Design World - Fastener Engineering Handbook 2022

December 2022
www.fastenerengineering.com
2022
Fastener
Handbook
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editorial
The value of good advice

There’s an old proverb that says, “Good advice is beyond all price.” This might
be true, but people generally tend to ignore advice, at least the unsolicited kind. For
business owners and entrepreneurs, the reason is simple: they’re too busy working.
Overwhelm and multi-tasking means there’s little time for heeding new information
outside of day-to-day operations.
However, growth is highly dependent on taking innovative steps and integrating
new insights — which often come from good advice. A 2021 survey from McKinsey
Global Survey found that the more transformation actions a company takes, the greater
its chances for success.
It states: “Transformation success relies on a comprehensive approach and is more
likely to be achieved when companies take a greater number of actions.” In other words,
the more open a company is to learning and incorporating new skills, technologies, and
ways of doing business, the more likely it is to last.
Flexibility and innovation are also critical to survival in challenging times, which
every business likely experienced over the last few years and may again, given the
ongoing supply-chain delays and a potential recession ahead.
Jennifer Sturm, COO of Empire Bolt, writes wisely on page 44, “Successfully
working in the fastener industry entails ongoing learning — even for experts in the field.”
In business (and life), to stop learning is to halt growth.
It seems seeking out good advice and putting it into practice is often worth the
price. In support of this initiative, here are just a few of the nuggets of wisdom found
inside the pages of this publication:
“Advanced companies want to work with other well-run organizations,” says Lonni
Kieffer of SmartCert (page 54). Obvious advice, perhaps, but how many outdated
processes does your company still run on? The digital era is here, and digitalization
ensures a traceable supply chain, saving time and long-term costs that are better spent
on further improving your business.
“The price point also matters,” says Brad Klippstein with Bosch Rexroth. “End users
require cost-effective measures that meet budgets and readily support manufacturing
| AdobeStock
orders.” (Learn more on page 34).

“The fastener industry is interfaced with many different sectors, where the right
product delivered on time is critical,” shares Rob LaPointe of AIM Testing Laboratory (see
page 56). “It’s worth the effort and expense to ensure that your industry contribution is
received without issue.”
So, how does one ensure an efficient and effective contribution to the fastener
industry? Sometimes it takes heeding advice from those companies already earning
success and respect. As Christie Jones with SPIROL International writes (page 42):
“It’s recommended that manufacturers partner with industry experts in joining and
assembling to identify the lowest and best cost solution for their assembly.”
DESIGN WORLD www.fastenerengineering.com December 2022 1
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Engineering
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Staff page 12-22_FE_Vs2_MF.indd 2 12/1/22 11:07 AM

Contents 12 • 2022 • fastenerengineering.com
4 _ADHESIVES: Intro 40 _NUTS

Understanding adhesives: What What are nut retainers?
different types are available?
42 _PINS
6 _ADHESIVES: Formulations What’s the difference between cold-headed
What projects require custom adhesive and machined solid pins?
formulations and why?
44 _QUALITY CONTROL: PLATING

10 _ADHESIVES: Biocompatibility
| AdobeStock
What is plating and what causes electroplated

Is your adhesive biocompatible? coatings to fail?
12 _ADHESIVES: Curing 46 _RIVETS

What benefits do UV curable adhesives How to best choose and install rivet nuts?
offer?
50 _SCREWS
16 _ADHESIVES: Threadlocker What are the more common screw-head types?
What are the common mistakes
and pitfalls when choosing a
52 _SEALS
threadlocker?
How to choose an O-ring for your application?
20 _ASSEMBLY: Fasteners
54 _SUPPLY CHAIN
How to keep fasteners from loosening?
Supply chain issues: How much is lost
paperwork costing your company?
| AdobeStock
22 _BOLTING
What is the load transfer factor?
56 _TESTING
Why should you test the fasteners you sell?
26 _HARDWARE
How advances in latches and hinges are
58 _TOOLS
enhancing user experiences
Why are battery-powered tools the preferred
choice?
30 _INSTALLATION
What are the different tightening
60 _TRAINING
methods for a screw?
What are thet answers to some of the most
common fastener failures?
32 _MANUFACTURING: Cold Forming
What is cold-form manufacturing?
| AdobeStock
62 _WASHERS
What are the advantages of using hardened
34 _MANUFACTURING: and unhardened flat washers?
Smart Manufacturing
What is “smart mechatronics” and how
64 _WELDING: Materials
can it support fastener manufacturing?
66 _PROFILES What is micro-welding and why is laser
an ideal fit?
72 _AD INDEX 36 _MATERIALS
How is lightweighting affecting fastener
materials and designs?
CONTENTS_FE_12-22_Vs2.indd 3 12/1/22 7:33 AM

ADHESIVES
Understanding adhesives: What

different types are available?
Adhesives are materials capable of fastening or binding two can reduce the time and cost of assembly, improving
surfaces. Also called glues, sealants, and cement, adhesives work by stress distribution. They can lengthen the working time,
surface attachment but without altering these surfaces. allowing for adjustments during assembly. They can
An adhesive’s ability to hold fast and bond to a surface is critical. also add performance by reducing assembly noise, for
However, those features are not the sole determinant of performance. example.
An ability to bond to dissimilar materials, form crystalline or Some adhesives are rigid and tough when cured, while
reliant structures, and bond quickly or slowly are also important others are soft and flexible. Some form permanent bonds,
considerations. while others offer impermanent bonds that be undone
The good news is there are many adhesives available tailored to without damage to the substrates. Typically, adhesives are
several applications. The bad news is there’s no one adhesive ideal more difficult to disassemble than mechanical fasteners.
for all applications. Knowledge of the attributes and shortcomings The reliability and durability of adhesives continue
of adhesives is required to choose wisely. The final application must to improve, but failures still happen. There is no single,
also be considered, including the environment or conditions it will be universal adhesive. The ideal adhesive choice requires
subject to. knowledge of the surfaces to be joined. Surface
Compared to other joining methods — such as mechanical preparation is essential and primers or other surface
fastening or welding — adhesives can offer several advantages. They treatments often maximize bond strengths.
Adhesives Intro 12-22_FE_Vs2_MF.indd 4 11/28/22 11:47 AM

Adhesives can be classified in several ways, such as
reactive or non-reactive. Reactive adhesives require
a chemical reaction to form a bond. Non-reactive
adhesives require no chemicals but might undergo a
physical change during bonding. Examples include hot-
melt, pressure-sensitive, and solvent-based adhesives.
Reactive adhesives raise the bar on performance
substantially but are nothing new. In fact, some ancient
adhesives take advantage of chemical reactions
during curing.
Modern reactive adhesives are thermoset polymers,
where a chemical reaction is responsible for curing the
adhesive. Typically, two components are mixed to start
the curing. Some adhesives also rely on reactants, such
as water. It’s wise to learn thoroughly about adhesives
before selecting a formulation for any application.
AdobeStock
|
Adhesives Intro 12-22_FE_Vs2_MF.indd 5 11/28/22 11:48 AM

FORMULATIONS
What projects require

custom adhesive
formulations and why?
Article courtesy of Gluespec
Some products, regardless of how big or small, require

custom-formulated adhesives. Although formulations vary
depending on technicality, the objective is a reliable and cost-
effective end product that complies with a company’s quality,
design, and manufacturing goals.
Scenarios calling for custom adhesives

Purchasing an off-the-shelf adhesive as a component for an
assembly or mechanical project is a common step in the design
process — but sometimes it’s simply not possible.
There are a few reasons why an adhesive with the ideal
combination of qualities might not exist for a specific assembly.
In such cases, a custom formulation is necessary. This is
particularly true in heavy industries where stringent manufacturing
requirements and performance are essential.
The following are a few examples where customization is worth
considering to ensure reliable manufacturing. It’s possible the custom replacement won’t only
match the performance possible with the old formula
No adhesive matches the project’s needs. If your design but also improve upon it.
specifications call for a specific level of bonding and no off-the-
shelf adhesive can meet the requirements, your whole production Existing adhesives fail to comply with regulations.
schedule might be in jeopardy. This is common when dealing with As governmental agencies tighten the restrictions
precision engineering in aerospace, transit, or defense projects. If around which chemicals are deemed safe, it’s not
no adhesive provides reliable results, it’s time to consider custom uncommon for older substances to be banned. An
formulation. integral ingredient in your company’s products might
be listed for non-compliance. As with discontinued
An off-the-shelf formula is discontinued. What happens when formulations, it’s important to find a lab that can
you’ve found an adhesive that works, but it’s removed from create a custom formulation to replace the lost
production? In such cases, keeping the assembly line moving chemical.
can be challenging, and it’s time to reach out to a lab that can The new formulation must deliver the same
formulate a new high-quality epoxy, urethane, silicone, or another performance or better while also complying with the
adhesive type. law in question.
6
December 2022 www.fastenerengineering.com DESIGN WORLD

FORMULATIONS 12-22_FE_Vs2_MF.indd 6 11/28/22 11:51 AM

When deciding on an adhesive
for an application, manufacturers
consider the tensile and shear
strength, dimensional stability,
temperature resistance, and
AdobeStock
compatibility of materials. |
Types of adhesives (according to Adhesives.org)

Between off-the-shelf options and new formulations, Structural adhesives are strong, known as load bearing,
acquiring an adhesive that fits just about any description and are useful for engineering applications. Consisting
or requirement is possible. To better understand why of epoxies, cyanoacrylates, and some acrylic adhesives,
certain products require custom adhesive formulations, it’s these products can undergo shock, vibration, and other
necessary to delve into the types of adhesives and what destructive agents and remain bonded.
they’re used for. Pressure-sensitive adhesives are typically purchased
An adhesive is a non-metallic binder that acts via as tapes or labels and do not solidify to form a solid
adhesion and cohesion. The classification of adhesives material. Bonds are formed by bringing the adhesive
depends on their: film in contact with the substrate and applying
pressure. Pressure-sensitive adhesives are typically
• Form (paste, liquid, etc.) used to temporarily hold objects in place during
• Chemistry (polyimides, epoxies, etc.) assembly.
• Type (hot melt, contact, etc.) Thermosetting structural adhesives are typically
• Load-carrying capability (structural or non-structural) available in two-part forms and are mixed carefully
within a limited time window. They usually have a “pot
FORMULATIONS 12-22_FE_Vs2_MF.indd 7 11/29/22 11:05 AM

FORMULATIONS
life,” which is the amount of
time the adhesive is workable
once mixed and able to make a
satisfactory bond.
Reactive versus non-reactive

Reactive adhesives can be
characterized by the formation
of permanent bonds between
substrates that create
resistance against chemicals,
moisture, and heat (think
structural adhesives). Typically,
AdobeStock
a reactive adhesive is made
of a monomer (resin) and an
|
initiator. Due to the chemical
bond, reactive adhesives have
long-term durability and high
bond strength.
When choosing an adhesive, it’s essential to consider Natural versus synthetics
what the product will need to endure. For example, Another categorization of the many forms
reactive adhesives cure to form a material, as opposed of adhesives is if they’re natural or synthetic.
to solvent or hot-melt adhesives. This means reactive Historically, adhesives were made of naturally
adhesives are more durable against the effects of extreme occurring components, but now it’s common
temperature and general environmental resistance. to find a combination of natural and synthetic
Epoxies are one of the most used structural adhesives compounds.
due to their range of forms, high-tensile strength, Natural adhesives are made from natural
dimensional stability, and ability to adhere to several materials, like animal and plant matter, and
materials. They can be room-temperature or heat-cured occasionally, minerals. Animal-based adhesives
(depending on the additives). Advances in additives are made from albumin, beeswax, casein, and
and formulation have made epoxies more resistant to gelatin. Plant-based adhesives are made from
chemicals. components like dextrin, natural resins (gum
arabic, balsam), oils, waxes, soybean protein,
A reactive two-part adhesive works as follows: and starch. Mineral-based adhesives come from
base resin + hardener/curing agent → plastic or rubber components of amber, paraffin, silicates, and
sulfur.
It transforms into a thermoset polymer via a cross-linking While these types of adhesives are generally
process. For a reactive one-part adhesive, UV light, heat, or affordable to manufacture and are still used
moisture is required (it’s a pre-mixed, two-part adhesive, for wood, paper, film, and foil materials, most
but the reaction requires light, heat, or moisture to begin). adhesives employed today belong to the newer
Other reactive adhesives include acrylic, silicone, urethane, synthetics category. Synthetic adhesives are
and cyanoacrylate (super glue). developed from human-made polymers.
Non-reactive adhesives do not have a permanent Although more costly than natural adhesives,
chemical bond, but bond through a physical change. synthetic alternatives are customizable and
Examples include polyvinyl acetate, construction adhesive, feature greater bond strengths.
hot glue, and contact adhesive.
To learn more, visit https://tinyurl.com/GlueSpec
An emulsion adhesive works as follows:
adhesive + evaporative solvent → solvent evaporates
As the solvent evaporates, it leaves the adhesive behind.
8

FORMULATIONS 12-22_FE_Vs2_MF.indd 8 12/2/22 1:38 PM

Ming Tai 12-22 (p.u. from 12-20).indd 9 11/28/22 12:06 PM
biocompatibility
Is your adhesive
biocompatible?
Michelle Evanoski, Group Product Manager
Global Business Development, Dymax
Biocompatibility is a general term

to describe that a material’s property is
compatible with living tissue or living system.
Non-toxic, injurious, or physiologically reactive
materials to the body or bodily fluids are
considered biocompatible and are often sought by medical device
engineers. USP Class VI biocompatibility testing
In simple words, biocompatibility tests are not used to prove Historically, standards were set by the US Pharma
chemical compatibility but to confirm a lack of immune reaction to Convention (USP), a non-profit organization focused
the material or device. on medications, healthcare technologies, food
Choosing the ideal material during the design process gives ingredients, and materials used in medical devices.
manufacturers more confidence in an FDA (Food and Drug These standards categorize materials into six
Administration), MDR (medical device regulation), or other device classes depending on the product’s specific use and
approval. duration of patient contact time (limited, prolonged, or
Biological reactivity testing is one such process used for permanent). Class VI is the most rigorous. It includes
determining suitability and safety. Two main tests indicate if the three reactivity assessments typically performed in
material is biocompatible or not. vivo on mice or rabbits to ensure accuracy.
1. Acute systemic toxicity (systematic injection) test:

Measures toxicity and irritation when a compound
sample is administered orally, applied to the skin, and
Medical device adhesives must inhaled.
meet various biocompatibility
approvals before being
2. Intracutaneous test: Measures toxicity and
released into the market.
localized irritation when the sample is in contact with
live subdermal tissue (specifically, the tissue that the
medical device intends to contact).
3. Implantation test: Measures toxicity, infection,

and irritation of the intramuscular implantation of the
compound into a test animal over several days.
10

BIOCOMPATIBILITY 12-22_FE_Vs2_MF.indd 10 11/29/22 11:02 AM

A lab tech applies adhesive
to a tube set assembly
to prepare it for physical
property testing.
Although Class VI is typically used to evaluate plastic materials that may be

in contact with injectable medications or other fluids, adhesives and sealants
that qualify for this designation are generally highly safe for medical devices.
However, materials passing the USP class VI tests are not guaranteed
to be biocompatible for every application. It’s simply a strong validation
that the materials meet low toxicity requirements usually associated with
pharmaceutical tubing, fittings, systems, and parts.
ISO 10993 biocompatibility testing

To standardize the biological evaluation of medical devices globally, the
International Standards Organization (ISO) developed ISO 10993 — a set
of standards outlining material categories, tests, and test methods used to
determine the biocompatibility of materials.
The ISO strategy categorizes medical devices by type of body contact
(surface device, external communication device, and implant device) and by
contact duration (limited, prolonged, and permanent). The ISO provides a set
of suggested evaluation tests for each medical device category.
Typical tests include:

