength and safety. The minimum allowable pitch (Pitch) depends on the loading method, the characteristics of the sheet material, the size of the rivets, and relevant standards. The following will be analyzed from four perspectives.

a. Load and Stress Distribution

The rivets may be subjected to shear, tension or fatigue loads during the connection process.

  • Shear load: The rivets mainly bear the transverse shear force. If the Pitch is too small at this time, the area between the holes will become too weak and may lead to failure by shearing.
  • Tensile load: The edge area of the sheet component is subjected to concentrated tensile stress. If the Pitch is too small, cracks are prone to expand.
  • Fatigue load: Under repetitive cyclic stress, the stress concentration around the rivet hole is a key risk point. Studies have shown that when the Pitch is less than 2.5D, the fatigue life may be shortened by more than 40%.

b. Influence of Plate Thickness and Material

  • Thick plate: High rigidity, capable of withstanding smaller pitch distances.
  • Thin plate: Insufficient rigidity. If the Pitch is too small, it is prone to bulging or cracking.
  • Soft materials (aluminum, copper alloys): Require larger pitch distances to avoid fatigue cracks between holes.
  • High-strength steel or titanium alloys: Can moderately reduce Pitch, but still need to follow the standard lower limit.

The pitch is usually no less than 3t (where t represents the plate thickness) to prevent the failure of thin plates.

c. Rivet Diameter and Pitch Ratio

International engineering experience is based on the reference of D (diameter of rivets).

  • Common recommended minimum value: 2.5D ~ 3D
  • Typical safe range: 3D ~ 6D
  • The edge distance and pitch distance are usually determined in multiples of D to ensure geometric stability.

For instance, for a 6mm diameter rivet, the minimum value of Pitch should be ≥ 15mm.

d. International Standards

The requirements for the minimum Pitch vary slightly among different rivet standards, but the principle remains the same: to avoid stress concentration and ensure fatigue life.

  • ASME (American Society of Mechanical Engineers): It is recommended that Pitch be ≥ 3D and the clearance be ≥ 2D.
  • ISO (International Organization for Standardization): Most standards adopt a lower limit of Pitch ≥ 3D.
  • MIL-STD (U.S. Military Standard): Depending on the material and thickness, typically Pitch ≥ 2.5D is specified.
  • FAA (Federal Aviation Administration): Requirements for aerospace structural components are strict. Pitch is generally ≥ 4D, and in fatigue zones, it can even be ≥ 6D.

In safety-sensitive industries (such as aviation and military), the standards are more stringent. It is preferable to sacrifice lightweighting in order to ensure the lifespan.

Practical Design Takeaway

  1. The minimum Pitch must not be lower than 2.5D, and it is recommended to choose 3D ~ 6D.
  2. For thin plates and soft materials, a larger Pitch should be selected.
  3. For fatigue zones or high-stress areas, follow the FAA ≥ 4D or stricter requirements.
  4. Always consider the three dimensions of D, t, and material together, and avoid considering only one aspect.

Recommended Minimum Rivet Pitch Values

Industry applications for zinc plated blind rivets

Table: Recommended Values for Minimum Allowable Pitch

Rivet Diameter (D)Minimum Pitch (P)Edge Distance (E)Row Spacing (R)Notes
1/8 in (3.2 mm)2.5D – 3D≥ 2D≥ 2.5DFor thin sheet assemblies, avoid cracking
3/16 in (4.8 mm)3D≥ 2D≥ 3DGeneral structural applications
1/4 in (6.4 mm)3D – 3.5D≥ 2.5D≥ 3DSuitable for high-strength joints
5/16 in (8.0 mm)3.5D – 4D≥ 2.5D≥ 3.5DUsed in automotive / railway structures
3/8 in (9.5 mm)4D≥ 3D≥ 4DHeavy-duty structures, bridges
> 3/8 in (>9.5 mm)≥ 4D – 6D≥ 3D≥ 4DAerospace, marine, and fatigue-critical joints

  1. Small diameter rivets (≤ 1/8 inch)

    Suitable for thin plate assembly. The pitch can be appropriately reduced to 2.5D – 3D, but it must maintain sufficient margins (≥ 2D) to avoid edge tearing.

  2. Medium-diameter rivets (3/16 in to 1/4 in)

    This is the most common range, widely used in general structures. It is recommended that the Pitch be set at 3D to 3.5D. At this point, the differences in plate thickness and material have a significant impact on the design, and the choice should be made based on the actual situation.

  3. Bolts with larger diameters (5/16 in to 3/8 in) It is mainly applied in automobiles, railways and heavy structures. Pitch suggests raising the level to 3.5D ~ 4D to ensure uniform stress distribution.

  4. Extra-large diameter rivets (> 3/8 inch) It is commonly found in critical fatigue areas of aerospace and shipbuilding. The minimum Pitch is usually ≥ 4D, and sometimes it needs to reach 6D to meet the strict requirements of FAA or MIL-STD.

Summary of Design Points

  • The Pitch must increase along with the D value to prevent crack propagation due to insufficient material between the holes.
  • The Edge Distance and Row Spacing are equally crucial. It is recommended to maintain ≥ 2D and ≥ 3D respectively.
  • Industry standards vary:
    • ASME/ISO: It is recommended that Pitch be ≥ 3D;
    • MIL-STD: Allows 2.5D, but requires stricter control of the Edge Distance;
    • FAA: In fatigue-sensitive areas, it often requires Pitch to be ≥ 4D, even ≥ 6D.

Minimum Rivet Pitch in Engineering Applications

The minimum Pitch is not a fixed value; it depends on industry requirements and the usage environment. Different rivet application scenarios have different focuses on fatigue life, plate thickness, corrosion, and assembly efficiency. The following summarizes the practical experiences in four typical fields.

① Aerospace Industry

In the aerospace field, riveted structures must withstand high cyclic loads, so fatigue life is the most critical design criterion. To ensure safety, Pitch usually requires a value of at least 4D. In the specifications of FAA and MIL-STD, some key areas even stipulate that Pitch must reach 6D. Taking the aluminum alloy fuselages of Boeing and Airbus as an example, they generally adopt Pitch ranging from 4D to 6D in their designs to reduce crack initiation and delay the occurrence of fatigue failure.

② Marine Engineering

In ship engineering, the selection of Pitch not only needs to consider structural strength, but also needs to take into account corrosion resistance and thick plate welding techniques. If Pitch is too small, stress concentration between holes will occur, and the corrosion expansion speed will accelerate. Therefore, ship design usually adopts 3D as the recommended value, especially in the connection area between decks and bulkheads. Practice has shown that for the bulkhead structure of steel cargo ships, 3D Pitch is the most common and reliable design choice.

③ Automotive Manufacturing

The automotive industry emphasizes lightweighting and high-efficiency assembly. Due to the generally thin body panels, the diameter of the rivets used is also smaller, so the Pitch can be appropriately reduced. Generally, non-critical load-bearing areas can adopt a 2.5D Pitch, which can not only ensure strength but also help improve production efficiency. 

Rivmate Automotive Blind Rivets Solution

However, in the chassis and key components involving safety, the Pitch often needs to be increased to above 3D to ensure long-term durability and safety. A typical application is the sheet metal assembly of the vehicle body, and 2.5D Pitch has become a common practice in the industry.

④ Civil and Structural Engineering

In construction and bridge engineering, thick steel plates are commonly used as the main load-bearing components. If the Pitch is too small, it is prone to cause crack propagation in the concentrated force areas, thereby reducing the overall lifespan. Therefore, design specifications generally require that the Pitch in the ordinary areas be no less than 3D, while at the nodes and stress concentration points, the Pitch needs to be increased to 4D or even higher. Taking steel bridges as an example, in the riveted joint areas, a Pitch of ≥ 4D is usually adopted to enhance the fatigue resistance and extend the service life.

Practical Takeaway: Practical Design Points

  1. Aerospace: Focus on fatigue life → Pitch ≥ 4D (Critical parts ≥ 6D).
  2. Marine Engineering: Balance thickness and corrosion resistance → Pitch usually takes 3D.
  3. Automotive Manufacturing: Pursue lightweight and efficiency → Pitch can be as low as 2.5D.
  4. Building Steel Structures: Pay attention to the force on joints → Pitch is generally ≥ 3D, and critical parts ≥ 4D.

The selection of the minimum Pitch must be based on industry standards and actual working conditions. A Pitch that is too small will reduce the fatigue life, while a Pitch that is too large may lead to material waste and assembly difficulties.

Common Design Errors and Failure Modes in Rivet Pitch

Special Tail Structure of Monobolt Rivets

The rationality of the pitch of the rivets directly determines the strength and lifespan of the connection components. Incorrect pitch design can lead to various types of failures, affecting safety and reliability. The following summarizes three common problems and their typical consequences.

Pitch Too Small

Typical failure modes: Plate tearing, inter-pore cracking.
Reason Analysis: When Pitch is less than 2.5D, the amount of material between the holes is insufficient, resulting in significant stress concentration. During tension, cracks are prone to propagate.
Engineering Example: Research shows that when the Pitch is reduced from 3D to 2D, the fatigue life may decrease by more than 40%.
Preventive Measures: Follow the principle of minimum Pitch ≥ 2.5D, and appropriately enlarge it based on the plate thickness and material.

Pitch Too Large

Typical failure modes: Joint opening, structural loosening, fatigue cracks.
Reason Analysis: The excessive pitch causes the load to be unevenly distributed, and the area between the rivets is prone to bulging or warping of the plates.
Engineering Example: In bridges and ships, an excessively large Pitch value can reduce the sealing performance of the joints, accelerating corrosion and fatigue damage.
Preventive Measures: Generally, it should not exceed 6D. For areas with high fatigue, it should be limited to between 3D and 4D.

Uneven Pitch

Typical failure modes: Stress concentration, structural offset, and concentrated fatigue cracks.
Cause Analysis: The pitch distribution is uneven, and some rivets are bearing excessive loads, resulting in excessively high local stress.
Engineering Example: In aircraft maintenance, the non-standard spacing arrangement often leads to local bulging of the fuselage skin.
Preventive Measures: Maintain pitch consistency. If special arrangements are required, finite element analysis (FEA) verification should be conducted.

Rivmate Expert Recommendations for Rivet Pitch Design

In the design of riveting, Pitch not only affects the structural strength but also determines the fatigue life. Rivmate engineering experts suggest considering it from three aspects: plate thickness, rivet diameter, and load type, and using standardized tools to enhance the design efficiency and reliability.

How to Determine Pitch Based on Key Factors

  • Plate thickness (t): For thin plates, a larger Pitch (≥ 3t) should be adopted to avoid bulging and cracks; for thick plates, the Pitch can be appropriately reduced.
  • Bolt diameter (D): Generally, Pitch should be ≥ 2.5D; the recommended range is 3D to 6D to ensure that the material between the holes has sufficient load-bearing capacity.
  • Load type:
    • Shear load → A smaller Pitch (≈ 2.5D ~ 3D) is allowed.
    • Tension load → It is recommended to be ≥ 3D.
    • Fatigue load → It should be ≥ 4D, and for critical parts, it should even be ≥ 6D.

The minimum Pitch should not be considered in isolation; instead, it needs to be evaluated comprehensively in conjunction with t, D, and the load.

Using Rivmate Pitch Verification Table

Rivmate has provided comparison and verification tables based on ASME, ISO, FAA, MIL-STD.

  • The table provides the recommended Pitch for different diameter rivets in thin plates, medium-thick plates and thick plates.
  • For shear, tension and fatigue conditions, the safety ranges are listed separately.
  • Engineers can quickly compare and avoid common design errors.

How Rivmate Products Reduce Pitch Sensitivity

Rivmate’s high consistency rivets achieve this by implementing strict tolerance control and surface treatment, thereby reducing the sensitivity of the Pitch design to failure modes.

  • Diameter tolerance control ±0.01 mm → Reduces the deviation between hole diameter and spacing.
  • Anti-fatigue surface treatment → Enhances the crack resistance around the holes.
  • Batch consistency verification → Ensures the minimization of Pitch deviation after assembly.

The result is: Even when the pitch approaches the design limit, the Rivmate rivets can still maintain a stable fatigue life. This is particularly crucial for industries with high reliability requirements such as automobiles and aviation.

FAQ

Q1: Are the minimum pitches for all types of rivets the same?

No. Different types of rivets (such as open-type, closed-type, and solid rivets) have different minimum Pitch requirements. The minimum Pitch (distance between nail centers) usually depends on the following factors:

  • Bolt diameter (D)
  • Material strength and thickness
  • rivet type and structural method

Take aviation standards as an example, the minimum Pitch of solid rivets is usually set at 2D to 4D. For opening-type rivets used in commercial or industrial applications, the Pitch can be appropriately reduced based on the material’s load-bearing capacity, but it is generally not recommended to be lower than 2D.

Q2: Can the Pitch value be less than 2D?

It is not recommended. A pitch value less than 2D will lead to the following risks:

  • Insufficient material spacing, prone to tearing
  • Installation tools interfere, insufficient operation space
  • Banging pins interfere or deform, affecting connection strength

Unless verified through finite element analysis in the design of extremely small components, general industrial standards typically recommend that Pitch ≥ 2D. For instance, the SAE ASME standards and guidelines from multiple OEMs all stipulate this lower limit.

Q3: How to balance Pitch and Edge Distance in the arrangement of multiple rows of rivets?

The following optimization principles are recommended to be followed:

  1. Set the margin first, then adjust the Pitch
    • The “Edge Distance ≥ 1.5D” is the starting point for conventional design.
    • At the edges in the direction of load (pull/ shear), priority should be given to ensuring the margin to prevent material tearing.
  2. Misalignment design is superior.
    • For layouts with more than two rows, “alternating arrangement” is recommended.
    • This method can reduce the Pitch requirement and enhance the connection strength.
  3. Use CAD/CAE for auxiliary analysis
    • Before optimizing the layout, it is recommended to conduct interference checks using a 2D model.
    • If there is a connection of thin plates, the effects such as plate warping and local yielding need to be evaluated.

Q4: Can Rivmate offer engineering consulting services for pitch optimization?

Sure. Rivmate offers the following professional services:

  • Bolts layout optimization suggestions (including Pitch, margin, and arrangement method)
  • CAD drawing review and modification suggestions
  • Connection strength analysis (can be combined with customer’s FEA report)
  • Engineering drawing standardization, in line with international standards (such as NAS, DIN, GB)

For more detailed inquiries, you can contact the Rivmate engineering support team and provide the specific part drawings and connection requirements.

Conclusion

The minimum pitch (spacing) for rivets has no “uniform standard”. It must take into account multiple parameters in actual applications, such as:

  • Bolt diameter (D)
  • Plate thickness
  • Load type (shear or tension)
  • Adopted standard (such as GB, DIN, NAS)

A proper setting of Pitch is the foundation for connecting strength, safety and structural lifespan.

An excessively small Pitch can cause material tearing, failure or installation difficulties. An excessively large Pitch may reduce onnection efficiency and increase material costs. When designing the layout of rivets, engineers should fully consider the margin, arrangement method and load path. It is recommended to combine industry standards with actual conditions and use CAD or FEA tools to assist in optimization.

For professional consultation or data support, Rivmate offers services for evaluating and optimizing riveted structures, helping you achieve lightweighting and high reliability of the structure.

Reference

Influence of Rivet Diameter and Pitch on the Fatigue Performance of Riveted Lap Joints Based on Stress Distribution Analysis

Rivet Pitch and Layout

Types of Rivets

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When to Use Rivets？

Table of Contents

During the product design and assembly process, the choice of the appropriate connection method directly affects the strength, cost and lifespan of the structure. Rivets, as a traditional yet efficient means of fastening, are still widely used in various industries. However, when faced with multiple alternative solutions such as screws, welding, and gluing, many engineers will ask: “When to Use Rivets?”

This issue not only involves technical judgment, but also relates to manufacturing efficiency, material compatibility and long-term reliability. Understanding the advantages and applicable scenarios of rivets can help engineers make better decisions at the initial design stage, avoiding rework, failure or unnecessary cost waste.

Core Advantages of Rivet Joints

Do Zinc Plated Rivets Rust

Permanent Joint

After assembly, the rivets will undergo irreversible plastic deformation. Compared to screws, they are less likely to loosen due to vibration or prolonged use. Especially in critical load-bearing structures, rivets can ensure long-term stability and safety.

Blind Installation

The rivets can be installed on one side, which is an advantage that cannot be matched by screws and welding. For structures that are narrow and cannot be contacted on both sides, blind rivets are the ideal choice. For example, in the assembly of car body interiors or electronic enclosures, rivets can effectively simplify the process.

Vibration and Fatigue Resistance

Bolts possess excellent vibration resistance and fatigue resistance properties. The reason why bolts are widely used in the aviation, automotive and railway industries is that they can maintain stable connections even under high-frequency vibrations and alternating loads. Research has shown that bolted structures often outperform welded components in terms of fatigue life.

Lightweight and High Strength-to-Weight Ratio

Lightweight materials such as aluminum alloys and titanium alloys can fully utilize their strength advantages during riveting without experiencing performance degradation due to high-temperature welding. This makes rivets particularly suitable for the aerospace and electric vehicle industries, allowing for enhanced strength while reducing the overall weight.

