Best Rivets for Aluminum How to Choose the Right Blind Rivets
- Author: Allen Zhao
- 20+ Years of Manufacturing
For most aluminum joints, the optimal choice of rivet is a standard blind rivet featuring an aluminum body and a steel mandrel. In practical applications, this material combination strikes a favorable balance among weight, formability, manufacturing costs, and final joint strength.
Table of Contents
Match the Rivet Body and Mandrel to Aluminum
In aluminum joining applications, the rivet body primarily determines how the rivet deforms, bears loads, and interfaces with the aluminum sheet, whereas the mandrel mainly influences the installation pull force, tail formation, and final joint performance. Therefore, different combinations of mandrel and rivet body must be selected based on the specific characteristics of the aluminum material.
Quick Guide to Matching Aluminum with Rivet Body and Mandrel Materials
| Aluminum Material / Joint Characteristics | Recommended Rivet Body | Recommended Mandrel | Selection Focus |
|---|---|---|---|
| General Aluminum Sheet | Aluminum | Steel | Balance strength, cost, and installation performance |
| Thin Aluminum Sheet | Aluminum | Aluminum / Steel | Reduce the risk of sheet deformation |
| Soft Aluminum | Aluminum | Aluminum | Provide gentler rivet setting and forming |
| Medium-Load Industrial Aluminum | Aluminum | Steel | Improve installation stability and joint strength |
| High-Load Aluminum Structures | Select According to Structural Requirements | High-Strength Mandrel | Prioritize structural blind rivets |
| Wet / Outdoor Aluminum | Aluminum | Steel / Stainless Steel | Evaluate corrosion resistance and material compatibility |
| High-Vibration Aluminum Structures | Structural Rivet Body | Mechanically Locked Mandrel | Focus on mandrel retention and vibration resistance |
How to prevent galvanic corrosion
Three necessary conditions for galvanic corrosion to occur:
- Two metals with different electrochemical potentials;
- Conductive contact between the metals;
- The presence of water, saltwater, or another electrolyte.
In aluminum riveting, to prevent electrochemical corrosion, you should minimize direct contact between aluminum and dissimilar metals and block electrolytes—such as moisture and salts—from entering the joint. Based on our project experience, you can insert an insulating layer between the dissimilar metals and, where necessary, apply an appropriate surface treatment.
Choose the Rivet Type by Joint Requirement
When selecting the appropriate blind rivet for joining aluminum plates, it is essential to consider the potential challenges the joint may face—such as insufficient strength, the risk of loosening, sealing requirements, or vibration resistance needs. By choosing a blind rivet with structural features suited to these specific issues, a more reliable connection can be achieved.
Quick Rivet Selection Guide for Aluminum Joints
| Joint Requirement | Recommended Rivet Type | Main Problem Solved |
|---|---|---|
| General Fastening | Open-End Blind Rivet | General-purpose aluminum assembly |
| Thin Aluminum Sheet | Large Flange Blind Rivet | Reduce head-side pull-through and sheet deformation |
| Variable Material Thickness | Multi-Grip Blind Rivet | Cover a wider grip range with fewer rivet sizes |
| Soft Aluminum Sheet | Peel-Type / Large Blind-Side Bearing Rivet | Increase the blind-side bearing area |
| Waterproof / Dustproof Joint | Closed-End / Sealed Blind Rivet | Reduce the risk of water or air leakage |
| High Load / High Vibration | Structural Blind Rivet | Improve structural strength and joint stability |
| Flush Surface Required | Countersunk Blind Rivet | Minimize rivet head protrusion |
Calculate the Correct Grip Range
When selecting aluminum blind rivets, the grip range must cover the total combined thickness of all materials being joined.
Total Grip Thickness = Layer 1 + Layer 2 + Layer 3 + …
The calculation tool below can assist you:
Enter the thicknesses of the various aluminum sheets or material layers to automatically calculate the Total Grip Thickness;
Enter the minimum and maximum grip specifications of a candidate rivet to automatically determine its suitability.
Blind Rivet Grip Range Calculator
Enter the thickness of each material layer to calculate the total grip thickness. You can also enter the grip range of your selected blind rivet to check whether it is suitable.
Choose Diameter and Hole Size from Load Data
When selecting the size of a blind rivet, the first step is to determine the actual shear and tensile loads the joint will bear. Based on the calculated load requirements, compare the rated shear and tensile strengths of specific rivet models to select a rivet diameter that meets the connection needs.
In the Rivmate product catalog, tensile and shear strengths vary according to diameter size. Please refer to the catalog data for specific selection.
Once the rivet diameter is determined, select the appropriate installation hole size according to the corresponding specifications to ensure proper installation and a reliable connection.
Different diameters correspond to different drill hole sizes. Rivmate has prepared a detailed rivet hole size chart for your reference.
Choose the Head Style
In aluminum joining applications, the rivet head style affects the load-bearing area, the height of the head above the surface, and the overall appearance. Common head styles include:
Dome Head: The default choice for most aluminum fittings.
Dome-head blind rivets are the most common choice for industrial connections involving standard aluminum materials. They are the preferred option when there are no specific requirements for a flush surface finish on the aluminum sheets and no need to distribute the load.
Large Flange Head: Better suited for soft, thin aluminum sheets.
When aluminum sheets are thin, standard-sized rivet heads can concentrate the load on a small area, causing the sheet to deform or even tear through. Large-flange blind rivets feature the largest head size, effectively distributing the load and helping you avoid issues with localized deformation.
Note: The large flange addresses the bearing issue on the rivet head side. To address the bearing issue on the reverse side, the blind-side rivet head formed after installation must be inspected.
Countersunk Head: Use only when a flush surface is required.