• ISO 10993-4 Hemolysis
• ISO 10993-5 Cytotoxicity
• ISO 10993-6 Implantation 14 Days
• ISO 10993-10 Intracutaneous: Sensitization and Irritation*
• ISO 10993-11 Systemic Toxicity
* Note: as of 2021, ISO 10993-10 now contains a

description of skin sensitization testing only (Part
10: Tests for Skin Sensitization), and the testing
for Irritation is now described in Part 23: Tests for
Irritation
In general, adhesives and sealants are not required

to pass all ISO tests. However, to be considered
of medical grade, it’s expected they pass the
cytotoxicity.
As a fast, standardized, sensitive, and
inexpensive test, the cytotoxicity test concludes if
an adhesive has any adverse effect on mammalian
cells. It involves culturing cells in vitro and
systematically exposing them to the material in
question to see if any reactions or signs of toxicity
show up over a few days.
Since the ISO system applies the USP test
methods as part of a larger, more rigorous strategy,
meeting ISO standards represents a higher level
Application engineers discuss
of biocompatibility than meeting USP Class VI
using a maskant with ISO
10993-5 cytotoxicity approval standards.
on an orthopedic implant.
BIOCOMPATIBILITY 12-22_FE_Vs2_MF.indd 11 11/29/22 11:03 AM

curing
What benefits do UV curable

adhesives offer?
Drew Richards, Marketing & Customer Experience Manager, Hernon
UV curable adhesives offer 100% solid material, near-instant curing times,

and immediate use or packaging directly from the assembly line. While significant,
these features can only be fully appreciated compared to alternative curing
methods.
For example, compare the 100% solid material with low-viscosity solvent-based
coatings. Only 5% might remain after the solvent has completely evaporated. Up to
95% of the chemical solvent is off-gassed into the air.
As a result, the Environmental Protection Agency has prioritized reducing
solvent-based materials. U.S. manufacturing has also shifted away from these
adhesives to decrease the volatile organic compounds created when the solvent
evaporates.
With up to 95% material loss, 100% solid materials such as UV-curable products
typically offer more savings than solvent-based products. Consider a company
purchasing 1,000 gallons of low-viscosity solvent-based materials. With a material
that’s 5% solid, they’ll receive 50 gallons of solid material.
• 1,000 gallons * 0.05 solid material = 50 gallons yield of residual material to
coat or adhere
If the solvent-based adhesive costs $80 per gallon, the invoice will be $80,000.00.
When evaluated after evaporation, the cost is higher.
• $80,000 / 50 gallons = $1,600 per solid gallon
If the 100% solid material costs 10 times as much ($800 per gallon), the material
gets the same 50 gallons of coverage.
• $800 * 50 gallons = $40,000
• $80,000 cost for solvent materials – $40,000 cost for solid materials =
$40,000 in savings
• The user saves 50% or $40,000
12

CURING 12-22_FE_Vs2_MF.indd 12 11/28/22 11:59 AM

A technician places a part-ejection
piston to remove ammunition
cartridges that fail to meet a specified
customer standard. When paired
with machine-vision inspection,
this quality-control measure allows
customers to fine-tune machine
settings so no unsealed parts proceed
to the next production stage.
The savings continue. The user any associated EPA penalties) are consistent coverage. Getting too close
who switches saves logistically by removed. or intense with the UV light leads to
transporting 50 instead of 1,000 gallons. bubbling or burning in the adhesive
The cost of filters for solvent-based The UV advantage material, requiring a goldilocks
material in the dispensing system and Photo-initiators in the adhesive formula approach to each application. If more
the labor are removed. must be triggered by a UV light of the distance is needed, the UVs can be
Most applications also require correct wavelength to activate UV-cure modified with a lens to focus the light
time to let the solvent evaporate. This products. For consistent results, the into a concentrated beam. This extends
necessitates a batch process and often intensity of the light must be uniform the practical curing distance and
includes a large amount of floor space and penetrate the adhesive materials improves efficiency.
for the drying racks. Sometimes heat to ensure sub-surface curing. There’s For ammunition sealants, the sealant
is used to reduce the drying time, so a science to distributing UV lights to is exposed in a small area around the
switching also saves oven and energy ensure optimal conditions. cartridge case mouth and primer, so
costs and maintenance. The emission LED lights create spherical radiance focusing the light with a lens is useful.
removal process and equipment (and zones, which must overlap and ensure Six to seven seconds of UV exposure is
CURING 12-22_FE_Vs2_MF.indd 13 11/29/22 11:01 AM

curing
required that’s set up in an array along the conveyor route, A UV LED curing light is
about 1.5 inches from the exposed sealant. The array’s used to test the curing
length depends on the speed of the conveyor — the faster time for a material sealing
it is, the longer the array should be to ensure the correct the bottom of a reservoir
exposure time. flange seal.
Photo-initiators can also be used in multi-cure
formulas to address specific manufacturing challenges.
For example, in some electric motor manufacturing
operations, an adhesive can bond magnets to the motor
housing. The specifications call for enough material to
create some squeeze-out.
Using a multi-cure formula, the adhesive under the
magnet can be activated and cured using a pre-applied
chemical activator or anaerobic curing process. The
squeeze-out material can be rendered inert by hitting
it with UV light. The near-instant speed of the UV cure to the curing station. The force of the movement caused
process makes it ideal for this process, solving the problem deformation and migration of the bead. The dispensing
with minimal time delay. station had to be cleared to make room for the next part,
so completely curing the bead in the same station did not
UV tacking work.
The high speed of UV curing allows for UV tacking, which By UV tacking, the cure material (UV FOG, in this
is when the material is briefly exposed to UV light to alter case) was fixed in place with only a second or two of UV
the physical properties without full curing. UV tacking exposure. The tacking raised the bead viscosity so it would
is employed for sealant dispensed as a bead around the not deform or migrate when transferred to the next station.
outer diameter of a circular oil shaft seal. Tacking represents the unique ability of UV materials to
For instance, one manufacturer had problems when cure to a set amount. The degree to which the material is
a robotic arm moved parts from the dispensing station cured can be directly controlled and manipulated through
the control of UV light exposure. This allows materials to
be cured to tacky or partially solid states. Until the material
is exposed to UV light, there’s an indefinite working
life, allowing an operator to make fine adjustments.
Although the UV curing process typically costs
more to implement with a conveyor and UV light
arrays, this is partially offset by a simpler dispensing
system. Most UV cure materials are one-part materials,
with the role of the second part (the activator) played
by UV light. This means the dispensing system follows
a single track with one reservoir, meter, and valve.
There’s no need for ratio controls or static mixers and
little chance of the material curing in the system.
These benefits make UV curing an excellent
choice for countless industries. The transition from
solvent-based adhesives to UV and other curing
methods makes this industry likely to grow as
manufacturing technologies upscale.
UV FOG sealant from Hernon is cured in place as a bead on

an oil shaft seal. The process takes only a few seconds, and
the part is immediately ready for handling, packing, and use.
14

CURING 12-22_FE_Vs2_MF.indd 14 11/28/22 12:00 PM

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P.O. Box 488
mail@pivotpins.com
Hustisford, WI 53034
pivotpins.com
Pivot Point 12-22.indd 15 11/29/22 11:11 AM

threadlocker
What are the common mistakes

and pitfalls when choosing a
threadlocker?
Article courtesy of Henkel LOCTITE
To bond any two surfaces, the right tool for the task is vital. This is
particularly true when working with threaded assemblies. These types of fasteners
can experience challenging service conditions. Subject to vibrations, environmental
extremes, torsion, bending, and shocks, they can be susceptible to loosening and
leaks.
Choosing the ideal adhesive for an application ensures assemblies stay locked in
place. But there’s more to finding success in locking threaded assemblies than
choosing the right threadlocker. Proper application and use are also important to
ensure performance.
Threadlocking pitfalls
The improper use of a threadlocker can impact its strength and performance.
Before applying any type of threadlocker, take the time to understand:
• The properties of the threadlocker

• Where to apply the threadlocker
• The best practice(s) for the application
Failure to understand the why, what, and how can lead to some of the most
common threadlocking mistakes.
Making the wrong choice

Threadlockers are typically graded by strength, operating temperature range, and
maximum thread size. The most common mistake is to assume the most powerful
threadlocker will always do the job, securing bonds as tightly as possible.
In reality, red threadlockers (labeled for high strength) are commonly deployed
in the strongest, most permanent applications. These include heavy equipment,
suspension, and bearing cap bolts.
16

THREADLOCKER 12-22_FE_Vs2_MF.indd 16 11/28/22 12:03 PM

It’s important to ensure the correct
threadlocker for each application. For
example, LOCTITE Red Threadlocker
offers the highest strength of
adhesive. Only use red threadlocker
for heavy equipment or industrial
applications that require an extremely
strong hold.
Deploying red threadlockers as The truth is that more adhesive does

general-purpose adhesives can cause not automatically equate to greater
issues, especially if a part needs future strength.
disassembly. Red threadlockers often Threadlockers are designed to fill
require heat for removal, which can small gaps in threads, so a little adhesive
damage some assemblies. goes a long way. Overuse may cause
Understanding the difference the adhesive to spread beyond the
between threadlocker colors ensures required surfaces.
the ideal product is chosen for the job. Also, any threadlocker outside of the
For example, purple threadlocker is ideal curing area (where the air is present) will
for low-strength and blue is best for remain liquid and not cure. In this case,
medium-strength assemblies. it’s easy to think the threadlocker failed
because it looks like the product is not
Applying too much adhesive drying properly, even after the 24-hour
If you’ve never used threadlocker, it’s curing period.
easy to err on the side of caution and To create an effective bond, you
apply a lot of the product to ensure a only need to apply a minimal amount
strong bond. You might assume this of threadlocker to the area where the
would improve the assembly’s reliability.
THREADLOCKER 12-22_FE_Vs2_MF.indd 17 12/1/22 7:38 AM

threadlocker
LOCTITE green threadlocker

is recommended for locking
preassembled fasteners, preventing
against loosening, rust, and corrosion.
This wicking-grade threadlocker is
categorized as a medium-to-high-
strength adhesive.
bond will be secured. The same holds true when using a time can be as little as a few minutes with some products.
low-strength product — a small amount will provide the But strength can still be gained after this point, so allow for
strength required. the full cure to avoid assembly failures.
If you try to shorten the threadlocker cure time or use
Lack of preparation the assembly beforehand, the fastener might loosen.
Quality threadlockers are designed to perform in the
presence of oil and other contaminants. But that does Repositioning the assembly
not mean you should ignore these when applying your One common misconception is to think it’s safe to
adhesives. Preparation is vital. reposition an assembly after the threadlocker has
Before applying threadlocker to a new surface, it’s been applied because it has not cured yet. However,
important to first clean the surface to avoid contaminants. repositioning a bond after it’s been locked in place can lead
Applying threadlocker to a dirty surface can prevent proper to threadlocker failure.
curing by affecting the chemical performance. As soon as the thread is tightened, the absence of air
Any grease, dirt, or oil present in the assembly can also starts an anaerobic reaction in the adhesive. If you rotate
affect the application and slow the curing process. This the fastener during this time, you’ll disturb and break the
can lead to a poor bond, which prevents the threadlocker chemical bonds, which will not reform again — even after
from meeting its full holding potential. the bolt has been tightened. This means your threadlocker
will never achieve its full strength and adhesion, reducing
Not heeding the cure time its ability to perform.
Every threadlocker has a specific curing time, detailed If repositioning the fastener is required before or after
within its technical data sheet (TDS), which should be curing, you’ll need to remove the existing threadlocker,
adhered to. Curing refers to the time it takes for the clean the surfaces, and apply a new one. Where the
threadlocker to achieve its maximum strength and optimal application allows, you may apply a wicking-grade
performance. threadlocker once the assembly position has been set.
Threadlocker curing time is different from fixture time. Wicking grades are typically green and help penetrate pre-
Fixture time is the point where the assembly has a certain assembled fasteners.
level of handling strength. Many confuse the two. Fixture
18

THREADLOCKER 12-22_FE_Vs2_MF.indd 18 11/28/22 12:04 PM

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A S S E M B LY: f a s t e n e r s
How to keep
fasteners from
loosening?
Article courtesy of JW Winco
Ensuring fasteners remain tightly sealed in applications

prone to vibration is a question engineers frequently attempt to
solve. Eventually, vibration loosens fasteners by creating relative
motion between the threads. This occurs to all nuts and bolts
subject to movement, no matter how well you tighten them.
Loose fasteners are certainly a maintenance nuisance but also
a hazard in several applications, including in power generation,
transportation, manufacturing, and others. The result can lead to
accelerated wear, damaged parts, reduced equipment longevity,
and safety concerns.
Adequate torque is an obvious first step to ensuring fasteners
are properly installed. Using washers to lengthen the ratio of
clamped length is another option for certain applications. The
washer can add extra friction to the joint and maintain the
clamping force.
Vibration-proof fasteners offer another alternative. These are
fasteners specifically designed to cope with small movements and
vibrations typical of some applications.
Understanding vibration-proof fasteners

Quality counts. Some fasteners are better designed to cope with
vibration than others. For example, vibration-proof fasteners are
engineered to prevent self-loosening due to vibration. These
include hex nuts with nylon inserts, jam nuts, lock nuts, slotted
hex nuts, tooth lock washers, lock washers, and spring washers.
Such fasteners may have a unique thread design that Vibration-proof fasteners
distributes stress more evenly or an extra clamping system that are a must for certain
reduces rotation. applications, such as those
There are also spring plungers with a nylon locking element subject to heavy vibration and
that are ideal for applications with limited space. They use challenging conditions. These
a spring force to apply pressure, so the ball or nose remains types of fasteners are better
positioned or locked. PFB (Polyamide) patch types are a thread- able to handle movement and
jamming material that also provides some anti-vibration prevent self-loosening for
AdobeStock
properties that can hold ball plungers in place. added security.

|
Assembly - How to keep fasteners loosening 12-22_FE_Vs3_MF.indd 20 11/29/22 10:59 AM

Unfortunately, there is no failsafe • Know the shear strength and the work with a quality manufacturer
solution. The efficacy of vibration- ability of the fastener to withstand or supplier who can make the ideal
proof fasteners will depend on the lateral force without breaking. recommendations for your project.
application, so maintenance checks are • Ensure regular maintenance and
essential. repairs. Is there a need for
disassembly? If so, you’ll want to
Tips for choosing vibration-proof consider low to medium-strength
fasteners fasteners, which require hand
• Consider the application. What tools. Higher-strength fasteners
environmental factors must it typically need the application of heat
withstand? What amount of stress is for disassembly. Either way, regular
typically placed on the fasteners? maintenance checks are critical in
• Is heat a factor? High temperatures high-vibration or harsh conditions.
are commonly used in critical • Thread size makes a difference.
industries, such as the energy, Smaller thread sizes make it more
aerospace, automotive,semi- challenging to remove fasteners,
conductor sectors, and others. whereas larger thread sizes typically
Specialty fasteners that can withstand reduce the effectiveness of the bond. The PFB patch is a jamming thread-locking
harsh conditions (and vibration) are Know the needs of your application material (Polyamide), which provides anti-vibration
required in these industries. to make the wisest choice. Also, properties that hold ball plungers in place.
HEX SOCKET SET SCREWS
SOCKET, FLAT & BUTTON HEAD CAP SCREWS
SQUARE HEAD SET SCREWS
SHOULDER BOLTS
HEX & TORX KEYS
ZINC PLATED SOCKETS
SPECIALS, STANDARDS & SECONDARIES
300 North Klick St.,

Hampshire, IL 60140
630.800.6377 / Sales@SetkoFasteners.com
Assembly - How to keep fasteners loosening 12-22_FE_Vs3_MF.indd 21 12/1/22 7:42 AM

BOLTS
What is the load transfer factor?

