Chapter 8

Rivets & Welded

Objectives: At the end of this chapter, the students/readers should be able to:

1. Define rivets;
2. Classify different types of riveted and welded joints;
3. Derive the formula of welded joints; and
4. Practice solving problems and answer the multiple choice test to master the usual
questions and problems in the licensure examination.

Rivets are made of wrought iron or soft steel. It is used as fastenings for joints in buildings,
bridges, boilers, tanks, ships, and miscellaneous framework.

Standard Rivet Heads

Pitch is the distance from the center of one rivet to the center of the next rivet measured parallel
to the seam.

Back Pitch is the perpendicular distance between the center of the successive rows.

Diagonal Pitch is the distance between the centers of the rivets in adjacent rows of
zigzag riveted joint.

Marginal Pitch is the distance between the centers of the rivets hole to the nearest edge
of the plate.

Common Rivet Materials

1. Low Carbon Steel

2. Nickel Steel
3. Brass
4. Aluminum
5. Copper

Types of Riveted Joint

1. Lap Joint is one plate overlaps the other and the two plates are then riveted together.
1.1 Single riveted lap joint
1.2 Double riveted lap joint
1.3 Triple riveted lap join
2. Butt Joint is the main plates are kept in alignment butting that is touch each other and a
cover plate is placed either on one side or on one both sides of the main plates.
2.1 Single riveted butt joint
 2.2 Double riveted butt joint
2.3 Triple riveted butt joint

Note: The actual stresses set up in the riveted joint are complicated and cannot be simply
computed.

Common Assumptions

1. The load is distributed among the rivets according to the shear areas.
2. There is no bending stress in rivets.
3. The tensile stress is equally distributed over the projected area of the rivets.
4. In a rivet subjected to double shear, the shear is equally distributed between the two areas
in shear.
5. The crushing pressure is equally over the projected area of the rivets.
6. The holes into which the rivets are driven do not weaken the member if it is in
compression.
7. After they have been driven, the rivets completely fill the holes.
8. Friction between adjacent surfaces does not affect the strength of the joint.

Failure of Riveted Joints

1. Tearing of the plate at an edge.

2. Tearing of the plate across a row of rivets.
3. Shearing of the rivets
4. Crushing of the plate or rivets.

Common Assumptions in Designing Boiler Joints

1. The load on the joints is equally shared by all the rivets.

2. The tensile stress is equally distributed over the section of metal between the rivets.
3. The shearing stress in all rivets in uniform.
4. The crushing stress is uniform.
5. There is no bending stress in the rivets.
6. The holes into which the rivets are driven do not weaken the member.
7. The rivet fills the hole after it is driven.
8. The friction between the surfaces of the plate is neglected.

Riveted Joint Formula

1. Design or Tangential Stress

𝑃𝑖 𝐷𝑖
𝑆𝑡 =
2𝑡𝑒

where: 𝑆𝑡 = design or tangential stress

𝑃𝑖 = internal pressure
𝐷𝑖 = inside diameter
t = wall thickness
e = joint efficiency
 2. Factor of Safety

𝑆𝑡𝑢
𝐹𝑆 =
𝑆𝑡

where: FS = factor of safety

𝑆𝑡𝑢 = ultimate tensile stress
𝑆𝑡 = design or tangential stress

3. Efficiency of the Joint

𝑝−𝑑
𝑒= × 100
𝑝

where: e = joint efficiency

p = pitch
r = rivet diameter

Welded Joint is a permanent joint which is obtained by the fusion of the edges of the two parts
to join together, with or without the application of pressure and filler material.

Common Forms of Welded Joints

Types of Welded Joint

1. Lap Joint or Fillet Joint is obtained by over lapping the plates and then welding the
edges of the plates. The cross-section of the fillet is approximately triangular.
Classification of Lap or Fillet Joints
a. Single transverse fillet
b. Double transverse fillet
c. Parallel filler joints
2. Butt Jointis is obtained by placing the plate edge to edge. The plate edges do not require
bevelling if the thickness of plate is less than 5mm.
Classification of Butt Joints
a. Square butt joint
b. Single V-butt joint
 c. Singlr U-butt joint
d. Douvle V-butt joint
e. Double U-butt joint

