B1.1mo7.8 Riveting

DCAM PART 66
CATEGORY B1.1
MODULE 7.8 : RIVETING

7.8 RIVETING (DCAM REF: 7.8, LEVEL 2)
IDENTIFICATION OF SOLID RIVETS
Types of Head and Rivet Length
Universal Head : used

where resistance to airflow is
no important
Countersunk : used where a

flush surface finish is
required
B1.1M07.8 Presentation Slide No 2

Length is total rivet length including

Length is total shank length
head measured from the top of the
measured from under the head
head to the end of the shank.
to the end of the shank

Riveted Joints, Riveting Terms
Objective: -
At the end of this lesson the student will be able

to:
Types of joints used in riveting
Understand the riveting terms;
Allowance
Clearance,
Spacing,
Land
Pitch

Riveted Joints
Different types of joint may be required depending on the strength of joint required
and whether a smooth aerodynamic finish is necessary.
Lap Joint
This joint would be the weaker than
a butt joint and used where an
aerodynamic finish is not necessary.
The term lap is a shortened version of

overlap.

Butt Joint
In this joint the joint area is

strengthened by a double row of
rivets and extra material being
used in the joint area.
The extra material would be

positioned on the inside surface
and countersunk rivets used if an
aerodynamic finish was required.

Butt strap joints
In this joint two straps are used as

shown, one on the top of the joint and
one on the bottom.
This provides additional strength and

rigidity.

QUESTIONS

Rivet Layout
When a sheet metal repair is to be done, there are certain minimums
that must be attained for:
Rivet spacing
Edge margin
Fastener diameter
Refer to Structural Repair manual (SRM) Chapter 51

Rivet layout consists of determining: -
The number of rivets required.
The size and type of rivet head used.
Its material, temper condition and strength.
The size of the rivet holes.
Distance of the rivet holes and rivets from the edges of the
patch.
The spacing of the rivets.

RIVETING TERMS
Allowance
Length of rivet shank protruding through the plates
Clearance
Difference the diameter of the drilled hole and the rivet shank diameter
(In most cases the clearance size is 0.1mm oversize)

Rivet Length
If the rivet is too long, the formed head will be too large,
or the rivet may bend or be forced between the sheets being
riveted.
If the rivet is too short, the formed head will be too small
or the riveted material will be damaged.
The length of the rivet:

The sum of the thickness of the metal plus 1 1/2 times
(allowance) L =the
T + diameter
T + 15D of the rivet.
Countersunk Head form, the length of shank required is equal to the
diameter of the rivet.
L=T+T+D

Example:
What length of 3 mm diameter rivet is required to form a snap head and
join two pieces of 1.2 mm sheet metal together?
Solution: L = T + T + 15D
= 16 + 16 + 15 x 4 mm
Rivet length = 32 + 6 mm = 92 mm
Example:
What length of 4 mm diameter rivet is required to form a countersunk
head and join two pieces of 275 mm plate?
Solution: L = T + T + D
= 476 + 476 + 95 mm
= 1902 mm
Rivet length = 19 mm

Edge Distance or Land

Distance measured between the centre of a rivet and the edge of the panel.
If insufficient land is used, the joint may fail due to the rivet tearing out. Too much
land leaves the edge of the panel unsupported and the edge lifting to allow
moisture and dirt ingress. There is a danger of airflow lifting the edge of the panel
if the land is too big.
Ideally the land should be 2D (thin) and 2 1/2D (thicker)

Rivet Pitch
Distance between adjacent rivets in the same row.
The pitch will normally be specified in a drawing as a multiple of the rivet size
and will vary depending on the strength of joint required.
This distance should be at least 4D
Single Row Riveting

Rivet Spacing
Distance between adjacent rows of rivets.
This should be a min of 4D
Double Row Riveting


QUESTIONS

Production of a Riveted Joint

In the production of a riveted joint we must consider the following factors:
The strength and type of joint required
Selection of the rivet
Layout of rivet pattern
In most cases all of these factors will already be specified in a repair manual
or in a diagram. All of these factors are necessary to ensure the joint is
correct.

HOLE PREPARATION
After laying out the rivet pattern the centres of the holes must be
marked with a centre punch to enable the drill to start cutting without
walking over the metal. The centre punch should not be hit hard
enough to distort the metal.

