Riveting vs Welding: Selecting the right method for Assembling Sheet Metal parts

Riveting vs welding: this phrase not only represents two distinct methods of joining metals but also indicates a critical decision-making process in the field of manufacturing. The choice between riveting and welding can greatly impact the overall design, strength, cost, and functionality of the final product.

In the realm of sheet metal fabrication, at Worthy Hardware, we often encounter queries about these two widely used metal joining methods. In this blog, we aim to bring clarity to such queries by demystifying riveting and welding, and providing detailed insights into their respective advantages, disadvantages, and applications.

Whether you’re an industry professional or an enthusiast in the manufacturing sector, the forthcoming sections of this blog will provide you with a comprehensive understanding of riveting and welding. And in the spirit of complete transparency, we’ll also answer some frequently posed questions to address any doubts you may have regarding these two methods.

Overview of Riveting

Riveting, as a method of joining metal, is a centuries-old technique that has stood the test of time. It is primarily employed in joining angle iron without welding, and also in connecting diverse types of materials including plastics, wood, and leather. Fundamentally, the riveting process involves the insertion of a metal pin or bolt, known as a rivet, into a hole and then deforming the end to secure the materials together.

The process begins by first creating matching holes on the surfaces to be joined. Next, a rivet is inserted, and pressure is applied on its head. This causes the tail of the rivet to expand and creates a secondary “head,” effectively clamping the two materials together. It is a simple yet effective way of joining metal and often described as a permanent fastening method.

One may be inclined to ask: what is riveted? Simply put, the term ‘riveted’ refers to the materials that have been fastened together through the riveting process. Some common examples of riveted items include metal bridges, ships, and even aircraft structures.

There are different ways of joining metal through riveting, which leads to various types of joints in sheet metal. These sheet metal joints include the lap joint, where two pieces overlap and are then riveted, and the butt joint, where the two pieces are placed end-to-end and then joined by a third overlapping piece.

However, it’s crucial to remember that each riveting metal technique may be better suited to particular applications. For example, the use of rivets manufacturing process in sheet metal corner joints provides an exceptional level of durability and strength, making it suitable for applications that need to withstand heavy loads.

Benefits and Drawbacks of Riveting

A. Benefits of Riveting

Riveting is a process that is revered for numerous reasons. As a way of joining metal, it offers a host of benefits that make it a prevalent choice in several industries, including construction, automotive, and aerospace.

The foremost advantage is the strength of the joints created by riveting. The process results in extremely robust joints that maintain the mechanical properties of the materials being joined, thanks to the absence of heat during the operation. This is an essential factor in applications where maintaining the original material properties is critical.

Riveting is also celebrated for its simplicity. The riveting process doesn’t necessitate specialized training or expensive equipment, making it an accessible method for joining metal.

The durability of riveted joints is another attribute that sets riveting apart. Unlike other metal joining methods, riveted joints can withstand dynamic and impact loads excellently. This feature is vital for structures that are exposed to variable forces or harsh weather conditions.

Lastly, riveting provides a level of flexibility that is unmatched by other methods of joining metals. With an array of rivets available in different materials, shapes, and sizes, it is adaptable to a wide range of applications, making riveting metal an incredibly versatile procedure.

B. Drawbacks of Riveting

Like any other process, riveting isn’t devoid of limitations. One primary downside is that riveted joints are often not as tight as welded ones, leading to potential leakages in applications that require airtight or watertight joints.

Secondly, riveting is considered a semi-permanent method of joining metal. Dismantling riveted structures for maintenance or repair can be quite challenging and time-consuming.

Another disadvantage of riveting lies in the weight of the rivets. For applications like aircraft manufacturing, where every gram matters, the added weight of the rivets could be a negative factor.

Moreover, the riveting process can cause deformation of the materials being joined if not handled correctly. Excessive force during the process can lead to material distortion and compromise the integrity of the structure.

Overview of Welding

A. Description of Welding

Welding is another popular method of joining metal pieces together. It’s a fabrication process that involves the application of heat to melt the base metals, resulting in a pool of molten material (called the weld pool) that cools to form a strong joint. Often, a filler material is added to the weld pool to help secure the joint.

