What damage can occur from using a rivet set that does not properly fit the rivet?

Using a rivet set that does not properly fit the rivet can indeed cause damage to the rivet head, which is the correct focus here. When a rivet set is misaligned or not designed to match the size and shape of the rivet, it can lead to an improper impact being applied during the riveting process. As a result, the head of the rivet can become deformed or damaged, which may compromise its ability to secure the structure effectively.

A damaged rivet head can lead to reduced shear strength, incorrect flush fitting, and an overall failure to meet the design specifications of the assembly. It's critical to use the appropriate rivet set to ensure that the rivet shape is preserved and that it forms properly against the workpiece.

In contrast, while it is true that a badly fitted rivet set could potentially lead to the rivet not holding adequately, this is a secondary effect of the initial damage to the rivet head, not a direct consequence of the mismatch in tool fit. Similarly, the possibility of warped sheet metal may arise from other factors during the riveting process or improper handling but is not a direct consequence of using an ill-fitting rivet set. Visibility of the rivet is also not an issue related to