EUTypes Of Rivets and Their Uses
- Written By: Gavin Leo
- Update By: Gavin Leo
- Published:
- Updated:
Share:
Table of Content
Table of Content
A rivet is a widely used and cost-effective permanent fastener, which is extensively employed for connecting and fixing thin sheet materials.
The most common types of rivets include blind rivets (pop rivets), solid rivets, semi-tubular rivets, flush rivets, split rivets, and self-piercing rivets, each designed for specific load requirements, access conditions, and material combinations.
This article will systematically review the structures, working principles and applicable scenarios of various types of rivets, helping you quickly find the most suitable option.
What Is a Rivet and How Does It Works?
A rivet is a permanent mechanical fastener consisting of a solid or hollow cylindrical shank with a pre-formed head on one end, which is inserted through a pre-drilled hole and deformed on the opposite end to create a second head that clamps two or more materials together.
All rivets work on the same basic principle: a shank is inserted through a pre-drilled hole and deformed on the opposite end to form a second head, clamping the materials together permanently. The installation method varies by rivet type, from hammering and pneumatic guns to hydraulic presses and simple hand tools.
Key Components of a Rivet
Understanding rivet anatomy helps you select the right type and install it correctly.
| Component | Description |
|---|---|
| Head | The pre-formed end that sits flush or proud of the material surface. Its shape determines how force is distributed and whether the finish is flush or protruding. |
| Shank (Body) | The cylindrical body inserted through the drilled hole. Diameter and length determine grip range and load capacity. |
| Tail | The headless end that is deformed during installation to form the second (shop) head. |
| Mandrel | Found exclusively in blind rivets. An internal pin pulled by a rivet gun to buckle the tail and form the blind-side head, then snaps off at a predetermined force. |
Common Types of Rivets and Their Uses
Rivets can be classified in two ways: by head shape, which determines surface finish and load distribution, and by mechanism, which determines how the rivet is installed and what access conditions it requires.
Types of Rivets by Head Shape
Head shape is the first classification dimension for rivets. It determines surface appearance, load distribution, and suitability for specific applications.
1. Flat Head Rivets
Flat head rivets have a wide, disc-shaped head with a flat top that sits nearly flush against the workpiece. Because the head is thin and broad, it distributes the clamping load over a large bearing area, which reduces stress concentration at the joint.
This makes them a practical choice for moderate-load, near-flush applications such as furniture hinges, jean pocket studs, leather belts, and decorative metalwork.
2. Snap Head (Round Head) Rivets
Snap head rivets have a dome-shaped, hemispherical head that stands higher above the surface than flat head variants. During installation, a rivet snap tool shaped to match the dome is held against the head to preserve its profile while the tail is upset on the opposite side, forming a matching dome.
They are widely used in high-strength structural joints where both sides are accessible and a protruding head is acceptable, such as steel bridges, crane booms, ship hull frames, and boiler shells.
3. Pan Head Rivets
Pan head rivets feature a cylindrical head with a flat top and nearly vertical sides, sitting in height between a snap head and a flat head. The vertical-sided profile resists pull-through effectively and distributes stress evenly at the head-shank junction, giving this type excellent fatigue resistance.
They are commonly found in aircraft interior frames, heavy machinery, automotive chassis reinforcement, and rail and transport structures.
4. Flush (Countersunk) Rivets
Flush rivets have a conical, tapered head designed to sit completely level with the surrounding surface, with the most common countersink angle being 100°, though 90° variants are also available.
Before installation, a countersink tool prepares the matching recess in the material; in critical aerospace applications, the finished rivet is then shaved smooth for a perfectly aerodynamic surface.
They are the standard choice wherever surface smoothness is essential, including aircraft skin panels, automotive body panels, and marine hull exteriors.
Types of Rivets by Mechanism
Beyond head shape, rivets are also classified by their internal construction and installation method, which determines what access conditions and joint strength they can deliver.
5. Blind Rivets (Pop Rivets)
Blind rivets consist of a hollow tube with a pre-formed head flange, paired with a steel mandrel pin running through the center.
To install, the rivet body is inserted into a pre-drilled hole from one side, and a rivet gun pulls the mandrel through the tube, expanding the blind end into a locking bulb against the reverse face; when the pulling force reaches the set point, the mandrel snaps at its breakneck groove with an audible pop.
They are the go-to fastener for any assembly where rear access is impossible, including HVAC ductwork, automotive door liners, metal signage, and electrical enclosures.
Blind Rivet Variants
| Type | Structure | Best For |
|---|---|---|
| Open-End (Standard) | Hollow tube with open blind end | General sheet metal, indoor assemblies |
| Closed-End (Sealed) | Hollow tube with cup-shaped closed blind end | Marine, outdoor, watertight joints |
| Multi-Grip | Engineered body with extended deformation range | Mixed-thickness panels, maintenance work |
| Drive Rivet | Short blunt mandrel pre-set in rivet head | Nameplates, plastic trim, light decorative work |
6. Solid Rivets
Solid rivets are a completely solid metal cylinder with a single pre-formed head and no internal mechanism, making them the oldest and strongest rivet type available. Installation requires access to both sides: a bucking bar holds the factory head while a pneumatic rivet gun upsets the tail, expanding the shank radially to fill the hole and locking the joint against vibration.