When Must Rivets Be Used Instead of Screws or Welding?

In mechanical manufacturing, automobiles, aerospace, and construction, the choice of fastening method is of great significance. Screws, rivets, and welding each have their own advantages. However, in some specific situations, rivets are the best choice.

1. One-Side Access → Blind Rivets

When the structure can only be installed from one side, screws and welding cannot complete the operation.
Blind rivets can achieve efficient connection on a single side.
This kind of situation is commonly seen in scenarios such as aircraft skins and the inner cavities of car doors.

Are there galvanic corrosion problems

2. High Vibration Conditions → Better Loosening Resistance

Nuts are prone to loosening under prolonged vibration. Even with the use of anti-loosening washers or thread sealants, it is difficult to completely prevent this from happening. The rivets are of a permanent mechanical locking type and have better vibration resistance than screws.

The data shows that in the aviation industry, more than 60% of structural connections use rivets instead of screws, precisely because of their superior fatigue resistance and anti-loosening properties.

3. Thin Sheet Metal / Composites → Avoid Thread Damage

The screw requires sufficient plate thickness to form a reliable thread.
For thin metal plates or composite materials, screws are prone to slip or break.
The rivets are fixed by deformation through riveting and do not rely on threads. Therefore, they are more suitable for thin-walled materials.

4. Appearance & Aerodynamics → Countersunk Rivets

Countersunk Head Open Type Blind Rivet

In automotive body parts, aircraft wings or high-speed rail car bodies, surface flatness and aerodynamic performance are of great importance.
The countersunk rivets can be flush with the surface of the material, reducing air resistance while maintaining a good appearance.

5. Welding Not Feasible → Riveting as an Alternative

Welding generates high temperatures, which may lead to:

  • The strength of the heat affected zone (HAZ) decreases
  • Material deformation
  • Failure of the coating or anti-corrosion layer

For high-strength alloys or heat-sensitive materials, riveting is a better option. In aircraft manufacturing, more than 70% of the aluminum alloy components are joined by riveting rather than welding, and this is for this reason.

  • Can only be operated on one side → Use blind rivets
  • High vibration conditions → Rivets are more reliable than screws
  • Thin plates or composite materials → Avoid thread damage
  • Requirements for appearance/airflow → Choose counter-sunk rivets
  • Welding is not feasible → Riveting is an alternative solution

Bolts are not only a traditional technique, but also the only reliable connection method under specific working conditions.

Rivets Compared with Other Fastening Methods

Fastening MethodKey AdvantagesLimitationsBest Use Cases
RivetsPermanent, vibration-resistant, blind installationNot removableAerospace, automotive, thin sheet metal
ScrewsRemovable, easy to installCan loosen under vibrationElectronics, furniture, repair parts
WeldingStrong, continuous jointsHeat distortion, requires skilled laborHeavy structures, pipelines
AdhesivesSmooth surface, distributes loadLong curing time, weaker in shearComposites, decorative panels

1) Rivets vs Screws

Can I Replace Rivets with Screws?

Comparison of Characteristics

  • Nails: Permanent connection. Once installed, they cannot be easily removed.
  • Screws: Removable. Suitable for areas that require frequent maintenance and replacement.

Analysis of Advantages and Disadvantages

  • The rivets have stronger vibration resistance. They are less likely to loosen under long-term vibration.
  • Screws may fail under high-frequency vibration, even with anti-loosening measures in place, and there is still a risk.
  • Screws are prone to damaging the threads in thin plates or composite materials. Rivets are more stable in such materials.

If you want maintainability → Choose screws.
If you need good vibration resistance and long-term stability → choose rivets.

2) Rivets vs Welding

Strength of Welded vs Riveted Ship：What Are the Differences？

Comparison of Characteristics

  • Nails: Cold connection, no heating required.
  • Welding: High-temperature operation, may affect material properties.

Analysis of Advantages and Disadvantages

  • Welding will create a heat affected zone (HAZ), resulting in reduced strength or structural deformation.
  • Rivets avoid thermal stress and are suitable for heat-sensitive alloys and composite materials.
  • Welding offers good overall sealing performance, but the process is complex and the quality consistency depends on the skill level of the welder.
  • Rivet connections do not require special environments and have more stable assembly cycle times.

If the material can withstand high temperatures and requires complete sealing → Choose welding.
If there is concern about heat effects or connection between different materials → choose rivets.

3) Rivets vs Adhesives

Comparison of Characteristics

  • Nails: Mechanical connection, they can bear weight immediately after installation.
  • Adhesives: Chemical connection, they require a curing time.

Analysis of Advantages and Disadvantages

  • Adhesives are widely used in composite materials and sealing applications, but the curing conditions (time, temperature, humidity) affect reliability.
  • Nails can be installed immediately without waiting.
  • Adhesives have limited shear strength and may fail due to long-term aging.
  • Nails have clear load-bearing capacity and more predictable fatigue resistance.

If lightweighting and sealing performance are the priorities → Adhesives can be used.
If one seeks immediate effectiveness and long-term stability → The rivet is superior.

Common Applications: When to Use Rivets

A rivet is a widely used permanent fastener. In many situations, screws or welding are not suitable, and rivets become the best choice. Here are some typical industry rivet application scenarios:

applications of black anodized pop rivets

1) Aerospace Industry → Skin Panels and Fatigue Resistance

In aerospace engineering, the answer to “when to use rivets” is very clear. A large number of rivets are used in the aircraft skin, wing frame and cabin section connections.

The reasons include:

  • In a high-vibration environment, the rivets are less likely to loosen.
  • The aluminum alloy material is sensitive to welding, and riveting avoids damage to the heat affected zone.
  • The arrangement of rivets can disperse the load and increase the fatigue life.

A modern commercial aircraft may contain more than 2 million rivets.

2) Automotive Industry → Body Panels and Chassis Components

In automobile manufacturing, rivets are commonly used for:

  • Body panels, such as doors, roof, and trunk lid.
  • Attachment of chassis components, such as heat shielding plates and reinforcement plates.

Advantages:

  • The process is quick. Assembly can be completed with a riveting gun.
  • It is reliable in a vibrating environment. It is more durable than screws.
  • It is suitable for connecting different materials, such as aluminum plates and steel plates.

With the trend towards lightweighting, aluminum alloy bodies are becoming increasingly popular. The welding process is difficult, while riveting has become a more economical alternative method.

3) Construction and Architecture → Curtain Walls and Roofing

In the construction industry, when to use rivets is commonly found in:

  • Fixing of aluminum alloy curtain wall keels and panels.
  • Jointing of metal roof panels.

Advantages:

  • Strong wind resistance capacity.
  • Quick installation, suitable for large-scale construction.
  • The rivets have a neat appearance and can be coordinated with the coating.

4) Electronics and Home Appliances → Thin Sheet Assembly

In electronic products and household appliances, rivets are used for:

  • The thin plate shell is fixed.
  • The internal support is connected to the heat dissipation component.

Reason:

  • Screws are prone to damaging thin plates, while rivets are more reliable.
  • The assembly process is highly automated, making it suitable for mass production.
  • The rivet heads are small, which does not affect the appearance.

5) Furniture & DIY → Fast and Permanent Assembly

In furniture, hardware and DIY applications, rivets are commonly found in:In furniture, hardware and DIY applications, rivets are commonly found in:

  • Metal frame furniture.
  • Toolboxes, storage cabinets.
  • DIY projects require quick and maintenance-free connection points.

Advantages:

  • The tool is simple and easy to install.
  • No professional welding equipment is required.
  • The cost is low and it is suitable for small-scale production or individual use.

Key Factors Affecting Rivet Selection

In engineering and manufacturing, choosing the appropriate rivets is of utmost importance. Different working conditions determine different selection strategies. The following factors are the core for determining “when to use rivets” and how to select them.

a. Material Type and Thickness

Custom Raw Material
  • Aluminum alloy: Lightweight, suitable for aviation and automobiles. Moderate in strength, but good in corrosion resistance.
  • Stainless steel: High in strength, resistant to corrosion. Commonly used in construction and ships.
  • Steel: Low cost, strong in bearing capacity. Suitable for general machinery.
  • Composite materials: Not suitable for threaded connections. Rivets can disperse stress and avoid inter-layer damage.

Thickness is also crucial. Thin plates (≤1.5mm) are prone to being pulled through and require large flange heads or back washers. Thick plates can withstand higher shear and tensile loads.

b. Load Type (Shear vs Tensile vs Fatigue)

  • Shear Load: Rivets are best suited for withstanding shear force. The hole wall is compressed, ensuring a stable connection.
  • Tensile Load: The diameter or quantity of the rivets should be increased. Otherwise, they may be easily pulled out.
  • Fatigue Load: Common in the aviation and rail industries. High-quality hole processing and proper arrangement are required.

Empirical data: In the aviation industry, more than 70% of rivet operations are carried out in a shearing state, rather than a stretching state.

c. Environmental Conditions

  • High Temperature: Avoid using aluminum rivets as their strength significantly decreases at high temperatures.
  • Damp Environment: It is recommended to use stainless steel or rivets with anti-corrosion coatings.
  • Corrosive Environment: Consider electrochemical corrosion. Contact between different metals will accelerate damage.

In the fields of marine engineering and chemical industry, choosing the appropriate materials and coatings is particularly crucial.

d. Appearance and Surface Treatment

  • Countersunk Head Rivets: Suitable for applications with high requirements for appearance and aerodynamics (such as aircraft skins and body panels).
  • Blind Rivets: Prevent leakage and ensure a complete surface.
  • Surface Coatings: Can enhance appearance and corrosion resistance.

In the consumer electronics and home appliance industries, the appearance quality directly affects the user experience.

Rivmate Material and Coating Options

Types of Blind Rivets

Rivmate offers a variety of materials and coatings to meet different working conditions:

  • Aluminum, stainless steel, carbon steel → Covering from lightweight to high-strength requirements.
  • Anti-corrosion coatings → Including galvanization, nickel plating, anodizing, etc.
  • Weather-resistant solutions → For humid, marine and chemical environments.

By combining materials and coatings, Rivmate can assist customers in balancing cost, strength and durability.

Rivmate Expert Advice: How to Select the Right Rivet

The selection of rivets is not simply a matter of size matching. Different materials, loads and working conditions all have specific requirements for diameter, clamping range and head shape. The engineering team at Rivmate has summarized the following suggestions to help customers avoid common mistakes and enhance connection reliability.

Select the Right Diameter, Grip Range, and Head Style

  • Diameter: Determines the load-bearing capacity. A common rule of thumb is that the diameter of the rivet is approximately three times the thickness of the sheet.
  • Grip Range: Must cover the actual layer thickness. Too small will cause the sheet to be pulled through, and too large will not allow for secure locking.

  • Head Type:

    Round head → Universal, easy to install.

    Large flange head → Suitable for thin sheets or soft materials, reducing surface pressure.

    Countersunk head → Suitable for occasions with high requirements for appearance or air power.

Types of Aluminum Blid Rivets Head

Avoid the Common Mistake: Ignoring Material Compatibility

Many users only focus on the size of the rivets while neglecting the material properties, which often leads to early failure:

  • Electrochemical Corrosion: Different metals coming into contact (such as aluminum and stainless steel) will corrode rapidly in a humid environment.
  • Strength Mismatch: Using a high-strength base material with a low-strength rivet may fail under fatigue.
  • Insufficient Environmental Adaptability: In marine or chemical environments, without a protective coating, the lifespan will be significantly shortened.

Solution:

  • Keep the base material similar to the rivet material.
  • If necessary, choose rivets with anti-corrosion coatings.
  • Conduct salt spray or fatigue tests under critical operating conditions.

Rivmate Engineering Support

Rivmate offers comprehensive engineering support to ensure that customers make the right decisions:

  • Consulting Services: Based on the design drawings and operating conditions, recommend the optimal riveting solution.
  • Sample Testing: Samples can be provided for actual assembly and tensile/shear tests.
  • Technical Documentation: Includes material compatibility tables, installation specifications, and failure analysis guidance.

FAQ

1) Are Rivets Stronger Than Screws?

  • Under high vibration and fatigue conditions, rivets are usually more reliable than screws.
  • Screws rely on preload and friction and are prone to failure due to loosening or vibration.
  • Rivets are of permanent mechanical locking type and have no rotating interface, so they will not loosen by themselves.

In aircraft structures, over 60% of the connection points use rivets, and the reason for this is that they offer better resistance to fatigue and loosening.

2) Can Blind Rivets Be Used in Plastics or Composites?

Yes, but it requires the correct selection of the model.

  • For soft materials or composite materials, a large flange head or a back washer should be selected to distribute the surface pressure.
  • Using closed-end blind rivets can prevent the core shaft from loosening and causing damage to the material.
  • In high-load situations, it is recommended to conduct actual tests to confirm the strength and fatigue performance at the edge of the hole.

3) Are Rivets Waterproof?

  • Ordinary open-type rivets are not waterproof. Water may seep through the pores and crack locations.
  • If waterproofing is required, sealed/closed-end rivets should be chosen and sealed with sealant during assembly.
  • In the aviation and automotive industries, sealing rivets are commonly used to ensure the sealing performance of compartments and the body.

4) How to Prevent Rivet Corrosion?

  • Material Matching: Try to use materials with similar electrical potential to the base material. For example, use aluminum rivets for aluminum plates.
  • Protective Coatings: Use galvanized, nickel-plated or anodized rivets to enhance corrosion resistance.
  • Isolation Measures: Add coatings, sealants or gaskets between different metals to reduce galvanic corrosion.
  • Environmental Selection: In marine or chemical environments, it is recommended to use stainless steel or special anti-corrosion rivets.

Rivmate Solution: Offers a variety of material and coating combinations, such as stainless steel closed-end blind rivets + anti-corrosion coating, which is suitable for high humidity or salt spray environments.

Conclusion: When to Use Rivets as the Best Choice

In industrial manufacturing, screws, welding and adhesives all have their application scenarios. However, under the following conditions, Rivets (bolts) are often the best choice:

  • Permanent connection → One-time installation, long-term reliability.
  • High-vibration environment → Better anti-loosening performance than screws.
  • Single-sided operation → Blind rivets provide the only feasible solution.
  • Thin plates or composite materials → Avoid thread damage, maintain structural integrity.
  • Welding not feasible → No heat affected zone, does not damage material properties.

Why Choose Rivmate?

Rivmate Rivet Factory in Jiangsu, China

Rivmate not only offers a full range of rivet products (blind rivets, structural rivets, countersunk rivets, waterproof rivets, etc.), but also provides:

  • Engineering Selection Guidance: Based on materials, loads and environment, recommend the best solution.
  • Samples and Testing Support: Assist customers in verifying connection strength and lifespan.
  • Technical Documents and Standards: Ensure that the installation process is controllable and traceable.

This combination of “product + engineering support” ensures that customers not only can purchase the appropriate rivets, but also can achieve long-term reliability in their applications.

Reference

Knowing When To Use Rivets

Types of Rivets And Their Applications

Types of Rivets

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What is the Difference Between Countersunk Rivets and Regular Rivets? – Rivmate Expert Guide

Table of Contents

In practical engineering applications, the difference between countersunk rivets and regular rivets (the distinction between countersunk rivets and regular rivets) often becomes a concern for selection personnel and engineers. This is not only related to the structural form of the rivets themselves, but also directly affects the assembly appearance, stress performance, and maintenance efficiency in the future. Countersunk blind rivets and regular blind rivets are common types of Blind Rivets. Although there are obvious differences in appearance, they each have their own advantages in different usage scenarios.

Blind Rivets play a crucial role in modern manufacturing, especially in assembly scenarios where operations can only be performed from one side. These rivets can achieve a secure connection without the need to apply force from the back. They are the preferred fastening method for enhancing assembly efficiency. This article aims to provide clear technical references for product design, process planning, and procurement evaluation.

Basic Definitions and Structural Characteristics

Countersunk Blind Rivets

The head of the countersunk rivet is of conical design. After installation, the head can be flush with the surface of the workpiece. A conical countersunk hole needs to be pre-drilled on the workpiece. This structure can effectively improve the flatness of the finished product’s appearance, and is particularly suitable for situations where surface smoothness is required. It is commonly used to reduce air or water resistance, such as in aircraft skins, ship hulls, or high-end equipment covers. Additionally, the flat structure also helps to reduce the risk of scratches and improve the safety of use.

Countersunk Head Monobolt Rivet

Regular Blind Rivets

The heads of conventional rivets are mostly round or large cap-shaped, and they are clearly exposed after installation. Compared with countersunk rivets, their installation process is simpler. No need to drill a deep hole; only a standard round hole is required. Due to the exposed rivet heads, the contact surface is larger, making them suitable for connecting structural components with high requirements for anti-tension performance. Such rivets are commonly found in mechanical structures, equipment frames, and industrial products with low requirements for appearance. The emphasis is on structural strength and reliability.

