Manufacturing and product design professionals rely on essential tools to connect and align components and structures effectively. These tools play a crucial role in assembly, and rivets are one of the key fasteners used for this purpose.
Rivets are a universal and low-cost tool for fastening two components together. Different types of rivets cater to specific design requirements, materials, applications, and properties, offering exceptional fastening capabilities suitable for light and heavy-duty applications.
This article will explain everything you need to know about rivets, including the types of rivets, the materials used to make them, and their uses. You will also learn how several industries apply riveting.
What is a Rivet?
A rivet is a small, cylindrical pin or rod with a head on one end. It is a type of fastener used to mechanically join two or more pieces of material together. To use a rivet, you first drill holes in the materials you want to join. The rivet is then inserted through these holes, with the head resting on one side. The other end of the rivet called the tail, is then deformed or “bucked” (usually with a tool like a rivet gun) to create a second head. This process locks the materials together, creating a tight and permanent bond.
It’s a simple but very effective tool that has been used for hundreds of years in construction, manufacturing, and engineering. Rivets are especially appreciated because they create strong, long-lasting, and vibration-resistant connections. This makes them a go-to choice in industries where reliability is crucial, such as aerospace, automotive, shipbuilding, and building construction.
How Do Rivets Work?
Rivets are small but strong fasteners used to join materials in machines and structures. The basic idea behind a rivet is simple: first, a hole is made in the materials using a drill. Then, the rivet is inserted, and its tail is pressed in, using heat or pressure to expand and hold everything tightly together.
A rivet has two heads. The first head, made during manufacturing, is called the “factory head.” After inserting the rivet into the materials, either pressure is applied to the other end using a rivet gun, machine or hammer, or heat which then creates a second head known as the “shop head.” This process, called “upsetting” or “buckling,” ensures the rivet stays securely in place. Here’s a step-by-step guide on how to install a rivet properly:
- Choose the Right Rivet: Pick a rivet that fits your materials in terms of size, type, and material.
- Mark the Drilling Spot: Decide where the rivet should go to create a strong connection.
- Drill a Hole: Make a hole slightly larger (about 1.5 mm more) than the rivet’s diameter.
- Insert the Rivet: Place the rivet into the hole through the materials you want to join.
- Position the Tail: The rivet’s tail should stick out on the other side, ready to be deformed.
- Flatten the Tail: Either apply pressure using a rivet gun, rivet machine or hammer or apply heat to flatten the tail, making it spread to about 1.5 times its original size. Ensure the rivet sits tightly against the materials for a firm hold.
What Materials Are Used for Rivets?
The materials used for rivets are carefully selected based on the application’s specific requirements. Each material brings unique properties that make it suitable for certain environments, loads, and conditions. Here are the different materials used for rivets and why they are chosen for particular tasks:
Aluminum
The most prevalent choice is aluminum rivets, which are prized for their lightweight nature and impressive resistance to corrosion and weathering. Their malleability makes them easily deformable during riveting. The aluminum quality is particularly advantageous for installing blind rivets in diverse settings.
Stainless Steel
Stainless steel rivets boast exceptional resistance to corrosion and weathering. Due to their hardness, however, installing stainless steel rivets with hand-operated tools proves challenging. Pneumatic rivet guns, on the other hand, achieve optimal results, especially when working with structural rivets.
Copper
Copper rivets are distinguished by their excellent electrical and thermal conductivity. Additionally, copper’s relative ease of forming enhances its appeal. Copper rivets find their place in scenarios where conductivity is crucial, which makes them suited for various types of rivets.
Steel
Carbon steel rivets, like other rivet materials, exist in both solid and hollow shank forms. Installation necessitates pneumatic, hydraulic equipment, etc for pressure, showcasing diverse rivet installation methods. Low-carbon steel is favored for its elasticity, offering a more pliable alternative to rigid, high-carbon steel in various structural rivet applications.
Brass
Brass, an alloy of zinc and copper, is characterized by exceptional corrosion resistance and strength. It also does not spark, which makes it particularly valued in the oil and gas industry. Brass rivets serve well in environments where non-sparking properties are critical. Additionally, their aesthetic appeal makes them a preferred choice in various settings, highlighting the aesthetic considerations for fasteners.
