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Orbitform’s Hot New Riveting Process

Orbitform recently developed a unique riveting process, Hot Upset.  This rivet/forming solution uses force and heat to form rivets or part tenons, providing greater strength, increased hole-fill, improved resistance to push-pull forces, and an overall tighter joint, due to material contraction during cooling.

Our customer, an automotive part manufacturer, needed to assemble a product with hardened rivets, each with a long tenon stick-out.  To meet their production requirements, we needed to form two rivets per machine cycle.  We examined both orbital and spiral forming options in our applications lab, but due to the extreme hardness of the rivets, final form characteristics did not meet our customer’s specification.  Also some samples showed signs of cracking, which in this application was unacceptable.  We then tested our Hot Upset forming solution, which resolved the forming challenges.  We offer both AC and DC Hot Upset systems.  In this case, the customer chose a DC system for its power consumption savings versus the lower initial cost of an AC system.

Orbitform designed and built a custom Hot Upset system.  The design included two standard Orbitform modular Powerheads, the same Powerheads used in their Orbital, Spiral, and Roller Forming products.  Using standard Powerheads instead of traditional weld cylinders eliminated the need for an external air/oil tank and intensification valve.  To stabilize the customer’s part during the forming process, the system was outfitted with a part clamping pressure pad.  To verify a quality form, process monitoring included: LVDT’s and load cells to monitor head stroke position and force, and sensors for Powerhead advance and retract.  The customer’s safety specification included: light curtain, guarding and palm button activation.

About Us:

Orbitform designs and builds assembly equipment solutions for manufacturing, including Riveting, Forming, Welding, Conveyors, and Custom-Engineered Assembly Systems.  Orbitform also manufactures its own line of standard assembly products, all made in the USA since 1984.  Services include Assembly Analysis, Tooling Development, and low-volume production runs. 

To learn more about Orbitform’s permanent assembly processes, visit


Orbitform Group

1600 Executive Dr.

Jackson, MI 49203


Assembly Equipment Solutions for Manufacturing since 1984