What is the risk of drilling completely through a solid rivet during removal?

Drilling completely through a solid rivet during removal primarily poses the risk of enlarging the hole. When a rivet is drilled out, the idea is to remove just enough material to allow the rivet to be extracted without damaging the surrounding structure. If the drilling is taken all the way through the rivet, there is a high likelihood that the drill bit will also drill into the structure itself, increasing the diameter of the hole and potentially compromising the integrity of the workpiece.

This enlarged hole can present significant issues, especially in aerospace applications where precision and material integrity are critical. An oversized hole may lead to difficulties in re-riveting or installing new fasteners, and it can affect the load distribution and mechanical properties of the assembly. Maintaining the correct size of the hole is vital for ensuring that the new rivet or fastener fits properly and does not weaken the join.

Additional risks, such as creating structural weaknesses and debris, may occur as consequences of improper drilling, but they are not the primary concern when it comes to the immediate act of drilling through the rivet itself.