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SAE J1200 Blind Rivets – Break Mandrel Type: Requirements and Cancellation Notice
SAE J1200 is a surface vehicle standard that establishes dimensional, mechanical, and performance requirements for inch and metric break mandrel blind rivets. It covers two basic head styles (protruding and flush) and defines multiple material grades, finishes, and acceptance criteria for shear strength, tensile strength, mandrel break load, and mandrel retention. This standard was cancelled in January 2017 and is superseded by IFI 114, Break Mandrel Blind Rivets. Engineers and designers should be aware of the content of J1200 for legacy applications but must refer to IFI 114 for current requirements.
1. Standard Overview
Break mandrel blind rivets are pull‑mandrel fasteners where the mandrel is pulled into or against the rivet body and breaks at or near the junction of the shank and its upset end. SAE J1200 classifies rivets by style and grade. The two basic styles are protruding head (regular and large) and flush head (120° countersunk). The material combination of body and mandrel is designated by a grade number (see Table 1). Tolerances on dimensions not otherwise noted are ±0.25 mm (±0.010 in).
| Grade | Rivet Body Material | Mandrel Material |
|---|---|---|
| 10 | Aluminum Alloy 5050 | Aluminum Alloy 7178 or 2024 |
| 11 | Aluminum Alloy 5052 | Aluminum Alloy 7178 or 2024 |
| 16 | Aluminum Alloy 5154 | Carbon Steel |
| 18 | Aluminum Alloy 5052 | Carbon Steel |
| 19 | Aluminum Alloy 5056 | Carbon Steel |
| 20 | Copper Alloy No. 110 | Carbon Steel |
| 30 | Low Carbon Steel | Carbon Steel |
| 40 | Nickel‑Copper Alloy (Monel) | Carbon Steel |
| 50 | Stainless Steel (300 Series) | Carbon Steel |
| 51 | Stainless Steel (300 Series) | Stainless Steel (300 Series) |
⚠️ Important: SAE J1200 has been cancelled as of January 2017 and is superseded by IFI 114. For new designs or certification, always consult the latest version of IFI 114.
2. Mechanical and Performance Requirements
Except where specifically exempt, rivets must meet minimum ultimate shear and tensile loads for their size and grade (see the standard’s Tables 2A–3B). Grade 20 rivets are not subject to either shear or tensile testing. For all other grades, protruding head rivets with a specified maximum grip length shorter than 1.0 times the nominal diameter, and flush head rivets with a grip shorter than 1.5 times the nominal diameter, are also exempt. Rivets that are not exempt must be tested in accordance with the methods described in sections 6.1 and 6.2 of the standard.
Mandrel break load limits are specified for each size and grade (Tables 4A and 4B) to ensure consistent setting force. In addition, the mandrel must be retained within the rivet body such that a force greater than 8.9 N (2 lb) is required to reduce its protrusion to the specified minimum.
3. Design Insights and Best Practices
🛠️ Engineering Design Insight: Select rivet grade based on required shear and tensile strengths – grades 50 and 51 offer the highest strengths. If certification of shear/tensile values is needed, ensure the grip length exceeds 1.0 D for protruding head or 1.5 D for flush head rivets. For Grade 30 rivet bodies, plating (zinc or cadmium, min. 0.004 mm) is mandatory; other grades are plain unless otherwise specified. Mandrel material choice affects setting behavior and the discarded mandrel can cause galvanic corrosion if incompatible with the joint materials – consider this especially in corrosive environments.
Common mistakes include assuming the standard is current (it is not), using the wrong grade for the required strength or environment, not verifying that grip length meets the exemption minimums, and omitting the required plating for Grade 30. Mandrel retention force is axial only; do not apply torque or other loading to the mandrel after setting.
Frequently Asked Questions
Q: What rivet grades are defined in SAE J1200?
A: Ten grades are defined, designated 10, 11, 16, 18, 19, 20, 30, 40, 50, and 51. Each grade specifies a unique combination of rivet body and mandrel material (see Table 1).
Q: When are rivets exempt from shear and tensile testing?
A: Grade 20 rivets are always exempt. For other grades, protruding head rivets with a maximum grip less than 1.0 × nominal diameter and flush head rivets with a maximum grip less than 1.5 × nominal diameter are also exempt.
Q: Why was SAE J1200 cancelled?
A: To advance harmonization, SAE cancelled J1200 in 2017 and it is now superseded by IFI 114, Break Mandrel Blind Rivets (published by the Industrial Fasteners Institute).
Q: What is the minimum mandrel retention force?
A: The mandrel must be retained so that a force greater than 8.9 N (2 lb) is required to reduce its protrusion to the specified minimum.
For complete details, consult the original SAE J1200 document (available from SAE) and refer to IFI 114 for current procurement and design specifications.
