What should be the length of a rivet joining a .032-inch and .064-inch aluminum alloy?

The correct approach for determining the length of a rivet joining two sheets of aluminum alloy, specifically .032-inch and .064-inch thicknesses, involves a specific formula that accounts for both the thickness of the materials being joined and the rivet diameter. The formula generally states that the required length of the rivet is equal to one and one-half times the diameter of the rivet plus the combined thickness of the sheets being joined.

In this case, with one sheet at .032 inches and the other at .064 inches, the total thickness is .096 inches. When applying the formula mentioned, the one and one-half times the diameter of the rivet adds extra material length required to ensure proper bonding and strength, especially to accommodate for the rivet's grip and the way it expands upon installation.

Using this formula takes into account not just the rivet leaving enough material to grip both pieces, but also ensures that there’s sufficient length for the deformation that occurs when the rivet is installed. Following this approach leads to achieving a strong and reliable connection between the two sheets, which is crucial in aircraft construction and repair.