A Comprehensive Guide to Open End Rivets and Blind Rivet Fasteners

What are Open End Rivets?

Open end rivets, also sometimes referred to as blind rivets or pop rivets, are a versatile and easy-to-use mechanical fastener used to join materials. They consist of a rivet body and mandrel which gets pulled through the rivet body to flare out the tail and clamp materials together between the rivet head and tail.

Benefits of Using Open End Rivets

There are several advantages to using open end rivets for mechanical fastening:

• They can be installed from one side making them ideal for blind attachments where you only have access to one side of materials.
• Installation only requires simple rivet tools making them fast and easy to apply.
• They come in a wide range of materials, sizes, head styles to accommodate many application needs.
• Open end rivets form a permanent mechanical attachment unlike screws or bolts which can loosen over time.
• They allow for flexibility and vibration dampening in connected materials.

Common Applications of Open End Rivets

Some of the most popular uses of open end rivets include:

• HVAC ducting and piping hanging systems
• Truck and automobile panels
• Outdoor signs
• Electronic enclosures
• Aircraft and aerospace interiors and structures
• Securing insulation
• Scaffolding connections

Essentially any application where permanent blind mechanical fastening is required, open end rivets deliver a reliable, cost-effective solution.

How Do You Install Open End Rivets?

Installing open end rivets is a quick and straightforward process with a rivet tool. It involves just a few simple steps:

1. Drill appropriately sized holes in the materials to be joined - hole size should match the rivet diameter.
2. Insert the rivet body through the holes.
3. Use a rivet tool like a rivet squeezer or rivet gun to grip and hold the rivet body.
4. Pull the mandrel stem which draws the tail of the rivet body against the blind side material.
5. Continue to pull the mandrel which flares out the rivet body tail and clamps materials between the rivet head and tail.
6. The mandrel snaps at a predetermined break point when optimal clamping pressure is achieved.

The entire installation process generally takes less than 10-15 seconds allowing for very high productivity rates.

Types of Rivet Tools

There are various types of tools used to install open end rivets including:

• Hand Rivet Tools - Best suited for occasional rivet setting. Offer good control and are highly portable.
• Pneumatic Rivet Guns – Rivet guns connected to an air compressor power the pulling and snapping of the mandrel for very fast application.
• Battery Rivet Tools – Rechargeable battery operated rivet setting tools for cordless convenience.
• Bench Top or Stationary Rivet Tools – Fixed head hydraulic or pneumatic squeezer tools for production line rivet installation.
• Robotically Automated Rivet Systems – Robotic arms with rivet tool heads for high volume, consistent automated riveting.

Selecting the Right Open End Rivets

With so many types, sizes and styles of open end rivets on the market, it can be challenging to select the best option for your specific application. Follow these key considerations when choosing blind rivets:

Material and Plating

Consider corrosion resistance requirements, strength needs and cost:

• Steel – Offers high shear and tensile strength at low cost.
• Stainless Steel – Ultimate corrosion resistance. 316 stainless steel delivers both strength and corrosion protection.
• Aluminum – Lightweight, moderate strength option.
• Monel – Corrosion resistant nickel-copper alloy.
• Plating – Zinc, cadmium and other plating adds corrosion protection.

Size

Match rivet diameter and length to material thickness. Grip range indicates the minimum and maximum material thickness the rivets can effectively join together.

Head Style

Choose head shape based on clearance needs and installation tooling. Common head styles include:

• Countersunk
• Universal
• Large Flange
• Low Profile

Consult manufacturers’ technical data sheets to select the optimal rivets for your specific demands.

Troubleshooting Open End Rivet Issues

While open end rivets generally provide reliable fastening, some potential problems and solutions include:

Rivets Not Setting or Holding

This usually occurs if the rivet is undersized for the material thickness. Choose a larger grip range rivet. Alternatively, jamming can prevent the mandrel from snapping resulting in no or poor set. Ensure rivet and tool alignment.

Loose Rivet Connection

If materials work loose over time, the rivet length may be too short allowing materials to separate. Select a longer grip range rivet for the material thickness.

Rivet Heads Popping Off

This happens if the pulling force is too high causing head separation. Reduce installation pressure on rivet tooling and ensure proper rivet size selection.

Material Distortion or Cracking

Thin or brittle materials can crack under rivet pressure. Use washers or pads to distribute clamping force or consider alternative fastening solutions.

Following manufacturer specifications and testing will help identify optimal open end rivets for secure connections.

Innovations in Open End Rivet Technology

Ongoing advances in materials, coatings and design continue to expand capabilities and performance of open end rivets. Some latest innovations include:

• New ultra-high strength alloys for lighter weight and higher shear/tensile ratings.
• Improved corrosion resistant platings and coatings.
• Plastics and composite rivet bodies compatible with lightweight materials.
• Longer mandrel shafts to allow access in confined spaces.
• Ergonomic hand tools for increased operator comfort during installation.
• Automated sorting, feeding and delivery systems for streamlined production.

The simplicity and flexibility of open end rivets ensures they will continue meeting evolving demands across countless industrial and commercial applications.

FAQs

What is the difference between solid rivets and blind rivets?

Solid rivets require access to both sides of a joint to be installed. Blind rivets, also called open end rivets, can be installed from one side making them ideal for blind attachments.

What materials can you use open end rivets to join?

Open end rivets can join almost all materials including metals, plastics, composites, glass, stone, ceramic and wood products.

How strong is an open end rivet connection?

Shear and tensile strength varies based on rivet material and size. But generally open end rivets produce permanent joints stronger than staples, screws or adhesive bonding.

Can you remove an installed open end rivet?

No, the flaring process expands the rivet body tail making blind rivets very difficult to remove without destroying them. They produce permanent joints unless drilled out.