Blind Rivet Series

Common Blind Rivet Failures and How to Fix Them

🔧 Common Blind Rivet Failures and How to Fix Them

KSEET Special Metal Products Co., Ltd. — 18 Years of Expertise in Blind Riveting Solutions

Blind rivets are widely used in industries like automotive, enclosures, air purification, and electrical lighting due to their simple, one-sided installation. However, certain issues may arise during installation if the rivet type or method is incorrect.

Based on KSEET’s experience serving over 500 industrial clients, here are 8 common blind rivet problems and how to fix them:

1️⃣ Mandrel Not Fully Pulled

  • Issue: The mandrel does not snap off completely, leaving a protruding pin.

  • Causes:

    • Rivet gun has insufficient pulling force

    • Mandrel strength is too high or defective

  • Solutions:

    • Check air pressure and tool condition

    • Use rivets with proper mandrel design

    • Choose softer mandrel materials like aluminum when appropriate

2️⃣ Loose or Weak Joints

  • Issue: Finished joint is loose or wobbly

  • Causes:

    • Rivet is too short for the material stack

    • Hole diameter is too large

  • Solutions:

    • Use rivets with the correct grip range

    • Ensure precise hole sizing (tolerance within ±0.1 mm recommended)

3️⃣ Cracked or Deformed Surface

  • Issue: Substrate material is dented or cracked

  • Causes:

    • Material is too soft (e.g., plastic or thin aluminum)

    • Using standard open-end rivets

  • Solutions:

    • Use peel-type or tri-fold rivets for soft or brittle materials

    • Add washers to distribute the load

4️⃣ Mandrel Falls Out After Installation

  • Cause:

    • Mandrel is not securely locked into the rivet body

    • Poor-quality rivet design

  • Solution:

    • Use interlock blind rivets

    • Choose high-quality rivets from trusted manufacturers like KSEET

5️⃣ Deformed Rivet Head

  • Issue: Rivet head is tilted or crushed

  • Causes:

    • Improper installation angle

    • Material hardness mismatch

  • Solutions:

    • Keep the rivet gun perpendicular to the surface

    • Match rivet materials appropriately (e.g., aluminum-to-aluminum, steel-to-steel)

6️⃣ Rivet Doesn’t Set Properly

  • Causes:

    • Hole size is incorrect

    • Rivet gun jaws are worn or slipping

  • Solutions:

    • Match hole size to rivet diameter (hole = rivet Ø + ~0.1 mm)

    • Replace worn jaw sets in the rivet tool

7️⃣ Rivet Head Breaks

  • Cause:

    • Material fatigue or defective rivet body

  • Solutions:

    • Use rivets that meet international standards (ISO, IFI, DIN)

    • Avoid repeated riveting on the same spot

8️⃣ Cracks Around the Hole

  • Cause:

    • Pulling force is too high

    • Base material is too thin or brittle

  • Solutions:

    • Distribute the load over multiple rivet points

    • Use closed-end rivets or multi-grip types for thin sheets

🏭 KSEET — Your Expert Partner for Blind Riveting Challenges

  • ✔️ 18 years of fastener manufacturing experience

  • ✔️ Full range of blind rivets, rivet nuts, pneumatic/electric/manual tools & accessories

  • ✔️ Products meet ISO, DIN, IFI standards

  • ✔️ Specialized solutions for sealed, soft material, and irregular joint applications

📩 Contact KSEET Special Metal Products Co., Ltd. today for customized solutions, free samples, and technical support!