Fasteners are essential components in virtually every industry, holding materials together to create durable and reliable assemblies. Unlike screws or bolts, which rely on threads to create detachable connections, rivets secure materials by deforming the tail to form a permanent joint, ensuring the connection remains strong under significant stress and vibration. But what makes rivets stand out? How do they manage to join dissimilar materials like metals, plastics, and wood, even when only one side of the joint is accessible?
You will find the answers in this article. It explores the details about rivets, including the advantages and disadvantages of rivets, their different types and uses. Let’s begin with the definition and working mechanism of rivets.
What Is a Rivet and How Does It Work?
A rivet is a mechanical fastener designed to create a permanent joint by holding two or more parts together. It typically consists of a head, a shank, and a tail. Some types, such as blind rivets, also include a mandrel. Rivets are commonly made from aluminum or steel, though other materials like copper are also used.
A rivet is installed by being inserted into a slightly oversized pre-drilled or self-pierced hole, with the head positioned on the accessible side of the material. The tail of the rivet is then deformed using a tool, such as a hammer, a rivet gun, or a hydraulic press. This deformation creates a second head (known as the shop head or bucktail) on the opposite side of the material.
As the tail deforms, it expands, clamping the materials tightly between the two heads and forming a robust, permanent connection. In some cases, such as with blind rivets, the process involves pulling a stem through the rivet to expand and secure the connection.
Advantages of Rivets
Rivets are a versatile and dependable fastening solution, offering several key benefits:
High Strength
Rivets create a permanent, durable connection capable of withstanding significant stress and vibration—particularly under shear or dynamic loads. Unlike screws or bolts, rivets are less likely to loosen over time due to vibration or fatigue, providing a secure and reliable joint that can last for many years in high-stress environments.
Rapid Installation
Many types of rivets are designed for quick and easy installation. For example, a blind rivet can often be installed in just a few seconds when using a pneumatic or handheld rivet gun. Certain types of rivets, such as blind rivets, drive rivets, self-piercing rivets, require access to only one side of the joint, unlike many other joining methods that often need access to both sides or the faying surfaces.
Low Cost
Rivets are typically less expensive than bolted connections and do not suffer from thread wear. In many cases, they are a low-cost alternative to bolts, especially when a permanent connection is required. Additionally, their simplicity in design and installation helps reduce labor and material costs.
Disadvantages of Rivets
There is hardly a solution without its limitations, and rivets are no exception. While they offer many benefits, rivets also come with a few downsides that should be considered:
Limited Flexibility
Unlike bolts or screws, which can be adjusted after installation (e.g., by tightening or loosening), rivets lack this flexibility. Once installed, they cannot be easily removed or reused. If removal is necessary, the rivet must be drilled out, which can be time-consuming and may damage the surrounding material. Moreover, rivets are less adaptable to thick materials or applications demanding very high strength, where bolts often provide a more suitable solution.
Potential to Weaken Material
Installing rivets requires drilling holes into the material, which can sometimes weaken the surrounding area. This is particularly a concern for brittle materials or those prone to cracking under stress.
Not Leak-Proof
Most rivets, especially standard and blind rivets, do not provide a seamless seal like welding. To achieve waterproofing, additional sealing materials or treatments are often required.
Increased Joint Weight
Rivet joints are typically heavier than welded or brazed joints the added weight of lap joints or cover plates. This can cause challenge for applications where minimizing weight is critical.
What Are the Different Types of Rivets?
From the above, we now have a general understanding of rivets. There are several types of rivets available, each designed for specific applications. Below are the seven most commonly used rivets in product design and assembly.
Solid Rivets
Solid rivets are the oldest type of rivets and have the most basic construction, consisting of a head and a cylindrical shank. The head can be rounded, conical, countersunk, flat, or oval. To install, solid rivets are placed into a pre-drilled hole, and then a hammer or a rivet gun is used to permanently deform the tail of the rivet on the opposite side of the hole. This deformation forms a second head, which securely clamps the two materials together. In some cases, the rivet is heated until red-hot to facilitate deformation and expansion, ensuring a tight fit and eliminating gaps.
Solid rivets are robust and provide a strong, durable connection. They are used in heavy-duty applications that require safety and durability, such as in airplanes, bridges, or ships. They are also used in structural steel frameworks and the restoration of historical armor.
Tubular Rivets
Tubular rivets are similar to solid rivets but feature a hollow shank on one side. This unique design has a smaller cross-sectional area, requiring less force to deform compared to solid rivets. Only the thin walls of the hollow shank need to be flared outward to secure the joint. However, tubular rivets generally have lower strength than solid rivets.
There are two common types of tubular rivets: full tubular and semi-tubular. Full tubular rivets have a completely hollow shank, making them lighter but reducing their load-bearing capacity compared to other rivet types. They are commonly used in lightweight and decorative applications, such as jewelry, signage, and garment fittings. Semi-tubular rivets, with a partially hollow shank, provide stronger joints than full tubular rivets while still requiring less force for installation. This makes them ideal for medium-strength and quick-assembly applications. Semi-tubular rivets are commonly found in HVAC systems, light machinery, and furniture.
