This paper presents the findings of a numerical and experimental study of the quality of 7050-T73 aluminum rivets formed by an extremely fast electromagnetic riveting process. It is found that without careful design of the rivet forming die large strains are produced which cause crack formation in the rivet heads. By the use of finite element and experimental techniques, it is shown that control of the radial component of the flow of material in the rivet head is essential in avoiding crack formation. A rivet die design which is effective in producing high quality, crack free, rivets is proposed.

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