Split Sleeve Cold Expansion (8101)

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FATIGUE TECHNOLOGY INC.
FTI Process Specification 8101

Revision L
Cold Expansion of Holes Using the

Standard Split Sleeve System and
Countersink Cold Expansion (CsCx )
July 29, 2019
RESTRICTION ON DISCLOSURE AND RELEASE
This specification and the information contained herein is proprietary to Fatigue Technology (FTI) and is not to be
released or disclosed to persons or organizations outside FTI without the express written consent of FTI corporate
management.
This serial numbered document is being released to the person named below, who is responsible for the control of
this document and for maintaining the proprietary data contained herein. This document is not to be released,
disclosed or duplicated in whole or in part for any purpose.
WARNING: This document contains technical data, export of which is restricted by the Arms Export Control Act
(Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., App.
2401 et seq.). Violations of these export laws are subject to severe criminal penalties.
Copy No:
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Date:
82054 REV L/ FTI-8101

8101 Revision Log
Revision # Description By Date

-C- Complete Rewrite. 7/28/1994
C-1 Note 5 on pages 47, 48 and 49, changed sleeve thickness 10/24/1994
tolerance from “+0.010/-0.000” mm to “+0.010/-0.005 mm
for all STDNs”; added paragraph regarding cutting tool and
mandrel materials for the CA system of tooling to Section 5.1.
C-2 Changed 20-2-N minor diameter from .5924 to .5942; WAS 6/4/1996
changed 30-0-N “A” gage diameter from .9101 to .9010;
changed 32-0-N “C” gage diameter from .9840 to .9780.
-D- Incorporated Advance Changes C-1 and C-2. Updated TGP/ 6/7/2002
Restriction on Disclosure and Document Introduction. JMS/
Updated nosecap model numbers in Tables 4.0-3 and 5.0-3 MRW
from CBCE and CACE style to MEN style. Completely
reformatted Table 4.0-2, metric dimensions for the CB
process. Added paragraph to Introduction describing
Revision D changes. Updated quality manual reference in
Section 1.6. Updated Figure 1.3-1 to show MEN nosecap.
Changed 52 Gage Diameter B from .2310 to .3210 in Table
5.0-1. Revised Sections 1.1, 3.1, 3.17.1, 3.83 and 4.2, and
added second paragraph in Section 5.2. Updated footers to
reflect new FTI address.
-E- Added Appendix A: Specification for Split Sleeve Cold EDL 8/18/2009
Expansion of Low Elongation Aluminum (Reduced
Expansion) and Appendix B: Specification for Split Sleeve
Cold Expansion of Low Elongation Materials (Close-
Tolerance Reduced Expansion. These Appendices added as
“Proprietary Releasable.” Updated approval positions and
titles “Document Control” and “Quality Engineer” for
signature lines to Revision Log. Updated logo and copyright;
removed “Inc.” from FTI name. Updated to current standards
for font, spelling out acronyms, consistent use of inch and
percent in text, releasability in footer; figure numbers and
titles on all graphics, with references in text; and current
patent numbers.
-F- Corrected Figure 6.2-1 to show nosecap sectioned with CCC 12/21/2009
components and display sleeve inside the outer jaw and the
inner jaw. Also added to Process Description more detailed
instruction on process in Section 6.3 criteria for wear of jaw.
-G- In Section 5.2 Applicable Materials, changed CA tooling WAS/ 3/18/2011
maximum material yield strength statement to include 160 ksi TLI
limitation, capability limits for material with higher yield
strength, and removed “compressive” from paragraph.
Revised Figures 2.1-1 and 6.2-2, Check Cold Expanded Hole
Diameter, from Go/No-Go Gage to Combination Gage.
Added Item 10 to Table 4.0-1. Rewrote Appendix A and B.
In Sections 1.2, 5.2 and 3.6 added “reference Section 5.2”
after references to 240 ksi maximum.
Use or disclosure of this data is subject to the restrictions on the title pages.
Fatigue Technology 401 Andover Park East Seattle WA USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886
82054-REV L / FTI-8101 NON-PROPRIETARY
Revision # Description By Date
-H- Changed title for Section 2.5 to Split Sleeve Cold Expansion JLD 9/12/2012
Tool Use Guidelines. Changed Section 2.5.1 to Safety
Precautions.
-J- Corrected the metric conversion in Table 4.0-2 for the 1/8- DLS/ 08/04/2014
inch family. Column (1A) “Diameter (1) Metric” will be the TRD
same as Column (1B) “Diameter (1) Metric”. Changed CB*-
4-0-N* to correct model number CB*-4-4-N tooling in Table
B.3.1-2, page B9. Added Export Administration Regulation
statement to cover page. Revision H never released.
Incorporated into Revision J.
-K- Corrected Nosecap assembly part number in Table B3.1-2 for BGF 2/17/2017
STDNs 8-0-N through 10-3-N.