Plastic
Plastic rivets are lightweight, inexpensive, and resistant to corrosion and chemicals. They are also non-conductive, making them safe for electrical applications. Thus, they are often used in electronics, automotive interiors, and lightweight consumer products.
Types of Rivets
Rivets come in many different types, each designed for specific applications and installation methods. They can be classified in various ways, such as by their structure, head shape, or how they are installed. Understanding these types helps in choosing the right rivet for a particular job. Here are the different types of rivets in detail.
Classified by Structure
Rivets can be grouped based on their internal structure and design. Each type has unique features that make it suitable for specific tasks. Here are the most common types of rivets classified by their structure:
Solid Rivets
Solid rivets are the simplest and most traditional type of rivet. They consist of a solid shaft with a head on one end. To install them, the tail end is pressed to form a second head, creating a strong, permanent bond. Solid rivets are known for their strength and reliability, which is why they are commonly used in structural applications, such as in aircraft and bridges. They are also used in heavy machinery and construction projects where durability is critical.
Semi-Hollow Rivets
Semi-hollow rivets have a partially hollow shaft, which makes them easier to deform during installation. This design allows them to use softer materials like plastic or leather, where a solid rivet might cause damage. Semi-hollow rivets are commonly found in electronics, automotive interiors, and consumer goods. They provide a good balance between strength and ease of installation.
Full Hollow Rivets
Full hollow rivets have a completely hollow shaft, making them lightweight and easy to install. They are typically used in lightweight applications, such as attaching nameplates or decorative elements. However, they are not as strong as solid or semi-hollow rivets because they are hollow. Full hollow rivets are often used in situations where weight is a concern, but high strength is not required.
Blind Rivets (Pop Rivets)
Blind rivets, also known as pop rivets, are designed for situations where only one side of the material is accessible. They consist of a hollow rivet and a mandrel (a small rod inside the rivet). A special tool such as a rivet gun, pulls the mandrel, causing the rivet to expand and form a second head. Blind rivets are widely used in construction, automotive, and aerospace industries because they are easy to install and provide a strong, reliable joint even when limited access.
Tubular Rivets
Tubular rivets have a hollow shaft but are stronger than full hollow rivets. They are often used in applications where a lightweight yet durable fastener is needed, such as in electronics, appliances, and lighting fixtures. Tubular rivets are also used in leather goods and clothing, providing a secure hold without adding too much weight.
Split Rivets
Split rivets have a split shaft that expands during installation, creating a tight grip. They are commonly used in soft materials like plastic, wood, or leather. Split rivets are often found in clothing, shoes, and handbags, providing a strong hold without damaging the material. They are also used in some industrial applications where a quick and easy fastener is needed.
Self-Piercing Rivets
Self-piercing rivets do not require pre-drilled holes. Instead, they pierce through the materials during installation, creating a strong joint. These rivets are often used in automotive manufacturing, where they join sheets of metal without the need for drilling. Self-piercing rivets are also used in other industries where speed and efficiency are important.
Friction Lock Rivets
Friction lock rivets are similar to blind rivets but rely on friction to hold the mandrel in place. They are used in applications where vibration resistance is important, such as in machinery and equipment. Friction lock rivets are easy to install and provide a strong, reliable hold even in high-vibration environments.
Special Rivets
Special rivets include unique designs like R-type and fan-shaped rivets. They are customized for specific applications, such as electronics or specialized machinery, where standard rivets may not work. Special rivets are designed to meet specific needs, such as providing extra strength, reducing weight, or fitting into tight spaces.