Article and images courtesy of Nord-Lock Group
When using hydraulic bolt tensioners to induce a that can be multiplied against the required preload
controlled preload into a bolted joint, several key factors including to generate an applied load, which overcomes the
the load transfer factor need to be examined. This is key in ensuring theoretical losses.
the selected tooling can provide a load greater than the required
preload of the joint to overcome any potential losses. Applied load = Preload x LTF
The LTF is important in tool design and tool selection.
The load can be lost in a joint due to several factors, including: The maximum output force of the tooling must, at
• Localized yielding a minimum, match the applied load — but it often
• Joint deformation exceeds this value.
• An imbalance in geometry Careful consideration of the stresses in the joint
and bolt is required to ensure loading conditions
It can, however, be observed that the difference in stiffness do not exceed accepted design criteria. In addition,
between the joint structure and the bolt can have an effect on the performing the LTF calculation can highlight the need
overall load loss in the joint. Load loss in a joint can be theoretically for changes in the loading conditions, joint design,
calculated using varying formulas, primarily based on the known and tensioner design solution.
data of the bolt diameter and clamp length. It’s important to remember that the load transfer
The resultant value of these calculations is commonly known factor is a theoretical value and cannot be used
as the load transfer factor (LTF). The LFT gives a theoretical ratio to determine the precise load lost within a bolted
LEFT RIGHT
When using hydraulic bolt tensioners, it’s important to ensure
the selected tool is capable of providing a load greater than the
required preload of the joint.
22

BOLTING - NORDLOCK 12-22_FE_V3_MF.indd 22 11/29/22 10:56 AM

joint. However, for design and load of the fastener greatly improves the
application, LTF provides loading properties of the joint, as it: Load transfer factor or LFT
conditions, which allow for the physical • Increases the elongation of the bolt, calculations can showcase
losses within the joint. reducing the settlement effect the need for changes in the
loading conditions, joint
For accurate load measurement, • Increases the flexibility of the fastener,
design, or tensioner design
systems such as bolt elongation reducing the risk of self-loosening under
solution.
measurement via dial indicators or vibrations and transverse loads
ultrasonic measurements can be used. • Improves the load factor, reducing the
amplitude of dynamic stresses in the bolt
Optimizing bolted joints and minimizing the risk of fatigue failure
To optimize a bolted joint, it’s • Minimizes the load transfer loss in case
recommended to design the clamped of hydraulic tensioning
length to at least three or five times the
bolt diameter. Increasing the elasticity
How to prevent bolt thread galling

and seizing?
Galling is caused by a combination of friction and adhesion
between metallic surfaces during sliding. When galling occurs,
material is adhesively pulled from one surface, leaving it stuck on
the other in the form of a lump. This process spreads rapidly as
the built-up lumps induce more galling.
The tendency of a material to gall is affected by the material’s ductility. Typically, softer materials are more
prone to galling and harder materials are more resistant.
In bolting, thread galling appears during fastener tightening as pressure builds up between the contacting
and sliding thread surfaces. Thread galling commonly occurs with fasteners made of stainless steel, aluminum,
titanium, and other alloys.
In extreme cases galling leads to seizing — the actual freezing together of the threads and bolt lock-up.
Continued tightening may lead to the breakage of the fastener or result in torn-off threads.
The solution:
1. Lubricating the internal and/or external threads.
2. Reducing the installation RPM speed.
3. Selecting different stainless alloy grades for the bolt and the nut to reduce galling resulting from different
degrees of hardness. Just remember, the strength of the nut always needs to be greater than the strength
of the bolt.
BOLTING - NORDLOCK 12-22_FE_V3_MF.indd 23 11/29/22 10:57 AM

• Customer Service Driven
• Vertically Integrated
• Innovative Products
• Global Presence
ADVANCED TECHNOLOGIES
Since 1955 ND Industries has specialized in the development of innovative
materials and processes which increase the safety and reliability of fastener
assemblies.
ND serves a global market with divisions across the continental US, Taiwan,
and licensees around the world. ND’s core business revolves around the
application of a wide variety of materials onto fasteners and assemblies to
aid in functions such as locking, sealing, masking, lubricating, and noise and
vibration dampening. ND also manufactures a line of bottled products under
the Vibra-Tite® brand name for MRO and retail use.
From two base products in 1965 to currently over two hundred

twenty, ND continues its tradition of cutting edge research and
development with the regular introduction of unique materials
along with competitive brand offsets.
ELECTROLOC®
High strength encapsulated epoxy threadlocker for use in electrical
systems where low halogen materials are necessary. Contains small
micrometer microcaps which reduce material extrusion on installation.
THERMOSEAL™
A high temperature, high pressure thread sealant which withstands up to
40MPa. Offering thread locking breakaway torques greater than 20Nm AUTHORIZED
and a maximum temperature of 428°F (220°C). Thermoseal is an APPLICATOR
extremely versatile product for challenging sealing conditions. Did you know that ND is an approved 3M
applicator? Further proof why ND should be
your one stop shop for pre-applied fasteners.
THERMOLOC® 1500
ND’s highest temperature chemical threadlocker. Initially performs like
a vibration dampening compound. Once temperatures reach 750°F
(400°C), a secondary activation begins, causing the fastener to be
permanently locked in place. Tested to over 1500°F (850°C).
ND INDUSTRIES spread 12-22.indd 24 11/28/22 3:01 PM

ND PATCH® HI-TEMP
Highest temperature pre-applied nylon threadlocker in the industry. Unlike the competition,
ND’s application process requires only 120°C, preventing plating damage. However, once
crosslinked, it can withstand temps up to 260°C. Meets MIL-DTL-18240F / QPL-18240.
THREAD ARMOR® GP
Prevents galvanic corrosion in assemblies with dissimilar metals, such as aluminum, and
steel, by electrically isolating the fastener. Specially bonded to the fastener, ND Galvanic
Patch is durable, chemical resistant, and non-conductive.
THREAD ARMOR® VC
An advanced anti-galling and lubricating thread coating designed to extend the life of
bolts up to 15 times while under intense torque and high friction loads. Helps to ensure
consistent clamp load. Works well on stainless steel fasteners.
EPOXY-LOCK® NUTS
This pre-applied threadlocker consists of separated epoxy hardener and expoxy resin.
Upon fastener installation, the two materials mix and activate. When fully cured, Epoxy-
Lock provides greater breakaway torque than conventional nylon fastener locking devices.
EXPAND-A-LOCK®
A unique pre-applied microencapsulated expanding threadlocking & sealing
compound. Increases in volume 20-50% on installation, penetrating the
gaps in fastener threads typically unfilled by conventional threadlockers.
EXPAND-A-SLEEVE™
CONTACT US Extruded ND Mastics are pre-applied to fasteners (threaded or non-threaded),
bound for e-cote cycles. Heat from the process causes the material to expand,
www.ndindustries.com
sealing large leak paths between fastener and assembly.
www.vibra-tite.com
info@ndindustries.com
SEALTEK™
An acrylic-based sealing material which is applied to the underhead of the
fastener. SealTek’s robust seal replaces the need for O-rings, gaskets, or
sealing washers.
ND INDUSTRIES spread 12-22.indd 25 11/28/22 3:01 PM

HARDWARE
How advances in latches and hinges are

enhancing user experiences
Steve Spatig, General Manager, Electronic Access Solutions, Southco
& James Stroud, Manager of Product Management, Southco
Recent changes in end-user application requirements have

been driving new developments in latch and hinge technology —
two common devices, often seamlessly integrated into applications.
New features and capabilities are providing more options that
optimize the end-user experience.
Latches range in complexity depending on the application zone,
security requirement, ease of use, and other ergonomic factors.
From simple cam locks securing an access panel to compression
latches that create a clamping force between two surfaces,
conventional latches fit several applications. Modern electronic
access solutions (EAS) combine electronic locks with electronic
credentials, such as RFID cards or smartphone-based access,
ensuring more secure and convenient latching with remote-access Hidden solutions feature sleek push-to-close
control and monitoring. operation with a space-saving design that facilitates
Door hinges offer a similar range of function-based options. interior door mounting. This is Southco’s R4 Rotary
Fixed-position detent hinges hold open doors at pre-determined Latch solution.
angles, eliminating the cost and labor of additional components.
Counterbalanced positioning hinges provide lift and freedom of
design for positioning panels or screens. use case has been extended to secure panels, such
Regardless of choice, design engineers are focused on as doors on ATMs or self-service kiosks in restaurants
innovation and greater functionality for today’s latches and hinges. and convenience stores. Access to these kiosks is
restricted to technicians and personnel refilling cash
The latest latching tech and printout materials (in the case of ATMs).
Demand is strong for all major categories of latching systems Rotary latches provide a more secure solution
— cam or rotary, compression, push-to-close, draw, and sliding than push-to-close latches and can be actuated
latches. One significant trend is the use of certain latches outside with a physical key. They can incorporate electronic
their typical applications. actuation and be controlled and monitored
For example, the rotary latch is a simple yet durable device electronically in applications where a higher level of
that’s the go-to mechanism for car and truck door handles. This security or remote actuation is necessary.
26

HARDWARE 12-22_FE_Vs2_MF.indd 26 11/28/22 3:03 PM

Electronic access solutions (EAS),
such as electronic locking and access
control devices, are increasingly used
in commercial vehicles such as delivery
vans and utility trucks, as well as off-
highway construction, agricultural,
and mining equipment. EAS can be
connected to an existing network to
track equipment access.
Additionally, rotary latches are now to provide a higher-end touch-point

used in industrial applications, such experience. This includes push-to-close
as exterior panels on rail cars. In such or “slam” latches that shut with a single
Constant torque positioning hinges, such
high-vibration applications, some push on the door. A physical and audible
as Southco’s E6 Series, provide reliable manufacturers are enhancing the latch “click” when closed assures a user the
positioning with consistent operating with rubber bumpers to protect against panel is secure, so the vehicle is safe to
efforts, eliminating secondary support vibration-generated wear and tear and operate off-road.
components to hold doors or panels in deliver longer lifecycle performance. Another development is the growth of
position. Other more sophisticated latching the electric vehicle (EV) market, which is
systems are also in demand in atypical leading to new challenges for electronic
applications, such as on and off- locks, which are standard devices in
road all-terrain vehicles (ATVs) and these cars.
utility task vehicles (UTVs). These A fundamental engineering task for
vehicles are designed for rugged EV manufacturers is power management
environments, but users are and maximizing the efficient use of the
requesting greater interior vehicle’s battery. Electronic latching
amenities and design suppliers are developing extremely low-
features similar to power mechanisms to minimize the
those in high-end power requirement of these devices and
automobiles. offering self-powered battery-operated
As a result, solutions.
ATV and UTV
manufacturers are New hinge positioning control
upgrading door and Hinge technology has become more
storage compartment latches sophisticated, with features incorporating
HARDWARE 12-22_FE_Vs2_MF.indd 27 11/29/22 10:54 AM

hardware
higher-quality experiences for users. it’s possible to unlatch and pull it open, and materials to enhance the touch
The fastest-growing types of hinges are where it remains until closed. point experience of users. Through
those with constant torque technology. Manufacturers have also advanced ongoing consultation, collaboration,
With this kind of positioning hinge the hidden hinge, particularly for use and engineering, expect even more
technology, designers can define and on the exterior of enclosures and innovations in the future.
adjust the operating effort required vehicles. Hidden hinges, which can
to move or position doors, display also incorporate constant torque
screens, safety shields, and lights — or technology, are easily installed on the
virtually any mounted component that’s back side of a door or panel and fit flush
opened, closed, and moved. with the fixed portion of the vehicle or
Hinges with integrated constant enclosure.
torque enable single-handed These hinges offer two advantages:
adjustment of connected monitors. security and design. Security is
Constant torque hinges use engineered enhanced because thieves and vandals
friction to provide a specific resistance can less quickly identify potential pry
against motion. For instance, they points, given the hidden hinge points.
enable the positioning of a cab Hidden hinges also let industrial
operator’s screen at any angle with a designers create sleeker, more
simple adjustment. The screen must streamlined designs, elevating the
maintain that angle until re-positioned, appearance of public enclosures and
even when the vehicle is in motion. enhancing a vehicle’s visual appeal.
These same hinges are also useful in Access hardware manufacturers
a vehicle’s center console. So, instead are continuing to innovate their
of using one hand to hold the console product portfolios, incorporating
door open (while searching for an item), new technologies, functionality,
Hardware trends
Market dynamics are continually impacting the development of latch and hinge technology and the
delivery of products to multiple industries. One ongoing trend is the global supply-chain disruptions caused
by the pandemic, which is still making it difficult for OEMs to obtain latches and hinges without high costs or
delivery delays.
This includes automotive, aerospace, railway, RV, and construction manufacturers. Few markets, if any, have
been spared.
Suppliers and customers can expect delays with latching systems that use electronics and require
microprocessors. There are also material shortages, such as plastics and steel, because supply plants were
mostly idle during Covid. Production restarts are still lagging.
The result is that suppliers are strengthening and diversifying their manufacturing footprints and material
supply chains to meet demands more effectively. Many companies are collaborating more closely with
customers and, for example, supplying alternatives when a specific model or type of latch or hinge is in short
supply.
It’s ideal to work with an innovative manufacturer or supplier that can offer options and expertise.
28

HARDWARE 12-22_FE_Vs2_MF.indd 28 11/28/22 3:05 PM

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NBK 12-22.indd 29 11/28/22 3:06 PM

installation
What are the different tightening

methods for a screw?
Hiroki Goto, Engineering Manager, NBK America LLC
There are several ways of securing parts together, but elongation in relation to the force increases rapidly. In this
the screw, a mechanical fastener with a threaded shaft, is still state, permanent elongation of the screw occurs, and it
the most common. The primary role of screws (and bolts) is to does not return to its original length.
fasten objects using axial force generated from tightening. If the screw continues to be tightened past this
Typically, the torque method is used to install a screw, point, it will eventually break. This is the plastic region,
which refers to managing tightening torque with a torque and tightening within this range is called “plastic region
wrench to control the axial force on the screw. A torque tightening.”
wrench is common because it’s relatively simple and easy to The variation in axial force on the screw in elastic
use. region tightening is quite large, so the screw can be used
However, there’s more than one control method for repeatedly with the torque method (and a torque wrench).
tightening screws and bolts. In plastic region tightening, permanent elongation of
the screw occurs, which has drawbacks and cannot be
The tightening regions done repeatedly. This tightening method takes time to
Before explaining the different tightening control methods, perform but offers more stable control of the axial force
let’s first cover what it means to tighten in the “elastic region” than elastic region tightening. Its often used in critical
and the “plastic region” of a screw. and industrial applications, such as automotive engine
assembly.
The relation between tightening torque (the force required
to rotate the screw) and axial force in the elastic region is The methods
expressed by this formula: T=kdF There are three control methods of tightening a screw or
bolt:
T : Tightening torque (N·m) – the force required to rotate a 1. Torque method
screw 2. Torque gradient method
k : Torque coefficient – the amount of variation in the axial 3. Angle of rotation method
force when screws are tightened under the same conditions,
so the larger the value, the greater the variation The torque method is a tightening control method that
d : Screw nominal diameter (m) – the size of the screw uses a linear relationship in the elastic region between the
threads tightening torque (T) and the clamp force (F). Since this
F : Axial force (N) – the applied stress or tension method is only for controlling the tightening torque during
tightening work, it’s a relatively simple and popular method
When you progressively apply an axial force by tightening a (typically, with a torque wrench).
screw, the screw elongates in proportion to the force up until However, the entire tightening torque does not act
the yield point. Yield load is the load at which the material as an axial force; some of it is expended through friction
deforms beyond return to its original state. When the force is with the screw’s thread face and the seating surface. As
removed, the screw returns to its original elongation. This is a result, the axial force will vary significantly according
referred to as the elastic region. Tightening within this range is to certain conditions, such as the surface roughness and
called “elastic region tightening.” lubrication condition. Care is needed in controlling the
If axial force is applied by tightening the screw beyond the friction characteristics, even when tightening with the
yield point, the proportional relationship disappears, and the same torque.
30

INSTALLATION 12-22_FE_V3_MF.indd 30 11/28/22 3:08 PM

Tightening torque is the force required to
rotate a screw. The torque method refers
to managing tightening torque with a
torque wrench to control the axial force
on the screw.
Therefore, it’s generally recommended that screw tightening

using the torque method is done with generated axial force around
60%~70% of the yield point within the elastic region.
The angle of rotation method regulates the clamp force by
controlling the tightening rotation angle from the snag point of the
screw head or nut. The snag point is the point at which the required
tightening torque forces the screw and seating surface tightly
together.
This method calculates the angle on a pointer scale (a protractor)
or with an electrical detector and is used for elastic and plastic
region tightening.
Typically, the torque method is preferred for elastic region
The effects of force: the elastic region is when a screw will
tightening because of its simplicity — and because the axial force
still return to its original, undeformed state after stress. The
varies when applying the rotation angle. But with the plastic region
plastic region is when this is no longer the case, and the
tightening, the change in the axial force due to tolerance in the screw deforms permanently.
rotation angle is smaller. For this reason, it’s sometimes possible to
control the angle by sight, watching the hexagonal form of the bolt
or nut.
The torque gradient method uses clamp force on the screw,
exceeding the yield point. So, the elongation of the screw increases
rapidly relative to this force. An electrical sensor detects the
tightening torque and rotation angle. The change point between
the elastic and plastic regions is calculated by a computer and
tightening is performed at the limit of the elastic region.
Large-scale equipment is required for this method, but variation
appears only in response to the material yield point. And the
variation is much smaller than with the torque or angle of rotation
methods. The torque gradient method is only used when high
tightening reliability is required, such as with the bolts in automotive
engines and cylinder heads.
There are also other methods to tighten a screw. One includes
the measured elongation method, in which the elongation of the
screw is assumed directly and controlled in that way. Another
The relationship between the tightening rotation angle and the
involves heat, in which a screw is heated at high temperatures to
clamp force. The snag point is the point of the nut tightening method
elongate it. Then, the temperature is controlled during mounting. at which the required torque acts to create close contact with the
Each method is application-dependent, so it’s important to have seating surface.
a good understanding of the parts to be fastened and the conditions
affecting them.
INSTALLATION 12-22_FE_V3_MF.indd 31 11/28/22 3:09 PM

cold forming
What is cold-form manufacturing?