-L- Changed starting reamer model number from CBLR-XXXX WAS 7/29/2019
to CBLSR-XXXX in Appendix A Table A.3.1-3. Removed
Appendix A and Appendix B document information, to be
maintained in each DM document.
Use or disclosure of this data is subject to the restrictions on the title pages
NON-PROPRIETARY 82054 –REV L/ FTI-8101
INTRODUCTION
The basic split sleeve cold expansion concept was developed by The Boeing Company in the late 1960s as a means
of retarding the growth of cracks at fatigue critical holes. The process works by imparting beneficial compressive
residual stress around the hole. The sleeve allows for one-sided processing and shields the hole from frictional
forces generated by the high interference of the expansion mandrel. Fatigue Technology (FTI) invented a cost
effective manufacturing method for the lubricated split sleeve that has lead to its wide spread use in the aerospace
industry.
Since 1969, FTI has continued research into the cold expansion technology and developed its own Split Sleeve
Cold Expansion (SsCx ) specification controlling applications in aluminum, steel and titanium. This
specification was first published in 1981 as FTI Process Specification 8101. In 1984, this specification was
updated by the release of 8101B, which has been adopted as the reference standard for Split Sleeve Cold Expansion
technology by the majority of aerospace companies and other industries.
Revision C of FTI-8101 transferred the knowledge gained from FTI’s continued research into the science of cold
expansion and from years of test data and service experience. Apart from format changes, the most significant
change in 8101C was the impact of final ream allowance on tooling selection. For example, the 8101B tooling
selection table was designed around a ream allowance of around 0.012 to 0.015 inch after Cx. Split Sleeve Cold
Expansion is now applied to a broader range of materials and conditions than when it was originally conceived.
This greater range of material properties results in ream allowances after Cx from about 0.008 inch to over 0.025
inch. To accommodate this variability and improvements in hole preparation technology, FTI has provided two
options in the Standard Tooling Diameter Number (STDN) selection tables to optimize ream allowance based on
manufacturing requirements. The 8101B tables are still applicable since the provision for a choice of tooling
selection was always allowed and covered by amplifying notes in the tables.
Another change to the specification at Revision C was a shift in the sleeve thickness tolerance. The old tolerance
was +0.0006/ 0.0000 inch; the new tolerance is +0.0004/ 0.0002 inch. The new tolerance conforms to
manufacturing standards for stainless steel strip material and is in line with other cold expansion specifications.
This specification is designed to cover standard cold expansion applications, and therefore the tables reflect only
standard tool selections. There may be occasions where these specification parameters need to be modified to suit
particular hole configurations or requirements, such as short edge distance, closely spaced holes, material
properties, etc. In these cases, you should contact FTI for assistance in defining your actual specifications or
tooling needs.
Although the tables in this specification cover standard tooling for hole diameters up to 1 inch, tooling is available
to cold expand holes up to 4 inches and in material thickness up to 7 inches. Contact FTI for further information.
FTI’s sole industry is in support of the cold expansion technology. Technical Support Personnel are backed by an
experienced Engineering Staff utilizing the latest finite element modeling and CAD programs to define and design
special application tooling based on specific parameters or requirements. All FTI specifications and
recommendations are tested and/or correlated to test programs conducted in FTI’s Materials Testing Facility before
being approved.
Revision D of Specification 8101 reflects a change in the design of nosecaps used in the cold expansion process.
Modular Extension Nosecaps (MENs) have replaced the CBCE and CACE caps from Revision C. Also, the metric
tooling table for CA tooling has been updated. This revision also elaborates on the effect of cold expansion of
some later aluminum alloys, especially in holes normal to the short transverse grain direction. It is important to
consider the base material elongation properties in different grain directions to ensure the cold expansion process
does not exceed these properties.
TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
PART 1:
GENERAL AND TECHNICAL INFORMATION
1.0 GENERAL INFORMATION .......................................................................................................... 2

