The Hot Upset Riveting & Hot Upset Forming Story

How The Assembly Process Came To Be

Posted on 06/19/2017 | by The Orbitform Blog Team


One of the more recent assembly processes Orbitform has developed is the hot upset riveting method of joining parts, fastening materials, or riveting components together.

The hot upset forming methodology came to life when Orbitform was helping a customer rivet a door striker assembly. The striker assembly included a very hard metal striker wire to be riveted to the striker plate. The striker wire’s metal characteristics were such that a large and expensive hydraulic orbital riveting machine was going to be needed to generate the forming force required to rivet the wire to the plate. Hydraulics was a no go with the customer. We were stuck.


An Orbitform machine design engineer asked some questions.


“What if we combined heat and pressure to deform the striker wire?”

“What if we used parts of the resistance welding process to heat up the striker wire prior to forming it?”


Good questions!


Orbitform had welding transformers and welding cables in the testing lab since we had built several resistance welding and spot-welding machines in the past, so our mechanical engineering group and controls engineering team, in conjunction with our lab technicians, configured an orbital riveting machine with welding equipment. The result was a machine that heated up the striker wire via the welding current, and then orbitally riveted the striker wire after the wire was hot.


Hot upset riveting was born!

We could now form with heat and pressure.

The customer was pleased, and we learned a ton about a new way of forming metals. The hot upset way!


Since the initial hot upset riveting application was invented we have helped many product assembly process engineers improve quality, reduce machine foot print, minimize assembly machine cost, and/or increase joint strength.


Orbitform engineers and laboratory techs have identified several areas where the hot upset forming process can be advantageously applied:

Hardened Rivets:  With hot upset riveting you can form harder rivets than with cold forming processes.

High Torque Joints:  Due to the increased hole-fill associated with hot upset forming, it is possible to create joints that will not fail even under very high torque situations. The rivet expands to fill the hole and prevents rotation even under high stress.

High Push/Pull Force Joints:  Create highly durable and long lasting joints with the hot upset joining process.

Resistant to Vibrational Fatigue:  Harder rivets, increased hole-fill, and torque resistance makes the hot upset formed rivets extremely resistant to vibrational fatigue.


You can outlast the competition with Orbitform's hot upset forming stations and hot upset riveting machines.



If you think this type of assembly process could help your manufacturing operation, please contact us by clicking here.