Riveting vs. Welding: Choosing the Right Metal Joining Method
When it comes to joining metal components, riveting and welding are two of the most commonly used techniques in fabrication. Both methods create strong, permanent bonds, but they differ significantly in process, aesthetics, cost, and ideal applications.
Whether you're assembling a structural frame, building an enclosure, or integrating components into an electro-mechanical assembly, the decision between riveted vs. welded joints can impact everything from durability and weight to production speed and long-term maintenance.
With over 30 years of experience, we know a thing or two about choosing the right metal joining method. Keep reading to better understand when to use one method over the other.
What is Riveting?
Riveting is a mechanical fastening method that joins two or more pieces of metal using a metal pin called a rivet. The installation process involves placing the rivet through aligned holes in the materials and deforming the tail end to create a second head, securing the materials together.
Common rivet types include:
Solid rivets
Blind rivets
Semi-tubular rivets
Pop rivets
Drive rivets
Riveting is one way of mechanically fastening materials without the need for heat or fusing.
What Is Welding?
Welding is a fabrication process that joins materials by causing fusion. It uses high heat to melt the base materials, often with a filler material added to form a strong joint upon cooling. The resulting connection becomes a single, unified piece with properties similar to the base material.
Common welding methods include:
MIG (Metal Inert Gas) welding
TIG (Tungsten Inert Gas) welding
Spot welding
Laser welding
Welding creates a permanent bond between metal parts and is ideal for applications that demand structural integrity, load-bearing capacity, and a smooth finish.
Riveting vs. Welding: A Side-by-Side Comparison
When to Use Riveting
Riveting is a great solution for lightweight assemblies, especially where material deformation due to heat could compromise function or aesthetics. It’s also ideal for joining dissimilar metals, which can be tricky to weld due to differences in melting points and metallurgical properties.
Use riveting when:
You're working with thin or heat-sensitive materials
Aesthetics are not the top priority
You want easier disassembly for repair or inspection
You need a cost-effective solution with simple tooling
Design incorporates pre-finished materials
Riveting is often used in electro-mechanical assemblies where repeatability, speed, and minimal thermal distortion are critical.
When to Use Welding
Welding is preferred for high-strength, permanent joints where performance, durability, and appearance are critical. It's particularly useful when you need structural integrity or fluid-tight seals, as in the case of enclosures, tanks, or frames.
Use welding when:
You need maximum joint strength
Appearance matters, and smooth, seamless joints are required
You're joining structural or load-bearing parts
You're fabricating complex shapes or high-volume parts that benefit from welding automation
Can You Use Both?
Yes, and many projects do. It's not uncommon to combine welding and riveting in the same assembly, particularly when balancing cost, strength, and accessibility. For example, welded frames may include riveted access panels, or thin enclosures may be riveted to avoid heat distortion, while internal supports are welded for strength.
A skilled fabrication partner can help you decide how to optimize your design using both joining techniques.
Choosing the Right Method: What to Consider
When determining whether welding or riveting is appropriate for your specific application, consider these factors:
Load Requirements: What loads will the joint need to withstand? Does the joint need to bear weight or resist vibration?
Material Types & Thickness: Are the metals compatible for welding? Are they thin enough to warp under heat?
Environmental Conditions: Will the joint be exposed to extreme temperatures or corrosive environments?
Finish Quality: Is the appearance of the joint important to the final product?
Production Volume: What quantity of items will be produced? Will automated welding or riveting save time?
Disassembly Needs: Will the part be serviced or repaired in the future?
Cost & Labor: What are your equipment, material, and labor constraints?
Welding or Riveting? We’ll Help You Decide.
Both welding and riveting have distinct advantages and appropriate applications in modern metal fabrication. Understanding the strengths and limitations of each method allows designers and engineers to make informed decisions that optimize product performance, cost, and manufacturability.
For complex projects that may benefit from a combination of joining methods or expert guidance on the best approach, Herold Precision Metals provides comprehensive design for manufacturability (DFM) consultation services. Our team can help you navigate these decisions to ensure your product meets all functional and aesthetic requirements.
Request a quote today to discuss your project requirements and discover how our welding and riveting expertise can help bring your precision metal fabrication needs to life.