1.1 Purpose .................................................................................................................................. 2
1.2 Scope...................................................................................................................................... 2
1.3 Process Description ............................................................................................................... 2
1.4 Process Benefits ..................................................................................................................... 3
1.5 Definitions ............................................................................................................................. 3
1.6 Applicable Documents........................................................................................................... 4
1.7 Patent Information ................................................................................................................. 5
1.8 Operator and Inspector Training Recommendations ............................................................. 5
2.0 TOOLING SELECTION AND PROCESS PROCEDURE .......................................................... 7

2.1 Cold Expansion Process Overview ........................................................................................ 7
2.2 Detailed Split Sleeve Cold Expansion Process Steps ............................................................ 9
2.2.1 Drill and Ream Starting Hole ................................................................................ 9
2.2.2 Check Starting Hole .............................................................................................. 9
2.2.3 Inspect Mandrel ................................................................................................... 10
2.2.4 Cold Expand a Hole............................................................................................. 11
2.2.5 Check Cold Expanded Hole Diameter ................................................................ 11
2.2.6 Post Reaming the Hole ........................................................................................ 12
2.2.7 Install Fastener .................................................................................................... 13
2.3 Standard Tooling Diameter Number Selection.................................................................... 13
2.4 Tooling Selection ................................................................................................................. 13
2.5 Split Sleeve Cold Expansion Tool Use Guidelines ............................................................. 14
2.5.1 Safety Precautions ............................................................................................... 14
2.5.2 Instructions for Safe and Effective Use of Tooling............................................. 14
3.0 TECHNICAL REQUIREMENTS................................................................................................. 16

3.1 Applicable Materials............................................................................................................ 16
3.2 Minimum Material Thickness.............................................................................................. 16
3.3 Multi-Material Stackups ...................................................................................................... 16
3.4 Edge Margin Requirement ................................................................................................... 17
3.5 Hole Spacing Requirement .................................................................................................. 17
3.6 Applied Expansion............................................................................................................... 17
3.7 Estimated Pull Forces .......................................................................................................... 18
3.8 Cold Expanded Hole Geometry ........................................................................................... 20
3.8.1 General Shape...................................................................................................... 20
3.8.2 Axial Ridge .......................................................................................................... 20
3.8.3 Shear Discontinuity ............................................................................................. 20
3.9 Surface Upset ....................................................................................................................... 21
3.10 Faying Surface Separation ................................................................................................... 21
3.11 Ream Allowance .................................................................................................................. 22
3.12 Post Sizing of Cold Expanded Holes for Fastener Fit ......................................................... 22
3.13 Fastener Interference ........................................................................................................... 22
3.14 Deburring, Chamfering, and Radiusing ............................................................................... 22
NON-PROPRIETARY 82054-REV L / FTI-8101
TABLE OF CONTENTS (Continued)
3.15 Countersunk Holes............................................................................................................... 22

3.15.1 Countersinking Holes After Cold Expanding Straight Hole ............................... 23
3.15.2 Cold Expansion of Countersink Holes Using the CsCx Nosecap Assembly ...... 23
3.15.3 Rework of Previously Countersunk Holes .......................................................... 23
3.16 Backup Block Usage ............................................................................................................ 24
3.17 Sleeves ................................................................................................................................. 24
3.17.1 Sleeve Orientation ............................................................................................... 25
3.17.2 Sleeve Stacking ................................................................................................... 25
PART 2:
TOOLING TABLES FOR THE SPLIT SLEEVE COLD EXPANSION PROCESS OF ALUMINUM
ALLOYS AND MILD STEEL
4.0 TOOLING SELECTION ............................................................................................................... 27

4.1 General ................................................................................................................................. 27
PART 3:
TOOLING TABLES FOR THE SPLIT SLEEVE COLD EXPANSION PROCESS OF TITANIUM AND
HIGH-STRENGTH STEEL
5.0 TOOLING SELECTION ............................................................................................................... 37

5.1 General ................................................................................................................................. 37
PART 4:
SPLIT SLEEVE COLD EXPANSION USING THE COUNTERSINK COLD EXPANSION PROCESS
6.0 GENERAL ....................................................................................................................................... 47

6.1 Purpose ................................................................................................................................ 47
6.2 Process Description ............................................................................................................. 49
6.3 Countersink Cold Expansion Nosecap ................................................................................ 49
6.4 Tooling Selection ................................................................................................................. 49
7.0 TECHNICAL REQUIREMENTS................................................................................................. 50