By Structure:
| Type | Description |
| Solid Rivets | Solid shaft with a head; cold or hot riveting to install. |
| Semi-Hollow Rivets | Partially hollow shaft; easier to deform. |
| Full Hollow Rivets | Completely hollow shaft; lightweight. |
| Blind Rivets | Installed from one side using a mandrel. |
| Tubular Rivets | Hollow shaft; stronger than full hollow rivets. |
| Split Rivets | Split shaft that expands during installation. |
| Self-Piercing Rivets | Pierces through materials without pre-drilling. |
| Friction Lock Rivets | Relies on friction to hold the mandrel. |
| Special Rivets | Custom designs for specific applications. |
Classification by Head Shape
The shape of a rivet’s head plays a significant role in determining how it sits on the material’s surface and how it performs in a given application. Here are the different types of rivets classified by their head shape:
Round Head Rivets
Round-head rivets have a dome-shaped head that sits above the material’s surface. This type of head is one of the most common and is often used in applications where appearance is not a primary concern. The rounded shape provides a strong bearing surface, making these rivets ideal for structural applications, such as in steel bridges, buildings, and heavy machinery. They are also used in situations where the rivet needs to withstand significant stress or load.
Flat Head Rivets
Flat-head rivets have a flat, low-profile head that sits flush with the material’s surface. This design creates a smooth finish, making them ideal for applications where aesthetics matter. Flat-head rivets are often used in furniture, decorative metalwork, and other projects where a clean, seamless look is desired. They are also used in applications where the rivet head should not protrude, reducing the risk of snagging or interference with other components.
Countersunk Head Rivets
Countersunk head rivets have a conical head that sits completely flush with the material’s surface. This is achieved by countersinking the hole, which means creating a tapered recess that matches the shape of the rivet head. Countersunk rivets are commonly used in applications where a smooth, flat surface is critical, such as in aircraft panels, automotive bodies, and machinery. The flush finish reduces drag and improves aerodynamics, making them a popular choice in the aerospace industry.
Mushroom Head Rivets
Mushroom head rivets have a wide, rounded head that resembles the shape of a mushroom. This design provides a larger bearing surface, which helps distribute the load over a wider area. Mushroom head rivets are often used in heavy-duty applications, such as in construction equipment, industrial machinery, and railroad tracks. The larger head also makes them suitable for use in softer materials, where a smaller head might pull through.
Pan Head Rivets
Pan head rivets have a slightly rounded head with short vertical sides, giving them a low-profile appearance. This design balances strength and aesthetics, making them suitable for applications where a strong yet unobtrusive fastener is needed. Pan head rivets are commonly used in electronics, appliances, and other consumer products where space is limited, and a smooth finish is desirable.
By Head Shape:
| Type | Description |
| Round Head Rivets | Dome-shaped head; sits above the surface. |
| Flat Head Rivets | Flat, low-profile head; sits flush with the surface. |
| Countersunk Head Rivets | Conical head; sits flush with the surface. |
| Mushroom Head Rivets | Wide, rounded head; distributes load over a wider area. |
| Pan Head Rivets | Slightly rounded head with short vertical sides. |
Classification by Installation Method
Rivets can also be classified based on how they are installed. The installation method affects the strength, durability, and suitability of the rivet for specific applications. Here are the two main installation methods:
Cold Rivets
Cold rivets are installed at room temperature using tools like hammers, presses, or rivet guns. This method is simple and does not require any heating, making it suitable for applications where heat could damage the materials being joined. Cold rivets are commonly used in electronics, plastics, and other heat-sensitive materials. They are also used in situations where quick and easy installation is required, such as in small-scale manufacturing or DIY projects.
| Rivet Type | Typical Materials | Application Scenarios | Description |
| Pop Rivet | Aluminum, Copper, Stainless Steel | Electronic Equipment, Lightweight Structures | No need for heating, can be directly riveted manually or with pneumatic tools, suitable for thin materials. |
| Semi-Hollow Rivet | Aluminum Alloy, Soft Steel | Automotive Bodies, Aerospace | Cold riveting after deformation, suitable for automated production lines and high-precision scenarios. |
| Drive Rivet | Aluminum, Brass | Furniture, Decoration | Fixed by striking the rivet mandrel, simple operation, no heat effect. |
| Self-Piercing Rivet (SPR) | High-Strength Steel, Aluminum Alloy | New Energy Vehicle Bodies | Cold riveting penetrates multi-layer materials, no pre-drilling required, energy-efficient. |
Hot Rivets
Hot rivets are heated to a high temperature before installation, making them easier to deform. Once installed, they cool and shrink, thermal expansion and contraction creating a tight, secure joint. This method is often used in heavy-duty applications, such as in shipbuilding, structural steelwork, and large-scale construction projects. Hot rivets provide a strong, durable connection that can withstand extreme stress and load. However, the heating process requires specialized equipment and expertise, making this method less common in everyday applications.