Core Structure and Installation Differences

When Would You Use a Countersunk Head Rivet

Before installation, Countersunk Blind Rivets require the processing of conical blind holes in the sheet material. This process has higher requirements for the accuracy of the angle and depth of the holes. Inaccurate blind holes can cause the rivets not to be flush, affecting the structural integrity and appearance. On the other hand, Regular Blind Rivets do not require any special pre-treatment. They can be installed with only standard round holes and are suitable for batch operations and ordinary workstation operations.

Although the two types of rivets show no difference when used on the “Blind Rivet Tools“, countersunk rivets require an additional pre-treatment process, making the overall installation procedure slightly more complex. This may affect the assembly cycle, especially when large-scale production is involved, where processing efficiency and cost investment need to be considered.

In terms of clamping capability, both have their own grip range. However, it is particularly important to ensure the precise matching of the total thickness of the sheet material and the selection of the rivets. If the countersunk rivets are not selected appropriately, it may cause the depth of the countersunk hole to not match the length of the rivet, thereby affecting the clamping force and the quality of the riveting.

From the perspective of force application, conventional rivets have a larger head surface, which can disperse more loads and reduce the surface stress per unit area. Therefore, they are suitable for withstanding large pulling loads. Although countersunk rivets have better appearance and fluid dynamics, their load distribution is relatively concentrated locally. When selecting the structural type, it is necessary to make a judgment based on the actual load conditions.

Countersunk Rivets VS Regular Rivets: Performance Comparison Table

Feature / PropertyCountersunk Blind RivetsRegular Blind Rivets
Head ProfileFlush with surfaceProtrudes above surface
Required Hole PrepNeeds countersinkingStandard drilled hole only
Aerodynamic/HydrodynamicBetter (reduced drag)Less aerodynamic
Aesthetic AppearanceSleek, seamlessVisible head
Load DistributionSmaller bearing areaLarger bearing area
Installation ComplexityHigher (extra machining step)Lower
Typical ApplicationsAerospace, automotive panels, marine hullsGeneral sheet metal, construction, machinery

Difference Between Countersunk Rivets and Regular Rivets in Application Scenarios

What is a Pop Rivet Tool and What is It Used For

a. Countersunk Blind Rivets Common Applications

Head-down blind-hole rivets are mainly used in product structures where there are requirements for surface flatness or aerodynamic performance. Their flush installation effect not only enhances the overall design sense but also reduces resistance in dynamic environments, and has a high degree of engineering adaptability.

  • Aerospace fuselage skins and wing structure: The aircraft skins must be highly smooth. Self-tapping rivets can prevent surface protrusions, reducing air turbulence during flight and improving fuel efficiency.
  • High-performance racing cars and motorcycle shells: During high-speed driving, any protrusions may increase wind resistance or cause structural interference. Self-tapping rivets effectively reduce the turbulence of the shell by concealing the rivet heads.
  • Ship decks and yacht outer plates connection: It can avoid local pressure concentration points caused by water flow impact, and at the same time reduce the corrosion risk of connection parts due to long-term water flow.
  • High-end electronic device shells: Such as laptop and instrument panels, metal shells often adopt self-tapping designs to enhance the finished product’s craftsmanship and reduce discomfort or scratches for users when contacting the equipment.

The common feature of these fields is that there are high requirements for the synergy of structural integrity, aesthetics and performance, and they are suitable for headless rivets to exert their structural advantages.

b. Regular Blind Rivets Common Applications

The conventional blind rivets emphasize ease of installation, structural strength and versatility, and are widely used in industrial manufacturing, building assembly and daily equipment maintenance.

  • Sheet metal structure, ventilation ducts, equipment supports: The rivet installation is quick, suitable for large-scale and low-cost operations. The structure has good stability and can withstand vibrations and loads during normal use.
  • Building curtain walls, metal furniture: The large-capacity design can effectively distribute loads, enhance connection strength, and reduce structural stress concentration caused by metal deformation.
  • Mechanical manufacturing and maintenance fields: In maintenance sites or structures where pre-processing is not possible, conventional rivets do not require counterboring processing, making it convenient for on-site rapid reinforcement or replacement.

Such applications typically focus on function first, with relatively low requirements for appearance. They emphasize the durability and operational efficiency of riveting, and are the standard configuration options for most industrial products.

Comparison of Materials and Corrosion Resistance

When discussing the difference between countersunk rivets and regular rivets, apart from the structural and installation differences, the choice of materials also directly affects the service life and applicable environment of the rivets. The corrosion resistance of different substrates determines the reliability of the rivets in marine, outdoor or industrial settings.

① Common Material Combinations

Custom Raw Material

Both types of rivets support various material combinations, which are commonly:

  • All-Aluminum: Lightweight, suitable for general indoor and well-ventilated environments, easy to install, and low in cost.
  • SS/SS (Stainless Steel): Extremely corrosion-resistant, suitable for high-humidity and high-salt environments, such as coastal facilities or chemical equipment assembly.
  • Steel/Steel: High in strength, suitable for load-bearing structures, but requires a protective coating to prevent rusting.
  • Copper/Copper: Excellent electrical conductivity, commonly used in electrical equipment and certain decorative structures.

In the Countersunk and Regular types, different materials of rivets can be selected according to the requirements. Countersunk rivets are often combined with stainless steel or aluminum to ensure both appearance and strength. Regular rivets, on the other hand, are more commonly made of steel or aluminum to control costs and enhance structural stability.

② Environmental Adaptability and Corrosion Resistance Properties

The adaptability of different materials to the environment varies significantly:

  • In oceanic or highly saline environments, stainless steel or aluminum rivets are the preferred choice. Steel is prone to corrosion and, without special treatment, it is highly susceptible to rusting.
  • In outdoor structures, it is recommended to use aluminum or galvanized steel rivets, supplemented by anti-corrosion coatings, to extend their service life.
  • In industrial environments (high humidity, chemical exposure), 316-grade stainless steel should be selected to resist acid and alkali erosion as well as moisture corrosion.

The average lifespan of stainless steel core-pulling rivets in marine environments can reach over 10 years. However, if ordinary carbon steel rivets are not treated, red rust and failure may occur within 2-3 years.

③ The anti-corrosion solution provided by Rivmate

As a professional provider of riveting solutions, Rivmate offers a variety of anti-corrosion coatings and customized material services. Including:

  • Coating-based anti-corrosion treatment (such as Dacromet, zinc-nickel alloy)
  • Mixed-material rivets (such as aluminum cap + stainless steel core)
  • Customized for specific purposes, such as electrochemical corrosion-resistant rivets

These services not only extend the service life of the rivets in harsh environments, but also help customers achieve a balance between lightweight and durability, optimize the structural design and reduce maintenance costs.

Recommendations for Model Selection: How to Make a Decision Between the Two Options

What types of blind rivets are galvanized

In actual projects, the core value of understanding the difference between countersunk rivets and regular rivets lies not in the theoretical distinctions, but in how to make precise selections based on specific application scenarios. The following are common decision-making dimensions and suggestions:

High requirements for appearance and aerodynamics → Choose Countersunk Blind Rivets

If the product surface needs to remain extremely flat, be aesthetically pleasing, or meet fluid dynamics performance requirements, such as for aircraft skins, racing car exteriors, yacht panels, etc., the countersunk blind-hole rivets should be given priority. Their embedded rivet head structure can be flush with the surface of the panel, effectively reducing wind resistance, water resistance or mechanical interference, and enhancing the overall design sense and performance.

Furthermore, in high-end consumer electronics or display devices, the under-cut design can enhance the brand’s quality, reduce contact friction, and improve the user experience.

Prioritize load-bearing capacity and installation efficiency → Choose Regular Blind Rivets

If the project prioritizes structural strength, construction efficiency or assembly cost, conventional pilot-hole rivets have an advantage. Their heads are large, and the force is distributed evenly, making them suitable for supporting loads or connections with high seismic requirements. Moreover, there is no need for a countersink process, significantly reducing the processing difficulty and making them suitable for mass installation and multi-station operations.

In the fields of building metal structure fabrication, mechanical maintenance, or equipment reinforcement, conventional rivets are almost the default choice due to their simple process and strong versatility, which can significantly enhance work efficiency and reduce error rates.

Comprehensive Consideration: Cost, Process Capability, Construction Conditions

In many scenarios, the choice is not an either-or situation. The project should comprehensively evaluate the following factors:

  • Budget Constraints: Head screws usually have a slightly higher cost and the installation process is more complex;
  • Factory Processing Capacity: Whether there is the capability for precise hole drilling and alignment;
  • Construction Environment Constraints: Is the site suitable for high-precision assembly and does it require the installation task to be completed quickly?

For the above complex judgments, Rivmate offers an online selection tool, allowing users to conduct precise filtering based on factors such as plate thickness, material, and application scenarios. Additionally, the technical team can provide 1-on-1 selection advice, helping customers balance performance and cost and improving procurement efficiency.

Installation Precautions and Common Errors

Rivet Gun Failure Prevention Recommendations and Daily Maintenance

Based on a clear understanding of the difference between countersunk rivets and regular rivets, the correct installation process is equally crucial. Even if the selection is appropriate, improper construction operations can still lead to structural failure or rework. The following are common mistakes and precautions for these two types of rivets:

1. Countersunk Bolts: Insufficient Depth of Counterbore

The installation of head-down blind-hole rivets relies on the accurate angle and depth of the blind hole. If the hole is too shallow, it will cause the rivet head not to be fully embedded, resulting in a “bulge” phenomenon, which will affect the appearance and pneumatic performance. In more serious cases, it may lead to “false connection” – the rivet does not actually press against the workpiece but is only supported by the rivet core, presenting a serious structural risk.

It is recommended to use a specialized countersink drill bit and combine it with a depth-limiting device to ensure that the cone angle matches the depth of the hole and the specifications of the rivets. The countersink should be processed in one go to avoid any subsequent rework that may affect the accuracy of the hole position.

2. Regular Rivets: Inappropriate Hole Diameter Matching

The conventional blind rivets have specific requirements for the hole diameter tolerance. If the hole diameter is too large or the burrs are not removed, it will result in reduced clamping force, movement of the rivet, and over time, possible loosening or structural fatigue cracks. It is recommended to refer to the manufacturer’s recommended hole diameter range (usually the rivet diameter plus 0.1 to 0.2 mm) based on the rivet diameter.

At the same time, the rivets should be inserted vertically to avoid uneven loading and to ensure the locking effect.

3. Installation of Tools and Maintenance

The pull pin gun (either manual or pneumatic) is a guarantee for the quality of riveting. If the pulling force is insufficient, it will result in the rivet core not breaking or not being properly pressed; if the pulling force is too large, it may cause local deformation of the sheet material or failure of the rivet due to breakage.、

Furthermore, if the clamping claws are severely worn, a “sliding pin” phenomenon will occur, causing repeated pulling or core jamming. It is recommended to conduct regular inspections and replace the worn parts to keep the tool clean and lubricated.

4. Installation Standard Operating Procedure Recommended by Rivmate Engineers

The Rivmate engineering team, based on extensive field tests and customer feedback, has compiled the following standard operating procedures (SOP):

  1. Verify that the rivet specifications match the clamping range
  2. Check the hole diameter and the quality of the blind holes
  3. Use the appropriate riveting gun and set a reasonable pulling force
  4. Align the hole position and press it vertically
  5. Complete the riveting in one go; do not interrupt or repeatedly pull
  6. Check the condition of the rivet head and confirm that the rivet core has been properly broken
  7. Clean up the remaining core and the surface burrs to ensure the quality of the finished product

Following the standard procedures not only enhances assembly efficiency, but also significantly reduces the rework rate and safety risks.

FAQs

Will Countersunk Blind Rivets be weaker than Regular Blind Rivets?

Not necessarily. The structural strength depends on several factors: including the material of the rivets, their diameter, the clamping range, and the installation quality. Self-drilling rivets have a smaller contact surface due to their heads being embedded in the sheet, and their bearing capacity under extreme pulling loads may be slightly lower than that of conventional large-head rivets. However, as long as the correct type is selected and installed properly, self-drilling rivets can meet the structural strength requirements in most engineering scenarios. The aviation and racing fields are typical applications of high-strength self-drilling rivets.

Can countersunk rivets be used on plastic or composite materials?

Yes, but special attention should be paid to the strength of the sheet material and the quality of the countersunk holes. Plastics or composite materials are relatively soft, so the countersunk holes are prone to indentation or cracking. It is recommended to use a special drill bit with a low cutting speed and select large-diameter countersunk rivets to distribute the contact pressure. If necessary, metal gaskets or pre-installed metal inserts can be added to the contact surface to enhance the clamping stability. For thin-walled composite materials, sample trial assembly evaluation should be given priority.

Are there any differences in the waterproofing performance between the two?

There are certain differences. Due to the large exposed area of the head of the conventional rivets, when they are combined with sealing gaskets or waterproof rubber rings, it is easier to achieve effective sealing. However, for the countersunk rivets, because of their embedded structure, if the machining accuracy between the blind hole and the rivet is insufficient, a small gap may form, which will affect the sealing performance.

However, this is not absolute. High-quality countersunk holes combined with the application of sealant can also achieve a good waterproofing effect. The actual waterproofing capability depends on the construction process, the sealing material, and the installation quality, rather than just the type of rivets.

Can the countersunk head rivets be replaced with regular rivets after installation?

Generally, direct substitution is not recommended. When installing headless rivets, the sheet material has already been processed into conical holes. If regular round-head rivets are used instead, it will result in uneven contact surfaces, reduced clamping force, and even detachment. Unless the countersunk holes are reamed to a larger size for repair (converted to standard diameters), the structural safety cannot be guaranteed. It is recommended to clearly define the type of rivets during the design stage to avoid the risk of rework caused by on-site replacement.

Choosing the Right Rivet Matters

In engineering structures, the selection of rivet type should be clearly planned during the design stage. This not only affects the appearance and connection performance of the product, but also directly determines the construction efficiency and long-term reliability. Through this analysis, we have systematically compared the structural differences, typical applications, and installation precautions of Countersunk Blind Rivets and Regular Blind Rivets.

A brief overview of the core differences between the two:

  • Screw Head Rivet: Suitable for applications with high requirements for appearance, aerodynamics, and smooth contact surfaces; installation requires drilled holes and high processing accuracy.
  • Conventional Rivet: Appropriate for connections with heavy structural loads and where construction efficiency is prioritized; no pre-treatment is required and it has strong versatility.

Choosing the right rivets not only improves assembly quality, but also reduces rework rates and maintenance costs.

Rivmate Rivet Factory in Jiangsu, China

As a supplier of riveting solutions, Rivmate offers a full range of Blind Rivets products, covering multiple material combinations such as aluminum, stainless steel, steel, and copper. Additionally, it provides various anti-corrosion treatment options, including Dacromet, electro-galvanizing, and waterproof type with caps, which are suitable for various extreme working conditions.

More importantly, Rivmate has an experienced application engineering team that can provide a one-stop service ranging from selection guidance, sample testing, to installation process training. We not only sell rivets, but also help customers ensure proper, stable and long-lasting connections.

If you are currently in the stage of product design, procurement or assembly planning, please feel free to contact the Rivmate engineering team for exclusive technical advice and prompt response support.

Reference

Types of Rivets: A Guide to Rivet Types and Their Common Uses

What Are The Various Types Of Rivets?

Types of Rivets

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What are Countersunk Blind Rivets Used for?

Table of Contents

In modern industrial assembly, countersunk blind rivets play an irreplaceable role. They are a type of single-sided installation rivet with a countersunk head design. After installation, the rivet head is flush with the surface of the workpiece, without any protrusion. This structure not only ensures a smooth and aesthetically pleasing appearance but also reduces air resistance or friction interference, making it particularly suitable for products that require streamlined designs or smooth surfaces. Due to the fact that installation only requires single-sided operation, countersunk blind rivets can quickly achieve reliable connections even when the backside of the structure is inaccessible.

The core value of countersunk blind rivets lies in their simultaneous fulfillment of both functionality and aesthetics. They ensure connection strength while keeping the surface free from obvious protrusions, thus avoiding issues such as scratches and jams. This is also the core concern of users when searching for this product – they want to know in which scenarios it is applicable, what structural advantages it has, and the key points to note when selecting.

Structure and Design of Countersunk Blind Rivets

Countersunk Head Design

Countersunk blind rivets feature a countersunk head structure, which becomes flush with the surface of the plate after installation. This design prevents surface protrusions, reduces the risk of scraping or interfering with moving parts, and enhances the aesthetic appeal of the finished product. It is commonly used in assembly scenarios where a smooth and flat appearance or a smooth touch is required.

Countersunk Blind Rivets

Blind Riveting Principle

This type of rivet is based on the blind riveting connection principle and can be installed from a single side only, making it highly suitable for structures where double-sided access is not possible. The installation process is fast and repeatable, reducing the time required for workstation adjustments. This feature is particularly important in confined spaces, closed cavities, or special structural components.

Material Diversity

Countersunk blind rivets can be made of various materials such as aluminum, stainless steel, copper, and alloy steel. Aluminum is lightweight and suitable for equipment where weight reduction is a requirement; stainless steel has strong corrosion resistance and can be used for a long time in damp or chemical environments; copper has good electrical conductivity and antibacterial properties, making it suitable for electrical equipment and medical devices. According to statistics, the service life of stainless steel countersunk blind rivets in outdoor structural components can be 2 to 3 times longer than that of ordinary steel.

