Riveting General Information - Ah60.00-P-0003-01S

Model 192, 206, 214, 223.0/1/9, 232, 236, 254, 294, 296, 297 

General 

DIN 8593 describes rivets as non-detachable fasteners for parts of the same or different materials. The connection is accomplished by the deformation of the fastening element (rivet). Riveting is a type of connection which has been tested and approved by Mercedes-Benz AG and which has significant advantages over shielding gas plug welding in terms of corrosion protection following repair work. Deformation of joined parts due to heating does not occur in the riveting process as connections are made cold. For this reason, the priorities for fastening techniques for aluminum repair have been redefined as follows:

• Riveting
• MIG weld joints

Rivet types, their application and positioning are described in the respective repair documents. For aluminum construction repairs, joints are both riveted and bonded. Adhesive bonding achieves higher strength as well as a sealed connection.

For load-bearing sections bonded as standard  , which are not bonded again following accident repair, the number of rivets is specified in the respective repair description. Always observe these specifications to ensure operating stability.

Riveted body flanges must always be sealed with body sealant.

Notes on preparation of rivet points 

Always drill and deburr rivet holes.

To prevent notch effects when riveting and to provide for good plastic flow of the shank in the hole, the edges of the rivet holes should be milled or countersunk.

The connections must be cleaned before riveting.

Ultra-high strength materials 

When processing ultra-high-strength materials, use only high-strength rivets approved by Mercedes-Benz AG. Only a riveter with increased draw-off strength can be used for this.

Rivet materials 

The rivet should always be of the same material as the component parts to be joined. At the very least however, they should be of the same type of material in order to avoid damage from electrochemical corrosion or loosening as a result of various thermal expansion rates.

The primary rivet materials are:

• Steel
• Aluminum alloys

Note on riveted joints (flow form, stamped and blind rivet joints) 

Only tools and repair materials that are approved by Mercedes-Benz AG may be used.

Riveted joints accessible on both sides must  be made again using the rivet press tool  .

Riveted joints accessible on one side must  be drilled out and replaced by blind rivets according to the clamping range involved.

Notes on work procedure when riveting 

To maintain the curing and processing time specified in the instructions for the 2-component adhesive, and depending on the scope involved, it may be necessary for several experienced workers to cooperate in performing the repair. while dividing up the operation steps appropriately and performing them as concurrently as possible. In some cases it is necessary to have and use several sets of the required tools. Rivet holes and rivets must be color-coded to match each other (see following graphic).

Courtesy of MERCEDES-BENZ USA

Countersunk head rivet (Z) 

• Z₁ = countersunk-head rivet 6.4x14.0
• Z₂ = countersunk-head rivet 6.4x15.5
• Z₃ = countersunk-head rivet 6.4x17.0
• Z₄ = countersunk-head rivet 6.4x19.0
• Z₅ = countersunk-head rivet 6.4x21.0

Blind rivet (Y) 

• Y₁ = rivet 6.4x12
• Y₂ = rivet 6.5x12.5
• Y₃ = rivet 6.5x14.5
• Y₄ = Rivet 6.4M6
• Y₅ = Rivet 6.4
• Y₆ = rivet 6.5x13.5
• Y₇ = rivet 6.4x14
• Y₈ = rivet 6.4x17
• Y₉ = rivet 6.4x20

Flow-form rivet with countersunk head (X) 

• X₁ = Flow-form rivet with countersunk head 1.3 mm to 2.5 mm clamping range
• X₂ = Flow-form rivet with countersunk head 2.3 mm to 3.5 mm clamping range
• X₃ = Flow-form rivet with countersunk head 3.35 mm to 4.1 mm clamping range
• X₄ = Flow-form rivet with countersunk head 4 mm to 5.15 mm clamping range
• X₅ = Flow-form rivet with countersunk head 5.0 mm to 6.1 mm clamping range
• X₆ = Flow-form rivet with countersunk head 6.0 mm to 7.2 mm clamping range
• X₇ = Flow-form rivet with countersunk head 7.1 mm to 8.3 mm clamping range

Flow-form rivet (W) 

• W₁ = Flow-form rivet structure up to 3.5 mm clamping range
• W₃ = Flow-form rivet structure 3.35 mm up to 4.1 mm clamping range
• W₄ = Flow-form rivet structure 4 mm up to 5.15 mm clamping range
• W₅ = Flow-form rivet structure 5.0 mm up to 6.1 mm clamping range
• W₆ = Flow-form rivet structure 6.0 mm up to 7.2 mm clamping range
• W₇ = Flow-form rivet structure 7.1 mm up to 8.3 mm clamping range

Blind rivet (V) 

• V₁ = rivet 3.2x4.5 (clamping range 1 mm to 1.8 mm)
• V₂ = rivet 3.2x6.5 (clamping range 1.5 mm to 3.5 mm)

Blind rivet (U) 

• U₁ = rivet 3.2x9.5

Flow-form rivet with countersunk head (T) 

• T₁ = blind rivet with countersunk head 3.0 mm to 5.0 mm clamping range
• T₂ = blind rivet with countersunk head 1.5 mm to 3.0 mm clamping range