Article courtesy of RISCO, Inc.
Cold heading or cold forming is a method that is ideal for high-volume requirements, providing cost-
has been used for well over 100 years. The technology has effective results for larger orders.
come a long way since its origin but, essentially, still involves Forming, as opposed to cutting, greatly reduces the
taking a piece of metal and forging it into a specific shape — amount of scrap metal, which saves costs. In fact, cold
without adding heat. forming is capable of producing up to 70,000 pieces within
Cold forming has become a high-speed process that an eight-hour shift.
lets manufacturers produce large amounts of metal-based
components in a fast, consistent manner. The machine
For fastener manufacturing, cold forming is a quick and The most common type of cold header is a one-die, two-
efficient method for producing standard and customized blow style. As the name suggests, these machines use
parts, including those with complex shapes. Compared one die to form the body of the fastener and two blows to
to machining methods, cold-formed components are forge the head of the fastener.
structurally stronger and more durable, offering products The first blow, or upset/cone blow, is the initial
without compromising the natural grain flow of the material progression used to create the proper geometry of the
by forming as opposed to cutting. This also provides a part. It loads the blank into the die while starting the head
smoother surface finish. forming. This process also forms the body of the part.
The material is never cut (it’s formed), so speed in The second blow is known as the finishing one, which
manufacturing and material strength are two major cold- puts the drive (such as a Hex, 6-lobe, Philips, etc.) in
forming advantages. This type of fastener manufacturing the fastener and completes the initial process of cold
forming a fastener. For more complex parts, some cold-
forming machines have several dies and blows, such as
2-die/3blow, 2-die/4-blow, or 3-die/3-blow — all the way
up to six or more dies.
After the fastener is cold-headed, secondary operations
are often used to complete the part, depending on the
requirements. These operations include trimming, thread
rolling, slotting, grinding, heat treating, plating, and others.
One thing to consider is that because parts are
produced in such a high volume, there can sometimes be
fluctuations for certain dimensions. It’s worth asking your
manufacturer what tolerances they can hold. The tolerance
is the acceptable amount of dimensional variation that will
still allow the part to function properly.
Cold-form manufacturing is typically not recommended
for low-volume, high-tolerance requirements.
A cold-header machine,
which is used to form metal
parts and fasteners.
32

COLD HEADING 12-22_FE_Vs3_MF.indd 32 12/1/22 7:35 AM

This is one of the most
common types of cold-header
machines — the one-die, two-
blow style.
The making of fasteners: Progression of a

hex head with a washer.
Manufacturer capabilities
Choosing a manufacturer that meets your requirements is essential to ensuring
production to spec, product reliability, and on-time delivery. When it comes to
cold-formed fasteners, here are a few considerations to discuss before placing
an order.
• Manufacturer’s experience and certifications

• Quality-assurance processes
• Material availability From start to finish: The manufacturing of
• Typical lead times a Phillips pan-head screw.
• Machine capabilities and tolerances
• Samples (ask if there’s a first article or part sample available before production)
COLD HEADING 12-22_FE_Vs2_MF.indd 33 11/29/22 9:52 AM

smart manufacturing
What is “smart mechatronics” and how can

it support fastener manufacturing?
Brad Klippstein, Product Management – Mechatronics
Bosch Rexroth
Assembly operations that use handling, joining, mechatronics” has evolved, offering more intelligence
and pressing tools for a range of production applications and functionality in handling and joining. Mechatronic
— including fastener manufacturing — continually seek to systems are devices that have fully integrated mechanical
improve the versatility, ease of use, production time, and and electrical components, thanks to the combination of
quality of such operations. sensors, circuits, and motion-control applications.
In today’s digital world, this means adding smarter, In some ways, mechatronic systems could be
Industry 4.0 capabilities to production platforms. For considered a forerunner of Industry 4.0 technology.
efficiency, this must entail data tracking of a machine’s They combine disparate mechanical and electronic
production and performance with real-time sharing components into solutions for specific product assembly
capabilities. and transport tasks, such as Cartesian robots (capable
As manufacturers begin to incorporate the benefits of of moving in multiple linear directions) and forming and
Industry 4.0 technology, a new concept called “smart crimping tools.
Meeting industry needs

At one time, mechatronic solutions were integrated
with components from multiple suppliers. That’s no
longer the case. Mechatronics suppliers are replacing
that time-consuming acquisition and integration step
with complete solutions that are “plug and produce.”
This includes the software necessary, which is pre-
programmed and delivered as a single production tool.
Manufacturers should know that all of the
components for a complete
mechatronic solution —
a Cartesian robot or a
pressing or joining tool
— can now be specified
Assembly operations are

shifting away from individual
products toward complete
system kits for manufacturing
equipment that produces fast
solutions for handling, joining,
and pressing tools — along
with real-time data.
34

Smart Mfg - Bosch Rexroth 12-22_FE_Vs2_MF.indd 34 11/29/22 9:50 AM

Smart mechatronics
solutions leverage easy-
to-use tools, such as drag-
and-drop functionality and
simple programming. Bosch
Rexroth’s Smart MechatroniX
system for pressing and
joining applications is one
example that demonstrates
this intuitive model.
in a single process. Users can enter that meet budgets and readily support • Feature an easy-to-use graphical
parameters such as stroke, workpiece manufacturing orders. Kitted solutions user interface that lets operators build
weight, and cycle time, which generates that provide flexibility in a space-saving production sequences simply and intuitively
an output that can be verified in the envelope with minimal integration time • Require no special motion-control or
CAD environment. are highly desired. programming skills
It’s clear end users require precise Easier, faster commissioning is one • Monitor systematic data such as position,
control and execution of motion significant advance provided by newer, velocity, and acceleration
sequences, but also automated smarter mechatronic systems and the • Include kitted solutions that offer simple
tracking of production data and easy technology that supports them. Equally integration, flexibility, and tracking options,
connectivity with machine-level and valuable are the improved efficiency, providing users with the ability to set
plantwide production management flexibility, and productivity it provides conditions for automated quality control
systems. end users looking for easy-to-automate • Provide real-time updates and recordings
Additionally, there’s a demand for solutions. as requested
easier and faster changeovers. Many • Offer a multi-axis system that can
production lines or mid-sized shops For those wanting to integrate interface with individual peripheral tools
seek tools that make it easier to produce mechatronics and update production such as gripping devices, nozzles, and
a range of batch sizes — from the low lines, consider systems that: actuators
end of only a few thousand parts up • Combine all the hardware and
to hundreds of thousands — without software into a single solution to Times are changing, and so are industry
extensive effort to reprogram tools for a support a broader range of applications, requirements and processes. To keep
new part. including pressing and joining, logistics, up, fastener manufacturers are wise to
The price point also matters. End packaging, pick-and-place, palletizing, digitalize their operations with Industry 4.0
users require cost-effective measures assembly operations, and more technology.
Smart Mfg - Bosch Rexroth 12-22_FE_Vs2_MF.indd 35 11/29/22 9:50 AM

materials
How is lightweighting affecting

fastener materials and designs?
Chris Kanaan, Sales Manager, ARaymond
As fastener manufacturing advances, the Currently, several manufacturers are moving away from
lightweighting of fastener designs is also evolving. This is when heavier steel as a material for fasteners and toward other
a fastener is made lighter than typical, usually by replacing materials, including:
steel with other materials, such as aluminum. • Aluminum
However, joining lightweight materials can present • Carbon fiber
challenges like different panel thicknesses, tolerances, • Multi-material assemblies
retention requirements, corrosion — and the need to • Nylon
reduce the complexity of fastening interfaces. New fastener • Plastic
designs must meet performance and reliability standards, so • Titanium
developing mechanically and chemically compatible solutions
are essential. These options typically let engineers shed weight from
This trend in lightweighting is primarily driven by market a manufactured fastener without shedding strength or
demands. This is especially true in the automotive sector, reliability. In fact, many of these materials offer the same
given the growth of electric vehicles (EVs). The efficiency strength as a fastener made with heavier metals.
of EVs relies heavily on lighter-weight parts. This is also a Multi-material assemblies can also lower production
requirement of the aerospace sector and several electronics costs. This is primarily thanks to new technologies and
manufacturers. manufacturing processes.
Material matters Assembly advances

Structural integrity and durability are critical when developing So, how can manufacturers lower the assembly costs
lightweight fasteners for any industry. Any new component of lightweight fasteners? One way is through the
design must include design and validation processes to ensure advancements in 3D printing. Another way is through the
it performs as intended in any given application. This can be recent advances in plastics and multi-material assemblies.
easier said than done.
Materials performance can vary depending on an 3D printing – Also known as additive manufacturing, 3D
application and the environmental conditions, so choosing printing builds a three-dimensional object from a CAD or
wisely is a must. Material costs are also a consideration with a digital 3D model. One benefit is that it’s possible to print
lightweight compounds. almost any design since there are no limitations on bends
36

MATERIALS 12-22_FE_Vs4_MF.indd 36 11/28/22 4:40 PM

and cuts. This makes this technology a A few examples of lightweight
worthy consideration for fastener designs automotive parts. They’re made with
alternative materials to reduce weight
compared to injection molding.
by up to 50%. These fasteners from
It’s particularly ideal for prototyping
ARaymond can adapt to a range of panel
ideas and for fasteners with unique molding process where one material
thicknesses, enabling a load distribution
shapes and materials. However, given is molded onto a second one. It lets that prevents damage to the parts.
today’s advances in 3D printing, if you engineers use nylon material with an
can think it, you can print it. overmolded compression limiter, installed
directly into the customer’s end item.
Plastics and material assemblies – In this case, end users retain the high
Multi-material assemblies typically functional product requirements but gain
combine mild steels and rubbers/plastics, critical cost and weight savings from their
with the same functional properties as overall assembly.
high-strength steels, but at a lower total
cost of ownership. They also offer an Automotive implications
overall reduction in mass, which is key for The fast-growing electric-vehicle market
lightweight fasteners. is providing an opportunity to upscale
While it’s best to avoid bolting or current production capabilities to support
screwing directly into nylons or plastics, lightweighting in several EV applications,
overmolding provides greater design including structural connections, power
possibilities. Overmolding is an injection- connections, and thermal and moisture
MATERIALS 12-22_FE_Vs4_MF.indd 37 11/29/22 9:48 AM

materials
An overmolded compression limiter,

which prevents creeping, for plastics
and composite materials.
sealing.
Lightweight fasteners are rapidly replacing
heavy metal joints and aiding in key EV areas of
concern, such as water sealing and battery-pack
optimization. There’s a safety aspect to these
lightweight fasteners, too, such as the importance
of securing the battery-pack lids.
Additionally, materials in EVs must have
significantly higher heat capacities for potential
thermal issues. For example, higher safety
requirements for durability and flammability must
be met, particularly for plastic or other resin-based
materials.
Lightweight fasteners might come with a higher
Go design.
price tag than conventional, off-the-shelf parts,
but for a good reason. And when the total cost of
ownership is considered, the lightweight choice
typically provides a greater long-term value.
New fastener designs also require
communication and collaboration between OEMs
and their supply base to best develop new standards
and product lines for future success.
No matter the industry, the trend is clear:
Lightweighting is a must-have tool for engineers
Emerson’s expertise in plastic joining and fluid control as they develop fasteners that meet industry and
make complex medical devices more compact and assembly demands. Lightweighting is providing a
easier to manufacture. key feature as manufacturers reinvent fasteners for
changing market conditions.
Learn more at Emerson.com/Medical
38 December 2022 DESIGN WORLD

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4:42 PM
NUTS
What are nut retainers?

Article courtesy of Advance Components
Nut retainers are self-retaining spring steel fasteners that How to apply cage nuts:
have a bolt-receiving nut floating inside a cage, which offsets 1. Insert one of the cage nut’s retaining legs into
typical hole misalignment. It does not turn when the bolt is the panel hole
tightened. Essentially, nut retainers combine the advantages 2. Snap the other leg into the hole by hand or with
of spring steel fasteners with the strength of a multi-threaded a simple tool
nut. 3. Align the second panel, and then thread the bolt
These components slide or snap into position (by hand) onto the captive nut.
at panel edges or center-panel locations, making them ideal 4. Tighten the bolt into the self-retaining nut
for blind assembly locations. They’re also a good choice for 5. A positive, high-torque, flush attachment is achieved
applications requiring extra-high torque and holding power.
No welding, clinching, staking, special skills, or equipment J-nut or J-type retainers combine the strength of
is required for installation. Another benefit: Nut retainers are a nut with the flexibility of a spring steel cage. They
rust-proof and can be applied after painting, eliminating costly easily snap over panel edges or can be inserted into
masking or retaping of paint-clogged threads. rectangular holes in central panel locations. Floating
alignment and retention are attained with extrusions
There are three main types of nut-retaining fasteners: in the retaining legs, which snap into panel mounting
• Cage nuts holes — allowing the fastener to shift or align but not
• J-nuts disengage.
• U-nuts Installing J-nut retainers does not require special
tools or skills because they simply snap into place
Cage nuts — also known as rack or captive nuts — combine anywhere on the assembly line. They serve as a heavy-
a strong spring steel cage and a multi-threaded nut. They’re duty fasteners for blind location assemblies, including
ideal for rack and equipment-mounting applications. for use in the automotive, appliance, HVAC, and other
Cage nuts have spring-steel “mechanical hands” or wings industries.
that keep the nut stationary in a square hole, which helps with
bolt insertion. As the nut is pressed to the locked position, the How to apply J-nuts:
mounting legs expand around the panel and force past the 1. Push the J-nut into place on the panel or a
retainer spring tabs, snapping back to lock the fastener firmly rectangular hole that’s in the panel’s center
in place. 2. Snap the extrusion into the hole
They can be applied at any convenient spot along 3. Position the second panel and the drive screw
the assembly line and are ideal for blind-assembly 4. Align the panels
attachments. Applications include automotive, electrical, 5. Flush-mounting is obtained by embossing
HVAC, cabinet construction, server racks, and others. either panel
40

