Solid rivets are one of the most common and reliable ways to join metal parts. They create strong, permanent connections that last a long time under stress and vibration.
This guide explains the main types of solid rivets, how to install them correctly, how to choose the right materials, design and spacing advice, important industry standards, cost factors, and safety tips. Use this information to select the best rivets and make your projects safer and more durable.
What is a Solid Rivet?
A solid rivet is made from a single piece of metal with two parts: a head and a shaft called a shank. To fasten two or more materials, you insert the rivet through aligned holes and then deform the tail end to form a second head.
This process clamps the materials tightly together. Solid rivets are strong and resist loosening from movement or vibration. They come in many metals, such as aluminum alloys, carbon steel, stainless steel, brass, and copper, each suited for different environments and strength needs.
4 Different Types of Solid Rivets
Round Head Solid Rivets
Round head rivets have a smooth, dome-shaped head that sits above the material surface. This type is very strong and commonly used in heavy structures like bridges, cranes, ships, and large metal frameworks.
They provide reliable and safe joints in places where strength is more important than a flat surface.
Countersunk or Flat Head Solid Rivets
Countersunk rivets have flat heads designed to sit flush or nearly flush with the surface of the material. They provide a clean, smooth finish and reduce drag in applications such as aircraft skins and automotive bodies.
These rivets are ideal when you want to avoid bumps or interference on the surface.
Truss Head Solid Rivets
Truss head rivets have wide, slightly rounded heads that cover a larger surface area than round heads. Their shape spreads the force over the material, which helps prevent damage to thin or delicate materials such as sheet metal or plastics.
This type is common in electrical enclosures and light framing.
Universal Head Solid Rivets (Button Head Solid Rivets)
Universal or button head rivets have a low-profile, rounded head with a smooth, wide surface. They are popular in aerospace and high-performance automotive work because they balance strength and a streamlined appearance.
Their large head surface helps resist pull-out forces and distributes pressure evenly.
Installation and Technical Details
Tools You Need
- Rivet gun or hammer
- Bucking bar to support the head
- Drill and correct drill bits
- Calipers or rulers to measure
How to Install
- Drill the right size hole.
- Put the rivet through the holes in your parts.
- Hold the head firmly with a bucking bar.
- Use a rivet gun or hammer to bend the tail and lock the parts tight.
Hole Size Matters
- For airplanes, holes must be very close to rivet size (up to +0.0015 inches larger).
- For general uses, holes can be a little bigger (up to +0.003 inches).
Always check standards for your project.
Tail Length to Set
The tail should stick out about 1.3 to 1.5 times the rivet’s diameter before you bend it. This helps form a good second head.
How Close Should Rivets Be?
- Aircraft: 4 to 6 times the rivet diameter apart.
- Other uses: At least 3 times apart.
Common Mistakes to Avoid
- Holes too big or too small.
- Tail too short or too long.
- Parts not lined up properly.
Choosing the Right Material
| Material | Strength | Corrosion Resistance | Cost | Typical Uses |
|---|---|---|---|---|
| Aluminum Alloys | High (400-500 MPa) | Good; watch for corrosion | Moderate | Aircraft, light frames |
| Steel | Very High (up to 800 MPa) | Moderate to High with coating | Low | Bridges, heavy steel work |
| Stainless Steel | High (500-700 MPa) | Excellent corrosion resistance | High | Marine, chemical plants |
| Copper/Brass | Medium (200-350 MPa) | Moderate corrosion | Moderate | Electrical, decorative parts |
Match rivet metal to the parts to avoid rust and corrosion. Think about where your project will be used and the temperature.
Design and Strength Tips
- Space rivets 3 to 6 times their diameter.
- Keep rivets at least twice their diameter from edges.
- Solid rivets hold strong under sideways (shear) force.
- They last well in places with vibration.
- Use them when you need a permanent and strong joint and can reach both sides.
Standards to Follow
| Standard | What It Covers |
|---|---|
| ASTM F959 | General fastener specs |
| ISO 1051 / 1050 | Metric rivet sizes and limits |
| MS20470, NAS1097 | Military and aerospace rivets |
| DIN 661-663 | European rivet standards |
Always check which standards your job requires.
Troubleshooting and Maintenance
Check Rivets
Look for smooth, full heads and tails. No cracks or rust.
Problems to Watch For
- Cracks mean bad fit or weak material.
- Loose rivets come from shaking or poor setting.
- Rust weakens joints, especially outside.
Removing Rivets
Drill off the head carefully, then push out the shaft.
Cost and Buying Rivets
| Rivet Type | Price per 1000 pieces (USD) | Notes |
|---|---|---|
| Aluminum Solid Rivets | $15 – $50 | Light, common choice |
| Steel Solid Rivets | $15 – $75 | Strong, often coated |
| Stainless Solid Rivets | $50 – $150 | Corrosion-proof but pricey |
Prices vary by size, metal, and seller. Buying in bulk usually saves money.
Safety Tips
- Always wear eye protection, gloves, and ear plugs.
- Work in a ventilated area when using coated rivets.
- Handle old rivets carefully; some may have lead.
- Watch out for sharp edges around holes and rivets.
Conclusion
Solid rivets make strong, lasting joints. Use the right type, size, and tools. Follow safety rules and standards to get the best results.
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