Product Advantages of Rivmate

Rivmate strictly controls the head forming accuracy of countersunk blind rivets to ensure that each rivet is flush with the surface of the plate after installation. At the same time, the stability of the clamping force is tested in batches to ensure the consistency of strength performance among different batches of products. This level of precision and stability can significantly reduce the rework rate, improve assembly quality, and meet the requirements of aviation, rail transit, and high-end industrial equipment.

Why Choose Countersunk Blind Rivets Instead of Ordinary Bolts?

a. Appearance and Functional Advantages

Tips of Installing Countersunk Rivets

Countersunk Blind Rivets are installed so that their surface is flush with the panel surface, preventing protruding parts from scratching people or snagging items. They result in a neater appearance and are suitable for assembly where high visual quality is required, such as in appliance housings, display equipment, and decorative panels.

Compared with ordinary round-headed rivets, countersunk rivets can better balance functionality and aesthetics.

b. Aerodynamic and Fluid Dynamic Advantages

A smooth surface can reduce the disturbance of air or water flow. In high-speed or fluid environments such as aircraft structures, automotive exterior parts, and ship decks, countersunk designs can effectively reduce wind resistance and water resistance.
The data shows that in the application of high-speed running aircraft skins, the use of countersunk rivets can reduce the surface resistance by approximately 3%.

c. Safety and Durability

Without the protruding parts, the risk of nail loosening and coating damage caused by collision or friction can be reduced. This is particularly important in outdoor facilities, rail transit, and public facilities. Because it can extend the service life and reduce the maintenance frequency.

d. Comparison of Installation Effect with Standard Round Head Bolts

After installation, the heads of ordinary round-head rivets will protrude above the surface of the board, making them prone to becoming attachment points or concentrated force points. In contrast, Countersunk Blind Rivets can make the connection more smooth, and the overall structure will be more evenly stressed. This not only improves the appearance but also enhances the safety of use.

What are Countersunk Blind Rivets Used for?

How to Install Countersunk Rivets

Countersunk Blind Rivets are a type of connection fastener that can be installed on one side and has a smooth surface. They are widely used in structures with high requirements for appearance and streamlined design. Here are a few key application industries and scenarios:

1. Aerospace: Reducing Aerodynamic Resistance

  • Typical Application: Skin of the fuselage, edge structure of the wings.
  • Advantage: The countersunk design is flush with the surface of the aircraft body, effectively reducing air resistance.
  • Result: Improves fuel efficiency, extends the service life of the aircraft.

The data shows that for every 1% reduction in aerodynamic drag, the flight range efficiency can be improved by approximately 0.5% (Boeing Technical White Paper).

2. Automobile Manufacturing: Anti-corrosion and Chassis Protection

  • Typical Applications: Body shell, sill panel, chassis covering parts.
  • Advantages: Anti-hooking， waterproof leakage， preventing local rusting.
  • Result： Enhances the durability and safety of the entire vehicle.

Compared with ordinary rivets, countersunk blind rivets reduce the surface protrusion by 15% to 20%, thereby reducing the risk of scratches. 

3. Ships and Offshore Structures: Smooth Surface to Prevent Water Flow Resistance

  • Typical Applications: Deck jointing, hull skinning, boat body armor.
  • Advantages: Smooth structure, avoiding increased resistance due to seawater turbulence.
  • Result: Improved speed and enhanced structural anti-corrosion performance.

In the design of high-speed boats, the use of countersunk rivets can increase the cruising speed by approximately 3% to 5% (source: ABS Ship Structural Standards). 

4. Electronic and Precision Equipment: Precision Shell Assembly

  • Typical Applications: Laptop cases, electronic control panels, cabinets.
  • Advantages: The outer shell is smooth, and the internal components are less likely to be disturbed.
  • Outcome: Combines aesthetics with functionality, facilitating the design of compact structures.

The use of countersunk rivets in the electronic housing can increase the available installation area for internal components by more than 20%. 

5. Furniture and Architectural Decoration: Beauty and Safety

  • Typical Application: Metal doors and windows, display cabinets, cabinet structures.
  • Advantages: Smooth installation surface, preventing scratches, enhancing decorative effect.
  • Result: Improves product grade, meets high-end design requirements.

Self-tapping screws are widely used in modern minimalist designs, balancing both aesthetics and functionality.

Suggestions for Material Selection of Countersunk Blind Rivets

Custom Raw Material

Choosing the appropriate rivet material directly affects the structural stability and service life. The following are selection suggestions based on actual working conditions:

Interior Assembly: Lightweight and Easy to Process

  • Recommended Materials: Aluminum, Copper.
  • Application Scenarios: Display cabinets, electrical equipment, furniture assembly.
  • Advantages: Aluminum is lightweight and easy to process, making it suitable for mass assembly; Copper has excellent electrical conductivity and is suitable for electrical connections.
  • Precautions: Aluminum is not resistant to corrosion and should not be used in humid or acidic environments.

The weight of aluminum rivets is only one third that of stainless steel ones, making them suitable for structures that are sensitive to weight.

Outdoor or Wet Environments: The Preferred Choice for Rust Prevention

  • Recommended Materials: Stainless steel (304/316) or anti-corrosion coated carbon steel.
  • Application Scenarios: Doors and windows, outdoor signs, vehicle exteriors.
  • Advantages: Stainless steel has excellent corrosion resistance and won’t rust over a long period of use; coated rivets offer better cost-effectiveness and are suitable for medium to short-term projects.
  • Precautions: Before installation, check the electrochemical compatibility of the substrate to avoid “galvanic corrosion”.

The Rivmate experimental data shows that the 316 stainless steel rivets can withstand corrosion for more than 1,000 hours in the salt spray test. 

High-strength Load-bearing Structure: Select Structural Alloy Steel

  • Recommended Material: Alloy steel structural type countersunk blind rivets.
  • Application Scenarios: Mechanical frames, engineering vehicles, steel structure connections.
  • Advantages: Possess higher shear strength and tensile strength, suitable for load-bearing parts.
  • Precautions: Installation requires cooperation with a hydraulic riveting gun to ensure the locking force meets the design requirements.

The shear strength of the structural blind rivets can be more than three times that of ordinary aluminum rivets (as tested by Rivmate).

Installation and Design Considerations

The shear strength of the structural blind rivets can be more than three times that of ordinary aluminum rivets (as tested by Rivmate).

①. Hole Diameter and Blind Hole Depth Standards

Applications of Monobolt Blind Rivets for Commercial Vehicles

Suggestion: The aperture should be 0.1 – 0.2mm larger than the diameter of the rivet rod to ensure a smooth insertion.
Drill hole depth: Ensure that the head of the rivet is precisely inserted and does not protrude or sink.
Risk: If the hole diameter is too small, it may cause the rivet to deform; if it is too large, it will not be able to effectively hold the object. Improperly sized countersunk holes may expose the bottom or affect the tightening force.

Reference standard: DIN ISO 7721 provides clear dimensional specifications for headless screw hole designs.

②. The grip range must be precisely matched

Definition: The grip range is the total thickness of the sheet material that the rivet can effectively grip.
Misconception: Exceeding the clamping range will result in “false tightness”, and it is prone to loosen over time.
Suggestion: Before designing, check the rivet specification table and choose values around the median for matching.

the grip range of blind rivet

Rivmate data shows that for rivets that are installed beyond the clamping limit, their tensile strength decreases by approximately 30%.

③. Limitations of Blind Installation Process

Application: Suitable for structures with single-sided contact, such as closed cavities and box structures.
Challenge: It is impossible to visually confirm the quality of the rear molding, and this requires reliance on the precision of the tools.
Tool Recommendation: Rivmate suggests using pneumatic or hydraulic riveting guns, with a breakaway control system.

Recommended model: Rivmate RM-725 (equipped with automatic clamping and travel feedback functions, suitable for batch assembly).

④. Avoid stress concentration and deformation of the sheet material

Design Tips: Try to avoid the edges of thin plates and the areas near welds; when the plate thickness is less than 1mm, shims or reinforcing ribs should be added.
Pitch Arrangement: The spacing between rivets should be no less than 3 times the diameter of the rivets, and the edge distance should be no less than 2 times the diameter.
Objective: To reduce local stress concentration caused by thermal expansion and contraction or mechanical shock.

The CAE simulation of the structure indicates that proper layout can reduce the peak stress concentration by up to 40%.

Countersunk Blind Rivets' Advantages in Projects that Balance Aesthetics and Performance

When Would You Use a Countersunk Head Rivet

Rivmate adopts precise molding technology to ensure a perfect fit between the countersunk head and the surface of the board. After installation, the surface is smooth without any protrusions, which will not affect the appearance and can also reduce the risk of scratches.

We offer a variety of anti-corrosion coatings and color options. Whether for marine environments, outdoor projects, or interior decoration projects, we can ensure both durability and visual appeal. The coatings have passed multiple salt spray tests, guaranteeing stable color and performance even after long-term use.

In a certain aviation part manufacturing project, Rivmate customized countersunk blind rivets for the client. By optimizing the angle of the rivet and the size of the countersink, the assembly quality was significantly improved. The client reported that the appearance consistency was enhanced by 20%, and at the same time, the rework rate due to uneven surfaces was reduced. This case demonstrates that high-quality rivets not only enhance structural strength but also improve the overall visual and brand image.

FAQ

Is the Countersunk Blind Rivet less strong than a regular rivet?

Not necessarily.

The strength mainly depends on the material and the type of structure, rather than the head shape. For instance, the tensile strength of the structural type stainless steel countersunk blind rivets can be exactly the same as, or even better than, that of the flat-head rivets of the same grade. However, if used for high-load connections, it is recommended to choose products with a locking core locking structure.

When designing, priority should be given to ensuring the “shear/stretch strength” matches the working conditions, rather than merely relying on the shape to determine the performance.

Can this type of rivet be disassembled repeatedly?

No.

Blind rivets are one-time fasteners. Once the core breaks, they cannot be restored. If disassembly is required, the original rivet must be destroyed by drilling. If the project requires a detachable structure, it is recommended to use screws, pull rivets, or detachable blind rivets. After disassembly, if reinstallation is needed, a new rivet must be replaced and the diameter of the hole checked to ensure it has not expanded.

Is it necessary to make a hole for installation?

Yes, if you want the surfaces to be flush with each other, pre-drilled holes must be made beforehand.

The angle of the blind hole needs to match the shape of the rivet head (commonly 120° or 90°). Direct installation without a blind hole will cause the rivet head to protrude above the surface of the board, which not only affects the appearance but may also cause contact interference. It is recommended to use a dedicated blind hole tool to ensure that the hole diameter and angle are consistent, avoiding the “floating head” problem.

Can it be used on plastic or composite materials?

Yes, but be aware of the risks of deformation and cracking. Plastics/composites have lower rigidity and are prone to damage due to excessive expansion force from the core pulling. It is recommended to choose a specialized model with less clamping force, or install a metal gasket at the hole opening to distribute the stress.

Some Rivmate models are suitable for plastic plate connections, featuring a low expansion force design and a large contact area with the large head plate.

Conclusion and Procurement Suggestions

Types of Blind Rivets

The head-down blind rivets, with their smooth shape, easy installation and reliable structure, are widely used in various fields such as aerospace, automobiles, electronics, and construction. They not only enhance the structural strength but also meet the design requirements that prioritize both aesthetics and safety.

Rivmate focuses on precise fastening solutions and offers:

  • Various material options (aluminum, stainless steel, alloy steel, etc.);
  • Multiple head angle and corrosion-resistant coating options;
  • Supports customized clamping range and special tool matching solutions.

Whether it is small-scale development and trial production, or large-scale automated assembly, Rivmate can provide you with stable performance and high cost-effectiveness in terms of fastening selection support

Please feel free to contact the Rivmate engineering team to obtain samples or get selection advice, to help you create high-standard industrial connection solutions.

Reference

What are blind rivets used for?

Types of Rivets: A Guide to Rivet Types and Their Common Uses

Types of Rivets

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Problem with Rivet Mandrel Breaking

Table of Contents

During the installation of blind rivets, “rivet mandrel breaking” is a critical issue that cannot be ignored. The core of the rivet, which is the part that transfers the tension to the cap body, plays a crucial role in the riveting process. It causes the cap body to undergo plastic deformation and secure the workpiece firmly. If the way the core breaks does not meet the design expectations, it may lead to insufficient clamping force. This not only directly affects the mechanical properties of the connection component but also may cause safety hazards and quality complaints. 

Rivet mandrels often break during installation. Breakage locations are frequently abnormal. Mandrels may remain inside the rivets. This affects riveting quality and product appearance. Understanding mandrel working principles is essential. Knowing fracture mechanisms helps address the problem. Identifying influencing factors is a key step. These are core paths to improve riveting stability.

Normal Mode and Abnormal Mode of Rivet Mandrel Breakage

In the standard design, the blind rivet mandrel will break at the preset “break point”. This position has been precisely calculated to ensure that the remaining part of the core pin is firmly locked within the rivet cap, thereby guaranteeing the clamping force and connection stability. This normal rivet mandrel breaking mode not only avoids the exposure of the core pin’s remaining part affecting the appearance, but also prevents the deterioration of the rivet performance due to the loosening of the core pin.

Steel Blind Rivets Body and Steel Blind Rivets Mandrel Materials

However, during actual production and installation processes, core pins often exhibit various abnormal patterns of failure:

  • Excessive fracture location: The core pin fractures after the neck groove, resulting in insufficient remaining part and decreased clamping force, and there is a possibility of loosening of the riveting.
  • Insufficient fracture location: The core pin fractures before the neck groove, leaving an excessively long exposed core pin, which affects the appearance and may interfere with subsequent assembly.
  • Fracture at the middle or tail end of the core pin: This indicates uneven force distribution, core pin quality defect, or abnormal installation tools, which is likely to cause the rivet to fail.
  • Core pin pulled out of the cap body: This is usually related to poor neck groove processing, material issues, or excessive installation pulling force, and will directly lead to the loss of connection force.

Main Reasons for Abnormal Rivet Mandrel Breaking

During the use of blind rivets, if the “rivet mandrel breaking” phenomenon occurs abnormally, it is usually caused by the combined effect of multiple factors. Only by accurately identifying the cause can an effective solution be formulated.

1. Quality Issues with Rivet

  • Insufficient hardness or excessive brittleness of the core pin material: Insufficient hardness will cause the core pin to undergo plastic deformation during the stretching process, resulting in a shift in the fracture location; excessive brittleness will easily cause brittle fracture at the moment of force application.
  • Poor processing of the neck groove (uneven depth, eccentricity): The neck groove is the designed fracture point of the core pin. Uneven processing of the depth will change the force distribution, leading to uncontrollable fracture; eccentric processing will also cause uneven force distribution on the core pin, resulting in premature or delayed fracture.

2. Installation Tool Factors

rivet tool
  • Excessive or insufficient pulling force: Excessive pulling force may cause the core pin to break at a position outside the neck groove, while insufficient pulling force may prevent complete breakage, thereby affecting the quality of the riveting.
  • Clamp wear and insufficient clamping force leading to sliding core: Insecure clamping may cause the core pin to slide during the stretching process, resulting in abnormal fracture location.
  • Improper calibration of pneumatic/electric riveting guns: Failure to set the pulling force value according to the specifications of the rivets will directly lead to abnormal fracture.

3. Structural and Process Factors

  • Excessive or insufficient hole diameter: An incorrect hole diameter mismatch will cause abnormal force distribution during the deformation process of the cap body, thereby affecting the fracture location of the core nail.
  • Thickness of the connected material exceeds the grip range of the rivet: Insufficient or excessive clamping force will result in a deviation from the designed fracture pattern.
  • Limited space at the riveting position causes eccentric force distribution: When riveting in a narrow or irregular space, if the rivet gun and the core nail are not kept coaxial, it will cause the core nail to bend and fracture or undergo irregular damage.

Comparison of Fracture Characteristics of Different Types of Rivet Mandrel Breaking

Different types of blind rivets have distinct characteristics in their core nail fracture patterns, which are closely related to their structural design, core nail material, and tensile strength. 

Closed End vs Open End Rivet

Open-End rivets are mostly used for general structural connections, and the stability of the fracture position depends on the accuracy of the neck groove.

The Closed-End rivets have a sealed cap design, which makes the requirements for the fracture position and remaining length of the core pin more stringent.

Structural Rivet is a type of structural high-strength rivet. Its core pin has high tensile strength and large breaking force. The consistency of fracture directly affects the connection’s load-bearing capacity and fatigue life.

The table below summarizes the typical fracture characteristics, tensile strength requirements, and the standards of Rivmate in the core break consistency test for three types of rivets. It is convenient for engineering technicians to quickly refer to when selecting and controlling quality.

