When joining sheet metal parts, it can be difficult to choose between welding and riveting. The two methods have unique advantages, but choosing the wrong method can result in increased costs, delays, and compromised structural integrity.
Riveting involves using metal pins to fasten parts together, which is excellent for projects where thermal distortions are a concern, as it doesn’t involve heat. Welding, conversely, melts the metal parts together, providing a robust and seamless bond ideal for high-stress applications. The outcome of a project can be significantly affected by the choice of welding or riveting.
Continue exploring the characteristics and benefits of welding and riveting to make an informed choice.
What is welding?
Welding is a fabrication process that joins materials, typically metals, by causing fusion. Unlike riveting, welding involves the application of heat, pressure, or both to melt the workpieces together.
Types of Welding
MIG Welding
Gas Metal Arc Welding, or MIG (Metal Inert Gas), is a type of welding that uses a wire electrode continuously fed with inert gases to protect the weld pool. This type of welding is preferred for its adaptability and speed, even when working with different metals such as thin sheets or thick plates.
TIG Welding
TIG welding (Tungsten inert gas) or Gas Tungsten Arc Welding is known for its precision. The tungsten electrode is non-consumable, and the shielding gas is inert. TIG welding produces clean, high-quality welds on thin materials. It is ideal for aerospace, automotive, and artistic applications.
Arc Welding
The arc welding process uses an electric arc to melt the metal at the weld point. Due to its strength and affordability, it is one of the oldest and most popular welding methods. For example, SMAW (Shielded Metal Arc Welding) is available in different variations depending on the requirements.
Laser Welding
Laser welding uses a high-intensity laser beam to fuse metal components. This method offers high precision, speed, and control. It is beneficial when delicate work, such as electronics or medical devices, requires minimal thermal distortion.
Pros and Cons of Welding
Pros
- Strength： Welded joints are often stronger than their base materials, which is essential for structural applications.
- Durability： Welds are highly durable and ideal in environments with thermal and stress cycles.
- Efficiency： Welding is fast, particularly with techniques such as MIG welding. This is great for projects that have tight deadlines.
- Versatility: Different welding methods are adaptable to different materials, thicknesses, and applications.
Cons
- Skill requirement： Welding is a skill that requires highly trained operators, and this can increase project costs.
- Equipment Cost： Welding gear and safety equipment can be costly, increasing your initial investment.
- Heat distortion: High temperatures during welding can lead to material distortions, which require further machining and processing.
- Safety Hazards： The process releases fumes of ultraviolet radiation and poses health risks to workers if precautions aren’t taken.
What is Riveting?
The riveting process is a mechanical method of joining metal parts using metal pins, also known as rivets. The rivet is inserted into pre-drilled holes on the parts to be connected, and the exposed end of the rivet is then deformed to secure the assembly.
The method is suitable for materials sensitive to thermal distortion as it does not use heat.
Types of Rivets
Solid Rivets
Solid rivets have been around for centuries and are still the most reliable. Rivets feature a simple head and shaft, making them suitable for applications requiring solid, permanent joints. The rivets are driven into the pre-drilled holes and then deformed using a hammer and a rivet gun to create a mushroom shape that holds materials together.
Shipbuilding, aerospace, and structural engineering commonly use this type of structure.
Blind Rivets
Blind rivets, also known as pop rivets, work well when only one side of a joint is accessible. They include a mandrel and a hollow rivet. After placing the rivet in the hole, workers pull the mandrel through it. This action expands the rivet until the mandrel snaps off.
Blind rivets are perfect for fastening quickly.
Pop Rivets
Pop rivets, a type of blind rivet, are used primarily for lighter and thinner materials. The name comes from the popping sound that occurs when the mandrel breaks.
They are popular in the automotive and electronic industries because they are easy to install and hold high power.
Structural Rivets
Structural Rivets are suitable for heavy-duty applications, such as bridge construction, structural steel, and heavy machinery manufacturing, due to their high shear and tension strength.
Due to their size, structural rivets often require hydraulic or pneumatic tools for installation.
Riveting: Pros and cons
Pros
- No heat is required： Riveting does not involve heating, making it ideal for materials that high temperatures could damage.
- Accessibility: Blind rivets are handy for securing materials with only access to one side.
- Simplicity： Riveting is more straightforward than welding and requires less training.
- Durability： Rivets are strong and fatigue-resistant joints, perfect for environments with high vibrations, such as aircraft or road vehicles.
Cons
- Less structural strength: Although strong, riveted joints are less intense than those welded, which can limit them in applications with high loads.
- Corrosion Potential： If adequately sealed, riveted joints can trap moisture, causing corrosion between fastened materials.
- Aesthetic： Rivets may protrude on the surface of a material, which is undesirable for products intended for consumer use.