Joining of Metals

Mechanical Soldering Welding Brazing

Brazing

Dip Gas Electric Furnace

Soldering

Wiping Sweating Soldering Ion

Welding

Pressure Fusion

Closed
Cold Forge Butt Gas Arc Thermic
Pressure
 Mechanical

Riveting Seaming

Welding is a process of joining metal by treating the metal to a state of fusion permitting it to
flow together into a solid joint. Most of the processes may be grouped into two main categories:
pressure welding, in which the weld is achieved by pressure; and heat welding, in which the weld
is achieved by heating. Heat welding is the most common welding process used today. Welding
replaced bolting and riveting in the construction of many types of structures, including bridges,
buildings, and ships. It is also a basic process in the automotive and aircraft industries and in the
manufacture of machinery.

The Advantages of Welded Joints over Riveted Joints

1. The welded structures are usually lighter than riveted structures. This is due to the reason
that in welding, gussets or other connecting components are not used.
2. The welded joints provide maximum efficiency which is not possible in case of riveted
joints.
3. Alterations and additions can be easily made in the existing structures.
4. As the welded structure is smooth in appearance, thus it looks pleasing.
5. In welded connections, the tension members are not weakened as in the case of riveted
joints.
6. As welded joint has a great strength. Often a welded joint has the strength of the parent
metal itself.
7. Sometimes, the members are of such a shape that they afford difficulty for riveting. But
they can be easily welded.
8. The welding provides very rigid joints. This is in line with the riveting requires enough
clearance.

The Disadvantages of Welded Joints over Riveted Joints

1. Since there is an uneven heating and cooling during fabrication, therefore the members
may get distorted or additional stress may develop.
2. It requires a highly skilled labor and supervision.
3. Since no provision is kept for expansion and contraction in the frame, therefore, there is a
possibility of cracks developing in it.
4. The inspection of welding work is more difficult than riveting work.

Types of Welding

1. Gas Welding is a nonpressure process using heat from gas flame. The flame is applied
directly to the metal edges to be joined and simultaneously to a filler metal in wire or rod
form, called the welding rod, which is melted to the joint. It has the advantage of
 involving equipment that is portable and does not require an electric power source. The
surfaces to be welded and the welding rod are coated with flux, a fusible material that
shields the material from the air, which would result in a defective weld.

2. Arc-welding is the processes, which have become the most important welding processes,
particularly for joining steels, require a continuous supply of either direct or alternating
electrical current. This current is used to create an electric arc, which generates enough
heat to melt metal and create a weld. It has several advantages over other welding
methods. Arc-welding is faster because of its high heat concentration, which also tend to
reduce distortion in the weld. Also, in certain methods of arc welding, fluxes are not
necessary. The most widely used arc-welding processes are shielded metal arc, gas-
tungsten arc, gas metal arc, and submerged arc.

3. Shielded Metal-arc Welding is a metallic electrode, which conducts electricity, is

coated with flux and connected to a source of electric current. The metal to be welded is
connected to the other end of the same source of current. By touching the tip of the
electrode to the metal and then drawing it away, an electric arc is formed. The intense
heat of the arc melts both parts to be welded and the point of the metal electrode, which
supplies filler metal for the weld. This process, developed in the early 20th century is used
primarily for welding steels.

4. Electric Arc Welding is a continuous electric discharge, giving intense light and heat,
formed between two electrodes in a gas at low pressure or in open air.

5. Gas-tungsten Arc Welding is used in place of the metal electrode used in shielded
metal-arc welding. A chemically inert gas, such as argon or helium, is used to shield the
metal from oxidation. The heat from the arm formed between the electrode and the metal
melts the edges of the metal. Metal for the weld may be added by placing a bare wire in
the arc or the point of the weld. This process can be used with nearly all metals and
produces a high-quality weld.

6. Gas-Metal Welding is a bare electrode shielded from the air by surrounding it with
argon or carbon dioxide gas or by coating the electrode with flux. The electrode is fed
into the electric arc, and melts off in droplets to enter the liquid metal that forms the
weld.

7. Submerged-Arc Welding is similar to gas-metal arc welding, but in those process no gas
is used to shield the weld. Instead, the arc and the tip of the wire are submerged beneath a
layer of granular, fusible material formulated to produce a proper weld. This process is
very efficient but is generally only used with steels.