Open-End Vs. Closed-End Vs. Structural Blind Rivet

Rivet TypeTypical Mandrel Breaking FeaturesRelationship Between Mandrel Tensile Strength & Breaking ModeRivmate Mandrel Consistency Standard
Open-End Blind RivetBreaks at designed neck groove, mandrel head remains inside the rivet body; suitable for general applications.Moderate tensile strength ensures controlled break at groove; too high strength may cause over-pull, too low may cause incomplete break.95%+ of samples break within ±0.5 mm of groove position.
Closed-End Blind RivetBreaks at neck groove with sealed mandrel head inside the closed-end shell; prevents leakage.Higher tensile strength required due to sealed structure; improper strength may cause premature break or mandrel pull-out.98%+ of samples meet design break location with no head extraction.
Structural Blind RivetBreaks at reinforced groove; mandrel tail locks mechanically inside rivet for high shear/tensile loads.High tensile strength critical for full clamp-up before break; incorrect strength can reduce structural performance.99%+ location consistency; break force deviation ≤ ±5% of spec.

Rivmate Professional Advice: How to Prevent Abnormal Rivet Mandrel Breaking

When addressing the issue of “rivet mandrel breaking”, prevention is far more efficient and cost-effective than repair. By implementing systematic control in the three aspects of selection, tools, and processes, the probability of abnormal core pin breakage can be significantly reduced, thereby ensuring the quality and structural reliability of the riveting from the very beginning.

Model Selection Optimization

  • Select the appropriate clamping range and rod diameter based on plate thickness and load: Ensure that the rivets operate within their designed clamping range to avoid position shift due to insufficient or excessive clamping.
  • Give priority to brands that have undergone tensile and core breakage consistency tests (Rivmate standard) : Rivmate conducts ≥95% core breakage position consistency and tensile deviation control tests on each batch of products to ensure batch stability and reduce batch quality risks.

Equipment Maintenance

  • Regularly replace the jaw of the puller and inspect the wear of the clamping claws: Worn jaws will reduce the clamping force, causing the core nail to slide or break at an abnormal position.
  • Adjust the air pressure or pulling force settings according to the manufacturer’s parameters: Excessive or insufficient settings will alter the force distribution on the core nail. It is necessary to regularly calibrate the riveting tool in accordance with the specifications of the rivets.

Process Control

  • Control the aperture tolerance: Ensure that the installation aperture matches the diameter of the rivet to avoid uneven force and abnormal fracture.
  • Avoid applying lateral tension when riveting in an inclined or restricted space: Eccentric force can cause the core pin to bend or fracture at an unexpected location.
  • Perform trial assembly and tensile testing on critical structures: Conduct sample verification before mass production to ensure that the fracture mode and clamping force comply with the design requirements.

Detection and On-site Investigation Methods for Abnormal Rivet Mandrel Breaking

What types of blind rivets are galvanized

When dealing with the rivet mandrel breaking anomaly, rapid and accurate detection and troubleshooting are crucial for reducing downtime and lowering rework costs.

Method 1: Using the naked eye or simple magnification for observation, first determine whether the fracture location is within the designed neck groove range. Then, based on the fracture morphology (smooth, torn, bent, etc.), preliminarily classify the causes, such as material issues, insufficient tool clamping, or installation eccentricity, etc.

Method 2: Use a caliper to measure the length deviation of the broken core, and inspect the depth and position of the neck groove, as well as whether there are any processing defects such as eccentricity, cracks, etc. through a microscope or a high-power magnifying glass. At the same time, observe the metallographic features of the fracture surface to determine whether it is a ductile fracture, a brittle fracture, or a mixed mode, so as to correspond to different improvement measures.

Method 3: Use a dedicated tensile testing instrument to measure the output tensile force of pneumatic or electric riveting guns, ensuring that it meets the requirements of the rivet specifications. If the test value deviates significantly from the standard, it should be immediately adjusted or the components (such as the jaws, clamping claws) should be replaced.

Case of On-site Diagnosis Service Provided by Rivmate

At a customer’s site, Rivmate engineers investigated structural rivet breakage issues. Fracture checks, groove measurements, and tensile tests identified the root cause. A larger hole diameter combined with excessive riveting gun air pressure was to blame. Process adjustments and partial rivet specification changes were implemented. Breakage rate dropped from 12% to under 0.5%. Production stability and assembly efficiency improved significantly.

Rivmate Solution and Product Recommendations

Drawing on extensive blind rivet expertise, Rivmate addresses various “rivet mandrel breaking” issues. A diverse product range and tailored services are offered. These help customers achieve consistent core breaking and reliable connections across different assembly environments.

Rivmate High Consistency Broken Core Control Rivet Series

Designed for high-frequency assembly and automated lines, the neck groove accuracy is kept within ±0.02 mm. Each batch undergoes full tensile strength and break position inspections for consistency. Ideal for automotive, appliance, and sheet metal industries with strict rhythm and consistency demands. Helps reduce stoppages and rework from abnormal core breaks.

Special Working Condition Reinforced Core Nail Bolts

For special environments such as Marine, Aerospace, and Heavy Duty, high-strength corrosion-resistant alloy core nail materials are adopted. A stress-relief structure is introduced in the neck groove design to enhance the tensile strength and fatigue life. Even under harsh conditions such as high humidity, high salt spray, vibration, and shock, the core breakage position remains stable and the connection performance remains durable.

Rivmate Customized Tension Setting and Installation Tool Matching Service

How Custom Rivets Are Made
How Custom Rivets Are Made

Based on the specific rivet model, plate thickness range and assembly cycle of the customers, a customized riveting tensile parameter setting plan is provided, and the optimal clamping system for pneumatic/electric riveting guns is matched. Rivmate engineers can conduct tool calibration and operation training on-site to ensure that the installation tensile force precisely matches the rivet design requirements, thereby reducing the probability of abnormal core breakage from the very beginning.

Case Analysis

Case 1: A shipyard had to rework due to frequent abnormal fractures of the core pins

At a large shipyard, blind rivets in deck hatches often broke outside the neck groove. This caused loose joints and leakage, with rework rates reaching 8%. Rivmate engineers visited the site for investigation. We examined fracture patterns, measured groove dimensions, and tested pull force. Batch material fluctuations and excessive air pressure were identified as causes. High-consistency Rivmate rivets and recalibrated pneumatic gun pressure were introduced. Break positions stabilized within ±0.5 mm after adjustments. Rework rate fell to 0.3%, saving the shipyard significant monthly costs.

Case 2: Upgrading an Electrical Appliance Production Line

After switching to semi-automation, an appliance maker saw rivet breakage rates hit 3%. This hurt both production efficiency and product appearance quality. Rivmate supplied high-consistency rivets with full inspection. Material and tension settings on the automated equipment were also adjusted. Breakage rate quickly dropped to 0.2% after changes. Line stoppages fell by 85%, boosting assembly efficiency. Product consistency and final appearance quality were fully maintained.

Conclusion

Rivet mandrel breaking is not an inevitable defect in riveting. By selecting rivets scientifically, ensure that the clamping range, material strength and application environment are matched. Through rigorous process control, maintain the stability of hole diameter tolerance and installation posture. Combined with regular tool maintenance and calibration. It is possible to significantly reduce the occurrence probability of abnormal breakage, ensuring the long-term stability and safety of the connection structure.

Rivmate Rivet Factory in Jiangsu, China

Secure Every Connection with Rivmate Rivets

Rivmate has always been committed to providing customers with full lifecycle riveting quality assurance from product design, production testing to on-site application. Whether it is an automated production line for high-frequency assembly or special working conditions in harsh environments, we can offer high-consistency core-break control rivets, reinforced core-nut solutions, and customized tool matching services. These help customers significantly reduce rework rates, improve assembly efficiency, and achieve lower total cost of ownership.

Reference

What are the typical riveting faults and how can they be avoided? What is a rivet? Understanding rivets and the different blind rivet types
Types of Rivets

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Rivet Corrosion: Causes, Prevention, and Engineering Solutions

Table of Contents

As a crucial connecting component, rivets play a vital role in maintaining the overall strength and stability of the structure. However, rivet corrosion (rivet rusting) is often a neglected yet highly destructive hazard. When rivets undergo corrosion in conditions such as moisture, salt fog, chemical media, or electrochemical action, it will lead to a decrease in the strength of the connection point, imbalance in the stress distribution of the structure, and even cause the overall structure to fail. For users, this means a higher likelihood of serious safety accidents.

This article will start from the corrosion mechanism, combined with actual cases, to comprehensively analyze the detection methods, protection plans and solution paths for stud corrosion. It will help you build a complete chain of anti-corrosion system from material selection, surface treatment to regular inspections. This will ensure the long-term reliability and safety of the structure.

Mechanical Analysis of Rivet Corrosion

1. Electrochemical Corrosion

When the rivets and the materials being connected are made of different metals (such as aluminum plates and stainless steel rivets) and are in an environment containing electrolytes (rainwater, seawater, industrial moisture), a galvanic cell reaction occurs, and the metal with a lower potential is corroded first.

This phenomenon is particularly common in ships, aircraft, and coastal buildings.

Monel Blind Rivets - Prevention of Galvanic Corrosion

2. Gaps Corrosion

There are often small gaps between the head of the rivet and the sheet metal, or around the installation holes. These gaps are prone to trapping moisture, salts and contaminants, resulting in local oxygen deficiency and thus creating a highly corrosive environment. Gaps corrosion not only progresses rapidly but is also difficult to be detected by the naked eye. It often leads to severe metal thinning and even structural loosening by the time it is detected.

3. Pitting Corrosion and Intergranular Corrosion

In an environment with a high concentration of chloride ions (Cl⁻), points of corrosion may occur on the surfaces of aluminum alloys and some stainless steel rivets, forming needle-like or crater-like corrosion pits. For stainless steel materials with a higher carbon content, improper heat treatment may also lead to intergranular corrosion, causing the material to crack along the grain boundaries and significantly reducing the fatigue life.

4. Stress Corrosion Cracking (SCC)

Stress Corrosion Cracking (SCC)

When rivets are subjected to constant or alternating loads for a long time and are in corrosive media, stress corrosion cracking will occur. SCC damage is delayed and may suddenly fracture after many years of service. In the aerospace industry, SCC is one of the important hazards causing the failure of the connection of aircraft fuselage skins. 

High-risk application scenarios and corrosion manifestations

Bolts have the advantages of high strength and good fatigue resistance in metal structure connections. However, in certain environments, the risk of corrosion significantly increases. According to the “China Corrosion Situation Survey Report”, global economic losses caused by metal corrosion account for 3% to 4% of GDP, and marine, aerospace and outdoor engineering are the areas with the most concentrated corrosion.

applications of black anodized pop rivets

Marine and Coastal Engineering

The application scenarios include ship hulls, dock structures, offshore wind turbine towers, etc. These environments are constantly exposed to high salt spray, high humidity and temperature fluctuations. Chloride ions can penetrate the paint film or protective layer, causing pitting corrosion and crevice corrosion.

  • Typical manifestation: Red-brown rust appears at the head of the rivet or at the joint, with local metal powdering. In severe cases, the rivet may become loose or even cause structural failure.
  • Data reference: The salt spray corrosion test (ASTM B117) indicates that on the surface of ordinary carbon steel rivets, obvious rust can be observed after 48 hours in a 5% NaCl solution.

Aviation and Transportation

In applications such as aircraft fuselage skins, train car bodies, and truck cargo compartments, rivets are often exposed to complex environments including periodic wet heat, de-icing fluids, and fuel vapors.

  • Typical manifestations: The coating around the rivets bubbles or peels off, the surface of the aluminum rivets is powdery (white corrosion products), and stress corrosion cracking (SCC) occurs at the structural bonding interface.
  • Risk description: Corrosion of aviation rivets not only affects the appearance, but also accelerates crack propagation under fatigue loads, shortening the maintenance cycle.

Outdoor Building Structures

Commonly found in curtain wall connectors, advertising board frameworks, metal roofs, etc., which are exposed to rain, acid rain and ultraviolet rays for a long time.

  • Typical manifestation: The rivets in the affected area show circular rusting due to rainwater erosion. Under acid rain conditions, the coating of the surface layer fails rapidly, causing the exposed metal to flake off and corrode.
  • Case data: In the acid rain simulation experiment with a pH of 4.0, the lifespan of the protective layer of galvanized steel rivets is approximately 40% shorter than that under neutral conditions.

Forms of Corrosion

  1. Rust Staining: Oxidation of iron-based alloys results in the formation of iron oxide, with colors ranging from orange-brown to dark brown.
  2. Chalking/Powdering: Loose white corrosion products form on the surface of aluminum alloys or galvanized layers.
  3. Exfoliation Corrosion: Layered corrosion causes sheet-like peeling of the metal, which is commonly observed in the aging process of aluminum alloy rivets in humid environments.

Comparison of Corrosion Resistance of Different Materials of Rivets

The corrosion resistance of rivets is not only determined by the material itself, but also depends on the usage environment, the risk of galvanic corrosion, and the protective treatment process. Inappropriate material selection can lead to accelerated local corrosion, especially in humid, salt spray or acid-base conditions.

Table: Corrosion Resistance Ratings of Common Rivet Materials

(Reference: ASTM G101, ISO 9223)

Rivet MaterialCorrosion Resistance (Grade 1–5, 5 = Highest)AdvantagesLimitationsTypical Applications
Aluminum Alloy (Series 2xxx, 5xxx, 6xxx)3–4Lightweight, oxidation resistant, easy to processSusceptible to pitting and exfoliation corrosionAircraft skins, lightweight structures
Carbon Steel (Plain or Galvanized)2–3High strength, low costRapid corrosion once coating is damagedBuilding steel structures, vehicle assembly
Stainless Steel (304/316)4–5Excellent corrosion resistance, high strengthHigh cost, potential galvanic corrosion with aluminumMarine facilities, chemical equipment
Copper and Copper Alloys3–4Good atmospheric and microbial corrosion resistanceLower strength, prone to color darkeningRoofing decoration, weather-resistant structures
Monel Alloy (Monel 400, etc.)5Outstanding seawater, acid, and alkali resistanceVery high costDeep-sea marine engineering, military equipment

Note: The corrosion resistance grade is determined based on comprehensive assessment of normal temperature, neutral salt spray test (ASTM B117), and long-term service experience. It is provided for reference only in engineering selection. 

Table: Corrosion Matching Table (Bolt Material vs Plate Material)

When two different metals come into contact in a conductive medium (such as seawater or rainwater), galvanic corrosion occurs. The greater the potential difference, the higher the risk of corrosion. The following table classifies these risks into three levels based on electrochemical potential difference and actual service data.

Rivet Material vs Sheet MaterialAluminum SheetCarbon Steel SheetStainless Steel SheetCopper SheetTitanium Sheet
Aluminum Alloy Rivet✅ Safe⚠ Medium Risk❌ High Risk❌ High Risk✅ Safe
Carbon Steel Rivet⚠ Medium Risk✅ Safe⚠ Medium Risk❌ High Risk⚠ Medium Risk
Stainless Steel Rivet❌ High Risk⚠ Medium Risk✅ Safe⚠ Medium Risk✅ Safe
Copper Rivet❌ High Risk❌ High Risk⚠ Medium Risk✅ Safe❌ High Risk
Monel Alloy Rivet⚠ Medium Risk⚠ Medium Risk✅ Safe✅ Safe✅ Safe

✅ Safe: Small potential difference, low risk of corrosion

⚠ Medium Risk: Requires measures such as isolation gaskets or protective coatings

❌ High Risk: Direct contact not recommended without isolation and protection

Rivmate's Recommended Material Selection Strategy

Custom Raw Material

Based on years of experience in using rivets and experimental data, Rivmate recommends the following selection approach:

① Marine/Salt Spray Environment

  • Preferred: 316 stainless steel rivets, Monel alloy rivets
  • In case of necessity, apply fluorocarbon coating or epoxy isolation gaskets
  • Avoid direct connection of aluminum and stainless steel

② Aerospace and Transportation

  • Preferred: 5xxx corrosion-resistant aluminum rivets, 7075-T73 aluminum rivets (anodized)
  • For high-stress areas, stainless steel can be selected and additional anti-corrosion isolation measures can be implemented

③ Outdoor Architecture and Curtain Walls

  • Preferred: 304/316 stainless steel rivets
  • If aluminum panels are used, apply sealing glue on the contact surfaces to prevent galvanic corrosion

④ Chemical and Acid/Alkali Environments

  • Preferred: Monel alloy rivets or titanium rivets
  • Conduct corrosion resistance level assessment based on the nature of the medium

Preventive Strategies for Rivet Corrosion

What is a Pop Rivet Tool and What is It Used For

The corrosion of rivets not only affects the appearance of the structure, but also may lead to a decrease in connection strength, shortened fatigue life, and even failure. According to statistics from NACE (American Society of Corrosion Engineers), by selecting appropriate materials and implementing protective design, approximately 30% – 50% of the corrosion losses during service life can be reduced. Here are systematic suggestions for anti-corrosion strategies.

1. Material Selection and Matching

  • Principle: Preferentially use homogeneous metals (such as aluminum plate + aluminum rivet, stainless steel plate + stainless steel rivet), and avoid combinations with strong potential differences (such as aluminum + stainless steel, carbon steel + copper).
  • Engineering basis: The rate of galvanic corrosion is directly proportional to the potential difference between two metals. In a 3.5% NaCl environment, the corrosion rate of the aluminum + stainless steel combination can reach 5 to 10 times that of the aluminum + aluminum combination.