NUTS 12-22_FE_Vs2_MF.indd 40 12/5/22 1:08 PM

The self-retention
feature of nut
retainers improves
assembly time
and eliminates
costly welding and
clinching costs.
J- and U-nuts
provide simple,
rapid, and
self-retaining
attachment of
mating panels.
They’re often
a preferred
U-nut or U-type retainers provide the
alternative for
same advantages as J-nuts. They offer larger screw sizes.
a low profile and heavy-duty fastening
when combined with a machine screw
that’s ideal for blind location assembly.
They’re self-retaining and will not turn
when the screw is driven.
U-nuts maintain constant alignment
with an extrusion on the lower leg.
Button-hooked into center panels
or pressed over flanges, they retain
themselves with “mechanical hands”
formed from the spring steel retainer
and are held securely under live
spring tension. They’re easily applied Cage nuts are used to
by hand or with simple tools and are attach components
used in several applications, including to panels with square
holes. The nut floats
electronics, vending, appliances,
within the cage to
automotive, marine, and others.
account for normal
build variation.
How to apply U-nuts:
1. Push the U-nut into a bolt-receiving
position on the panel or in the
rectangular hole in the center of the
panel
2. Snap the extrusion into the mounting
hole
3. Position the second panel and drive
in the screw
4. Ensure flush mounting is obtained
5. Access to the back of the panel is
unnecessary to complete the assembly
NUTS 12-22_FE_Vs2_MF.indd 41 12/5/22 1:08 PM

pins
What’s the difference between

cold-headed and machined solid pins?
Christie Jones, Vice President, Director of Marketing
SPIROL International Corporation, U.S.A.
Solid pins are fasteners used for aligning, joining, and assembling multiple Cold heading sometimes includes
components. Ideally, these pins are selected when the clamp load of a bolt a wire-drawing process that work
is unnecessary. They’re typically used for specific functions such as locating hardens the material, increasing the
components, hinges, tamper-resistant designs, etc. yield and tensile strength. Machined pins
Cold heading and machining are two of the most common manufacturing produced with the same base material
methods used to produce solid pins, and both result in high-quality, consistent parts. will have a lower yield and tensile values
It’s important to understand the differences between cold heading and machining because the material grain structure has
when designing solid pins for an assembly, as the manufacturing method directly been interrupted.
impacts the design specifications (including the tolerances, geometry, and material).
The objective is to design a solid pin that optimizes performance and reduces the Design specifications
total manufactured costs of the assembly. The first step in designing a joint is to
establish the functional requirements
Manufacturing methods of the host components and fasteners.
Machining is the process of cutting raw material (rod) into the desired geometry Performance requirements should
using cutting tools. This operation is typically performed on a lathe. Machining be achieved without over-specifying
produces scrap in the form of chips. the design. An ideal joint satisfies
performance and quality requirements at
Cold heading is the process of forming raw material into the desired geometry by the lowest possible cost.
upsetting the material (wire) in one or more dies. The most common method of
cold-heading fasteners uses one die and two blows, which is sufficient for forming Tolerance
chamfers and heads. The dies provide the cavities used to form the preferred Typically, the outside diameter (OD) is
geometry and the blow describes the physical process of upsetting material with a the most critical solid pin dimension.
machine stroke. Cold heading and machining can
There are limitations to the amount of material that can be displaced per blow. achieve the tolerance specifications
And as the geometry becomes more complex, additional dies and blows are needed for most of these applications.
required. In fact, cold heading produces solid pins
42

PINS 12-22_FE_Vs3_MF.indd 42 11/28/22 9:38 PM

with OD total tolerances of 0.05mm and holes must be reamed and/or • Scraps. Machining generates leftover
(.002”), which is less than the thickness honed. This increases cycle time and material, so more is needed for the
of human hair. Machining can achieve manufacturing costs associated with the same part. The only scrap generated
tighter OD tolerances, but this usually hole preparation. during cold heading is that produced
requires a special ground OD rod, Also, note that free-fit hinges do during set up.
which should be avoided if possible (the not require press-fit holes and or pin
ground OD rod can be more than three diameter tolerances tighter than • Expense. Ground OD rods can cost
times the cost of a standard rod). ± 0.025mm (± .001”). more than three times as much as a
For the length tolerances, machining standard rod used for machining.
and cold heading can achieve the same Material
tolerance levels of approximately ± The most common materials for solid However, setup costs are significantly
0.25mm (± .010”), which varies by pin pins are carbon and stainless steel. The lower for machining. Companies that
length. raw materials are available in different standardize on solid pin sizes can
The chamfer is used for ease of forms depending on whether pins will be mitigate setup costs, so there’s only a
assembly. A chamfer angle between 25° machined (rod) or cold-headed (wire). negligible cost impact for customers.
to 40° is suitable for most applications, Commercially available material Custom designs are a different story,
allowing for maximum pin engagement. grades for rod and wire can differ. Rod especially at low volumes.
From a manufacturing standpoint, the is available in material grades best suited It’s recommended that
optimal cutting angle (machining) is 45°, for machining, and wire is available in manufacturers partner with industry
and the optimal forming angle (cold material grades suited for cold heading. experts in joining and assembling to
heading) is 30° or less. Best engineering practices dictate that identify the lowest cost solution for
It’s worth noting that press-fit dowels material specifications on drawings their assembly.
and straight pins are typically retained remain general (i.e., carbon steel with
in the assembly by being pressed into hardness rating RC 27-33).
holes smaller than the pin diameter. The
interference, therefore, must be limited Costs
in most applications to keep insertion Machined solid pins are typically 10 times
forces within practical limits. the cost of cold-headed pins.
The acceptable press fit for most
metals (steel, brass, and aluminum) Here are a few reasons why:
is 0.0125 to 0.025mm (.0005 – .001”) • Speed. Cold heading produces solid
of material displacement. Since this pins at a rate of about 300 parts per
tolerance threshold includes the sum of minute (ppm), while machining yields
the pin and hole diameter tolerances, about 4 ppm.
pins must be precision machined
Know when to use…

A machined solid pin:
• Low-volume custom parts
• Highly critical alignment applications
• When functional requirements dictate complex pin geometry
A cold-headed solid pin:

• Majority of applications (as most do not require machined tolerances)
• Free-fit axles/hinge pins where the pins are slip fit into place
PINS 12-22_FE_Vs3_MF.indd 43 11/28/22 9:38 PM

PLATING
What is plating and what causes

electroplated coatings to fail?
Jennifer L. Sturm, Chief Operations Officer, Empire Bolt & Screw Inc.
Mason Smith, examining the

plating surface under 100x
magnification at Empire Bolt &
Screw’s Quality Control Lab. Smith
is the company’s account manager
and a QC technician.
Successfully working in the fastener industry entails ongoing learning, even Manufacturers rely on different
for experts in the field. Case in point: a recent learning experience was on plating tests to ensure the reliability of their
adhesion. fasteners. For example, salt-spray
Plating is a thin layer of metal bonded or fused at the molecular level to the testing is common. The coating will
fastener. Depending on its purpose, plating can alter a fastener’s appearance, typically indicate the minimum hours
hardness, electrical conductivity, or ability to withstand corrosion or wear. to rust when tested in a salt-spray test.
There are several types of plated coatings available, including zinc, phosphate, There are also plating adhesion tests
chromium, nickel, bronze, brass, and many others. In this case, type 260 brass to ensure the coating does not peel
fasteners with nickel plating per ASTM B733 SC1, Type III were in production. Nickel or flake. Additionally, it’s important to
plating provides a unique combination of wear and corrosion resistance, including ensure the plating provider’s equipment
visual appeal. and process standards also meet quality
The problem was that a plating process change occurred without verification. requirements.
The reason: the screw manufacturer moved plating facilities to meet the For this project, everything seemed
customer’s production deadline. Although this plating facility indicated it could fine at first. Dimensionally, the plated
properly plate the screws to specification, no testing was performed to confirm the parts conformed to print, and their
plating or qualify the new plater. appearance was nearly identical
44

Quality Control 12-22_FE_Vs2_MF.indd 44 11/29/22 9:47 AM

Amanda Lundberg, a QA trainee,
is setting up the comparator for
fastener thread inspection.
to previous lots. However, during

installation, these parts proved faulty
due to plating adhesion failure. The
nickel flaked off when installed in the
application.
Flaking can occur for a few reasons,
including inadequate surface treatment,
incorrect coating thickness, or
interruptions or errors during the plating
process.
This customer’s print called for
a nickel-plated brass fastener that
would be inserted into a mating
threaded terminal and then installed
into a terminal block. The process also
employed automation, so there were a
lot of considerations to examine to find Finding the right test adhesion. Unfortunately, the parts failed
the root cause of the failure. The next challenge was finding a in the application and plating flakes were
Through a process of elimination, method to ensure the adhesion of the found after removing the fasteners from
the terminal, block, and automated plating on subsequent manufactured the terminal.
processes were eliminated as the cause. lots would be described on the print. A more reliable method was necessary,
Following the results from the XRF scan, Within ASTM B571, appropriate adhesion ensuring the parts functioned properly
there were two contributing factors that test methods are indicated for a in the application. Even ASTM places a
led to the plating failure. variety of coatings. ASTM International, disclaimer on the “precision and bias of
1. The electroless nickel plating was formerly known as American Society for these tests, because of their qualitative
not to spec. It was less than half of the Testing and Materials, is an international nature” (ASTM, 2013, 15.1). In other words,
required thickness. All documentation standards organization. For nickel the results of the tests can be open to
indicated that the plating process was plating, there are 11 test methods. interpretation.
followed according to the standard, The bend test was considered at first, Ultimately, this customer specified
but under XRF, it was clear that the but there was no way to adequately the plating process must contain a nickel
plating was insufficient. (XRF is an bend these parts around a mandrel flash, and the parts must be plated with the
X-ray fluorescence spectroscopy that to achieve accurate testing results. full thickness of .0002 nickel (per ASTM
determines the elemental composition Next, the Heat-Quench test method B733 SC1, Type III or Type IV). The testing
of materials.) was used as it’s non-destructive. The methods accepted must also meet Class 1
2. A copper flash was used to help the test subjects electroplated parts to for adhesion (ASTM B571 verified) or Class
electroless nickel adhere to the part. elevated temperatures, determining the 5 (heat treating) per ASTM B571.
However, on all lots that pre-dated the sufficiency of coating adhesiveness. To ensure conformance, additional
rejected lot, a nickel flash was used At first, the plating passed with no testing with an XRF device will be
instead of copper. visible blistering to indicate inferior employed to ensure an adequate deposit
of nickel. Documentation will be provided
with each plating batch within each
manufactured lot.
So, what was learned overall? Although
conformance is critical, it’s also wise to
build strong, supportive relationships in
the industry with those who are available
for consultation. Even with the best of
intentions, errors and unexpected events
Gaging threads with a tri-roll occur. It’s also essential to keep learning.
gage — specifically, the functional
diameter.
Quality Control 12-22_FE_Vs2_MF.indd 45 11/29/22 9:47 AM

rivets
How to best choose and

install rivet nuts?
Rosa E Hearn, CFS, Product Manager
Proferred Rivets Brighton-Best International
Since the original rivet nut was invented in 1936 to attach

de-icers to aircraft wings, this versatile fastener has found new uses
in several industries. Developed by BF Goodrich, these components
were initially sold under the trademark name RIVNUT, but today
you’ll find several brands in various shapes and sizes as a type of
blind fastener.
Rivet nuts are unique, internally threaded fasteners anchored
from only one side of a workpiece or application. Like a blind rivet,
they’re installed from the front of a workpiece and are ideal for use
when there’s limited or no access to the backside.
Rivet nuts are tough, versatile, and dependable. They reduce or
eliminate the use of loose hardware, typically reducing assembly
costs. They’re commonly used in aerospace, automotive, electronic,
HVAC, appliance manufacturing, and any other industry using thin
materials.
Proper installation
Did you know that a socket-head cap screw is required to install a
rivet nut? This is called the mandrel. It was created to provide load-
bearing threads in thin sheet materials that are too thin for a tapped
thread. Rivet nuts add strength to thinner materials, making them
an excellent choice for manufacturers focused on lighter-weight
applications.
Most rivet-nut tools come standard with two or three socket screws. The standard sizes are 3/8, 5/16, and
M8. For non-standard sizes (1/4-20, 1/4-28, M6, M10, etc.), the purchase of a separate mandrel is necessary.
Too often, the socket-head cap screw (mandrel) is not given the attention it deserves to ensure proper
rivet-nut installation. A correctly sized mandrel must extend beyond the face of the anvil — far enough to
allow at least one thread of the mandrel to protrude past the end of the insert.
If the cap screw has damaged threads, installation problems can and will occur. Damaged threads prevent
the mating part from fastening correctly, leading to costly rework or scrapped parts. To prevent this from
occurring, ensure the cap screw occupies all the rivet nut’s threads. This will help ensure the internal threads
avoid distortion or uneven compression when the rivet nut is cinched to a workpiece.
Rivet-nut setting tools use an alloy socket-head cap screw. This prevents wear on the threads of the tool
since they’re stressed repeatedly during the pulling of the part. Typically, the longer the screw (within reason),
the better the performance because the forces are spread across more threads.
If the threads are repeatedly damaged, it’s possible that a worn (softer) bolt is the problem. A well-worn
bolt typically leads to the first few threads getting marred, which ruins the nut — and, therefore, the screw.
46

RIVETS 12-22_FE_Vs2_MF.indd 46 11/28/22 9:43 PM

Rivet-nut tool guidelines
recommend using a high-quality
socket-head cap screw (mandrel)
that’s the correct length for the
application.
Condition of the mandrel

For most tools, the mandrel is a
Quality counts
standard ASTM A574 socket-head cap
The advantages of using high-quality rivet nuts:
screw. The threads should be clean and

lightly lubricated to ensure a proper
• Provide a strong thread in thin materials that cannot be tapped
and smooth installation. It also extends
• Can be installed from one side of the workpiece, known as a “blind application”
the life of the mandrel. If unwaxed, the
• Can be installed in many kinds of materials, including steel, plastic, and fiberglass
installers should apply oil to the cap
• Ideal for use when easy disassembly and reassembly of products are necessary
screw end before use.
• Once installed, additional components with threaded fasteners can be attached
The condition of the tool will affect
the pull-up force required for ideal
rivet-nut installation. Keep the tool
properly maintained, ensuring the head
thrust bearing is lubricated.
RIVETS 12-22_FE_Vs2_MF.indd 47 11/29/22 9:45 AM

rivets
Types of rivet nuts

Ribbed or splined rivet nuts provide extra
torque strength over standard rivet nuts
with no spline. This is thanks to their
knurled expansion surface. The splined
body provides increased torque-to-turn
resistance.
When installing the knurled part of the
fastener, it bulges out and clamps the parent
material on the blind side, offering excellent
resistance to vibration and spinning. This is
why knurled body “nutserts” are commonly
used in the automotive industry with trucks
and trailers — or with anything that might
need a firm fix.
Overall, when choosing rivet nuts, the
hardness of the material matters. Rivet nuts
must be annealed to create a soft crimp. Rivet nuts, which are internally threaded fasteners, are also known as
rivnuts, nutserts, threaded rivet nuts, blind rivets, and blind inserts.
How to install a rivet nut?