| Rivet Type | Typical Materials | Application Scenarios | Description |
| Solid Rivet | Steel, Titanium Alloy | Bridges, Ships, Heavy Machinery | Large diameter (>10mm) or high-strength requirements, need to be softened by heating before riveting, and then cooled to enhance connection strength |
| Large Diameter Rivet | High-Temperature Alloy Steel | Boiler, Pressure Vessel | Maintain stability in high-temperature environments, reduce residual stress after hot riveting |
| Forged Rivet | Carbon Steel, Stainless Steel | Railway Tracks, Building Structures | Need to be forged at high temperatures, commonly used in non-weldable scenarios |
By Installation Method:
| Type | Description | Material Properties | Application Requirements | Process Cost |
| Cold Rivets | Installed at room temperature | Materials with good ductility (such as aluminum, copper) or small-sized rivets can be directly cold formed. | Lightweight, corrosion-resistant, or precision assembly scenarios (such as electronic products, aircraft skins) | Cold Riveting is suitable for rapid mass production |
| Hot Rivets | Heated before installation; cools to create a tight joint | High-hardness materials (such as steel, titanium) or large-sized rivets require heating for softening | High load-bearing, high-temperature resistance scenarios (such as bridges, boilers) | Hot Riveting equipment is complex and energy-intensive |
Check several common riveting installation methods from the video below:
Applications of Various Types of Rivets
Rivets are used in many industries and applications because they provide strong, reliable, and permanent fastening solutions. Each type of rivet is chosen based on its unique features and the application’s specific needs. Here are key applications and the types of rivets commonly used for each.
Aircraft Construction
In aircraft construction, rivets are used to join metal panels and structural components. Solid rivets are commonly used because they provide strong, reliable joints for airplane frames and wings. Blind rivets are used in areas where only one side of the material is accessible. Countersunk head rivets also create a smooth, flush surface, which helps reduce drag and improve aerodynamics.
Bridges and Buildings
Rivets connect steel beams and structural elements in bridges and buildings. Solid rivets are often used because they provide strong, permanent joints for heavy-duty structures. Hot rivets, which are heated before installation, are also used in large-scale projects to create tight, durable connections.
Automotive Industry
In the automotive industry, rivets are used to assemble car bodies, interiors, and engines. Blind rivets are commonly used to attach panels and trim where only one side is accessible. Self-piercing rivets join metal sheets without the need for pre-drilled holes, making them ideal for car body assembly. Friction lock rivets secure components in engines and chassis, providing resistance to vibration.
Electronics
Electronics use rivets to fasten components in devices like smartphones, laptops, and circuit boards. Semi-hollow rivets are often used because they are easy to install and ideal for softer materials. Tubular rivets are also used because they are lightweight and strong, making them perfect for assembling small devices. Pan head rivets provide a low-profile, secure connection for electronic components.
Furniture and Decorative Metalwork
Rivets are used in furniture and decorative metalwork to create strong, aesthetically pleasing joints. Flat-head rivets are commonly used because they provide a smooth, flush finish for visible areas. Round-head rivets are used in structural joints where appearance is not a concern. Brass rivets are often chosen for their decorative, gold-like finish, making them ideal for artistic designs.
Marine and Shipbuilding
In marine and shipbuilding, rivets are used to join large metal plates and structural components. Stainless steel rivets are commonly used because they resist rust and corrosion in seawater. Monel rivets are also used because they are highly durable and corrosion-resistant, making them ideal for harsh marine environments. Hot rivets are used to create strong, permanent joints in ship hulls and decks.
Heavy Machinery
Rivets are used in heavy machinery to assemble parts that need to withstand high stress and load. Solid rivets are often used because they provide strong, durable connections for heavy-duty equipment. Mushroom head rivets are also used because they distribute load over a wider area, making them ideal for high-stress applications. Steel rivets are chosen for their strength and ability to handle extreme conditions.
