FOCUS ON FASTENERS on one end of it. Installation involves passing the rivet shaft through holes in the parts to be joined and then expanding the tail end of the rivet to form a second head, the‘ shop head’ or‘ buck-tail’, by mechanical means. This secures the sheets tightly in place against each other,” added TZR Shengen Metal.
Self-tapping screws.
Solid rivets
“ Solid rivets offer the highest shear strength but can only be installed from both sides of the sheet, one side for the manufactured head and the other for the shop head using a hammer and bucking bar or riveting machine, as the solid shaft provides additional support during installation,” commented TZR Shengen Metal.
Semi-tubular rivets
These are like solid rivets but have a small hole in the tail part and, therefore, less force is used to form the shop head.
Blind rivets( pop rivets)
These are used in cases where access to the area to be joined is restricted to one side only.
“ A blind rivet is made up of a rivet shank and a mandrel. In this process, the mandrel is pulled and the rivet body on the blind side expands to form the second head, and the mandrel is then removed,” added TZR Shengen Metal.
Rivets have a high shear load and are suitable for withstanding vibrations. They are used to form permanent joints and widely used in aircraft structures, bridge construction and general sheet metal working.
Sheet metal screws
Sheet metal screws are screws that are intended to create their own threads in sheetmetal when they are inserted in pre-drilled or punched holes.
Self-tapping screws have sharper threads and may need a pilot hole to be drilled before the screw is inserted. They form threads by the process of displacement of material. Selfdrilling screws feature a drill point at the head that drills a hole and creates threads at the same time, saving time in assembly.
“ Sheet metal screws come in different head types( pan, hex, flat) and drive types( Phillips, slotted, Torx). The main benefits are that they are easy and fast to install, using only driving tools with no tapping operation needed. Their holding power is, however, comparatively lower than self-clinching fasteners and they are more likely to strip if over-tightened, especially when used on very thin materials. They are widely applied in HVAC ducting, automotive interiors, refrigerators and other home appliances, as well as light gauge construction,” outlined TZR Shengen Metal.
Weld fasteners
Weld fasteners are nuts or studs that are intended to be permanently affixed to a sheet metal part through precise alignment and welding techniques such as resistance welding, projection welding, arc welding or capacitor discharge( CD) welding.
“ The main benefit is a very strong and permanent fastening for high loads or for applications where different materials have further parts that must be screwed on. Weld fasteners do not require the creation of holes for the fastener itself( although there may be locating features), which maintains the strength of the sheet. Disadvantages include the need for specialised welding equipment and experienced operators, heat that affects or marks the sheet metal surface and the need for the fastener to be compatible with the workpiece. These are widely used in automotive frames and bodies, heavy vehicles and equipment, and industrial machines,” added TZR Shengen Metal.
Bolts and nuts
While often associated with thicker materials, bolts and nuts are also utilised in sheet metal applications, particularly when a high degree of clamping force or the ability to disassemble the joint is required. Typically, this method involves pre-drilling holes in the sheet metal and then securing the components together by tightening the nut onto the bolt.
Washers are often used to distribute the load and prevent damage to the sheet metal surface. Various types of bolts( e. g. carriage bolts, hex bolts) and nuts( e. g. standard nuts, lock nuts) are available, depending upon the specific application requirements.
Threaded inserts
Threaded inserts are used to create strong, durable and reusable threads on materials that cannot be threaded directly( due to their thinness or softness, such as sheet metal).
“ Rivet nuts( nutserts) are installed from one side like the blind rivet. A tool pulls a threaded mandrel, which causes the insert body to compress and expand against the blind side of the sheet to form a threaded anchor. Press-in inserts are similar to self-clinching fasteners that are pressed into holes and may use specific profiles to engage the parent material,” said TZR Shengen Metal.
Threaded inserts are very useful when there is a requirement for strong and reusable threads in thin panels where access is only possible from one side( for rivet nuts). They are used in the automotive industry, aerospace industries and in the joining of parts to enclosures.
Cage nuts and clip-on nuts
Cage nuts are made up of a nut with a square head and a spring steel cage with two wings or clips. These wings enable the cage nut assembly to be screwed into a square or rectangular aperture in a sheet metal panel, usually a rack rail or enclosure. Clip-on nuts( or U-nuts) work in the same way, being clipped over the edge of a panel or into a rectangular hole to create a threaded hole.
“ The main benefit of both is that they afford a certain amount of slop or play, so that the holes in the panel do not have to align perfectly with the component being fastened. They also have serviceability, as they can be easily disassembled and replaced in case they are damaged. They are commonly used in IT equipment racks, electrical cabinets and some automotive applications where devices are mounted on panels,” concluded TZR Shengen Metal.
In conclusion
Effective sheet metal fastener selection and installation are critical for product quality, integrating design engineering with manufacturing precision. Understanding fastener types, selection factors and installation best practices is essential. n
ISMR March 2026 | ismr. net | 47