The countersunk design of these blind rivets helps minimize surface protrusion, enhancing the overall appearance of the assembled product. They are ideal for use on visible surfaces, sliding surfaces, locations requiring subsequent installation of cover panels, and areas with limited assembly space. Note that a countersunk hole must be prepared prior to installation.
Rivet for Aluminum Selection Table by Application
Rivet Selection for Aluminum by Application
| Application | Main Joint Requirement | Recommended Rivet Type | Why Choose It |
|---|---|---|---|
| Aluminum Enclosures & Equipment Housings | General fastening, cost efficiency, and easy installation | Open-End Blind Rivet | Simple construction and suitable for general aluminum sheet assembly |
| Thin Aluminum Sheets, Panels & Signs | Reduce head-side pull-through and sheet deformation | Large Flange Blind Rivet | Larger head bearing area helps distribute the load over the aluminum sheet |
| HVAC, Appliances & Variable-Thickness Assemblies | Accommodate different material stack thicknesses | Multi-Grip Blind Rivet | Wider grip range can cover multiple material thicknesses |
| Outdoor Aluminum Enclosures & Electrical Housings | Rain resistance, moisture protection, and reduced leakage | Closed-End / Sealed Blind Rivet | Helps reduce water and air leakage through the rivet body |
| Aluminum Roofing & Solar Structures | Outdoor exposure, water resistance, and long-term durability | Sealed / Application-Specific Blind Rivet | Better suited to outdoor joints requiring weather resistance and durability |
| Truck & Trailer Aluminum Components | High loads, vibration, and long-term joint stability | Structural Blind Rivet | Better suited to joints requiring higher structural performance and vibration resistance |
| Industrial Machinery & High-Vibration Equipment | Vibration resistance and higher shear and tensile loads | Structural Blind Rivet | Improves joint strength and mandrel retention under demanding loads |
| Visible Surfaces, Sliding Surfaces & Cover Panels | Minimal rivet head protrusion | Countersunk Blind Rivet | Reduces head projection and provides a flatter finished surface |
Installation Steps and Tool Requirements
- Insert the rivet into the pre-drilled hole, ensuring that the rivet head sits flush against the workpiece.
- Place the rivet gun’s nozzle over the rivet mandrel and hold the tool vertically.
- Activate the rivet gun and pull the rivet mandrel to expand the rivet body and secure the workpiece.
- Once the rivet mandrel breaks off, the riveting is complete. Check that the rivet is secure and flush.
Tool Requirements
| Tool | Purpose |
|---|---|
| Drill / Drilling Machine | Drills the installation hole for the blind rivet |
| Correct-Size Drill Bit | Creates the hole according to the rivet manufacturer’s specified hole diameter |
| Deburring Tool | Removes burrs from the drilled hole before rivet installation |
| Blind Rivet Gun | Pulls the mandrel and sets the blind rivet |
| Correct Nosepiece | Matches the mandrel diameter and allows proper rivet setting |
| Caliper / Measuring Tool | Checks material thickness, hole diameter, and other relevant dimensions |
Common Rivet for Aluminum Failures
- Rivet is loose after installation. Check if the total material thickness matches the rivet’s grip range and verify proper formation on the blind side.
- Aluminum sheet is pulled through by the rivet. Check the rivet’s strength and the local bearing capacity of the aluminum sheet.
- Significant indentation of the aluminum sheet around the rivet. Check the bearing surface area of the rivet head.
- Rivet undergoes shear or tensile failure. Check shear strength and tensile strength.
- Abnormal mandrel breakage. Check the installation tool and conditions.
- Rivet head does not sit flush against the aluminum sheet. Check the installation hole.
- Rivet hole gradually enlarges or deforms. Check if the hole diameter matches the rivet specifications.
FAQs
Can stainless steel rivets be used with aluminum?
Yes. Stainless steel rivets offer good corrosion resistance and high strength. However, be aware of the potential for galvanic corrosion.
You can prevent galvanic corrosion by using a suitable insulating layer.
Do aluminum rivets cause galvanic corrosion?
Under normal circumstances, the use of aluminum rivets alone does not result in galvanic corrosion. However, if an aluminum rivet connects dissimilar metals—and given that the rivet body contains a steel mandrel—galvanic corrosion is highly likely to occur in coastal or salt-spray environments.
What rivet material is best for marine aluminum applications?
For most aluminum applications in marine environments, we recommend using aluminum rivets. Aluminum blind rivets offer superior material compatibility, thereby preventing galvanic corrosion.
Are all-aluminum rivets better than aluminum rivets with steel mandrels?
Not necessarily. For joining standard industrial aluminum sheets, a combination of an aluminum body and a steel mandrel is a very common and practical choice.
However, if the priority is to minimize dissimilar metals, join softer aluminum materials, or enhance material compatibility, an aluminum body with an aluminum mandrel would be the preferable option.
Get a Rivet Recommendation for Your Aluminum Joint
If, after reviewing the selection methods above, you are still unsure which blind rivet to choose for joining your aluminum sheets, please contact Rivmate and provide the following details:
- Materials to be joined
- Thickness of each material layer
- Existing hole diameter
- Primary load
- Operating environment
- Waterproofing requirements
- Surface finish requirements
- Drawings or photos
- Estimated purchase quantity
Based on the details you provide, we will tailor a suitable riveting solution for you.
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Rivmate is blind rivets manufacturers in china. The company is IATF 16949 certified and offers high-strength structural blind rivets that serve as alternatives to Huck and Avdel products.
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I am the boss of Rivmate. For over two decades, we have specialized in the manufacture of blind rivets, providing our customers with reliable riveting solutions. Need riveting services? Feel free to contact us.