How to Choose the Right Type of Rivet
Choosing the right rivet ensures a strong, reliable, and long-lasting connection. With so many types of rivets available, it can be challenging to decide which one is best for your project. Here are key factors to consider when selecting the right rivet:
Check the Materials
The type of materials you are joining is one of the most important factors in choosing a rivet. Different materials require different types of rivets for the best results. For example:
- Metal: Use solid or blind rivets for strong, durable joints.
- Plastic or Leather: Use split or semi-hollow rivets to avoid damaging softer materials.
- Wood: Use tubular or split rivets for lightweight applications.
Always ensure the rivet material is compatible with the joined materials to prevent corrosion or weakening over time.
Assess Strength Needs
Consider the amount of stress or load the joint will face. If the joint needs to handle heavy loads or high stress, choose strong rivets like solid or blind rivets. For lighter applications, such as attaching decorative elements or lightweight materials, hollow or plastic rivets may be sufficient. Matching the rivet’s strength to the job ensures the connection will hold up over time.
Consider Accessibility
Think about how easy it is to access the materials being joined. Solid or tubular rivets are a good choice if you can reach both sides of the materials. However, if you can only access one side, blind rivets (pop rivets) are ideal because they can be installed from one side using a special tool. Accessibility is a key factor in determining the type of rivet you can use.
Think About the Environment
The environment where the rivet will be used plays a big role in your choice. For example:
- Wet or Outdoor Environments: Use stainless steel, aluminum, or Monel rivets for corrosion resistance.
- High-Temperature Areas: Use steel or titanium rivets that can withstand heat.
- Indoor or Dry Environments: Most rivet types will work, but consider the material and strength needed.
Choosing a rivet to handle the environment ensures it will last longer and perform better.
Decide on Appearance
The appearance of the rivet may matter, depending on the application. Use countersunk or flat-head rivets if you need a smooth, flush finish. These sit flat against the surface and are often used in furniture, automotive panels, or decorative metalwork. If the rivet will be visible and you want a decorative look, round-head or mushroom-head rivets are a good choice. Appearance is especially important in applications where the rivet is visible.
Rivet Size
The rivet’s diameter and length should match the thickness of the materials being joined. A properly sized rivet ensures a secure hold without damaging the materials. The diameter should typically be at least three times the thickness of the thickest material, while the length should allow for proper deformation or expansion.
Installation Method
Different rivets require different installation techniques. Solid rivets need hammering or a rivet gun, blind rivets are installed with a rivet tool from one side, and self-piercing rivets eliminate the need for pre-drilled holes. Choosing the right installation method depends on accessibility and the required strength of the joint.
Conclusion
Rivets serve as pivotal connectors, aligning components in structures with universal appeal. From solid rivets to blind rivets, each type offers a versatile, cost-effective solution. The meticulous riveting process involves steps from hole preparation to joint formation, highlighting its attention to detail.
Rivets are timeless, adaptable elements that weave through manufacturing processes and applications. The riveting process can be complex, especially when producing high-quality custom metal rivets or custom riveting for sheet metal. At Zintilon, we have experts with the right amount of experience to help you succeed in your project and achieve your goals.
FAQs
What are the most common types of rivets and their uses?
The most common types of rivets include solid rivets (used in aircraft and bridges), blind rivets (used in construction and automotive), and self-piercing rivets (used in car manufacturing). Each type is chosen based on factors like strength, accessibility, and the materials being joined.
How do I choose the right rivet for my project?
To choose the right rivet, consider factors such as the materials being joined, the strength required, accessibility, the environment, rivet size and type, and ease of installation. For example, use stainless steel rivets for wet environments, blind rivets for one-sided access, solid rivets for heavy-duty applications, and aluminum rivets for lightweight assemblies.
Can rivets be used in soft materials like plastic or leather?
Yes, rivets like split rivets and semi-hollow rivets are specifically designed for soft materials like plastic, leather, or fabric. They provide a strong hold without damaging the material, making them ideal for clothing, handbags, and lightweight assemblies.
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