Key principles.
Match rivet
Hole diameter = rivet diameter + 0.05-0.1 mm clearance. Press fit not required (mechanical lock from formed head).
2× diameter
Rivet hole at least 2× diameter from edge. Less risks edge tear.
3× diameter
Rivet-to-rivet spacing 3× diameter typical. For specific load, calculate.
Set during forming
Rivet expands to fill hole and forms head, clamping sheets. Force from forming.
Same family
Aluminum rivets in aluminum sheet. Stainless rivets in stainless. Avoid galvanic mismatch.
For weather
Sealed pop rivets for waterproof joints. Standard for outdoor sheet metal.
FAQ
Solid: stronger, requires access both sides. Blind: one-sided installation, common for sheet metal.
Less than equivalent solid rivet but adequate for most. Specific shear/tensile per rivet body.
Shear: rivet body shears between sheets. Tear-out: sheet tears around rivet hole. Fatigue: cyclic loading.
Round head (universal), countersunk (flush), pan head (decorative). Application specific.
Hand pop riveter for low volume. Pneumatic for production. Robot-installed for high volume.
Riveted: assembly with mixed materials, no heat distortion. Welded: stronger, more compact, requires same materials.
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