Guide to Metal Joining Rivets Vs PEM Fasteners Compared

Imagine attempting to weld a wooden panel to an aluminum frame inside a shaking RV—the results would be predictably disastrous. Or consider the challenge of reducing aircraft wing weight while maintaining structural integrity during high-altitude operations. These scenarios highlight a critical question: how does one select the optimal metal fastening method? Rivets, ancient yet reliable fasteners, remain indispensable in modern industry. But are they always the best choice? This article examines rivet types, applications, pros and cons, and explores more efficient alternatives.

With origins tracing back centuries, rivets consist of a head and shank slightly longer than the combined thickness of materials being joined. The shank end is deformed to create a second head, permanently securing components. Rivet connections offer exceptional shear resistance, good tensile strength, and near-immunity to vibration loosening—qualities that ensure their continued use in critical applications.

• Structure: Single-piece construction with head and solid shank
• Head Variants: Round, pan, mushroom, and countersunk profiles
• Advantages: Unmatched durability for permanent connections in bridges, structural frameworks, and heavy machinery

• Applications: Pipe connections, vehicle assembly where only one-side access exists
• Installation: Mandrel pulling expands rivet body within pre-drilled holes
• Data Insight: 30-40% lower tensile strength than solid rivets, offset by installation convenience

• Design: Forked shank legs that splay outward
• Best For: Leather, plastics, fabrics where solid rivets might damage materials

• Key Feature: Partially hollow shank reduces installation force by 25%
• Ideal Uses: Hinges, rotational joints, and weight-sensitive applications

• Design: Conical heads flush with material surfaces
• Critical Applications: Aircraft wings, high-performance vehicles requiring laminar airflow
• Precision Requirement: ±0.1mm installation tolerance for optimal performance

• Common Options: Aluminum, carbon steel, stainless steel, brass, copper
• Selection Criteria: Match material properties to environmental conditions (e.g., stainless for corrosive environments)

While cost-effective and reliable, rivets present limitations: permanent installation, added weight, and labor-intensive processes. PEM (Press-in) fasteners offer compelling alternatives:

• Advantage: Superior vibration resistance versus weld nuts
• Minimum Thickness: 0.048" metal sheets

• Benefit: Single-side installation with fixed orientation

• Application: PCB mounting, thermal management spacing

• Aerospace: Solid/countersunk rivets for vibration resistance
• Electronics: PEM fasteners for serviceable connections
• Marine: Waterproof rivet variants

Optimal fastening depends on:

1. Material compatibility
2. Required permanence
3. Environmental factors
4. Available installation equipment

For 5052-H32 aluminum sheets, reference manufacturer specifications for:

• Minimum/maximum material thickness
• Hole diameter tolerances
• Surface treatment options