2. Surface Protection

  • Process Selection:
    • Aluminum alloy: Anodizing (AA, hard film anodizing), polyurethane/flexo-fiber coating.
    • Carbon steel: Hot-dip galvanizing, electroplating nickel/zinc alloy layer.
    • Stainless steel: Passivation treatment (ASTM A967), fluoropolymer coating.
  • Data Support: Through ASTM B117 salt spray test, the corrosion resistance lifespan of hot-dip galvanized carbon steel rivets can be increased by 5 to 8 times.

3. Optimization of Structural Design

  • Avoid water accumulation: In the design, ensure that there are drainage channels at the connection points of the rivets to prevent water accumulation.
  • Reduce gaps： Ensure close fit to avoid water absorption due to capillary action.
  • Optimize airflow and drainage： In aircraft or vehicle exteriors, adopt streamlined layout to reduce water droplet retention.
  • Example： After changing the drainage design at the rivet connection points of a high-speed train to a sloping surface， the annual corrosion rate at the connection area decreased by 40%.

4. Sealing Measures

  • Gasket: Use EPDM (ethylene propylene diene monomer) or fluorine rubber gaskets, which have excellent resistance to ultraviolet rays and salt fog.
  • Sealant： Select neutral anti-corrosion sealing glue (such as silicone sealant, polyurethane glue) to seal around the rivet holes.
  • Closed-end rivets： Effectively prevent water vapor from entering the hollow part, especially suitable for outdoor and marine environments.

5. Installation Process Control

  • Anti-scratch: Construction tools should avoid direct contact with the coating surface. If necessary, add protective films.
  • Diameter tolerance: Follow ISO 15977 or MIL-STD-403 standards to ensure a tight fit between the hole diameter and the rivet diameter, reducing crevice corrosion.
  • Tension setting: Use the specified tension setting values for the riveting gun to avoid excessive deformation of the rivet or insufficient clamping.

Corrosion Detection and Maintenance Recommendations

Once the corrosion of rivets reaches the stage of structural failure, the repair cost will increase exponentially. According to the research of NACE (American Society of Corrosion Engineers), 80% of structural corrosion accidents could have been avoided through early detection. Therefore, establishing a scientific detection and maintenance system is the key to extending the service life of rivets and ensuring the safety of the structure.

Visual Inspection

Checkpoints：

  • Color Changes: The iron-based rivets show orange-brown rust, the surface of the aluminum alloy becomes powdery and turns white, and the stainless steel becomes yellowish or develops brownish spots locally.
  • Rust Spread: Check if the rust spreads along the joints and the arrangement direction of the rivets.
  • Coating Bubbling or Peeling: This indicates the failure of the protective layer, which is prone to cause crevice corrosion.

Are there galvanic corrosion problems

Frequency Recommendation: In general environments, it is recommended to perform the operation once every 12 months. For marine or high-humidity environments, it is suggested to do so once every 6 months.

Non-destructive Testing

Ultrasonic Testing (UT): This method can be used to detect internal cracks or metal thinning at the junction of rivets and plates. It is suitable for thick plate structures and critical connection areas.

Eddy Current Testing (ET): Suitable for aluminum alloy and stainless steel rivets. It can detect early cracks and corrosion pits beneath the surface.

Magnetic Particle Testing (MT): Suitable for ferromagnetic rivets, it is convenient for detecting surface and near-surface defects.

Engineering Data: According to the aviation industry standard (SAE AIR4843), it is recommended that critical load-bearing rivets undergo a magnetic particle inspection every 1,000 flight hours to ensure that fatigue and corrosion cracks are not overlooked.

Evaluation of Corrosion Rate and Replacement Cycle

Rate Calculation: The commonly used unit is mm/year (mm/y), which can be obtained through the weight loss method (weight difference method) or electrochemical testing (LPR linear polarization method).

Change Strategy:

When the corrosion rate is ≥ 0.1 mm/year, it is recommended to replace it in advance.
For high-risk scenarios (offshore wind power, chemical pipe racks), a preventive replacement cycle of 3 to 5 years can be set.

Case Reference: A coastal dock shortened the inspection cycle of stainless steel rivets from 12 months to 6 months, resulting in a 42% reduction in corrosion failure rate.

Rivmate Inspection and Maintenance Service

Rivmate offers a complete cycle maintenance solution for rivet connections:

The role of rivet nickel plating layer

Portable eddy current detector: Capable of conducting on-site rapid detection of concealed corrosion defects within a depth range of 5 to 10 mm.
Corrosion Rate Sensor: Monitors the environmental corrosion rate at critical locations in real time.
Maintenance Training: Offer training courses on visual inspection, non-destructive testing and anti-corrosion maintenance for the engineering team.
Data Management Platform: Records the service status of rivets, generates replacement and protection recommendations, and supports the ISO 55000 asset management standard.

Conclusion

Rivet Corrosion is not only a common problem in structural maintenance, but also a key factor related to safety, lifespan and the total life cycle cost. According to the NACE International Corrosion Cost Study, the economic losses caused by corrosion globally account for 3% – 4% of the GDP. Among them, more than one-third are related to metal connection components. For this crucial connection component, establishing a systematic prevention, detection, repair and replacement strategy can effectively extend the service life, reduce maintenance costs, and enhance the structural reliability.

Choose Rivmate for Rivets You Can Trust

Rivmate is a professional supplier of bolting solutions. We possess comprehensive resources and technical capabilities in areas such as bolt material selection, anti-corrosion design, inspection tools, and maintenance training.

Rivmate Rivet Factory in Jiangsu, China
  • Material and Design Support: Offers a wide range of corrosion-resistant rivets including aluminum alloy, stainless steel, and Monel alloy, along with guidance for electrochemical corrosion matching.
  • Testing and Maintenance Tools: From portable eddy current detectors to corrosion rate sensors, helps customers achieve precise diagnosis and predictive maintenance.
  • Industry Application Cases: Serves multiple industries such as ports and docks, aviation manufacturing, rail transportation, and offshore wind power, and has accumulated rich practical experience and reliable data.

The process of engineering material selection – structural design – surface protection – regular inspection – timely repair runs throughout the entire lifecycle management of rivets. Rivmate can help customers significantly reduce the risk of corrosion and ensure that the structure remains stable and operational for a long time in harsh environments.

Choose Rivetfix now to make your connection stronger and more durable!

Reference

Rivet Nut Corrosion Protection

Galvanic Corrosion: Effects On Rivet Nuts And Blind Rivets

Types of Rivets

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What Is Metal Riveting?

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In the field of industrial manufacturing, metal riveting is a time-honored yet highly reliable mechanical connection technology. It is widely used in key areas such as automotive manufacturing, sheet metal processing, and equipment assembly. Compared to welding or bolt connections, riveting offers advantages such as stable structure, no need for threads, and less susceptibility to heat. It is suitable for long-term connection requirements in different materials, non-detachable, or vibration environments.

Many manufacturing workers often search for “what is metal riveting” through search engines at the beginning of a project to quickly understand the basic structure, working method, and performance of riveting in practical applications. This article will systematically explain the definition, structure, and working principle of metal riveting, and provide practical design and assembly suggestions around these common questions.

Metal Riveting – Definition and Basic Principles

What is RivetingThe Comprehensive Guide to Riveting

a. Definition

Metal riveting is a process that permanently connects two or more pieces of metal through mechanical means using rivets. The rivets are inserted into the connection components through pre-drilled holes, and then the tail end of the rivet undergoes plastic deformation to form a “rivet head”, creating a clamping force between the parts, thus achieving a secure connection.

b. Working Principle

During the riveting process, the rivet passes through the aligned holes of the workpiece and forms a second rivet head at the stressed end (or breaks to form a clamping structure). This process does not rely on threads or melting and has good structural strength and shear strength.

c. Riveting vs. Other Joining Methods

Joining MethodAdvantagesLimitations
RivetingSuitable for lightweight structures, requires no electricity, allows one-sided installation; no heat treatment needed, good fatigue resistanceDifficult to disassemble, poor reusability
WeldingHigh joint strength, excellent airtightnessRequires heat source, heat-affected zones, risk of structural deformation
Bolted ConnectionRemovable and easy to maintainRequires regular tightening, relatively poor vibration resistance

d. Application Areas

It is widely applied in industries such as aviation, rail transportation, construction and sheet metal processing, and is particularly suitable for structural scenarios that require lightweight and high strength while minimizing heat influence.

Common Types of Metal Rivets and Structural Classifications

1. Blind Rivet / Pop Rivet

Structural Features: Composed of the cap shell (outer cylinder) and the core pin. During installation, it only requires a single operation on one side. After the core pin is pulled out, it forms a back rivet.

Advantages: One-sided installation, simple operation, high efficiency, suitable for thin plate connections.

Disadvantage: The strength is average and the load-bearing capacity is limited. It is not suitable for high-load situations.

Installation Tools: Manual or pneumatic riveting gun.

3 8″ Blind Pop Rivets Wholesale

Applicable scenarios: Electronic enclosures, sheet metal parts, household appliances, and lightweight structural assemblies.

2. Structural Rivet

Interlock Structural Rivet

Structural Feature: The core pin is tightly locked with the housing. After being pulled apart, it has higher shear and tensile strength, making it suitable for high structural load requirements.

Advantages: High strength, anti-loosening, anti-vibration. Some models feature a lock mechanism design.

Disadvantages: High cost, requires more specialized installation tools.

Applicable scenarios: Automotive body, truck trailers, heavy machinery structures, steel structure connections.

Installation Tools: Heavy-duty pneumatic riveting gun or electric riveting equipment.

3. Closed-End Rivet

Structural Feature: The tail is sealed, which prevents leakage of liquids and gases; the core pin remains inside the sealed cavity.

Advantages: Excellent sealing performance, suitable for applications with high sealing requirements.

Disadvantage: The shear strength is slightly lower than that of structural rivets.

Applicable scenarios: Electrical cabinets, sealed containers, air conditioning housings, waterproof joints.

Installation Tools: Ordinary riveting gun or pneumatic sealing riveting tool.

4. Peel Pattern / Snap Collar and Grooved Rivet

Structural Characteristics

  • Flowering Type: The tail of the rivet expands into four petals when tightened, providing a large supporting area.
  • Groove Type: The rivet body is equipped with grooves, suitable for soft materials (such as plastic, wood).

Advantages: Suitable for fragile and soft materials. It can disperse stress without damaging the substrate.

Disadvantage: The structural strength is relatively low and it is mainly used for non-structural connections.

Applicable scenarios: Toy assembly, plastic shells, woodworking products, small electronic devices.

Installation tool: Ordinary riveting gun.

Advantages and Limitations of Metal Riveting

Rivet Gun Failure Prevention Recommendations and Daily Maintenance

Analysis of Advantages

  1. No need for heat source
    Bolted connections do not require high temperatures and are suitable for materials that are prone to deformation or alteration, such as aluminum alloys and thermoplastic composites. Industrial data shows that bolted connections can reduce energy consumption by approximately 20-30% compared to the arc welding process.
  2. High consistency
    The riveting process has a high degree of standardization, resulting in stable product quality. It is suitable for mass production and automated operations.
  3. Strong anti-vibration performance
    After plastic deformation, the rivets form a fastening structure, which has excellent vibration resistance and anti-loosening capabilities.
  4. Single-Sided Construction
    Through structures such as core-pulling rivets, it is possible to install from only one side of the structure, which is suitable for situations with limited space.
  5. Lightweight
    Compared with bolt connections, the rivet assembly is lighter and aligns with the trend of lightweight design, making it particularly suitable for the transportation industry.
  6. Installation speed
    Each riveting cycle only takes 1-3 seconds (using manual or pneumatic tools), significantly longer than the 6-8 seconds required for torque-controlled bolts. This can increase the production line efficiency by approximately 15-20%.

Analysis of Limitations

  1. Irreversible disassembly Bolted connections are a permanent connection method. Disassembly requires damaging the components, which is not conducive to maintenance or repeated assembly.
  2. Limited connection strength The shear strength of conventional blind rivets is approximately 200 – 300 N/mm², which is significantly lower than the 800 N/mm² of grade 8.8 bolts. Therefore, they are not recommended for use in structures that need to withstand large axial loads.
  3. High requirements for hole positions The riveting effect depends on the precise positioning and matching of the holes, and the construction process requires strict control of tolerances.
  4. Material Compatibility Issues Different metal combinations (such as aluminum + stainless steel) will generate a 0.5 – 0.8 V potential difference in a humid environment. According to the Galvanic Series data, the corrosion rate can accelerate by several times within one year.
  5. Lack of Adjustability After the riveting is completed, the structure cannot be adjusted, and it lacks flexibility compared to bolt connections.

Overview of Metal Riveting Application Scenarios

applications of black anodized pop rivets

In the aerospace field, metal riveting is mainly used for assembling the fuselage skins, wings, cockpits and other structures of aircraft. Solid rivets or high-strength structural type coreless rivets are adopted, and the materials are mostly aluminum alloys or titanium alloys. Since the entire aircraft requires tens of thousands of riveting connections, extremely high strength, fatigue life and lightweighting are required.

In the automotive manufacturing industry, riveting is commonly used for connecting car doors, chassis, seat brackets and energy absorption structures. To meet the requirements of impact resistance, anti-loosening and corrosion resistance, structural type ejector rivets (such as MGR or Monobolt) are usually selected. They are combined with welding and screwing methods to form a mixed connection, enhancing the overall structural reliability.

In the building assembly scenario, metal riveting is widely used in curtain wall systems, steel structure splicing, and bridge installation. Closed-type or high-strength structural rivets are selected to meet the requirements of waterproofing, wind load resistance, and outdoor durability.

In the manufacturing of sheet metal and equipment shells, such as electrical control cabinets, chassis, and automation equipment frames, etc. Riveting is an efficient, aesthetically pleasing, and corrosion-resistant connection method. Typically, open-type or closed-type blind rivets are selected, which are suitable for thin plate structures.

Design and Engineering Guidelines for Metal Riveting

1. Design of Aperture, Edge Distance and Center Distance

Recommended Design Value (D = Bolt Diameter):

  • Diameter Ø: Generally, it is recommended to be slightly larger than the diameter of the rivet by 0.1 – 0.2 mm to ensure smooth insertion and stable clamping.
  • Pitch ≥ 3D: Prevents interference between materials and facilitates uniform load distribution.
  • Edge ≥ 2D: Avoids material edge tearing during riveting. Example: If 4.8 mm rivets are selected, it is recommended that the center distance be ≥ 14.4 mm, the edge distance be ≥ 9.6 mm, and the hole diameter be approximately 4.9 – 5.0 mm. >

NOTES

  • Irregular center distance will cause concentrated load, reducing fatigue life.
  • Insufficient edge distance is prone to cause tearing and sliding risks, especially under tensile load.

2. Grip Range and Nail Type Selection Process

Definition: The grip range refers to the total thickness of the connected materials (including the gap) being within the clamping thickness range permitted by the design of the rivet.

Selection Process:

  1. Confirm the total thickness of the materials (for example: 1.2 mm + 2.0 mm = 3.2 mm)
  2. Refer to the rivet specification table, select a gripping range that covers this thickness (for example 2.5 – 4.0 mm)
  3. Ensure that the outer diameter of the pull pin head matches the hole diameter, avoiding gaps or being too tight
  4. Choose the appropriate head type (flat head, countersunk head, large flat head), based on the assembly position, appearance or requirements for blind holes
the grip range of blind rivet

Note: Selecting the wrong gripping range can result in poor formation of the riveting joint. In severe cases, it may lead to failure or cause the appearance of “false riveting” phenomenon. 

3. Material Matching and Corrosion Protection Design

Material Matching Principle: Preferentially select rivets with an electrochemical potential similar to that of the base material to avoid electrochemical corrosion.

Rivet MaterialRecommended Base MaterialsCharacteristics
Aluminum AlloyAluminum, plastics, compositesLightweight, rust-resistant, moderate strength
Stainless SteelStainless steel, steelHigh strength, corrosion-resistant, may cause galvanic corrosion with aluminum
CopperCopper, brass structuresExcellent conductivity, corrosion-resistant
Steel (Zinc-coated/Painted)Steel structuresHigh strength, requires anti-rust treatment

Anti-corrosion Measures Suggestions:

  • Anode protection coating (such as anodic aluminum oxide, zinc coating)
  • Isolation gasket or anti-corrosion rubber ring, preventing direct contact between metals
  • Regular application of anti-rust agent or sealant to the bolt connection area
  • Sealed bolts can prevent water vapor from entering the connection holes, suitable for humid environments

Common Riveting Implementation Errors and Preventive Measures

1. Incorrect selection of nail type or size

Problem Description:

  • The rivets are too short: They cannot be securely clamped, resulting in false riveting and prone to falling off.
  • The rivets are too long: The core pulling process is insufficient, leading to failure of the riveting or deformation of the head.
  • Incorrect rivet type selection: For structural requirements, ordinary core-pulling rivets are used, resulting in insufficient strength.

