Riveting vs Welding:Choosing the Right Metal Joining Process

Welding and riveting are both common methods of joining two pieces of metal together. However, they are used for different purposes and have different properties. If you are making a part that needs to be joined together. Then it is very important to understand the difference between riveting and welding. In this article, we will go over what welding and riveting are and their advantages and disadvantages. In addition, we will learn how to use them to create stronger, longer-lasting parts.

What is Riveting?

Riveting is the joining of sheet metal parts together with mechanical fasteners or rivets (metal parts with domed heads). It is a semi-permanent, non-thermal connection.

To rivet two pieces of sheet metal together, a hole is punched in each piece and a rivet is installed. How you install the rivets depends on the type of rivets you use. You may need to place the rivets in the holes, drill them, or punch them into the holes.

Once the rivet is in the hole, the end of the rivet needs to be bent. You can do this by pounding or tapping. The head and tail of the rivet are flat, which prevents the rivet from falling out.

Types of Riveting

To perform the riveting process, you need to drive rivets into holes that have been drilled in each metal plate. Common riveting can be categorized into three main types.

Depending on the position of the rivet

According to the location of the rivets, riveted joints are categorized into two types:

• Lap Joints: To make a lap joint, two pieces of sheet metal are turned over. Then rivets are placed on the covered part. Lap joints can be single or double-riveted, depending on the number of rivets used.
• Butt Joint: To make a butt joint, the two parts are first butted together (hence the name). The two parts are then joined together on one or both sides using additional material (such as a cover plate or strap). Finally, the cover plates are riveted into place.

Depending on the number of Cover Plates

When you want to drill a hole in a workpiece, you can put a cover plate on top to hold it in place. This type of riveted joint is suitable for butt joints.

• Single-band Butt Joint: The main parts are placed close together so that they do not overlap to form a single-band butt joint. The cover plate is then pressed against the side of the main plate and riveted in place.
• Double Strap Butt Joints: Double strap butt joints are similar to single strap butt joints. They differ in that there is a cover plate on each side. Place a piece on each side of the two sheet metal components and rivet each piece in place.

According to the Arrangement of Rivets

This category focuses on how the rivets are installed to join the pieces of metal together. There are two types of rivets:

• Chain Riveted Joints: To make chain riveted joints, the rivets need to be lined up in a row. They are then made perfectly opposite each other and in a straight line.
• Zigzag Riveted Joints: The rows of rivets in zigzag riveted joints do not match each other as in the case of chain strap butt joints.

Advantages and Disadvantages of Riveted Joints

Riveting is a common joining method in sheet metal fabrication services. However, it has some advantages and disadvantages.

Advantages:

• Riveting is a non-heat metal joining method
• More suitable for dissimilar and non-ferrous metal parts
• Flexible design
• It is more efficient and reliable
• It is easy to perform a quality inspection
• Disassembling does not lead to damaged riveted parts

Disadvantages:

• High overall cost
• Increase in overall weight
• Riveted joints create more noise
• Corrosion can occur in the riveted area leading to an increase in maintenance cost
• Due to holes, plates become weak

What is Metal Welding?

Welding is the thermal process of joining two identical or dissimilar metal parts. Metal welding is a permanent process. It involves aligning the metals, melting the metal parts, and then allowing them to cool and form a rigid joint. There are several different sheet metal welding processes. The following are common methods:

Stick Arc Welding (SMAW)

Stick arc welding, or SMAW is a method of joining pieces of metal together by inserting a flux-coated tool into a power source.

A molten electrode enters the space between the two metal sheets to be joined. In order to melt the electrode and flux together, gases and slag are formed. These substances protect the molten electrode and the arc.

Stick welding is a simple, portable, and inexpensive method of joining metallic materials. It can be used to join low alloy steels, high alloy steels, carbon steels, cast iron, and nickel alloys.

Gas Tungsten Arc Welding (GTAW)

GTAW, also known as TIG (tungsten inert gas) welding, can be used on ferrous or non-ferrous metals such as titanium, aluminum, and stainless steel. A tungsten electrode can be used to melt the workpiece, creating a liquid pool that is then joined together after the workpiece has hardened.

TIG welding requires no flux and must be very precise. In addition, TIG welding produces a strong, high-quality workpiece.

Gas-shielded Metal Arc Welding (GMAW)

This is the most common method of welding a number of different materials together.MIG welding (Metal Inert Gas) is another name for GMAW. It can be fully or partially automated and uses a solid wire electrode the same length as the workpiece to join the workpieces. It has a shielding gas that protects the workpiece from external influences. MIG welding differs from TIG welding in that it does not produce impacts and is continuous.

Flux Cored Arc Welding (FCAW)

Flux Cored Arc Welding (FCAW) is a type of outdoor welding. It can be used on thicker contaminated materials such as cast iron, stainless steel, carbon steel, high nickel alloys, and low alloy steels.

This metal welding process uses a continuous hollow wire electrode with a flux compound. In addition, it produces welding slag. Therefore, the welding slag needs to be cleaned away from the welded part to give it a better look.