Choose the correct clearance drill for the rivet selected. A pilot hole
should normally be drilled first. This should be at lease one drill size
smaller than the correct size.
Note: # 31 = undersize of 1/8

drill
# 29 = oversize of 1/8
drill Slide No 21
B1.1M07.8 Presentation

Note:
A rivet will not fit in a hole with the same diameter as the rivet
shank; it must be installed in an oversize hole.

Using one hand to steady the drill and hold it back will help prevent the drill
from going too far past the back of the sheet.
A PILOT HOLE SHOULD NORMALLY DRILLED FIRST
All holes shall be drilled normal (at 90

degrees) to the working surface

When drilling through more than one sheet, hold the sheets securely
together so there is no misalignment of holes due to shifting or
separation of the sheets..
Use gripping pins (Cleco or skin pins) to ensure the holes are aligned
correctly.

Use of Clecos
A cleco is a springloaded clamp used to hold parts together for

riveting.
Special pliers are used to insert clecos into holes.


BY HAND ONLY! NOT IN A DRILL!
After drilling, all holes must be carefully de-burred to eliminate stress

raisers and to allow correct seating of rivet heads
Remove any sharp edges from the hole

Surface Protection
Alodine
Primer

QUESTIONS

Riveting And Dimpling
Objective: -
At the end of this lesson the student will be able to:

identify tool used for riveting and dimpling.

Countersunk
If flush rivets are to be installed, the hole must be either cut countersunk or
dimpled, depending on the thickness of the material
Allows the depth of the cut to be accurately controlled and consistent
Other methods of countersinking are:.

Use rose bits and specialised countersinking bits.
Use a special countersinking bit with a pad to stop drilling too
deep.

Dimpling
The metal shape is change to fit a CSK rivet
Applied when the skin too thin for cut countersinking
Various methods are used:

1. Radius dimpling
2. Coin dimpling
3. Spin dimpling


Installation of Rivets
Riveting Methods:
Pneumatic rivet gun reaction riveting
Rivet gun used with a back-up
dolly/bucking bar, form the upset head
Hand hammering percussion riveting

Small component repairs workshop
Continuous squeeze riveting pneumatically

or hydraulic operated

Forming the Rivet
Before driving any rivets, make sure all the holes line up
perfectly, all the shavings and burrs have been removed,
and the parts to be riveted are fastened securely
together.
It is important that the sheets be held firmly together

near the area of the rivet being driven.
Two operators are required to drive conventional

solidshank rivets using the conventional gun and
bucking bar method when there is easy access to both
sides of the work

NEVER USE W/O A RETAINER SPRING
DO NOT PLAY WITH RIVET GUNS!!!!
WEAR EAR PLUGS WHEN RIVERTING OR BUCKING


Tapping Code
A tapping code has been established to enable the rivet bucker to communicate
with the mechanic driving the rivet:

i. One tap on the rivet by the rivet bucker means: start or resume
driving the rivet.
ii. Two taps on the rivet by the rivet bucker means that the rivet is
satisfactory.

iii. Three taps on the rivet by the rivet bucker means that
the rivet is unsatisfactory and must be removed.
Always tap on the rivet; do not tap on the skin or any part of the
aircraft structure.

INSPECTION AFTER RIVETING

Manufactured heads should be smooth, free of tool marks and have no gap
under the head after riveting. No crack should be in the skin around the rivet
head. The driven head should not be cocked or cracked.
The height of the bucked head should be

0.5 times the rivet diameter and the width
should be 1.5 times the rivet diameter



QUESTIONS

Rivet Gun
The hand tool used to drive a rivet is called a pneumatic rivet gun or rivet
hammer.
Rivet gun vary in size, type of handle, number of stroke per minute, provisions for
regulating speed.
Rivet guns are normally powered by compressed air and are classified as:-
i. light-hitting
ii. medium-hitting
iii. heavy-hitting.


Rivet guns are normally powered by compressed air and

are classified as:-
i. light-hitting
ii. medium-hitting
iii. heavy-hitting.
Light hitting gun is used to install 3/32 and 1/8 inch

diameter rivets.
Medium-hitting guns are used to install 5/32 and 3/16 inch

diameter rivets.
Heavy-hitting guns are used to install larger diameter

rivets and some special fasteners.