Preventive Measures

  • Use the “grip range chart” to confirm the model
  • For high-load or critical structures, preferentially select “structural rivets” and combine with shear/extension strength calculations
  • Regularly train the selection personnel to master the logic of material and function matching

2. Incorrect Hole Size Matching

Problem Description:

  • Too large hole: The rivets are loose and the clamping force is insufficient.
  • Too small hole: The rivets are difficult to insert and may cause deformation or damage to the coating.
  • Hole position deviation: It affects alignment and the quality of forming.

Preventive Measures

  • Use standard diameter drill bits (recommended gap 0.1 – 0.2 mm)
  • Introduce positioning fixtures or laser marking to ensure the accuracy of the hole positions
  • For automated production, it is recommended to configure online visual inspection or hole position deviation alarm mechanisms

3. Installation with Angle Deviation

Problem Description:

  • The rivets entered at an angle, resulting in an asymmetrical deformation on the back.
  • Poor shaping led to uneven distribution of clamping force and loosening of the connection.

Preventive Measures

  • The tool is equipped with a vertical guide sleeve to ensure consistent force application direction.
  • The operation platform design should maintain horizontal rigidity and stability.
  • Educate the operators to follow the vertical pressure application process and conduct regular rechecks.

4. The core extraction was incomplete or the core pin did not break

Problem Description:

  • The core pins remain partially connected and the riveting is not secure.
  • The core pins are misaligned or have fallen off, which affects the structural integrity.

Preventive Measures

  • Use an air pressure-stabilized riveting gun to avoid insufficient core pin pulling force.
  • Regularly maintain the tool’s gripper to prevent slippage.
  • It is recommended to set up a visual confirmation station or sensor feedback to ensure the core pin breaking action is completed.

5. Inappropriate selection of materials

Problem Description:

  • Electrochemical corrosion: The combination of aluminum and stainless steel undergoes accelerated corrosion in a humid environment.
  • Incompatibility of material strength: The strength of the rivets is higher than that of the base material, which may cause damage to the base material.

Preventive Measures

  • Establish a material compatibility comparison table to assist in selection
  • In humid and hot environments, it is recommended to use closed-type rivets + anti-corrosion coating
  • For soft materials (such as plastics, composite panels), choose flower-shaped or slot-type rivets

Quality Control and Inspection Recommendations for Metal Riveting

Rivet inspection machine.

Tensile/Shear Test

Regularly conduct stretch and shear strength tests to verify whether the riveted structure can meet the design load requirements. It is recommended to sample test different batches and different workstations, using standard test fixtures (such as ASTM F606 or ISO 14589 specifications), and set warning thresholds for abnormal values.

Fatigue Testing

For critical load-bearing structures, especially in cases of vibration or dynamic loads, cyclic fatigue tests should be conducted to simulate the reliability of the riveted joints under long-term conditions. It is recommended to combine the results of FMEA analysis and prioritize the verification of high-risk areas.

Visual & Dimensional Checklist

Establish a standardized inspection checklist to visually and dimensionally confirm the integrity of the rivet head shape, core pin fracture, hole diameter fit, and rivet verticality. Using a graphical template can enhance the identification efficiency of front-line employees and support QA for quick review.

Assembly SOP and Process Control Recommendations

Establish clear assembly standard operation procedures (SOP), covering:

  • Process for confirming and verifying the model of rivets
  • Parameter verification of tool settings (force/extension)
  • Control of riveting sequence and operation cycle
  • Countermeasures for defects and rework procedures

It is suggested to integrate the SOP with the “digital tool feedback system” (such as workstation scanning for confirmation and automatic recording of torque/position), to achieve full-process traceability.

Conclusion – Ensuring Reliable Riveted Connections

Metal riveting is a highly efficient, lightweight and standardized connection method. It plays an irreplaceable role in various industries such as aviation and automobiles. Its key value lies in its ability to combine structural strength, vibration resistance performance and assembly efficiency. It is suitable for scenarios where single-side operation is possible and heat influence is limited.

It is suggested that enterprises establish a systematic riveting knowledge base and standardized design process. This should cover selection principles, mechanical compatibility, material compatibility and quality control. At the same time, combine simulation modeling, fatigue testing and on-site verification. This can continuously enhance structural reliability and promote the transition from process stability to engineering optimality.

Conclusion – Ensuring Reliable Riveted Connections

Metal riveting is a highly efficient, lightweight and standardized connection method. It plays an irreplaceable role in various industries such as aviation and automobiles. Its key value lies in its ability to combine structural strength, vibration resistance performance and assembly efficiency. It is suitable for scenarios where single-side operation is possible and heat influence is limited.

It is suggested that enterprises establish a systematic riveting knowledge base and standardized design process. This should cover selection principles, mechanical compatibility, material compatibility and quality control. At the same time, combine simulation modeling, fatigue testing and on-site verification. This can continuously enhance structural reliability and promote the transition from process stability to engineering optimality.

Reference

Types of Rivets And Their Applications

Rivet Inspection: Revolutionary TCC Assembly Inspection

Types of Rivets

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Blind Riveting Design Guide

Table of Contents

Blind riveting is a simple operation that does not require back support. It is widely used in various fields such as sheet metal connections and shell structures. In actual engineering, blind rivets directly affect the strength and assembly consistency of the entire structure. The key parameters for riveting connections during the design stage are of great significance. These include aspects such as the accuracy of hole positions, the selection of rivet types, the matching of rivet head shapes, and the layout method (such as spacing and arrangement direction). If these are overlooked, it is highly likely to result in the following problems:

  • Structural failure or loose connections
  • Accelerated expansion of fatigue cracks
  • Interference or mismatch during installation
  • Affecting the service life and safety of the product

 

Therefore, developing a professional and systematic Riveting Design Guide is of vital importance for ensuring structural stability, enhancing assembly efficiency, and reducing the risks of later maintenance. This article will delve into the key technologies in blind riveting design from aspects such as design points, material selection, and mechanical analysis. It aims to assist engineers in avoiding potential problems at an early stage and creating a more reliable connection system.

Fundamentals of Blind Riveting Design Based on Mechanical Principles

Types of Blind Rivets

Blind riveting is a non-detachable connection method widely used in aviation, automobiles, electronics and sheet metal structures. Its structural design must be based on precise mechanical principles to ensure long-term reliability and safety. The following explains the key design points starting from the force mechanism, which is applicable to structural engineers, product developers and quality engineers.

Analysis of the Force Mechanism

  1. Shear Load Concentration
    In most applications, rivets mainly bear shear loads. Blind rivets, due to their closed structure at one end, usually have an incompletely symmetrical shear surface. This may cause shear stress to concentrate in the area close to the point where the rivet rod breaks. If the hole position is improperly designed, it can easily lead to local yielding or the accumulation of micro-cracks, thereby weakening the connection strength.
  2. Tensile Load Path
    When subjected to tension (such as when a sheet is pulled apart along the vertical direction), the blind rivet converts the tension into the clamping force between the two plates through its “pulling pin tail ball head”. However, the tension path is long, which makes it prone to causing slight deformation along the axial direction of the rivet. If the fit between the rivet rod and the hole is too loose, it may result in micro wear.
  3. Impact of Fatigue Cycles
    Under repeated loads (such as vibration or periodic forces), the riveted area becomes a region with high stress concentration, especially when there is a gap between the rivet rod and the hole wall. Fatigue cracks often originate from the edge of the hole or the clamping surface. Therefore, a reasonable design of pre-tightening force and control of hole spacing are the key to improving fatigue life.

Key Points of Structural Design

What are monobolt rivets
  1. Rivet Pattern
    The rivets should be evenly distributed along the load path to avoid interruption or premature change of the force flow. Usually, a “trapezoidal” or “rhombic” arrangement is adopted to achieve stress diffusion. Although continuous linear arrangement is convenient for assembly, it may result in concentrated force. The arrangement should be optimized according to the actual load direction.
  2. Pitch and Edge Distance
    • Pitch: It should be greater than 2.5D (D is the diameter of the rivet), to prevent the overlapping of the cutting surfaces and the resulting material tearing.
    • Edge Distance: It is recommended to be ≥ 2D, to avoid edge cracks or edge deformation, especially in low-strength materials such as aluminum and magnesium, where caution should be exercised.
  3. Load Path Architecture
    It is necessary to ensure that the force flow of all connection nodes is continuous, and avoid “floating” or “bridging” designs. For example, using triangular reinforcement plates combined with blind rivets at structural corners to distribute the load can effectively prevent stress concentration.
  4. Distribution of Force Direction
    Bolt connections are best used for connections in the direction of shear, avoiding applications where axial tension is the main force. If tension is unavoidable in the design, structural reinforcements (such as washers, conical seats) should be used to enhance the tensile resistance.

Key Design Parameters for Reliable Blind Riveting

When conducting the blind riveting design, the structural strength, durability and manufacturing feasibility all depend on a series of detailed parameter designs. The following explains five key elements, providing professional suggestions based on actual working conditions. Ensure stable connection quality, reasonable stress distribution, and reduce the risks of corrosion and fatigue.

a. Bolt Type, Rod Diameter and Grip Range

How to Choose the Appropriate Rivet Grip Range
The “holding range” refers to the total thickness of the material that the rivet can effectively grip (the combined thickness of the two plates). It is necessary to ensure that the total plate thickness falls within the middle value of the selected rivet’s Grip Range plus or minus 10%. If it is too small, it will result in unstable gripping; if it is too large, it will create a blind end residual gap, causing the structure to loosen.

the grip range of blind rivet

The influence of rod diameter on shear/tear strength
The shear strength of the rivet is in a square relationship with the diameter of the rod, while the drawing strength is affected by the shape of the head and the deformation form at the tail. For example:

  • 3/16″ (4.8 mm) aluminum rivets have a shear strength of approximately 800 – 1,000 N
  • 3/16″ stainless steel rivets can achieve a shear strength of over 2,000 N (The specific values should be referred to the manufacturer’s data sheet.)

In the design process, an appropriate rod diameter and material should be selected after the load direction is clearly defined.

b. Hole Diameter and Fit Tolerance

The Influence of Hole Size on Tensile Force and Clamping Effect

An excessively large hole size will result in “empty motion” under axial force, leading to micro-movement wear; while a too small bore diameter is prone to causing installation difficulties or compression damage. The correct hole size design should be slightly larger than the rod diameter, allowing for a smooth insertion while ensuring good contact.

Suggested Aperture Margin

  • The recommended range is bolt rod diameter +0.003″ to +0.005″ (0.08—0.13 mm)
  • For stainless steel materials or precision structures, it can be controlled to +0.002″

It is essential to prevent the formation of burrs or elliptical deformations on the hole walls, as these can significantly reduce the fatigue life.

c. Layout Parameters: Edge Distance, Center Distance and Line Spacing

Recommendation Ratio Rule

  • Edge Distance (Margin) ≥ 2D: Prevents edge materials from tearing, especially in soft metals such as aluminum.
  • Pitch (Center Distance) ≥ 3D: Avoids overlapping of the cutting surface or stress concentration.
  • Row Spacing (Row Distance) ≥ 2.5D: Ensures structural integrity when multiple rows of rivets are used.

Asymmetric Force Flow Design Suggestions

For structures with non-uniform load directions (such as trapezoidal connection areas), offset arrangement or “interlaced layout” should be used to distribute the stress. For example, by staggering the middle row by half a pitch to form a triangular grid, the fatigue life can be increased by more than 30%.

d. Selection of Rivet Heads (Dome, Countersunk, Large Flange)

Types of Rivet Heads
Different Types of Rivet Heads
  • Dome Head (Round Head): Universal type, with moderate contact area, suitable for most metal plate connections
  • Countersunk Head (Sunk Head): Used for structures requiring a flat surface alignment, suitable for areas with low stress or for appearance requirements, but has a small clamping area and should avoid high load usage
  • Large Flange Head (Large Flange): Suitable for soft materials such as plastics and composite boards, with good distribution of load, preventing surface indentation and cracking

The choice of hairstyle should be based on a balance between the hardness of the base material and functional requirements. It is not recommended to make a decision solely based on cost.

e. Material Matching and Corrosion Prevention Design

Electrochemical corrosion risk

When the material of the rivets has a significant potential difference from the base material (for example, aluminum plate paired with stainless steel rivets), it is prone to form galvanic corrosion in humid or salt-spray environments. The design should consider the following matching strategies:

  • Priority given to the same material (such as aluminum versus aluminum, stainless steel versus stainless steel)
  • If avoidance is not possible, insulating washers or anti-corrosion coatings should be used instead.

Waterproof Sealing Design

For outdoor or enclosed structure applications, it is recommended to choose those that have:

  • Rubber sealed tail design (sealed rivet)
  • Or it can be used in combination with a sealing washer (neoprene washer)

This type of design can effectively prevent moisture from penetrating into the intermediate layer, thereby extending the service life.

Practical Workflow for Implementing Blind Riveting in Engineering Design

During the product structure design phase, the introduction of the “blind riveting solution” requires a systematic consideration of material stacking, mechanical structure, processing accuracy, and batch assembly efficiency. The entire process is recommended to be divided into two stages: the “design decision stage” and the “manufacturing implementation stage”. At each stage, a verification mechanism should be established at key nodes to ensure that each rivet from the drawing to the product is controllable and consistent.

Design Decision Phase

The primary task is to accurately assess the material thickness at all connection points, including nominal thickness, tolerance, surface treatment, and functional coating layers. For instance, electrophoretic coatings and sealants can add additional thickness. If not accounted for, this will result in insufficient gripping or abnormal tail deformation. When selecting rivets, the Grip Range should be strictly used for selection to ensure that the total stack thickness falls within the middle-upper part of the clamping range, and avoid using total length as a substitute for Grip specifications. Additionally, when positioning and arranging the rivets in CAD, the layout should be optimized based on the structural force direction (such as triangular grid layout can improve fatigue life), and the basic design specifications of margin ≥ 2D and center distance ≥ 3D should be maintained to avoid sheet tearing or deformation due to too dense arrangement or being close to the edge.

Manufacturing Phase

The key points lie in the quality control of hole processing and the setting of assembly process parameters. The hole diameter must meet the recommended fit tolerance (generally the rod diameter +0.003″ to +0.005″), and must maintain roundness and perpendicularity to prevent uneven loading or micro-motion after the pin is inserted. The production line should use automated or semi-automated riveting equipment, preset parameters for tension, stroke and time window, and lock and trace them through the industrial control system or MES platform. Key positions should implement the first-piece full inspection and process sampling inspection mechanism to ensure that the clamping force, tail deformation quality and surface indentation are within the control range.

Common Mistakes in Blind Riveting Design and How to Avoid Them

① Ignoring the tolerance of plate thickness leads to insufficient clamping force

Do Zinc Plated Rivets Rust

Common Misconceptions:
During the design process, the selection of rivets was solely based on the nominal thickness of the plate, ignoring the actual thickness tolerance of the material and the coating thickness. This resulted in a smaller or excessive grip range of the rivets, affecting the clamping force and deformation control.

Consequences:

  • Residual gap between plates → Causes loosening or structural “shaking”
  • Insufficient tail deformation → Clamping failure or incomplete riveting

Avoidance Suggestions:

  • When calculating the total thickness, the following factors should be taken into account: ±sheet thickness tolerance + coating thickness + film thickness
  • Prefer to choose the specifications whose gripping range is located in the middle of the total thickness by ±15%
  • For mass production， a thickness grading table should be used to assist in selection

②. Incorrectly Taking the Total Length of the Rivets as the Design Basis

Common Misconceptions:
Some designers mistakenly used the total length of the rivets to match the plate thickness, ignoring the structural differences between it and the grip range.

Consequence:

  • The rear end did not deform correctly after installation.
  • The gun cannot complete the disconnection action after being installed.

Avoidance Suggestions:

  • Design strictly according to “Grip Range” rather than “Total Length”
  • All drawings or BOM annotations should indicate the “Grip” parameter, not the total length

③. Excessive spacing between nails or insufficient margins

Common Misconceptions
Due to the need for stronger connections or space constraints, the spacing of the rivets was designed too small, even violating the minimum Pitch and edge distance rules. Consequences:

  • Board cracks along the edge of the hole
  • Local warping or deformation, reducing fatigue life

Avoidance Suggestions:

  • Follow the experience rule: Pitch ≥ 3D, Edge Distance ≥ 2D
  • When the material is relatively soft (such as aluminum, plastic), it is recommended to increase the margin to ≥ 2.5D
  • Avoid using rivets close to weakened areas such as folded edges, slots, or punching holes

④. Incompatibility of materials causes galvanic corrosion

Common Misconceptions:
To achieve higher strength or lower costs, unassessed combinations of dissimilar metals such as stainless steel nails with aluminum plates or copper nails with galvanized parts were adopted.