They are used in the most demanding structural applications, including aircraft wings and fuselage frames, steel bridges, military vehicle armor, and pressure vessels.
7. Semi-Tubular & Tubular Rivets
Semi-tubular rivets have a partial hole drilled into the tail end, extending to approximately 112% of the shank diameter in depth, so only the thin tail walls need to flare outward during installation. This requires significantly less force than a solid rivet, making them well suited for high-volume automated assembly and for joining soft or thin materials without damage.
Typical applications include automotive seat belts and door panels, HVAC sheet metal joints, and leather hinges.
8. Split (Bifurcated) Rivets
Split rivets have a shank tail divided into two or more pointed prongs that can be pressed or hammered directly through soft materials without pre-drilling, and then bent outward in opposing directions to form a mechanical lock.
They are most commonly made from brass or copper, and are the practical choice for leather saddlery and handbags, bookbinding, fabric, cardboard packaging, and children’s toys where loads are light and drilling is impractical.
9. Self-Piercing Rivets (SPR)
Self-piercing rivets are semi-tubular, cold-forged high-strength steel rivets with a precisely engineered blunt tip that punches through the top material layer without a pre-drilled hole. A hydraulic press drives the rivet under 20–100 kN of force, causing it to flare outward inside a shaped die cavity and form a mechanical interlock within the bottom material rather than penetrating it fully.
They are widely used in high-volume automotive production for joining aluminum body panels, mixed aluminum-steel structures, solar panel frames, and railway carriage bodies.
Common Rivet Materials
The material of a rivet must be compatible with the base materials being joined, the service environment, and the required strength. The wrong material choice can cause galvanic corrosion, inadequate strength, or installation failure.
Aluminum
Aluminum rivets are the most widely used rivet material. They are significantly lighter than steel and offer excellent natural corrosion resistance due to their self-forming oxide layer.
Brass
Brass is a copper-zinc alloy combining good strength with outstanding corrosion and tarnish resistance. Its most distinctive property is that it cannot generate sparks, making it a critical safety requirement in certain environments.
Copper
Copper rivets are prized for their conductivity and their ability to be formed easily without cracking. They form a protective patina over time that provides ongoing corrosion protection.
Stainless Steel
Stainless steel rivets (typically 304 or 316 grade) offer the best combination of strength and corrosion resistance among standard rivet materials. Grade 316 provides superior resistance in marine and chemical environments due to its molybdenum content.
Steel (Carbon Steel)
Steel rivets are the strongest standard rivet material by tensile and shear load, though they are susceptible to corrosion without protective coatings. Low-carbon steel is preferred for rivet manufacture because it can be deformed (headed and upset) without cracking.
Common Rivet Materials
Advantages
Vibration Resistance
Unlike bolts, rivets do not loosen under vibration, making them ideal for joints subject to repeated stress and cyclic loading.
Shear Strength
Rivets resist forces perpendicular to the shank extremely well, making them the preferred choice for lap joints under shear loading.
No Heat
Installation is a cold process, so there is no thermal distortion, no heat-affected zone, and no damage to surface coatings.
Material Flexibility
Rivets can join dissimilar materials such as aluminum to steel, composites to metal, or plastic to fabric, where welding is not possible.
Easy Installation
Blind rivets require only a basic rivet gun and no specialist skills, making them accessible for both factory and field use.
Disadvantages
Permanent
Removing a rivet requires drilling out the head, which risks damaging the base material. Rivets cannot be reused.
Lower Tensile Strength
Rivets resist shear well but provide less clamping force than properly torqued high-strength bolts.
Pre-drilling Required
Most rivet types require a precisely sized hole before installation, adding time and tooling to the process.
Adds Weight
Each rivet adds weight. In large structures with thousands of rivets, this accumulates and becomes a concern in weight-sensitive applications.
Not Leak-Proof
Standard open-end blind rivets are not watertight. Sealed rivets or sealant compound is required for fluid-tight joints.
How to Choose the Right Rivet Type
Material Selection
Match the rivet material to the base material to avoid galvanic corrosion. Aluminum rivets for aluminum structures, stainless steel for marine or outdoor environments, and brass where spark resistance is required.
Rivet Types
Use countersunk rivets where a flush surface is needed, snap or pan head for structural joints where head profile is not a concern. If both sides are accessible, solid rivets give the highest strength. If only one side is reachable, blind rivets are the practical choice.
Rivet Size
The rivet diameter should be at least three times the thickness of the thinnest material being joined. The length must allow enough tail material to form a solid second head.
Load Requirements
For high shear loads, solid rivets are the strongest option. For moderate loads with one-sided access, multi-grip blind rivets provide a reliable balance of strength and convenience. Split and tubular rivets are suited to light-duty, low-load applications only.
Use Environment
For wet, marine, or outdoor conditions, use closed-end blind rivets with stainless steel or aluminum material. For standard indoor applications, open-end blind rivets are sufficient.
Related Topics:
Written By
Gavin Leo
Custom Quality Parts By Aria
Send your specs. We’ll get back with a quote in 12 hours.