Rivet Set
There are two types of gun sets:
i. Universal gun set.
ii. Countersunk gun set.
Universal gun
set Countersunk gun set


The universal gun set is sized to fit the various shapes of manufactured
heads on the rivets driven end. The opposite end of the universal gun set
fits into the rivet gun barrel and is held in place by a beehive retainer
spring. Universal set can be identified with the tool number and size of the
rivet
The countersunk gun set fits all sizes of flush head rivets. The countersunk
rivet cannot use the beehive retainer ring. The countersunk rivet set uses a
specially designed retainer spring. Countersunk set can be identified only
with the tool number.
Rivet Gun Countersunk gun set
Universal gun
set
Spring

Bucking bars
Bucking bars are tools used to form buck tails (the head formed
during riveting operations) on rivets.
Bucking bars are normally made from an alloy steel similar to

tool steel.
The particular shape to be used depends upon the location and

accessibility of the rivet to be driven.
The size and weight of the bar depend on the size and alloy of the
rivet to be driven.


Hold the bucking bar in such a manner that will allow

the longest portion of the bar to be in line with the rivet.
You should hold the bucking bar lightly but firmly against
the end of the rivet shank so as not to unseat the rivet
head. The inertia of this tool provides the force that bucks
(upsets) the rivet and forms a flat, head like buck tail.


BLIND RIVETING
1. Drill a hole 0.1 mm larger in diameter than

the blind rivet into the items that are being
joined together.
1. Drill a hole 0.1 mm larger in

diameter than the rivet nut into the
workpiece.
2. Open the handle catch and insert the blind

rivet shaft into the mount..

3. Push the blind rivet shaft through the drill hole.
4. Press handles together. Repeat the

process until the rivet shaft breaks off.
4.Guide rivet nut through the drill

hole, set travel limiter and press
handle together.
5. The blind rivet is now in place.

QUESTIONS

B1.1mo7.8 Riveting

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DCAM PART 66

MODULE 7.8 : RIVETING

IDENTIFICATION OF SOLID RIVETS

Types of Head and Rivet Length

Universal Head : used

Countersunk : used where a

B1.1M07.8 Presentation Slide No 2

Length is total rivet length including

B1.1M07.8 Presentation Slide No 3

Riveted Joints, Riveting Terms

At the end of this lesson the student will be able

B1.1M07.8 Presentation Slide No 4

The term lap is a shortened version of

B1.1M07.8 Presentation Slide No 5

In this joint the joint area is

The extra material would be

B1.1M07.8 Presentation Slide No 6

Butt strap joints

In this joint two straps are used as

This provides additional strength and

B1.1M07.8 Presentation Slide No 7

B1.1M07.8 Presentation Slide No 8

Refer to Structural Repair manual (SRM) Chapter 51

B1.1M07.8 Presentation Slide No 9

Rivet layout consists of determining: -

The number of rivets required.

The size and type of rivet head used.

Its material, temper condition and strength.

The size of the rivet holes.

The spacing of the rivets.

B1.1M07.8 Presentation Slide No 10

B1.1M07.8 Presentation Slide No 11

The length of the rivet:

B1.1M07.8 Presentation Slide No 12

B1.1M07.8 Presentation Slide No 13

Edge Distance or Land

Ideally the land should be 2D (thin) and 2 1/2D (thicker)

B1.1M07.8 Presentation Slide No 14

This distance should be at least 4D

Single Row Riveting

B1.1M07.8 Presentation Slide No 15

Distance between adjacent rows of rivets.

This should be a min of 4D

Double Row Riveting

B1.1M07.8 Presentation Slide No 16

B1.1M07.8 Presentation Slide No 17

B1.1M07.8 Presentation Slide No 18

Production of a Riveted Joint

B1.1M07.8 Presentation Slide No 19

B1.1M07.8 Presentation Slide No 20

Note: # 31 = undersize of 1/8

B1.1M07.8 Presentation Slide No 22

B1.1M07.8 Presentation Slide No 23

A PILOT HOLE SHOULD NORMALLY DRILLED FIRST

All holes shall be drilled normal (at 90

B1.1M07.8 Presentation Slide No 24

B1.1M07.8 Presentation Slide No 25

A cleco is a springloaded clamp used to hold parts together for

Special pliers are used to insert clecos into holes.

B1.1M07.8 Presentation Slide No 26

B1.1M07.8 Presentation Slide No 27

BY HAND ONLY! NOT IN A DRILL!

After drilling, all holes must be carefully de-burred to eliminate stress