When joining 0.032-inch and 0.064-inch aluminum sheet, what length of rivet should be used?

When selecting a rivet length for joining sheets of varying thickness, such as 0.032-inch and 0.064-inch aluminum, it is crucial to consider the combined thickness of the materials being joined. The general guideline for rivet length is to add the thicknesses of the sheets together and then add a suitable allowance for the grip of the rivet.

In this case, the combined thickness of the sheets is 0.032 inches + 0.064 inches, which equals 0.096 inches. Following industry practices, a common rule of thumb is to select a rivet length that provides a grip capacity that slightly exceeds the combined thickness. This ensures a secure and effective joint.

The 5/16 inch (0.3125 inches) rivet provides an appropriate length for this combination, allowing enough material beyond the combined thickness to properly form a head and ensure solid attachment. The other options do not align with the optimal length for achieving a strong rivet joint in this scenario.