Consequences:

  • Forming an electrochemical corrosion circuit in a humid environment
  • The corrosion spreads from around the rivet hole and eventually leads to failure

Avoidance Suggestions:

  • Use the same or similar metal materials (such as aluminum paired with aluminum, stainless steel paired with stainless steel)
  • If unavoidable, add anti-corrosion measures (epoxy coating, sealing the tail end, nitrile rubber gasket)
  • For important structures, conduct accelerated corrosion tests using ASTM G44/G85

⑤. Ignore the effects of thermal expansion and contraction or dynamic loading conditions

Common Misconceptions
Structures that are exposed to alternating temperatures, high-frequency vibrations or near heat sources do not have stress release designs for the rivets, and are still designed according to the normal temperature static load scheme.

Consequences:

  • The material expands thermally, resulting in internal stress.
  • The rivets develop fatigue cracks or undergo creep loosening.

Avoidance Suggestions:

  • In areas with significant thermal deformation, use a floating hole design or elastic gaskets
  • In high-frequency vibration environments, adopt a tail-locking structure (such as Huck Bolt) or enhance the clamping force

Validation and Quality Control in Blind Riveting Design

In terms of design verification, it is recommended to prioritize the introduction of finite element analysis (FEA) to conduct stress simulations at key riveting points, identifying stress concentration areas, fatigue hotspots, and potential failure risks. This is especially necessary in cases of variable loads, thermal-cold cycling, or eccentric loading. For the structural prototype stage, standard tensile/shear tests should be conducted to verify whether the rivets’ load-bearing capacity meets the design requirements, and at the same time, perform fatigue cycle tests (such as according to the ASTM E466 standard) to assess the durability of the structure over a long period of use. If there are multi-material or mixed connection structures, comprehensive tests such as vibration tables and climate chambers can also be introduced to simulate multiple factors of environmental conditions.

In terms of the quality control system, it is recommended to establish standardized SOP (Standard Operating Procedures) covering all stages from incoming material inspection, hole processing, rivet assembly to final inspection; in conjunction with special installation clamps and fixtures, ensure the consistency of workers’ clamping force and reduce human errors. At the same time, a tolerance caliper inspection standard needs to be formulated, regularly measuring key dimensions such as hole diameter, edge distance, and tail deformation, and introducing a regular quality inspection mechanism (e.g., every 500 pieces / every shift), recording the measurement data in the quality traceability system to achieve full-process closed-loop control.

Reference

What are the typical riveting faults and how can they be avoided?

Exploring the World of Rivet Heads: Types, Applications, and Materials

Types of Rivets

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Common Rivet Installation Mistakes - How to Avoid When Using Rivet

Table of Contents

In industrial manufacturing and daily maintenance, rivet connections are efficient, reliable and do not require tapping. However, the seemingly simple riveting process often harbors risks. Errors in rivet installation are easily overlooked by operators. In reality, they may become the root cause of structural loosening, water seepage, rusting and even failure. To understand and avoid these issues, this article will systematically summarize the common mistakes to avoid when using rivets in practical applications. Combined with engineering cases, it will provide a series of professional and actionable prevention and correction suggestions to help technicians, purchasing engineers and production managers improve riveting quality and extend product service life.

The Basic Principles and Installation Process of Rivet Connections

Applications of Interlcok Blind Rivets - Cabinets and Enclosures

Bolt connection is a type of connection that achieves permanent mechanical fixation through plastic deformation. It is widely used in the structural assembly between metals, plastics, and composite materials. Depending on the structural requirements and the installation tools, the common types of bolts include the following:

  • Solid Rivets: Have a long history and are suitable for high-strength structures, such as in aviation and bridges. Installation requires double-sided operation.
  • Blind Rivets: Also known as blind rivets, they are suitable for single-sided contact conditions and are commonly used in sheet metal parts, appliance shells, etc.
  • Structural Rivets: Based on the principles of blind rivets, they have enhanced shear strength and vibration resistance, and are often used in high-load scenarios such as vehicles and construction machinery.

Basic Steps for Installing Rivets:

  1. Drilling: Select the appropriate hole diameter based on the diameter of the rivet to ensure the hole wall is smooth and free of burrs.
  2. Inserting the Rivet: Insert the rivet into the hole of the workpiece, ensuring a tight fit.
  3. Breaking/Securing: Use a special tool to apply tension to the mandrel or lock the nail rod, causing the tail end to expand and form, completing the fixation.
  4. Installation Inspection: Confirm that the head of the rivet is tightly attached to the workpiece, and the tail end is fully deformed without cracks, ensuring the integrity of the structure.

The quality of rivet installation has a direct impact on the structural performance, which is mainly manifested as:

  • Shear strength: If the rivets are not tightly attached or the hole diameters are too large, it can lead to uneven force distribution, thereby reducing the overall connection strength.
  • Waterproofing: If the rivets are not compacted or the installation angles are incorrect, it can result in gaps, causing leakage problems.
  • Fatigue life: An improper breaking process may introduce residual stress, affecting long-term stability and increasing the risk of fatigue failure.

Top 10 Common Errors in Rivet Installation and Analysis of Their Causes

Common mistakes and ways to avoid them when using rivets on solar panels

Although rivets are small, they directly affect the overall stability and service life of the connection structure. Here are the most common mistakes to avoid when using rivets in actual engineering projects. Each one is worthy of attention and is accompanied by practical corrective suggestions.

①. Misalignment of aperture (too large/ too small)

When the aperture is too large: The rivets will shake within the holes, causing the connection to become loose, the shear force to decrease, and even falling off in a vibrating environment; When the aperture is too small: The rivets are difficult to insert, which may cause scratches or deformation on the surface of the rivets, further affecting the riveting strength and sealing effect. Solutions Proposed:

  • Follow the reasonable ratio between the diameter of the rivet and the diameter of the hole. Generally, it is recommended that the hole diameter = rivet diameter + 0.1 to 0.2 mm;
  • Refer to the rivet hole size chart provided by the manufacturer
  • Refer to the drill bit size comparison table provided by the manufacturer and use dedicated drill bits to ensure accuracy.

②. Incorrect determination of clamping thickness

The grip range of the rivet is a key parameter that determines its performance. If the clamping range of the rivets is less than the total thickness of the sheet material, the rivet feet cannot fully expand, resulting in loosening or failure of the riveted connection.

On the contrary, if the clamping range is too large and the nail head shrinks excessively, it is also prone to deformation and bulging, which will affect the structural strength and appearance.

Therefore, accurately determining the total thickness of the workpiece and selecting the appropriate clamping range for the rivets is the fundamental requirement for avoiding the mistakes when using rivets.

③. Incorrect selection of Rivet Length

The length of the rivet determines whether it can effectively cover the connecting material. Rivets that are too short cannot grip the sheet metal tightly and are prone to the “empty pull” phenomenon, resulting in an insecure connection. On the other hand, rivets that are too long are likely to bulge or deform at the nail head during the riveting process, thereby compromising the structural integrity.

How Do I Choose The Right Size Pop Rivet? - Select the Length of the Pop Rivets

The general principle for reasonably selecting the length of the rivets is: Grip Range = Total Thickness of the Plate ± Tolerance. This judgment criterion should be clearly defined before the design and construction.

④. Installation with Angle Deviation

When the rivets are not perpendicular to the connection plate surface, during the riveting process, the rivet tail will be skewed and spread out. This may lead to problems such as cracks and uneven internal stress in the structure.

When the rivets are not inserted vertically into the holes, resulting in an inclined installation, the axis of the rivets forms an angle with the plate surface, leading to uneven stress distribution. The expansion of the rivet feet is asymmetric, which is very likely to cause material cracking, surface warping or sealing failure. Especially in high-strength connections or structural riveting, such problems will seriously reduce the shear and tensile performance.

Avoid such mistakes when using rivets, and instead use positioning fixtures or alignment devices to assist in the installation, ensuring verticality.

⑤. Failure to remove burrs at the edge of the hole or surface contamination

Impurities such as burrs, oil stains, and iron filings at the hole edges can affect the bonding density of the rivets, leading to sealing failure and even initiating corrosion.

  • Perform edge deburring treatment around the holes before riveting;
  • Clean the riveting area to ensure a clean and flat surface.

⑥. Incorrect Tool Settings

If the pulling force setting of an air or electric pull-pin gun is not reasonable, it will directly affect the locking effect of the rivets.

Use Air Rivet Nut Tool

If the clamping force is too small, the rivet will not be fully locked, resulting in a situation where it is partially pulled or loose. If the clamping force is too large, it may cause the pull pin to break, the rivet to be misaligned, or the sheet material to be damaged.

Different materials and specifications of rivets need to be matched with corresponding set values. The installation personnel should calibrate the equipment regularly.

⑦. Ignore Sealing Measures

When using nails or sealing gaskets in outdoor or humid environments, if they are not of the enclosed type, problems such as water seepage, rusting, and leakage are likely to occur. It is recommended:

  • In sealed application scenarios, choose Closed-End Rivets (closed-type rivets);
  • Use in conjunction with rubber gaskets or sealants to enhance the protection level.

⑧. Using low-quality or mismatched rivets

The material of the rivets should match that of the connecting components; otherwise, electrochemical corrosion is likely to occur. Especially when carbon steel rivets are used in aluminum plates, problems such as corrosion damage, darkening of color, and reduced strength often arise. Moreover, inferior rivets have poor processing accuracy and easily break the core rod, frequently causing structural expansion and deformation, or even fracture during use. To avoid such mistakes when using rivets, it is necessary to select regular brand products with quality certification. And the material should be chosen according to the working environment (such as stainless steel, aluminum, copper, etc.).

⑨. Rivets are not properly centered and aligned

If the installation position of the rivet is not accurately aligned with the hole: it will affect the uniformity of the rivet tail expansion, reduce the connection strength and affect the consistency of the appearance.

If the center of the rivet is not accurately aligned with the hole position: during installation, eccentric force will occur, reducing the shear bearing capacity and also affecting the flatness of the appearance.

Especially in decorative panels and precision components, the alignment deviation can lead to significant uneven stress, which may cause crack propagation or failure. This can be achieved through:

  • Use laser drilling or CNC drilling equipment to ensure high-precision alignment;
  • Conduct manual inspection to confirm that the hole positions are concentric.

⑩. Failure to conduct post-operation inspection

Failure to conduct the necessary tail extension inspection after riveting is the most easily overlooked yet high-risk operational error. If the core is not broken, the broken part is unstable, or the nail feet do not fully extend, the connection strength will be greatly reduced, and the connection may fail rapidly during use. It is recommended to conduct a post-riveting inspection after each batch of construction. This includes observing the tail condition, conducting random destructive tests, etc., which are the basic operational norms for controlling the reliability of riveting.

How to Avoid Installation Mistakes When Using Rivets?

To ensure the firmness and durability of the rivet connection, it is crucial to master the correct rivet installation method. Below are the common types of problems and their corresponding preventive measures and recommended tools, which will help you complete the riveting work efficiently and avoid errors.

Type of MistakePrevention MethodRecommended Tools/Assistive Devices
Incorrect Hole SizeFollow rivet specifications strictly to avoid oversized or undersized holesUse depth-limiting drill bits, verify with calipers, refer to rivet size charts
Misaligned Installation AngleEnsure the rivet is installed perpendicular to the work surfaceUse vertical positioning jigs, assist with laser alignment or marking tools
Incorrect Rivet Length SelectionChoose the correct rivet based on total material thickness (Grip Range)Use Grip Range calculators (e.g., Excel tools), consult manufacturer handbooks
Improper Tool SettingsEnsure the pull force is correctly set for the specific rivetCalibrate regularly with a pull tester, use air pressure regulators for pneumatic tools
Material IncompatibilityPrevent galvanic corrosion by using compatible metal combinationsRefer to a galvanic corrosion chart to select metals with minimal potential difference

How to confirm if it is installed correctly after installation?

How to Install Countersunk Rivets

To ensure that each rivet installation meets the quality standards, it is recommended to conduct the following checks and verifications:

Critical Checkpoints:

  • Nail head symmetry: The nail head should be firmly in contact with the surface of the workpiece, without being tilted or deformed.
  • Tail end expansion integrity: The tail end should fully expand, securely clamping the base material, without any detachment or loose connection.
  • No cracks on the plate surface: The plates in the riveted area should have no obvious cracks, bulges, or stress marks.

Recommended Tools:

  • Expansion Inspection Gauge: Quickly determine whether the tail end expansion meets the standard.
  • Bolt Strength Pull Test Instrument: Conduct random inspections on key structures to verify if the tensile force meets the requirements.

Quality Traceability Suggestions:

Establish a standardized installation record sheet, including key information such as tool settings, inspection results, and operator signatures, and document each abnormal situation with pictures and text to form a complete feedback loop mechanism, which facilitates continuous optimization of the installation process.

Examples of Common Error Scenarios

Fully Automatic Installation of Blind Rivets

1. Installation with tilted angle vs. Correct vertical connection

Error manifestation: During the installation of the rivets, the gun head was tilted, resulting in eccentricity of the pull pin, and the expansion of the rivet tail was asymmetrical. This made it prone to instability in clamping and loosening of the rivets.

Correct Method: Ensure that the stud gun is kept perpendicular to the surface of the workpiece. Use positioning fixtures or laser-assisted positioning devices to help stabilize the direction and improve the consistency of the riveting.

2. Excessive hole diameter leads to failure of the rotating function of the core-pulling rivet

Error manifestation: The diameter of the hole exceeds the recommended range for the rivet, preventing the rivet from generating sufficient frictional force with the hole wall. During the installation process, “idling” occurs and the tail end deformation cannot be completed.

Prevention Suggestions:

  • Use the limiting drill bit to control the hole diameter;
  • Refer to the pop rivet hole size chart to strictly match the recommended hole size;
  • For critical areas, you can increase the frequency of inspection with the inspection calipers.

3. Comparison between Half-Expanded and Normal Expanded Tail States

Error manifestation: Some rivets failed to fully expand at the tail end due to insufficient tension setting, premature return of the gun head, or too short rivets (commonly referred to as “half-pulled”). The connection strength significantly decreased.

Identification Method

  • Observe whether the tail shape is symmetrical and plump;
  • Quickly screen suspicious areas using the “expansion inspection gauge”;
  • For key structures, it is recommended to use the “pull-out tester” to verify the installation strength.

FAQs

What if the rivets cannot be pulled out?

The possible reasons are as follows:

  • Incorrect selection of rivet diameter or length leads to excessive load on the core;
  • Incompatible model of pull pin gun results in insufficient power or worn-out grippers, making it impossible to grip the core tightly;
  • There are burrs or impurities inside the hole, causing the tail to fail to expand smoothly;
  • The rivet material is too hard (such as stainless steel). It is recommended to use reinforced pneumatic or electric tools.

Solutions Proposed: First, confirm whether the rivet specifications match the firearm. Clean any foreign objects inside the holes. Then, check the wear condition of the clamping爪 of the pull pin gun or replace it with a tool that has greater pulling force.

The core puller broke but didn't grip tightly？ Can it be remedied?

This situation is usually referred to as “cracking of the core but no formation”. The following are the handling methods:

  • Minor deformation: You can try using a special core extraction tool to remove the broken core, and then re-bolt it;
  • The bolt is stuck: It is recommended to remove the entire bolt (using a special bolt removal drill), and then reinstall it;
  • If using stainless steel bolts, it is recommended to avoid forcibly extracting to prevent damage to the base material.

Prevention Tips: Check the condition of the gun clamping mechanism to ensure stable force output; if the pull pin is rusty or has burrs, it will also increase the risk of breakage.

How to determine if the rivet clamping force meets the standard?

To determine whether the clamping force meets the standards, one can start from the following aspects:

  • Tail appearance inspection: The qualified rivet tail should be symmetrically and fully expanded, without any skew or creasing;
  • Manual inspection: Gently twist the riveted part, and there should be no looseness;
  • Torque test or pull test: For critical structures, it is recommended to use professional testing instruments to confirm the connection strength;
  • Destructive sampling inspection: Sample the already riveted part for dissection, and observe whether the tail end deformation completely clamps the sheet metal.

Why do aluminium rivets start to rust after only a few months?

Aluminum itself does not rust. However, if corrosion occurs, the reasons usually include:

  • The environment contains salts, acids, bases or industrial pollutants, which accelerate the corrosion of aluminum materials;
  • It is combined with carbon steel core wires, causing electrochemical corrosion (contact between different metals);
  • The surface is not anodized, making the aluminum material more prone to corrosion when exposed to harsh environments;
  • Water accumulates in the structure, accelerating oxidation.

Suggested Usage:

  • For outdoor or humid environments, it is recommended to use all-aluminum or stainless steel rivets;
  • Avoid mixed structures of aluminum and steel;
  • Or choose industrial-grade rivet products with anti-corrosion coating.

Conclusion: How to Avoid Installation Errors When Using Rivet

Although the installation process of rivets may seem simple on the surface, it actually directly affects the strength of the structural connection, the anti-corrosion ability, the sealing performance, and the overall service life. A seemingly minor installation error can often lead to serious structural problems in the later stage.

Therefore, it is recommended that enterprises conduct regular professional training for installation personnel, establish detailed installation operation guidelines and operating procedures, and provide corresponding measuring tools and equipment (such as tension gauges, expansion inspection gauges, etc.) for random inspection and verification.

Reference

What are the typical riveting faults and how can they be avoided?

Analysis of Common Problems And Causes During the Use of Blind Rivet

Types of Rivets

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