Several types of rivet-nut installation tools are available. Regardless of the tool,
the process is the same:
48

RIVETS 12-22_FE_Vs2_MF.indd 48 11/28/22 9:43 PM

BROUGHT TO YOU BY:
MOTION CONTROL
DESIGN
GUIDES
The editors of Design World produce key
technology content compiled in individual
PDFs available for download.
CABLE CARRIERS DC MOTORS LINEAR MOTORS

Motion control systems DC motors are motion Linear motors are one of the
can vary from simple, components that take latest motion components
straightforward single-axis electrical power in the form to go mainstream for OEMs
direct-drive systems with little of direct current and convert building moving machinery
wiring to large and complex it into mechanical rotation. In requiring high precision.
multi-axis robotic systems this Design Guide, the editors This exclusive Design Guide
with a hornet’s nest of cables. of Design World detail the reviews the functions and
This is usually where cabling, most common dc motor variations of linear motors
which was an afterthought, types as well common ways for precision automation as
now takes center stage. This to quantify their output during well as their connectivity and
Design Guide details cable the design-engineering configuration requirements.
carrier subtypes as well as the process.
different designs into which
cable carriers integrate.
Find these and additional guides in our DESIGN GUIDE LIBRARY,

bookmark this site as guides are added on an ongoing basis!
designworldonline.com/design-guide-library
DESIGN GUIDES AD 12-22.indd 49 12/1/22 10:47 AM

SCREWS: COMMON SCREW-HEAD TYPES
What are the more

common screw- Socket-head cap screws
head types?
Article courtesy of UC Components
Did you know the first known recorded use of screws occurred
during the time of the ancient Greeks? These early fasteners were
used in devices to press olives and grapes. From those humble
beginnings, screws have become one of the most widely used pieces of
manufactured hardware.
And today, these fasteners are available in several types, ranging in
style, shape, size, and material. One of the top considerations when
choosing the fastener for any application should be the type of screw
Button-head
head selected for use.
socket cap screws
Here’s a brief overview of some of the most common screw head
types, including their typical applications.
Socket-head cap screws are machine screws with a cylindrical barrel-

shaped head containing a hexagonal socket that fits a wrench for turning
(instead of a slot or external hexagonal). These properties mean that
socket-head cap screws are ideal for use in confined spaces. Socket cap
heads are small, so the size of the component parts can be reduced,
saving material costs. Smaller parts cost less to drill and tap, take less Socket set screws
energy to drive, and weigh less than alternatives.
Button-head socket cap screws have a rounded, low-profile head

containing a hexagonal socket that fits a wrench. These screws offer
a flush profile, making them ideal for use in areas with little overhead
or clearance and in confined spaces. They work best in light-duty
applications such as in removable panels. Their wider bearing surface and
high-tensile strength mean they’re also reliable in security applications.
Socket set screws are typically used to secure an object within or against
another object. They’re commonly used to secure a pulley or gear to
a shaft, serving well in confined spaces. These fasteners are headless,
meaning the screw is fully threaded and has no head projecting past the
major diameter of the screw thread.
A socket set screw contains a hexagonal socket that fits a wrench
instead of a slot or external hexagonal, and fastening these components
requires no external clearance. The socket set screw passes through
a threaded hole in the outer object and is tightened against the inner Pan-head Phillips screws
SCREWS-COMMON SCREW-HEAD TYPES 12-22_FE_Vs3_MF.indd 50 11/28/22 9:48 PM

object to prevent it from moving Pan-head Phillips screws take their Twelve-point flange head-cap screws,
relative to the outer object. It exerts name from the appearance of their also known as 12-point bolts, are an
compressional or clamping force head, which looks like an upside-down alternative head design for hex socket-
through the bottom tip that projects frying pan. This is a common head cap screws. The flange diameter and
through the hole. type of the non-countersunk used in head height are designed to fit a range
machine screws. They have wide heads, of applications and counterbored holes
Flat-head socket caps feature a low- a flat bearing surface, high vertical, made for standard hex socket cap
profile and countersunk head. They’re chamfered, or curved sides, and a flat or screws. The 12-point design permits
ideal for applications requiring a strong slightly domed top. A pan-head Phillips this style bolt to be tightened with a
fastener with a flush mount and are head has two partial slots crossed 12-point socket wrench, which allows
often used in applications that require at right angles, driven by a special for the application of higher torque than
moving parts to pass over a fastened screwdriver called a Phillips screwdriver. a standard internal hex-drive socket
area. Thanks to their ability to mount As mentioned, this system is self- head-cap screw. Another advantage:
flush with the surface, flat-head socket centering. the 12-points have 30° between flats (as
caps are less apt to snag objects moving opposed to hex heads, which have 60°).
overhead. They’re produced with a Fillister-head slotted screws have This enables increased wrench flexibility
socket drive that contains a hexagonal an oversized head, which is ideal for (or placement) when manipulating the
socket to fit a wrench for turning. counterbored holes. These fasteners are fastener.
like pan-head slotted screws but with
Flat-head Phillips screws have a low- greater side height. Fillister-head slotted
profile and countersunk head. They screws are also compared to cheese-
feature similar characteristics as the head slotted screws because they
flat-head socket caps and are ideal for have cylindrical sides and a flat mating
applications requiring a strong fastener surface. But where the cheese-head Twelve-point flange
with a flush mount. Flat-head Phillips slotted has a flat top, the fillister slotted head-cap screws
screws have two partial slots crossed at screw head has a domed top resulting in
right angles and are driven by a special an overall deeper head (these fasteners
screwdriver called a Phillips screwdriver. are sometimes called raised cheese-
An advantage of the Phillips system head slotted screws).
is the screw and screwdriver, when The fillister is manufactured with a
used together, are self-centering. The slotted head drive. Slot screw heads
x-shape of the screwdriver head fits into have a single horizontal indentation
the similarly shaped slot of the screw, referred to as the slot with a flat bottom,
which is held in place so the force of the which is ideal for low-torque, low-
Fillister-head slotted
torque is centered naturally. This ensures speed applications. The fastener head
screws
the screw is driven straight. is driven by a flat-bladed (flat-head)
screwdriver.
Flat-head slotted screws are also ideal
for applications requiring a strong Hex-head screws, also known as hex
fastener with a flush mount but are bolts, are bolt fasteners with a six-
typically used in projects with moving sided hexagon head and an externally
parts that must pass over the fastened threaded body. The hexagonal profile
area. These screws are manufactured enables easy wrenching while ensuring
with a slotted head drive. Slot screw enough torque to the bolting joint. Hex
heads have a single horizontal bolts are typically used with a washer
indentation, referred to as the slot. The and hex-nut assembly or a tapped hole. Hex-head screws
fastener head is driven by a “common Hex-cap screws allow for greater torque
blade” or flat-bladed (flat-head) than conventional screws with a circular
screwdriver. The slot has a flat bottom, head.
which is a good choice for low-torque,
low-speed applications.
SCREWS-COMMON SCREW-HEAD TYPES 12-22_FE_Vs3_MF.indd 51 11/28/22 9:50 PM

seals
How to choose an O-ring for your

application
Kim Keating, Director of Customer Success
ZAGO Manufacturing Co.
Once torqued, the O-ring squeezes

outward to form an unbreakable
360-degree seal that prevents gases
and liquids from entering or exiting
equipment operating in hazardous,
treacherous, and/or pressured
environments. The undercut groove
ensures that the O-ring will not break
or crack once installed, and the metal-
to-metal contact prolongs the life of
Sealing screws with O-rings
engineered onto each fastener.
the O-ring, which is not compromised
under pressure.
With its impervious, unbreakable
O-ring seal, the sealing fastener
has the added benefit of protecting
the environment from harmful
contaminants. This can include
disinfectants, oil, gas, humidity, dust,
moisture, saltwater, or any debris or
chemicals that can damage or destroy
equipment. At the same time, it prevents
equipment leakage of contaminants (i.e.,
acid leakage from lithium batteries) into
the environment.
Equipment applications include
hydraulic cylinders, water flow pumps,
An O-ring is a circular-shaped seal or gasket that’s made from vacuums, and pneumatic medical
an assortment of materials depending upon the application and the devices such as pneumatic respirators.
environment it will be used in. Sometimes called a packing or toric joint
(because of its shape), it’s used to seal two working surfaces. O-rings are Material choices
essential for protecting industrial machinery, electronic equipment, and a Choosing the ideal material for an
system’s inner components from wear and tear, including the detrimental O-ring is important to ensure reliability
effects of contaminants, seepage, or leakage. and longevity. This choice should be
Rubber O-rings are commonly used as they’re available in rigid and based on the application, including its
flexible materials with different strengths and tolerances. In the case of a exposure to contaminants, temperature
sealing fastener, the rubber O-ring is engineered under the head of the range(s), and required standards.
screw or face of the nut or washer. Sealing fasteners provide a unique ability For example, military-grade sealing
to protect conventional machinery and complex equipment with high-tech O-rings that meet the requirements of
properties — thanks, to the inclusion of an O-ring. the Military Standard MS3212/MS3213/
52

SEALS 12-22_FE_Vs2_MF.indd 52 11/29/22 9:41 AM

NASM 82496 and that are pressure-
tested to 1500 psi are available. This is
also true of FDA-approved O-rings.
Below are six types of O-ring
materials that work in various
applications.
The ZAGO team inspecting parts
1. Silicone – an inert synthetic after manufacturing.
compound that’s available in a variety
of forms (including rubber). Silicone is
highly flexible and tolerates extreme
temperatures without becoming brittle
if exposed to cold. Silicone O-rings
are used in several industries (such as 4. Fluorocarbon – active surfactants 6. Chloroprene – a synthetic rubber
aerospace, automotive, and electronics). offering high chemical and thermal better known by its trade name,
This material is not recommended for stability. Fluorocarbon O-rings can Neoprene. This material has strong
dynamic seals because it lacks optimal withstand high temperatures, harsh chemical stability and can be used over
solvent and oil resistance. chemicals, greases, and fuels. They’re a wide temperature range. Neoprene
ideal for sealing aircraft engines O-rings are excellent at resisting
Temperature range: -80° to 400° F | and equipment in the automotive, ammonia, freon, oil, oxygen, as well as
-62° to 204° C transportation, and chemical industries. ozone and sunlight. They’re used in the
Shelf life: Unlimited DuPont trademarked the well- automotive, HVAC, and refrigeration
known Viton brand — a fluoropolymer industries.
2. Buna-N – also known as Nitrile and elastomer and synthetic rubber
NBR rubber, is one of the most cost- compound that’s reliable in harsh Temperature range: -40° to 225° F |
effective and widely used elastomers. environments. -40° to 107° C
It offers a versatile resistance to water, Shelf life: 15 years
saltwater, petroleum-based substances, Temperature range: -20° to 400° F |
hydraulic fuels, and alcohols. However, -29° to 204° C
Buna-N is unsuitable for strong acids, Shelf life: Unlimited
weathering, and sunlight. It’s typically
used in marine and offshore equipment 5. EPDM – a synthetic rubber
applications. made of ethylene, propylene, and
diene monomers. EPDM O-rings
Temperature range: -40° to 225° F | are extremely durable, providing
-40° to 107° C outstanding ozone, heat, steam, and
Shelf life: 15 years chemical resistance. They’re typically
used to seal outdoor equipment,
3. Fluorosilicone – a variation of silicone including weather and water-resistant
rubber that maintains high-temperature applications and appliances.
stability and durable mechanical
properties. O-rings offer excellent Temperature range: -65° to 225° F |
fuel, oil, and solvent resistance and are -54° to 107° C
commonly used in the automotive, Shelf life: Unlimited
aerospace, and military industries.
Temperature range: -67° to 350° F |

-55° to 177° C
Shelf life: Unlimited
SEALS 12-22_FE_Vs2_MF.indd 53 11/29/22 9:42 AM

s u p p ly c h a i n
Supply chain issues:

How much is lost paperwork costing
your company? Lonni Kieffer
Marketing & Customer Success, SmartCert
For hundreds of years, paper documentation has been used to deliver critical Physical paperwork leads to:
information, from receipts and prescriptions to certifications. This medium • Increased risk of errors due to unreadable or
has faded from daily use. missing documents
The digital era is here. Email, software, and automated systems are • Time wasted filing and organizing paper
commonplace. However, in the fastener industry, several organizations have documentation (keeping employees from other
yet to fully integrate digital processes or eliminate physical paperwork. essential tasks)
The problem is paper costs supply chains thousands of dollars, not • An inability to quickly share documents
counting the price of paper, ink, and printing, which undoubtedly adds to between departments or remote parties
these expenses. Supply chains are most affected by paper documentation • Challenges in quick accessibility, particularly if
when this antiquated system fails. products are recalled or fail
Paper results in a lack of visibility, traceability, and efficiency. There’s a • Risks of delays in manufacturing or shipping
chance important documents could get lost, misplaced, or damaged. These
risks are not as negligible as one might think. The disadvantages of losing vital There’s also a negative environmental impact
records in the supply chain are vast and showcase why digitization is the ideal as paper copies are printed and eventually
way forward. discarded. In fact, an average American office
worker goes through as many as 10,000 sheets
of paper each year.
Here are a few common scenarios that further

outline the problem:
1. A distributor handles $30M of products yearly
and scraps $180k because of related certification
problems. The issue? The paperwork got lost,
and the products could not be shipped due to
the lack of certification required for compliance.
The certification process for fasteners —

the inbound and outbound exchange of
quality certifications – has changed little
for many organizations, which still rely
on paperwork. But paper results in a lack
of traceability and efficiency. Fortunately,
digital options are available.
For example, SmartCert automates the

transfer of required documentation
between companies, replacing paper
and printing costs to reduce missing
documents and promote sustainability.
54

SUPPLY CHAIN 12-22_FE_V3_MF.indd 54 11/30/22 7:24 AM

The consequences of antiquated processes
There are three costly ways companies lose
2. A customer has installation problems Time is money. According to a recent money with paper certifications.
and thinks they might have the incorrect Gartner study, it takes an average of 25
inserts. The supplier must first find and hours for lost documents to be recreated. 1. Organizations lose 20 to 30% of revenue
review the certification. In the meantime, This results in wasted time and money for a annually due to inefficient processes.
the parts are quarantined, with several company. 2. Approximately 40% of workers spend a
employees affected. Instead of getting the Another report estimates that the quarter of their week on repetitive tasks.
job done, they’re spending time tracking average business spends $8,000 on paper 3. Up to 40% of on-the-clock time is wasted
down the paperwork and dealing with the and another $8,500 on filing and storage. searching for missing paperwork.
stalled implementation. This process also requires a dedicated file
When the supplier finally locates manager to ensure the organization of Advanced companies want to work with
the correct documentation, it’s clear these documents, which can cost another other well-run organizations. Adopting an
the inserts were provided by a different $30,000 or more per year in labor. automated solution gives team members the
manufacturer and require a different tools necessary to spend less time worrying
installation process. Four employees Reducing lost paperwork about paperwork and more time improving
spent a couple of hours each addressing Many organizations still rely on legacy the business.
this issue, costing the company in the procedures. Some lack department time or
hundreds. insight to update these processes or fear
investing in new technology. Awareness is
3. A distributor sells parts to a customer key. Tracking the actual cost of paper and
but accidentally includes the wrong the risks involved can help supply chain
documentation. As a result, it’s organizations decide to change. • Share a unique QR code or email for each
necessary to quarantine the parts and Going digital is not as challenging as product to let any user in the chain access
send replacements. The new parts also it might sound. Ideally, the software or relevant and up-to-date certifications
include incorrect paperwork, leading the automated processes selected should allow • Search active and archived certifications
distributor to recommend an alternate your company to easily store, access, and • Update certifications even if a product
source. This customer is now potentially edit certifications for your products in the is already in transit, sitting on a warehouse
lost for good. cloud. shelf, or in use
In this case, the cost for the distributor Additionally, the technology should: Digital documentation creates a traceable
includes: • Establish the origin and complete history supply chain in which all actors in a
• Labor of $1,500 of a product as it travels through your distribution life cycle can review a product’s
• Red shipping and two lost sales for supply chain history and legitimacy. As a result, your
$120 + $2,400 + $2,500 = $4,920 • Create a centralized repository for organization can significantly reduce the risk
• The loss of a customer at $66,000 ARR documents that are accessible to your of counterfeit or defective products making
teams their way to your customers.
SUPPLY CHAIN 12-22_FE_V3_MF.indd 55 11/28/22 9:58 PM

testing
Why should you test the

fasteners you sell?
Rob LaPointe
President & CEO, AIM Testing Laboratory
Hardness testing is one of the most

common and informative fastener tests.
Fastener testing is integral to making or distributing a product with
proven performance and reliability for its intended job. While not all
fasteners require testing, it’s a good business strategy to understand the
performance and quality of the products you sell. Let’s explore three main
reasons for fastener testing.
The most important reason to test fasteners is that it’s required by the
drawing or manufacturing specification. Most fasteners made to specific
standards — such as ASTM A574 or ISO 898-1, grade 12.9 — have specific
performance requirements such as chemistry, hardness, ultimate tensile,
and yield tensile. Many products have additional requirements, including
shear strength, proof load, and microstructure.
These tests and others are often required, with the results provided
to a customer upon sale. Typically, the manufacturer is responsible for
testing, performing it at an in-house accredited laboratory, or submitting
the work to an accredited third-party testing lab.
After testing, the seller is given certified test reports showing the
product tested with identifying information such as the part description,
heat number, lot number, manufacturing specification, testing
specifications, acceptance criteria, and test results.
56