Compared to riveting, welding typically creates a stronger bond as the materials are essentially fused together, forming a connection that’s as strong as (or stronger than) the materials themselves.

B. Types of Welding

In the vast domain of welding, numerous techniques have been developed to accommodate different materials and situations. However, two main types stand out in the context of our riveting vs welding discussion: Gas Metal Arc Welding (GMAW) and Flux-cored Arc Welding (FCAW).

1. Gas Metal Arc Welding (GMAW): Also known as MIG welding, GMAW is a commonly used welding process that uses a continuous wire feed as an electrode and an inert or semi-inert gas mixture to shield the weld from contamination.
2. Flux-cored Arc Welding (FCAW): FCAW is similar to GMAW, but instead of using a wire and a shielding gas, it employs a tubular wire filled with flux. This flux provides the necessary shielding from the atmosphere, making FCAW more suited to outdoor applications where wind could disperse the shielding gas used in GMAW.

C. Varieties of Welded Connections

In the welding landscape, various joint configurations are used depending on the nature of the workpieces and the required strength and functionality of the joint. For our exploration of riveted vs welded joints, let’s focus on two main types: Tee Joint Welding and Corner Joint Welding.

1. Tee Joint Welding: Named for its T-shape, this joint is created when two metals are joined at a right angle where one is touching the middle of another.
2. Corner Joint Welding: As the name suggests, a corner joint is formed when two pieces of metal are joined at their ends, creating a corner. This type of joint is common in the construction of boxes or cabinets.

Advantages and Disadvantages of Welding

A. Advantages of Welding

1. Strength: Welded joints are typically as strong as the material itself, sometimes even stronger. This is because the welding process fuses the materials together, forming a bond that is more secure than one created by rivets.
2. Seamless connections: Welding melts the metals together and allows them to cool and solidify as a single piece, resulting in a virtually seamless joint. This aspect makes welding a superior choice when aesthetics are of importance.
3. Variety of Applications: The welding process is highly adaptable to a wide range of metals and shapes, making it ideal for different types of projects and requirements.

B. Disadvantages of Welding

1. Safety Risks: The process of welding involves extreme heat and potentially hazardous gases and fumes, which may pose significant safety risks to operators if not properly managed.
2. Cost and Skill: Welding can be more expensive than riveting due to the cost of equipment, materials, and energy. Additionally, welding requires a higher skill level, which might add to labor costs.
3. Post-Welding Distortions: The high heat involved in welding can lead to distortions in the metal, which might require additional work to correct.

Welding VS Riveting Comparison

1. Durability of the connection

When we pit welded vs riveted connections, the durability of each method stands out as a critical differentiator. Welded joints can often be as strong or even stronger than the parent material, creating a robust and enduring bond. However, the high heat used in welding can also introduce stress and potential distortions, which may need additional work to correct.

In contrast, riveting creates a mechanical bond that is resistant to heat and less prone to distortions. However, the durability of a riveted joint also depends on the material and quality of the rivets used.

2. Safety factors

In our riveting vs welding comparison, safety is a vital aspect to consider. Welding processes involve extreme heat, electric currents, and potentially hazardous gases and fumes. This means that operators need to follow strict safety measures to mitigate these risks.

On the other hand, riveting involves less risk. The absence of extreme heat and harmful gases makes riveting a safer method of joining metal pieces, particularly in environments with less control over safety measures.

3. Uses

Welding is versatile, able to accommodate a wide range of materials and shapes. It’s commonly used in situations where a strong, seamless joint is required, such as in the construction of buildings, bridges, or heavy machinery.

Conversely, riveting is common in areas where inspection of the joint for integrity is necessary or where disassembly may be required in the future. This includes applications like aircraft assembly, where rivets are widely used.

4. Visual appeal

While welding can create seamless joints that enhance the visual appeal of a piece, it can also result in discoloration and distortions due to high heat. On the other hand, riveting provides a clean, consistent appearance. However, the visible rivet heads may be less appealing for some designs.

5. Effectiveness

Welding is typically more effective for creating strong, seamless joints, while riveting is effective for maintaining joint integrity in high-stress or variable temperature environments.