- Difficult Disassembly： Unlike bolts or screws, rivets can be challenging to remove without damaging materials.
Welding vs Riveting: Comparative Difference
Each has specific characteristics that make it suitable for different scenarios. Understanding the differences will help you make the right choice for your project.
Materials
Welding is better for similar materials, as it creates seamless joints when melted together. Riveting is best for dissimilar materials because it avoids issues caused by different melting points.
Speed up
Welding creates bonds faster without the need for pre-drilling. Riveting is slower because it requires additional steps, such as drilling and fastening.
Cost
Welding is more expensive initially, but its efficiency may lower long-term costs. Riveting is less expensive to start, but it can become more labor-intensive over time.
Strengthening Your Body
Welding is ideal for applications requiring a more substantial and permanent joint. Riveting offers strong but less durable connections. It is suitable for applications where extreme strength may not be required.
Safety
Welding is a dangerous process that involves high heat, toxic fumes, and other risks. It requires strict safety measures. Riveting, which does not involve heat, is a safer alternative but can still be physically challenging.
Applications
Construction, heavy industry, and automotive industries all prefer welding. Riveting is suitable for aerospace, electronics, and other areas where the materials are sensitive or may need disassembly.
Welding vs Riveting: What is better?
The specific needs of your project will determine whether you should use riveting or welding to join sheet metal. It’s better to look at the specific factors that influence each technique rather than attempting to find a universally superior method.
When to Choose Welding?
Consider welding under the following circumstances:
Weight Sensitivity: If you need to manufacture products that are weight sensitive, then welding is the better choice. Unlike riveting, it adds no additional materials, which can increase the overall weight due to the metal fasteners used.
Efficiency: Welding is an excellent option for projects that require quick execution due to its automation. This process is faster because it requires no preparatory steps, such as drilling or fastening.
Aesthetics： Welding is often more pleasing to the eye than riveting. Riveting leaves visible bulges, which some people may not find attractive.
Strength Joint： Welding produces a permanent and rigid joint stronger than a riveted one. This makes it ideal for products that require robust frames.
Different Shapes： Welding can handle a variety of shapes and configurations. This makes it possible to join complex shapes seamlessly.
When to Choose Riveting？
Riveting is preferable in specific scenarios:
Types Of Materials： It is an effective method for joining materials with different melting points.
Heat requirement: When using materials sensitive to heat (such as certain alloys and aluminum), riveting can be an advantageous alternative, as it prevents thermal distortion.
Disassembling： Riveting is a method of disassembling components that does not cause damage. This technique is handy for parts that require regular inspection or replacement.
Flexible Design： Riveting allows for greater design flexibility without compromising structural integrity.
Conclusion
The choice between welding and riveting depends on the material, accessibility, and permanence of a project. Welding offers seamless, durable joints for high-stress zones, while riveting is best for heat-sensitive materials or maintenance-friendly designs. To ensure durability and cost efficiency, evaluate each method against the project’s needs.
Do you need a reliable sheet metal parts manufacturer? Shengen is the place to go. We specialize in sheet metal laser cutting, bending, surface finish, and CNC Machining. Reach out to Shengen Today and seek help from professionals!
FAQs
What is the best method to use for large-scale projects?
Welding often proves more cost-effective for large-scale projects because of its speed and minimal labor requirements once set up. Automated welds can significantly reduce production costs.
How does weather affect the decision between welding and riveting for a project?
The weather conditions are crucial. Welding can be problematic when it is wet or in windy conditions. This may affect the integrity of the weld. Riveting can be more reliable in environments subject to change or weather.
What are the latest advances in welding and riveting technology?
Friction stir welding is a recent advancement that offers high strength and low distortion. New high-speed automated riveting machines have improved joints’ efficiency and consistency.
What is the best method for quick field repairs?
Due to its simplicity and minimal equipment needed, riveting is often the best option for quick field repairs. It is a simple and fast way to fix problems without elaborate setups.
How does the choice between riveting and welding affect the structure’s durability?
The choice has a significant impact on durability. Welding generally increases a structure’s strength by creating a continuous, strong bond. While riveting is robust, it may not be able to withstand as much stress as welding and could introduce failure points.
More Resources:
Optimal Materials for Riveting – Source: Essentra Components
Latest Advances in Welding Technology – Source: Yeswelder
Innovations in Riveting Tools and Equipment – Source: Medium
Hey, I'm Kevin Lee
For the past 10 years, I’ve been immersed in various forms of sheet metal fabrication, sharing cool insights here from my experiences across diverse workshops.
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Kevin Lee
I have over ten years of professional experience in sheet metal fabrication, specializing in laser cutting, bending, welding, and surface treatment techniques. As the Technical Director at Shengen, I am committed to solving complex manufacturing challenges and driving innovation and quality in each project.