Custom rivets in aerospace?

Material usage: Address the requirements of demanding settings

-Titanium alloys (e.g., Ti-6Al-4V), aluminum alloys (e.g. 7075-T6) and special rivets for composite materials - used for weight reduction with good strength.

Materials resistant to high temperature: Nickel-based superalloys (Inconel 718, etc) are applied in the engines and high temperature region, resistant to high temperatures above 1000 °C.

Corrosion resistance treatment: surface coating (cadmium plating, galvanized nickel, etc.) or nonoxide treatment to prevent salt spray and humid environment corrosion.

Design features: Make properties and operations efficient

Recessed (Countersunk Head) - to reduce airflow effect, used on exterior skin of an aircraft. Round head rivets are used in non-exposed areas.

Fatigue preventing: Interference Fit Rivets dissipate concentration of stress and lengthen the life span of structure.

Special function design: Blind Rivets: use for hard-to-reach parts; High lock rivets (Hi-Lok) have combined advantages of bolts and rivets, provide removable connections.

Application scenario

Aircraft fuselages and wings: Hundreds of thousands to millions of rivets are required to fasten skin, stringer and frame (the Boeing 747, for example, uses about 6 million).

Engine components: heat-resistant rivets fastened on combustion chamber, turbine blades, etc. Anti-loosening design.

Titanium Alloy rivets for satellite structures, and Heat resistant rivets (such as ceramic coatings) down come use in the reentry chamber thermal protection system.

Composite structure: special rivets (such as carbon fiber reinforced rivets) to prevent galvanic corrosion, adaptability thermal expansion coefficient.

Technical advantages

Lightweight and efficient: custom rivets can be 30%-50% lighter than traditional bolts, with considerable improvements in fuel efficiency.

Structural reliability – Using finite element analysis (FEA) to optimize design to remain stable under vibration and shock loads.

Simple assembly process: Automated riveting robots (e.g. electromagnetic riveting technology) can increase assembly efficiency and reduce errors in the hands of workers.

Challenges and solutions

Material compatibility: The use of spacers or coatings to prevent contact corrosion of dissimilar materials (aluminum and carbon fiber for example).

Q/C Inspection 100% NDT (X-ray / Ultrasonic) No Internal Defects

Cost and cycle time: 3D printing or precision casting low volume custom production, is an easy way to lower costs and lead times.

Innovation trends

Bead smart rivets: Integrated micro sensors to monitor structural health (e.g. strain, temperature).

Eco-friendly manufacturing: rivet using recycled material and environment-friendly surface processing technology.

Additive manufacturing: Personalisation — You design the rivet; we print it

Sum up

Just as the custom rivet is an indispensable “invisible hero” of the aerospace industry, performing a central role in ensuring flight safety while driving performance improvements and reduced costs through material, design and process innovation creating airplane integration solutions galore, this data has been used with a better micro fabrications and manufacturing process to develop a new and stronger rivet that requires less maintenance and lower risk. Over the years as technology will evolve it will bring very intelligent and sustainable applications.

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