Conditions to Choose Welding

A. Material Type

The types of materials to be joined are a crucial factor when deciding on welding. This technique works best with materials that can endure high temperatures without warping or damaging their structural integrity. Metals such as steel, stainless steel, aluminum, and copper are commonly welded.

B. Strength Requirements

Welding typically creates joints that are as strong or even stronger than the base material. Therefore, it’s a perfect choice in scenarios where high strength and durability are crucial, such as in the construction of buildings, bridges, or heavy machinery.

C. Visual Aesthetics

Welded joints can be ground and polished to blend seamlessly with the surrounding material, creating a smooth and continuous surface that’s often more visually appealing than the more industrial look of riveted joints.

D. Permanent or Semi-Permanent Structures

Welding creates a permanent joint, making it an excellent choice for structures intended to be long-lasting or permanent. This is because the welded joint effectively becomes a continuous piece of metal, providing a robust and durable connection.

E. Heat Resistance

Welded joints are typically more heat resistant than riveted ones because the welding process fundamentally changes the structure of the metal, making it more resistant to heat. This can be a crucial factor in industries such as aerospace and automotive manufacturing, where components often need to withstand high temperatures.

F. Skills and Equipment

Welding requires a certain level of skill and specific equipment to perform. Therefore, the decision to weld could depend on whether you or your team have the necessary skills and access to the right tools.

G. Cost and Time

Welding can be more cost-effective and quicker than riveting for certain applications, as it often requires fewer materials (no need for rivets) and can create a bond quickly.

Conditions to Choose Riveting

A. Material Sensitivity

If you are working with materials sensitive to heat, such as certain plastics or thin sheets of metal, then riveting would be an excellent choice.

B. Dissimilar Materials

If you are joining two pieces of different types of materials together, riveting can be the ideal solution. Rivets can effectively join dissimilar materials, such as metal and plastic, where welding might not be suitable or even possible.

C. Accessibility

Riveting is often preferred when the joint has to be done in hard-to-reach places or at odd angles. Because a rivet gun can be positioned in different ways, it can reach locations that might be challenging for a welding apparatus.

D. Non-Permanent Structures

If the structure being created does not need to be permanent, riveting can be an excellent choice. Rivets can be removed relatively easily, which makes disassembling the joint a straightforward process.

E. Visual Appeal

Rivets give an industrial or vintage look, which can be desirable in certain design contexts.

F. Cost and Time

Depending on the specifics of the project, riveting could be a quicker and more cost-effective method.

Conclusion

When it comes to joining sheet metal parts, the choice between riveting and welding depends on several factors. Each method offers unique advantages and considerations to keep in mind.

Ultimately, the decision between riveting vs welding depends on the specific requirements of your project, the materials being used, the desired strength and durability of the joints, and other factors unique to your application. Consulting with experts and evaluating the specific conditions and goals of your project will help you make an informed decision.

At Worthy Hardware, we understand the importance of choosing the right method for your sheet metal assembly needs. As a reliable supplier of high-quality customized CNC machining parts and sheet metal fabrication, we offer a range of services to meet your specific requirements.

FAQ

1. Is riveting stronger than welding?

No, in general, welding tends to create stronger joints than riveting. Welded joints can be as strong or even stronger than the base material itself, providing excellent structural integrity.

2. Why are planes riveted and not welded?

Airplanes are often riveted rather than welded due to several factors. Rivets provide structural integrity, easy inspection, and the ability to disassemble and replace damaged components. Additionally, riveting allows for flexibility and movement in response to stress and temperature changes, which is essential for the performance and safety of aircraft structures.

3. What is the hardest weld to do?

Welding thick materials or welding in challenging positions such as overhead or vertical can be more complex and demanding.

4. Are rivets cheaper than welding?

In some cases, riveting may be more cost-effective due to simpler equipment requirements and faster installation times

5. What are the two failures of riveted joints?

The two common failures of riveted joints are:

• Shear Failure: This occurs when the applied force along the joint exceeds the shear strength of the rivets, causing them to shear off.
• Bearing Failure: Bearing failure happens when the bearing stress on the rivet hole exceeds the material’s capacity, leading to deformation or failure of the material surrounding the hole.