8. Resistance Welding is obtained from the resistance of metal to the flow of an electric
current. Electrodes are clamped on each side of the part to be welded, the parts are
subjected to the great pressure, and a heavy current is applied briefly. The point where
the two metal meet created resistance to the flow of the current. This resistance causes
heat, which melts the metals and created the weld. Resistance welding is extensively
employed in many fields of sheet metal or wire manufacturing and is particularly
adaptable to the repetitive welds made by automatic or semiautomatic machines.
 9. Thermit Welding is a heat generated by the chemical reaction that results when a
mixture of aluminium powder and iron oxide, known as thermit, is ignited. The
aluminium unites with the oxygen and generates heat, rehearsing liquid steel from the
iron. The liquid serves as filler metal for the weld. It is employed chiefly in welding
breaks or seams in heavy iron and steel sections. It is also used in welding of rail for the
railroad tracks.

10. Forge Welding refers to the parts to be joined are first heated to a proper temperature in
a furnace or forge and then hammered. An electric resistance welding is an example of
forge welding.

Welded Joint Formula

1. Average Shearing Stress On The Throat Area

𝐹
𝑆𝑠 =
ℎ𝐿𝑐𝑜𝑠45

where: 𝑆𝑠 = shearing stress

h = height
L = length
F = lathe load

2. Factor of Safety For Static Load

𝑆𝑠𝑦 0.50𝑆𝑦
𝐹𝑆 = =
𝑆𝑠 𝑆𝑠

where: FS = factory of safety

𝑆𝑠 = shearing stress
𝑆𝑦 = yield stress
𝑆𝑠𝑦 = shearing stress based on yield

3. Maximum Shearing Stress

𝑆𝑠𝑚𝑎𝑥 = 1.118𝑆𝑠

where: 𝑆𝑠 = shearing stress

𝑆𝑠𝑚𝑎𝑥 = maximum shearing stress

4. Maximum Tensile Stress

𝑆𝑡𝑚𝑎𝑥 = 1.618𝑆𝑡

where: 𝑆𝑡𝑚𝑎𝑥 = maximum tensile stress

𝑆𝑡 = tensile stress
Table 19.1 Design Stress for Welds

Type of Welded Shielded Welding Unshielded Welding

Joint and Stress
Static Loading Fatigue Loading Static Loading Fatigue Loading
Fillet welds 14,000 psi 5,000 psi 11,300 psi 3,000 psi
Butt welds: 10,000 psi 5,000 psi 8,000 psi 3,000 psi
Shear loading
Butt welds: 16,000 psi 8,000 psi 13,000 psi 5,000 psi
Tension loading
Butt welds: 18,000 psi 8,000 psi 15,000 psi 5000 psi
Compression
loading
Source: Design of Machine Members by Doughtie and Vallance

Table 19.2 Typical Efficiency of Commercial Boiler Joints

Type of Joint Typical Efficiency Maximum Efficiency

Lap joints:
Single riveted 45%-60% 63.3%
Double riveted 63%-70% 77.5%
Triple riveted 72%-80% 86.6%
Butt joints:
Single riveted 55%-60% 63.3%
Double riveted 70%-80% 86.6%
Triple riveted 80%-90% 95.0%
Quadruple riveted 85%-94% 98.1%
Source: Design of Machine Members by Doughtie and Vallance

Table 19.3 Allowable Loads for Mild-Steel Welds

Size of Weld Allowable Static Load per inch of weld, lb

Bare Welding Rod Shielded Arc
Normal weld Parallel Weld Normal Weld Parallel Weld
1 1 1,000 lbs 800 lbs 1,250 lbs 1,000 lbs
×
8 8
3 3 1,500 lbs 1,200 lbs 1,875 lbs 1,500 lbs
×
16 16
1 1 2,000 lbs 1,600 lbs 2,500 lbs 2,000 lbs
×
4 4
5 5 2,500 lbs 2,000 lbs 3,125 lbs 2,500 lbs
×
16 16
3 3 3,000 lbs 2,400 lbs 3,750 lbs 3,000 lbs
×
8 8
1 1 4,000 lbs 3,200 lbs 5,000 lbs 4,000 lbs
×
2 2
5 5 5,000 lbs 4,000 lbs 6,250 lbs 5,000 lbs
×
8 8
3 3 6,000 lbs 4,800 lbs 7,500 lbs 6,000 lbs
×
4 4