TESTING 12-22_FE_V5_MF.indd 56 11/30/22 7:26 AM

Each report should be serialized and traceable by the are critical to a successful business. The fastener industry is
laboratory and declared with a global conformance or non- interfaced with many different sectors, such as aerospace
conformance statement. To obtain a global conformance and automotive, where a reliable product delivered on time is
statement, all test results pertaining to the order must critical. It’s worth the effort and expense to ensure that your
be conforming. If there are mixed conforming and non- industry contribution is received without issues, complaints, or
conforming results, the test report should have a global concerns.
non-conformance statement and give attention to the
specific non-conforming results.
The second most important reason to provide fastener
testing to customers (even if testing is not required) is to
position your business as a provider of quality and reliable
products. Providing certified test results, or at least making
them available on request, means that you stand behind
your products — and can provide proof of your assertions. The most important
Additionally, this is an excellent profit strategy. There are reason to test fasteners
is that it’s required by the
enormous and often unaccounted-for costs when recalling
drawing or manufacturing
or replacing faulty fasteners. Most profits are lost when a
specification. An ISO 898-1,
customer returns a product because it fails to perform. The Class 12.9 hex cap screw is
fastener must be scrapped or reworked and then replaced. shown here.
In such cases, your company not only loses money
on the cost of goods but also on the labor of servicing
the replacement part, additional vendor costs, and
administration and shipping costs. And then... there’s your
reputation to account for.
Several of these expenses are not ascribed to a particular
product replacement and show up in the profit and loss
statement under general operation. Typically, a more
detailed accounting indicates the financial penalty of
shipping a faulty product.
It’s far less costly to submit fasteners for testing, gaining
the assurance they’ll perform as anticipated before they’re
sold. This also provides recourse should a customer
experience a problem with the product. You’ll have the
evidence and supporting documentation that the fastener
meets or exceeds the advertised performance.
The third most important reason to test the fasteners
you sell is to understand the process and product as you
manufacture or perform secondary processing. In-process
testing can provide insights into making gains in efficiency
and eliminating waste from manufacturing. It can also help
you catch mistakes before they are incorporated into
a product.
It’s inefficient to find out that a product fails to perform
as expected after completing the manufacturing or
secondary processing of a product. Finding mistakes at this
stage often requires undoing a process, fixing the issue, and
then redoing the process. A significant amount of time and
money is lost by not first testing and proving the process
from start to finish.
There are many more reasons to test fasteners and fully
understand the products you’re selling, but these three
DESIGN WORLD December 2022 57
TESTING 12-22_FE_V5_MF.indd 57 11/30/22 7:27 AM

TOOLS
Some studies show energy savings of

up to 95% by shifting from compressed
air to motor-driven tools. This is leading
to a new generation of fasteners and
cordless installation tools, proving
ideal for use at remote worksites.
Why are
battery-powered tools the
preferred choice? Article courtesy of STANLEY Engineered Fastening
In the past, pneumatic tools promised a consistent level of power, air compressors produce must be conditioned to avoid
justifying the costs of maintaining and monitoring the systems contaminating downstream machinery. The oily condensate
driving them. As energy costs rise and demands increase to improve produced by compressors is also expensive to dispose of properly.
operational efficiency, the cost-to-benefit ratio has diminished. To ensure an acceptable level of efficiency in an air-powered
In fact, it’s been estimated that generating compressed air system, proper maintenance is essential — adding further costs.
accounts for up to 10% of the total electricity consumption in Site-specific installations mean an independent electric source
many production facilities. Considering that on average 30% of the is required, and there’s always the risk of trailing air lines across
compressed air leaks out before getting to the end-users, operators public walkways.
are losing money every minute that a compressor is running. While cordless tools are gaining traction in every market, the
In addition to the high volume of air wasted in air-driven end-users of cordless equipment with the greatest impact are in
production line systems, there are considerable adjacent the manufacturing industries. Commercial manufacturers use the
costs associated with pneumatic systems. The hot, wet, oily same tools daily and require efficiency, reliability, and precision.
58

TOOLS_12-22_FE_Vs3_MF.indd 58 11/30/22 7:29 AM

Manufacturers are also experiencing As environmental regulations change,
demands to increase efficiency and compliance can be costly for production
capacity. Forward-thinking manufacturers facilities using air-driven tools and require
are meeting these demands by upgrading expensive equipment upgrades.
tools and equipment, and this is where
cordless handheld tools hold an advantage Cutting the cord
over air-driven ones. There are few places where user experience
Cordless fastener tools are currently is more important than in the manufacturing
representing one of the fastest-growing industry, where reliability is essential and
segments of the battery-powered tool repeated tool use is commonplace.
market for several reasons and not just cost Two of the most compelling reasons
savings. users favor cordless tools are versatility and
mobility. Cordless tools are untethered to a
The decision to go cordless centralized air system, making them easy to The latest smart tools provide adjustable
By some estimates, shifting from take to remote sites (such as wind or solar settings and performance-tracking features
compressed air tools to motor-driven tools energy projects). that make it possible to shift from one
can result in energy savings of up to 95%. The lack of a cord at a work site allows task to another with the same tool. Alerts
One study determined that pneumatic operators freedom of movement and let operators know when fasteners are
power tools use about seven to 13 times increased ergonomic efficiency. The mobility inadequately tightened or torque specs are
more energy than electric motor-driven and advanced features of battery-operated not met. Such error prevention features
power tools, and motor-driven tools are tools give operators the ability to be used to ensure every stroke or pull is precise and to
only becoming more efficient. assemble multiple products on a single line. spec, reducing manufacturing defects.
Cordless hand tools are more cost- Tool users are often subject to long A new generation of cordless tools is
efficient in manufacturing operations for hours of repetitive motions. Comfort and designed to be “one battery fits all,” meaning
a few reasons. The maintenance costs of ergonomics are critical to worker longevity. that with the same battery, you can operate
motor-driven tools are negligible and they’re Data from a McMaster University study a fastening tool and a wide range of other
extremely energy-efficient. There’s no comparing battery-operated and pneumatic tools, offering flexibility and convenience.
wasted energy like with air-driven systems. tools suggests that using cordless tools The newest generation of cordless tools
Companies also enjoy a lower incidence of reduces the demand on the forearms is free of past limitations: they deliver more
workplace safety incidents caused by the during use. accurate torque, repeatability, and reliability
hoses attached to air-driven tools, leading to Research has also positively correlated than ever before.
fewer liabilities and risks of costly payouts. hand-arm vibration from pneumatic tools
The environment is another with permanent hearing loss independent
consideration. Cordless tools produce of noise exposure. Overall, battery-operated
better working conditions than air-driven tools are the safer bet, reducing trips from Safety check
tools, from reduced noise production to cords and overuse injuries due to vibration.
Before using a tool, first ask:
improved air quality. Motor-driven tools are
considered “cleaner” because they generate Meeting demands
no oily by-products. Such oil-free operation With demand for cordless tools in • Is this the ideal tool for the job? The wrong
means there’s no hazardous waste to manufacturing at an all-time high, advances choice increases the risk of accidents and
manage, such as the oily wastewater caused in tooling are providing new options. injuries.
by industrial pneumatic systems. • Is the tool safe to use? Does it have damage
or any faults that could lead to mechanical
hazards?
• Has the tool been maintained and tested?
Power tools are typically used in harsh
environments and should be regularly
maintained.
• Is the environment safe for the use of
the tool?
• Do you have the proper safety gear?
TOOLS_12-22_FE_Vs3_MF.indd 59 11/29/22 9:19 AM

Training and product knowledge
training lead to greater safety, accuracy, and
confidence on the job. It’s important
to know your fastener facts.
| Adobe Stock
What are the answers to some of the
most common fastener failures?
Article courtesy of the Fastener Training Institute
If you spent time in the fastener industry, you’re aware of Here are a few of the questions he received with his
the complex technology and engineering behind seemingly answers to common fastener failures…
basic nuts, bolts, screws, and washers. Mechanical fasteners
have been around for centuries, but that does not mean When a customer reports a fastener failure, what information
they’re failproof. should be gathered before trying to remedy the problem?
Fortunately, that’s where training comes in. The When a customer reports fastener failures, the information
experts in the field guide us to better products, installation that should be gathered immediately before starting to try to
techniques, and overall application success. remedy the problem includes:
One such expert was the late Joe Greenslade, an icon
• The exact part number
in the fastener industry. He taught mechanical fastener
• The exact lot number
technology for 45 years, publishing more than 300
• The precise description of the failure and/or pictures of
informational articles. He also served eight years as the
the failed parts
director of Engineering & Technology at the Industrial
• Where the parts are used
Fasteners Institute, a trade organization for North American
• How the parts are driven and how tightening is controlled
mechanical fastener manufacturers.
• A sample of the broken and unused parts for analysis
In 2015, Greenslade compiled a list of his most
frequently asked fastener questions with answers — When a customer complains about bolts and/or nuts
including a section dedicated to fastener failure analysis. As vibrating loose, what is the likely cause?
he once pointed out, determining the reason for the failure The most likely cause of bolts and/or nuts vibrating loose
is critical: “It is worthless to propose failure remedies before is insufficient tightening. The most effective remedy is to
a definitive ‘root cause’ of the failure is determined. A root use correctly calculated higher tightening torque or better
cause needs to be discovered before an effective remedy determine the correct tightening value experimentally using
can be proposed.” extra components.
TRAINING-12-22_FE_Vs2_MF.indd 60 11/30/22 7:32 AM

When a bolt failure has a “necked When a bolt or screw has an What is the critical hardness above
down” area in the threads, what is the intergranular fracture surface which hydrogen-induced failures can
most likely cause of the failure…and the immediately under the head or at the occur?
most likely remedy? first unengaged thread of the bolt or HRC 39 is the critical hardness above
When a bolt failure has a “necked down” screw, what is the reason? which hydrogen-induced failures can
area in the threads, the most likely When a bolt or screw has an occur.
cause of the failure is tensile overload intergranular fracture surface within
due to over-tightening, or the bolt 48 hours of installation, the most likely Why should designers avoid
has insufficient strength for the load cause is hydrogen embrittlement (see FTI applications where dissimilar materials
requirements of the design. The most note below). This can be remedied by come in contact with one another?
likely remedy is to reduce torque if the baking the parts at 400° F for 14 or more And what are the two approaches that
failure occurs during installation or hours. Or better yet, change to a finish can be taken to avoid failures when
increase bolt strength if failure is during not subject to hydrogen embrittlement. dissimilar materials must be mated with
product use. Check the tightening one another?
calculation and/or do a tightening What if this same failure occurs weeks Designers should avoid applications
experiment. or months after installation? where dissimilar materials come in
When a bolt or screw has an contact with one another to avoid
When the fracture surface of a failed intergranular fracture surface potential galvanic corrosion.
bolt exhibits a “shoreline” pattern, what immediately under the head or at the The two approaches that can be
is the most likely cause? first unengaged thread of the bolt or taken to avoid failures when dissimilar
When the fracture surface of a failed bolt screw weeks or months after installation, materials must be mated with one
exhibits a “shoreline” pattern, the most the most likely cause is stress corrosion another is to select fastener materials
likely cause of the failure is fatigue. The — also called environmental hydrogen that are closer to the component
most likely remedy is to increase the embrittlement failures. materials on the “galvanic scale,” and/
tightening value. or coat/paint the joint to keep moisture
This can be remedied by using fasteners away from the joint.
with a core hardness of less than HRC
39. Otherwise, consider paint, coating, FTI note… Galvanic corrosion refers to
or a method that protects fasteners from corrosion damage induced when two (or
the moist environment. For example, more) dissimilar materials are brought
redesign the joint to prevent fasteners into electrical contact under water.
from being in moisture or avoid the
use of dissimilar materials in the joint
construction. For additional FAQs from Greenslade:
https://tinyurl.com/FastenerFacts
FTI note… Hydrogen embrittlement
(HE), is a permanent loss of ductility in
a metal or alloy caused by hydrogen
in combination with stress — either
Meeting standards is critical to applied externally or from internal
ensure a safe and reliable assembly. residual stress. Generally, HE is classified
Organizations, such as the American under two broad categories based
Society of Mechanical Engineers
on the source of hydrogen: internal
(ASME) and ASTM International,
hydrogen embrittlement (IHE) and
support the industry with the latest
codes and standards for testing, environmental hydrogen embrittlement
materials, and engineering. (EHE), according to the “Fundamentals
of Hydrogen Embrittlement in Steel
Fasteners,” by Salim Brahimi.
The late Joe Greenslade, an industry

expert in the fastener sector.
TRAINING-12-22_FE_Vs2_MF.indd 61 11/30/22 7:33 AM

WASHERS
The top and side views of a

hardened and unhardened
flat washer.
What are the advantages of using

hardened and unhardened flat
washers? Michael Eusanio
Applications Engineer, Optimas Solutions
It’s common to assume a single part can be more reliably tightened. In fact, can make a difference in an engineer’s
is stronger than an assembly of parts. research shows these fasteners can be part design. The result: fastener
However, fasteners can ensure the torqued with up to 50% higher clamping assemblies that are more reliable,
strength and reliability of a product, pressures, resolving bolt failure issues durable, and longer lasting.
given certain considerations. without making significant changes to
For example, by tweaking the type the product design. Hardened vs. unhardened flat washers
of fastener material, size, or other Mild steel is a generic low-carbon Hardened flat washers are designed
specifications, manufacturing engineers material used in typical washers and for assembly with a Grade 5 or higher
can resolve torque, weight, stability, and fastening systems. In comparison, strength bolt between the bearing
durability concerns with no change to unhardened steel is any steel material surface of the fastener and the part
assembly or procedure. that has not undergone the hardening to which it’s attached. These washers
One such tweak: using hardened steel process. Understanding the difference are carbon steel and can be through-
washers. Replacing standard washers between mild, low-carbon, and hardened to Rc 38-45 or carburized
with hardened steel means fasteners unhardened and hardened steel washers (case hardened) to a minimum depth of
62

WASHERS_12-22_FE_Vs2_MF.indd 62 11/30/22 7:36 AM

The specifications of hardened
and unhardened flat washers
.015“. They have a surface hardness of

37-45 Rc with a minimum core hardness
of Rc 30.
Unhardened flat washers are designed
for assembly with Grade 2 or lower
strength bolts or tapping screws between
the bearing surface of the fastener and
the part to which it’s attached. Narrow
(SAE) and wide (USS) flat washers are
available for specification, depending on
the required outside diameter.
The benefits
Hardened and unhardened flat washers
offer several advantages in a fastener
assembly, including:
• Protecting the mating surface from

damage during assembly
• Improving the stress distribution on the
mating surface
• Spanning larger clearance holes
• Providing a consistent bearing surface
between the mating surfaces for
torquing
The standards
In hardened and unhardened flat
washers, the dimensional characteristics
are covered by ANSI B18.22.1*, and the
mechanical properties are covered by
ASTM F844. Both ANSI (the American
National Standards Institute) and ASTM
(formerly the American Society for
Testing and Materials), develop and
oversee technical standards.
Understanding the effect a washer
has on the entire fastener solution and
assembly is critical before deciding on
the ideal match for an application. This
includes the fastener material and the
tool and torque used during installation.
A washer can be instrumental in
adjusting torque — ultimately adding
more strength and longevity to an
assembly.
WASHERS_12-22_FE_Vs2_MF.indd 63 11/30/22 7:36 AM

welding: materials
What is micro-welding and why is

laser an ideal fit?
Emma Wood, Global Product Manager, Emerson
Laser welding
does not generate
particulates. This is
especially important
in the microfluidic
systems used in
many biomedical
applications where
narrow pathways
could become
contaminated or
clogged by debris.
All Images courtesy of Emerson
Several of today’s advanced applications size. Product quality, durability, precision, Choosing laser
involving plastic components are also and aesthetics are also critical objectives. There are several reasons why a laser is
some of the smallest. Developing So, what is the ideal way to assemble ideal for micro-welding, including the
compact devices that contain sensors these small yet significant plastic following.
and other tiny, delicate internal devices?
elements is a high priority for designers Many designers rely on micro- Control. It’s possible to accurately
and manufacturers, particularly in the welding laser technology as an control the power dissipation within the
automotive and electronics industries. alternative to conventional fasteners weld by varying the power of the laser
The same is true in medical devices used or adhesives. The precision and source. In Through-Transmission Infrared
for in-vitro diagnostics (IVD), vital-signs controllability of laser welding make (TTIr) laser welding, radiation travels
monitoring, and injection and inhalation- it ideal for meeting the challenge of through an IR-transparent part and heats
therapy applications. creating small and reliable joints. Such the surface of the mating part, but only
There’s a lot of complexity — joints can be as short as a few tenths of to a specified depth. Heating is precise
geometric and electronic — inside these a millimeter and as narrow as 100 μm and highly localized to the area touched
small devices as manufacturers attempt in parts with a surface area the size of a by the narrow IR beam. This is critical for
to offer more features without increasing postage stamp. parts with small sections and thin walls,
64

