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Stud-Lock Inserts

Simplify Casting Repairs by Eliminating Oversized Studs


Application: Gear box and pump castings Challenge A military parts rebuilder and refurbisher required a more reliable solution to repair and refurbish large pump and gearbox castings that utilize interference fit studs for assembly. Traditionally maintenance includes dis-assembly and cleaning of each casting followed by inspection for cracks and wear. All tapped holes are inspected and new interference fit studs installed. Each and every stud is inspected and must exhibit a specified torque range on installation. If the running torque is too low, a larger stud must be used in place of the original stud, creating additional stress in the parent material creating an inventory need for non-standard studs. Customer Requirements Consistent running torque from stud to stud No surface damage or imperfections Improved reliability and speed of maintenance and repair process are a high torque version of the Heli-Coil Screw-Lock insert and allow the use of standard studs in place of the typical oversize interference fit stud. This eliminates the need for multiple inventories of oversize studs to fit varied degrees of oversize holes. At the same time running torque from stud to stud is maintained to a closer range.

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Eliminate need for oversize studs and additional inventory Solutions Emhart proposed the use of Stud-Lock wire inserts to repair any and all damaged holes uncovered during the inspection process. Stud-Lock inserts

Features & Benefits Allows standardization to one size


stud, eliminates inventory of larger size studs Eliminates stress in parent material Maintains consistent locking torque Prevents possible surface damage due to stress concentrations from interference fits Available for both straight and step studs, #10 through 1/2" UNC and UNF
Meets AS3080, 3081, 3082, 3083

Cast aluminum application using Heli-Coil Stud-Lock inserts adds strength to original casting.

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HeliCoil Stud-Lock Inserts


As shown in the Torque Comparison chart, Stud-Lock inserts offer more consistent torque when compared to interference fit studs. Heli-Coil Stud-Lock inserts offer several distinct advantages over both solid-bushing-type studs and interference-type studs. With Stud-Lock inserts, a lower-cost threaded rod can be used, resulting in a lower per piece cost. For purposes of identification, inserts for straight studs are dyed green and inserts for step studs are dyed lavender.
Stud Driving Torque Comparison
450 400 350 300 Driving Torque (in-lbs.) 250 200 150
150 in-lbs 240 in-lbs 425 in-lbs

Stud-Lock Insert Interference Fit Stud

100 50 0 1 2

125 in-lbs

3 4 5 6 Sample Number

NOMINAL THREAD SIZE


10 (.190)-24 10 (.190)-32 1/4 (.250)-20 1/4 (.250)-28 5/16 (.3125)-18 5/16 (.3125)-24 3/8 (.375)-16 3/8(.375)-24 7/16 (.4375)-14 7/16 (.4375)-20 1/2 (.500)-13 1/2 (.500)-20

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MAXIMUM MINUMUM LOCKING BREAKAWAY INSERT PART NUMBER TORQUE TORQUE MAXIMUM LOCKING TORQUE MINUMUM BREAKAWAY TORQUE NUT END THREAD SIZE HAND

STRAIGHT STUDS PER AS 1229-1 INSERT PART NUMBER


0285 0380 0475 0570

STEP STUDS PER AS 1229-2

INSTALLATION TOOLING POWER (F.E.Assy.)

3758-3CN 3759-3CN 3758-4CN 3759-4CN 3758-5CN 3759-5CN 3758-6CN 3759-6CN 3758-7CN 3759-7CN 3758-8CN 3759-8CN

5551-3 5552-3

5651-3 5652-3 5651-4 5651-4 5651-5 5651-5 5651-6 5651-6 5651-7 5651-7 5651-8 5651-8

45 lbf-in

23 lbf-in

{ {

0375 0500 0625 0750

5758-4CN

90

52

5759-4CN

{ {

0375 0500 0625 0750 0469 0625 0781 0938 0562 0750 0938 1125 0656 0875 1094 1312 0750 1000 1250 1500

45 lbf-in

23 lbf-in

[ [

10-24

5551-4

10-32

5552-4

{ { {

0469 0625 0781 0938 0562 0750 0938 1125

5758-5CN

180

105

5759-5CN

{ { {

90

52

[ [ [

1/4-20 1/4-28

5551-5 5552-5

5758-6CN

5/16-18

5551-6

240

140

180

105

5759-6CN

5/16-24 3/8-16 3/8-24

5552-6

0656 0875 1094 1312

5758-7CN 5759-7CN

5551-7 5552-7

300

175

240

140

0750 1000 1250 1500

5758-8CN

7/16-14

5551-8

450

260

300

175

5759-8CN

7/16-20

5552-8

Americas Emhart Teknologies P.O. Box 859 50 Shelton Technology Center Shelton, CT 06484 USA To order, call customer service at Tel: (877) EMHART-1 Tel: (877) 364-2781 Fax: (800) 225-5614 Canada: (514) 351-0330 Brazil: + 55 11 3871-6460 Mxico: + 52-55-5326-7100
2011 Emhart Teknologies

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HC1030 Rev.3 (07/11)

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