Split Rivets
Split rivets consist of two parts: a short body (including the head) and a tail that splits into two or more legs. After being inserted into a pre-drilled hole, the legs are bent and flattened against the rear material using a hammer, securing the joint. They are light-duty rivets and suitable for plastics, textiles, and thin metal sheets.
Blind Rivets
Blind rivets, also known as POP rivets, are a type of fastener that can be installed with access to only one side of the joint, as their name implies. Similar to tubular rivets in their hollow structure, blind rivets differ by incorporating a mandrel—a metal rod running through the center of the rivet. During installation, a rivet gun or specialized tool pulls the mandrel, causing the rivet's tail to expand and form a second head (the back head). During installation, a rivet gun or other specialized tools are used to pull the mandrel, causing the tail of the rivet to expand and form a second head (the back head). Once the desired clamping force is achieved, the stem snaps off, creating an audible "pop" sound—hence the name "POP rivet."
While their connection strength is generally not as high as that of solid rivets or tubular rivets, blind rivets offer a practical and cost-effective solution for many lightweight applications and environments where space is limited or access to the back side is not possible.
Drive Rivets
Similar to blind rivets, drive rivets can be installed from one side, which is useful when the backside is inaccessible. However, they do not require a mandrel. During installation, the rivet is driven by striking or hammering, causing the tail to expand and secure the connection.
Drive rivets require no specialized tools, and the installation process is both simple and cost-effective. This makes them popular for quick-assembly applications such as fastening electronic enclosures. However, due to their limited strength and load-bearing capacity, drive rivets are not recommended for high-strength connections.
Self-Piercing Rivets
Self-piercing rivets are unique in that they do not require pre-drilled holes and do not pass completely through the second material. With a chamfered or beveled tip, they pierce the top layer of material and partially deform in the bottom layer. During installation, an upsetting die (or "die anvil") expands the rivet's tail, forming a low-profile button (or shop head) to securely join the layers.
This fast, efficient installation process creates sealed joints that are often waterproof or airtight. This makes them suitable for applications that require high sealing standards, especially in industries like aerospace. More importantly, self-piercing rivets are preferred for high-stress applications and can hold together dissimilar materials that are almost impossible to weld, like steel and aluminum.
Flush Rivets
Flush rivets, also called countersunk rivets, have strength comparable to that of standard solid rivets. Their defining feature is the conical design of the head, which, once installed, sits flush with the material's surface. This design reduces air resistance and improves aesthetics, making flush rivets highly valuable in applications requiring smooth surfaces or optimized aerodynamics, such as in aerospace and high-performance automotive industries. Compared to other rivets, the installation of flush rivets requires countersinking the material, which demands higher precision and technical expertise.
Materials Used for Making Rivets
Rivets are manufactured from a variety of materials to meet specific application needs, including strength, durability, corrosion resistance, and weight considerations. The choice of material depends on the type of rivet and the operating conditions it will face. Below are the most commonly used materials for rivet production:
Aluminum
Aluminum is one of the most widely used materials for rivets due to its lightweight, corrosion-resistant, and highly ductile properties. Aluminum rivets are easy to deform during installation, allowing for quick and reliable joints with minimal effort. For example, blind rivets made from aluminum can be installed using a hand-operated rivet tool.
Stainless Steel
Stainless steel rivets have exceptional corrosion resistance, suitable for marine, chemical, and outdoor applications. Although it is harder to deform compared to softer materials like aluminum or copper, its high tensile strength ensures the rivets remain secure in high-stress or high-vibration environments.
Low Carbon Steel
Low carbon steel, or mild steel, is a popular material for making rivets due to its affordability, strength, and workability. With a carbon content below 0.25%, it is softer and more malleable than high-carbon steel, making it easier to deform during the riveting process while still providing reliable structural performance. Though prone to corrosion in moist environments, coatings like zinc are often applied to enhance rust resistance.
Copper
Copper is chosen for its high electrical and thermal conductivity. More importantly, copper is soft and ductile, which allows it to deform easily during installation, ensuring a secure fit even in delicate or thin materials.
Brass
Brass offers a combination of copper’s corrosion resistance and zinc’s enhanced strength, resulting in a material that is both durable and highly malleable. Its ease of deformation ensures reliable installation, and its attractive gold-like appearance is ideal for decorative applications such as furniture and architectural panels. Additionally, its non-sparking properties are well-suited for environments with flammable materials.
Conclusion
Rivets are a dependable alternative to bolts, nuts, screws, and welding, offering versatility across various industries. From the lightweight efficiency of aluminum rivets in aerospace to the corrosion-resistant durability of stainless steel in marine applications, rivets effectively meet diverse project demands—particularly for permanent installations. Their success largely depends on choosing the right material and a trusted manufacturer.
At Chiggo, we offer a wide range of CNC-machined metal rivets and provide customized precision CNC machining services to meet your specific project needs. Our skilled engineers, machinists, and quality control experts work collaboratively to deliver your product with precision and efficiency. For the best CNC-machined metal rivets and precision machining solutions, reach out to Chiggo today—we’re here to bring your projects to life!