WELDING-MATERIALS_12-22_FE_Vs5_MF.indd 64 11/30/22 7:39 AM

and the resulting welds are nearly as
strong as the parent material(s).
Particulate-free. The laser-welding
There are solutions that
process is non-intrusive, and parts
address the challenges of
typically exhibit excellent cosmetic micro-welding applications
properties, which are essential for small involving small and intricate
parts where a minor aesthetic flaw plastic components. For
is obvious. Also, there’s no frictional example, the Branson GLX-1
motion between the parts, so the welds laser welder is Industry 4.0/
are entirely free of particulates. This is IIoT (industrial internet of
critical for components with narrow things) capable, delivering
pathways (such as micro-fluidic systems actionable operational data
used in many biomedical applications), via OPC-UA interfaces.
which risk contamination or clogging
from debris during the welding process.
The precisely controlled heat and
pressure are beneficial, minimizing the
risk of polymer displacement or channel
collapse.
Design flexibility. The versatility of

the laser-welding process makes it
ideal for assembling extremely small
components. Weld lines that span
different three-dimensional spatial
planes can be problematic with other
bonding methods but are joined easily
with lasers. Lasers can bond several Speed. Laser
materials, such as thermoplastic welding is virtually
elastomers and other soft plastics, instantaneous, with reliable
including combinations of dissimilar bonding in as little as 0.5 seconds, so
materials. Intricate internal welds are also it suits the high-volume production of
possible. small components. Unlike welders that
focus laser light on only a small portion
Gentle. Several small products — such as of the weld line at a time, simultaneous
earphones, smartwatches, or automotive laser welding is an option that heats
sensor packages — contain delicate the entire weld surface at one time —
electronic components that are easily dramatically reducing cycle time without
damaged during assembly. Micro- compromising quality.
welding bonds sensitive electronic and
mechanical without damage because There’s increasing demand for
there’s little movement of the parts smaller and more intricate plastic
during joining and no excitation or components, often housing sensitive
vibration. The welding machine parts electronics, in several important markets.
make no contact with the weld line. Manufacturers are looking for systems
Force is applied to hold the parts, but at that deliver strong, clean joints in a
non-critical areas or surfaces, protecting highly compact package that suits
them from damage. installation in automated process lines.
Such a solution is found in laser welders
that specifically target micro-welding
applications.
WELDING-MATERIALS_12-22_FE_Vs5_MF.indd 65 11/30/22 7:39 AM

2022A D V E R T I S E M E N T
Vendors in the fastener industry
Emerson
Branson metal and plastic welding
technologies from Emerson support manufacturing
efficiency and enable innovative new product
designs in such markets as medical, automotive,
electronics, packaging, and others. Emerson invented
ultrasonic plastic welding 75 years ago and has
since expanded its range of joining technologies to
include vibration, laser and infrared plastic welding
systems, and heat-staking equipment. Digital
controls ensure increased precision and quality, while
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regulatory compliance. Branson application

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development laboratories help customers

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shape brilliant ideas into workable designs,

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bringing ready-to-manufacture
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products to market, quickly and

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sustainably. The global Emerson

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aftermarket network delivers

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expert maintenance, reliability,

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and performance-
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enhancement services.
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Emerson
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120 Park Ridge Road

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Brookﬁeld, CT 06804
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Phone: 203-796-0400
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Branson.Info@Emerson.com
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www.emerson.com/branson
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Emerson_Fastener Engineering Hbk 2022_Vs2.indd 66 11/29/22 11:32 AM

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2022A D V E R T I S E M E N T
Smalley
Founded over 100 years ago, Smalley has
evolved to become the world leader in the
manufacturing and development of Retaining
Rings, Spirolox® Retaining Rings, Constant
Section Rings, and Wave Springs. Smalley
has led the way in introducing state-of-the-
art products and continues to lead the way in
innovations for the future.
Smalley stocks over 10,000 standard
parts across 30 configurations and 400
sizes. If a standard part doesn’t meet your
requirements, you’ll work with our team of
over 30 industry-specialized engineers to
quickly create an economical custom part in
the material of your choice, all without new
tooling. Prototype or production volume, our
No-Tooling-Charges™ manufacturing process
meets the design flexibility your application,
budget, and timeline requires.
While all of our manufacturing is made in
our U.S.-based 300,000 ft2 facility, our global
network of offices, engineers, and distribution
partners allows you to receive parts
and support from anywhere in the
world quickly. Smalley’s dedication
to quality and manufacturing
excellence has earned us multiple
service and quality awards and the
trust of OEMs worldwide.
Smalley
555 Oakwood Road
Lake Zurich, IL 60047
Phone: +1 847 719 5900

Email: info@smalley.com
smalley.com
Smalley_Fastener Engineering Hbk 2022_Vs1.indd 67 11/29/22 11:31 AM

Selecting the Optimal Washer
Flat: Generally used for load disbursement
Tab/Lock: Designed to effectively lock an assembly into place
Finishing: Often found on consumer products
Wave: For obtaining loads when the load is static or the working range is small
Belleville: Delivers the highest load capacity of all the spring washers
Fender: Distributes a load evenly across a large surface area

Boker’s Inc.
Shim Stacks: Ideal for simple AND complex applications 3104 Snelling Avenue
Minneapolis, MN 55406-1937
Phone: 612-729-9365
TOLL-FREE: 800-927-4377
(in the US & Canada) 
bokers.com
J.W. Winco, Inc.
Spring Loaded Devices from JW Winco
When you need to align, hold, or latch different parts

of equipment together, you need a spring loaded
device.These locking systems are designed to
facilitate repetitive positioning operations on
machines and equipment or parts undergoing
machining. Spring loaded devices create a secure
connection with limited play. JW Winco has many different
versions and types for your application requirement.
Check out www.jwwinco.com to find out more!
J.W. Winco, Inc.

Phone: 800.877.8351
sales@jwwinco.com
www.jwwinco.com
68

FASTENER TIPS 12-22.indd 68 11/29/22 11:14 AM

Wide variety of spring to meet
your innovation needs
When it needs a specific spring to empower mechanical function
of your product for best performance, such as Tensioning & Loading,
Counterbalancing, Retrieving & Returning, Drive Motor, you are
welcome to contact design engineer of Ming Tai Industrial Company
for best solution. Based on 60 years manufacturing experience of
steel strip spring, well experienced engineers of Ming Tai Industrial
Company are capable to provide you with the best solution to meet
your innovation needs.
Check out www.powerspring.com.tw for more

interesting innovation stories!
Ming Tai Industrial Co., Ltd.
No. 250, Sing Jhong Road
Tamsui, New Taipei City 251
Taiwan
Phone: 886-2-26228651
Fax: 886-2-26220202
E-mail: mtis@powerspring.com.tw
NBK Acquired Solid Spot’s Plastic Fastener

Business and Expanded Lineup
NBK is a manufacturer of Specialty Screws including Plastic Fasteners.
In this April, NBK acquired Solid Spot LLC’s plastic fastener business and then,
more various product lineup are available such as PEEK, RENY, PC,
PVDF, PTFE, POM, etc.
NBK manufactures not only plastic screws but also low profile (low head),
miniature size(less than M3), vacuum application, anti-galling, chemical
resistance, non-magnetic, and more.
Flexible customization is available.
NBK America LLC

307 East Church Road, Suite 7
King of Prussia, PA 19406
Phone: 484-685-7500
https://www.nbk1560.com/en-US/

A family-owned business since 1955, ND Industries
specializes in the development of innovative materials and processes
which increase the safety and reliability of fastener assemblies.
Headquartered outside Detroit, Michigan, ND serves a global
market with divisions across the continental US, facilities in
Taiwan, and licensees around the world. ND’s core business
revolves around the application of a wide variety of custom
formulated materials onto fasteners and assemblies
to aid in functions such as locking, sealing, masking,
lubricating, and noise and vibration damping. ND also
manufactures a line of bottled adhesive and sealant
products under the Vibra-Tite brand name for MRO
and retail use.
ND Industries, Inc.
www.ndindustries.com
info@ndindustries.com
Assemble Faster with SLIC Pins

Pin and Cotter All-In-One
Eliminates Cotters, Clips, Nuts
Speeds Assembly Time
No Tools Needed
Safer Retention, More Secure
As Strong as Corresponding Cotters
The SLIC Pin from Pivot Point features a strong, spring-

loaded plunger that acts as an automatic cotter. Upon insertion, the
plunger automatically ramps down to pass through the application,
springing back up to lock the pin in place. More consistent and easier
to install, SLIC Pins eliminate the wasted motion to install a cotter,
clip or nut. With separate pin/clip systems, clips can be mis-installed,
forgotten altogether, or fall off later. The one-piece design of a SLIC
Pin eliminates those risks, reducing product failures in the field and
leading to a more consistent product. Manufactured on automated
equipment, SLIC Pins are affordable, making them an ideal solution
for optimizing high-volume assembly.
Pivot Point, Inc.
Tens of millions of SLIC Pins are installed each year, touching every
industry and saving countless hours. Tel +1 800 222-2231
Email: mail@pivotpins.com
Explore SLIC in your application today. www.pivotpins.com/SLIC

SET SCREWS • HEX KEYS • SHOULDER BOLTS • NYLON TIP
• SOCKET CAP SCREWS • STAINLESS • METRIC / INCH •
ZINC PLATED SOCKETS • SHORT ARM HEX KEYS • 6-LOBE
SOCKETS • BUTTON HEAD CAP SCREW • DOWEL PINS •
IMPORT / USA • BRASS TIP • STANDARDS / SEMI-STANDARDS
• SQUARE HEAD SET SCREWS • HEX JAM SCREWS •
LONG ARM HEX KEYS • NYLON PATCH • LOW HEADS 6-LOBE
(TORX) KEYS • BUTTON FLANGE CAP SCREWS
Setko Fasteners & Distribution
Please visit us at www.SetkoFasteners.com 300 N. Klick St. Unit A • Hampshire, IL 60140
Sales@SetkoFasteners.com
setkofasteners.com
(630) 800-6377
Fastener Engineering
This area has long been one of the most read and sought after by our Engineering
engineering audience! From screws to bolts and adhesives to springs,
September 2019 A supplement of Design World
these critical but often overlooked components are the key to every
successful design.
FastenerEngineering.com will serve readers in the mechanical covering nuts, bolts, rivets,
screws, u-clips, eye bolts, washers
design engineering space, providing news, product developments,

and more.
application stories, technical how-to articles, and analysis of

engineering trends. This site will focus on key issues facing the
engineering markets around fastener technology, along with technical
background on selected components.
ADDITIONAL RESOURCES:
• Special print section in select issues of Design World
• Fastener Engineering monthly newsletter
LEARN MORE AT: FASTENERENGINEERING.COM

AD INDEX
Able Electropolishing ......................... IBC SALES LEADERSHIP TEAM
Boker’s, Inc. ............................................... 19 Ryan Ashdown Publisher

Emerson Industrial Automation .......38 rashdown@wtwhmedia.com Mike Emich
216.316.6691 memich@wtwhmedia.com
J.W. Winco, Inc. ....................................... 57 508.446.1823
Jami Brownlee @wtwh_memich
Ming Tai Industrial Co., Ltd. ................. 9 jbrownlee@wtwhmedia.com
224.760.1055 Managing Director
NBK America LLC ...................................29 Scott McCafferty
Mary Ann Cooke smccafferty@wtwhmedia.com
ND Industries .................................... 24,25 mcooke@wtwhmedia.com 310.279.3844
781.710.4659 @SMMcCafferty
Pivot Point Inc. ........................................ 15
Jim Dempsey EVP
Rotor Clip .................................................IFC jdempsey@wtwhmedia.com Marshall Matheson
216.387.1916 mmatheson@wtwhmedia.com
Setko Fasteners ..................................... 21 805.895.3609
Mike Francesconi @mmatheson
Smalley Steel Ring ............................... BC mfrancesconi@wtwhmedia.com
630.488.9029
Jim Powers
jpowers@wtwhmedia.com
312.925.7793
@jpowers_media
Courtney Nagle
cseel@wtwhmedia.com
Emerson Industrial Automation .......66 440.523.1685
@wtwh_CSeel
Smalley Steel Ring ................................. 67
2
December 202
ring.c om
neren ginee
www. faste
Check out the digital edition!

So much happens between issues that even another issue would not be
enough to keep up. That’s why it makes sense to visit
fastenerengineering.com and stay on Twitter, Facebook
and Linkedin. It’s updated regularly with relevant technical information
2022
and other significant news for the design engineering community.
FasHtaendnboeork
fastenerengineering.com
PM
11/22/22 1:37
.indd 1
HBK 12-22_FINAL2
COVER_FE
AD INDEX_FE_12-22_Vs1.indd 72 12/1/22 10:02 AM

ABLE Electropolishing 12-22.indd 1 11/22/22 1:42 PM
SIC K OF
R IN GS?
SNA P
We were too.
That’s why we are the only

manufacturer of Spirolox®.
• Easy and Quick Install/Removal

• Interchangeable with Snap Rings
• Large Selection from Stock
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Spiral Retaining Rings
Request Free Samples at 847-719-5900 or smalley.com
Smalley 12-22.indd 1 11/22/22 1:44 PM

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December 2022

Product Focused, Tapered Section

Rotor Clip 12-22.indd 1 11/22/22 1:39 PM

The value of good advice

orders.” (Learn more on page 34).

DESIGN WORLD www.fastenerengineering.com December 2022 1

Editorial_FE Hbk 12-22_Vs3.indd 1 12/1/22 7:28 AM

EDITORIAL Director, Audience EVENTS Digital Production Manager

Webinar Coordinator Customer Service 2014 - 2016

2 December 2022 www.fastenerengineering.com DESIGN WORLD

Staff page 12-22_FE_Vs2_MF.indd 2 12/1/22 11:07 AM

4 _ADHESIVES: Intro 40 _NUTS

44 _QUALITY CONTROL: PLATING

What is plating and what causes electroplated

12 _ADHESIVES: Curing 46 _RIVETS

DESIGN WORLD www.fastenerengineering.com December 2022 3

CONTENTS_FE_12-22_Vs2.indd 3 12/1/22 7:33 AM

Understanding adhesives: What

4 December 2022 www.fastenerengineering.com DESIGN WORLD

Adhesives Intro 12-22_FE_Vs2_MF.indd 4 11/28/22 11:47 AM

DESIGN WORLD www.fastenerengineering.com December 2022 5

Adhesives Intro 12-22_FE_Vs2_MF.indd 5 11/28/22 11:48 AM

What projects require

Some products, regardless of how big or small, require

Scenarios calling for custom adhesives

FORMULATIONS 12-22_FE_Vs2_MF.indd 6 11/28/22 11:51 AM

Types of adhesives (according to Adhesives.org)

DESIGN WORLD www.fastenerengineering.com December 2022 7

FORMULATIONS 12-22_FE_Vs2_MF.indd 7 11/29/22 11:05 AM

Reactive versus non-reactive

As the solvent evaporates, it leaves the adhesive behind.

FORMULATIONS 12-22_FE_Vs2_MF.indd 8 12/2/22 1:38 PM

Biocompatibility is a general term

1. Acute systemic toxicity (systematic injection) test:

3. Implantation test: Measures toxicity, infection,

BIOCOMPATIBILITY 12-22_FE_Vs2_MF.indd 10 11/29/22 11:02 AM

Although Class VI is typically used to evaluate plastic materials that may be

ISO 10993 biocompatibility testing

Typical tests include:

* Note: as of 2021, ISO 10993-10 now contains a

In general, adhesives and sealants are not required

DESIGN WORLD www.fastenerengineering.com December 2022 11

BIOCOMPATIBILITY 12-22_FE_Vs2_MF.indd 11 11/29/22 11:03 AM

What benefits do UV curable

UV curable adhesives offer 100% solid material, near-instant curing times,

CURING 12-22_FE_Vs2_MF.indd 12 11/28/22 11:59 AM

DESIGN WORLD www.fastenerengineering.com December 2022 13

CURING 12-22_FE_Vs2_MF.indd 13 11/29/22 11:01 AM

UV FOG sealant from Hernon is cured in place as a bead on

CURING 12-22_FE_Vs2_MF.indd 14 11/28/22 12:00 PM

PINS / COTTERS SLIC PINS™

U.S. Patent No. 6,872,039 & 7,147,420

• Proven and Popular

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What are the common mistakes

• The properties of the threadlocker

Making the wrong choice

THREADLOCKER 12-22_FE_Vs2_MF.indd 16 11/28/22 12:03 PM

Deploying red threadlockers as The truth is that more adhesive does

DESIGN WORLD www.fastenerengineering.com December 2022 17

THREADLOCKER 12-22_FE_Vs2_MF.indd 17 12/1/22 7:38 AM