Types of Welded Joints

Welding is the linking of two metal plates by heating the molten metal. There are several common types of welded joints:

• Butt Welding: Butt welding is the most common and straightforward welding process. Before welding, the metals to be fused are placed on the same plane.
• Lap Weld Joint: If two pieces of metal are overlapped and then welded together on one or both sides, a lap weld joint is formed. This is an improved form of butt joint. This type of welding is suitable for joining metal sheets of different thicknesses.
• T-Joint Welding: Two pieces of metal are joined at a 90° angle to form a T-joint. One sheet of metal is placed in the center of the other sheet of metal and a T-shape is formed, hence the name T-joint welding.
• Corner Weld: When welding a corner joint, the metal is placed at the corner instead of in the center as in a T-joint. Thus, an L-shape is formed.

Advantages and Disadvantages of Welding

When comparing riveting and welding, metal welding is the more common choice. Again, welding has both advantages and disadvantages.

Advantages:

• Welded parts are stronger
• Suitable for both similar and different materials
• Look better because they make things look smoother
• Can be machined into many shapes and ways

Disadvantages:

• They have brittle joints and lower fatigue strength
• Additional stress due to deformation
• Require skilled workers, which can increase labor costs
• Requires electricity, which may increase operating costs

Difference Between Welding and Riveting

Riveting and welding each have their advantages and disadvantages, which means they can be used for a wide range of products. However, a key difference between the two processes may limit their use to certain items. Below we will discuss the differences between the two processes and how to choose the right one.

Materials

These two methods of joining metals can be used for similar or different components. Riveting is the best method for joining items made of different materials. This is because riveting does not require the melting point of the sheet metal part to be considered like welding, which is a key consideration for welding.

Speed

This is a major difference between welding and riveting. Welding is a great way to join different metal parts together. This is because it increases the speed of production and automation. Riveting on the other hand involves many steps such as cutting holes, joining, and flattening the rivets.

Cost

Although the rivets themselves are cheap, the overall process of riveting is usually more expensive than welding. This is due to the fact that riveting requires different steps that are costly in terms of material, handling, and labor.

Strength

Welding is stronger than riveting because it is fixed and rigid. Welding is therefore well suited for making metal assemblies with rigid frames. Therefore, welding is the best method for making items that require these qualities.

Safety

In some ways, both methods are safe. However, welding is safer because most of the work is done by machines.

Applications

Riveting can be used to manufacture consumer goods, airplanes, bridges, and ships. Whereas welding can be used to manufacture parts for the military, aerospace, and electrical industries.

Is Welding or Riveting Better?

Your needs determine the best way to join sheet metal parts. So, instead of trying to find a better method, you should understand the factors that have an impact on both methods. Read on to find out which situations lend themselves to welding or riveting.

When to Choose Metal Welding?

When you decide to weld, you should consider the following points:

• Weight Sensitivity: If what is being made needs to be very light, then welding is the better option. It does not add weight to the finished product as riveting does. This is because no other material is used to join the metal sheets together.
• Efficiency: Metal welding is also the best way to join if efficiency is a priority. Since most of the steps are done automatically. Therefore joining two metals together will be faster and easier. In addition, you won’t have to drill holes or make nails or anything else.
• Aesthetics: Welded surfaces are more aesthetically pleasing because the surface is smooth after welding. This is unlike riveting, where the bumps are often considered ugly.
• Strength of Joints: Welded joints last longer and are stronger compared to riveted joints. Frames that use welded parts are strong, long-lasting, and do not bend. Therefore, they are the best way to make strong and rigid products.
• Different Shapes: Welding is the best method when it comes to machining parts of different shapes. Unlike riveting, any of the above metal welding processes can be used to join cylindrical metal parts together.

When to Choose Riveting?

While welding is usually the best method for making items from sheet metal, sometimes riveting is a better choice. If you know this, you can make a better choice between riveting and welding. Here are some things to consider when choosing riveting when working with sheet metal.

• Material Type: Welding may not be the best way to handle materials with different melting points. This is because sheet metal fabricators must consider the melting point. This is not the case with riveting, which simply involves drilling a hole in the material and attaching rivets or fasteners.
• Heat Demand: Riveting is the best method for joining items that do not require heat. For example, aluminum is not stable at high temperatures. As a result, high temperatures are usually not suitable for joining several aluminum sheet metal parts together. This means that rivets are more suitable for aluminum items such as cooking tools.
• Disassembly: Products connected with rivets can be disassembled without damaging any of the parts. This method of joining is, therefore, suitable for parts that need to be checked again for quality, or parts that need to be replaced frequently due to rust. In contrast, welded joints are permanent. This is one of the main reasons why riveting is superior to spot welding in some products.
• Flexible Design: Riveting is the best method without destroying the structure of the product.

Conclusion

There are many different ways to join sheet metal parts together. Metal welding and riveting are the most common methods. These two methods have different working principles and advantages and disadvantages. Therefore, it may be difficult to choose.

You may need a professional to help you choose the best method for your job. Therefore, if you need help choosing between welding and riveting, you can contact us. Yonglihao Machinery will provide you with professional advice.

In addition, Yonglihao Machinery is a professional Metal welding service company, known for high quality, fast output, and low prices. With precise production methods and a dedicated team of professionals, we are committed to making the best prototypes and parts possible.