7.1 General ................................................................................................................................. 50
7.3 Starting Hole Requirements ................................................................................................. 50
7.4 Prelubricated Split Sleeves .................................................................................................. 50
7.5 Rework of Previously Countersunk Holes........................................................................... 50
7.6 Minimum Material Thickness.............................................................................................. 51
7.7 Cutting Countersink Prior to Cold Expansion ..................................................................... 51
7.8 Backup Blocks ..................................................................................................................... 52
PART 5:
EQUIVALENT/OTHER COLD EXPANSION SPECIFICATIONS
8.0 EQUIVALENT/OTHER COLD EXPANSION SPECIFICATIONS ........................................ 56
FIGURES
Figure 1.3-1 Split Sleeve Cold Expansion ........................................................................................................... 2
Figure 1.4-1 Residual Stresses Induced by Cold Expansion ................................................................................ 3
Figure 2.1-1 Cold Expansion Process Steps Using Standard Nosecap ................................................................ 8
Figure 2.2.1-1 Starting Hole Preparation ................................................................................................................ 9
Figure 2.2.2-1 Starting Hole Diameter Verification ............................................................................................... 9
Figure 2.2.2-2 Verifying the Starting Hole Diameter ............................................................................................. 9
Figure 2.2.3-1 Mandrel Check Fixture .................................................................................................................. 10
Figure 2.2.3-2 Inspecting the Mandrel Major Diameter ....................................................................................... 10
Figure 2.2.4-1 Cold Expansion Process ................................................................................................................ 11
Figure 2.2.5-1 Verification of Cold Expansion ..................................................................................................... 11
Figure 2.2.5-2 Inspecting Final Hole Diameter ..................................................................................................... 12
Figure 2.2.6-1 Final Reaming Operation............................................................................................................... 12
Figure 2.2.7-1 Fastener Installation....................................................................................................................... 13
Figure 3.4-1 Edge Margin Requirement............................................................................................................. 17
Figure 3.5-1 Hole Spacing Requirement ............................................................................................................ 17
Figure 3.7-1 Estimated Pull Forces for Different Materials and Hole Diameters ............................................. 19
Figure 3.8.2-1 Axial Ridge .................................................................................................................................... 20
Figure 3.8.3-1 Shear Discontinuity ....................................................................................................................... 20
Figure 3.9-1 Surface Upset................................................................................................................................. 21
Figure 3.10-1 Faying Surface Separation ............................................................................................................. 21
Figure 3.17.2-1 Sleeve Stacking.............................................................................................................................. 25
Figure 6.2-1 Countersink Cold Expansion System Components ....................................................................... 47
Figure 6.2-2 Countersink Cold Expansion Process Description ........................................................................ 48
Figure 6.3-1 Countersink Cold Expansion Nosecap Assembly ......................................................................... 49
Figure 7.6-1 Minimum S/D Ratio ...................................................................................................................... 51
Figure 7.7-1 Procedure for Adjusting Countersink Depth ................................................................................. 52
Figure 7.8-1 Backup Block Usage for Countersunk Holes ................................................................................ 53
TABLES
Table 4.0-1 High Interference Cold Expansion Requirements–Cold Expansion Process
Aluminum and Mild Steel ............................................................................................................. 28
Table 4.0-2 High Interference Cold Expansion Requirements–Cold Expansion Process–Metric
Aluminum and Mild Steel ............................................................................................................. 31
Table 4.0-3 Standard Tooling List–Cold Expansion Process, Aluminum and Mild Steel ............................... 34
Table 5.0-1 High Interference Cold Expansion Requirements–Cold Expansion Process
Titanium and High-Strength Steel ................................................................................................. 38
Table 5.0-2 High Interference Cold Expansion Requirements–Cold Expansion Process–Metric
Titanium and High-Strength Steel ................................................................................................. 42
Table 5.0-3 Standard Tooling List–Cold Expansion Process, Titanium and High-Strength Steel ................... 44
Table 7.0-1 Standard Tooling List–Cold Expansion Process: Using the CsCx Nosecap Assembly ............... 54
Table 8.0-1 Equivalent/Other Cold Expansion Specifications ......................................................................... 57
APPENDICES
Appendix A Specification for Split Sleeve Cold Expansion of Low Elongation Aluminum
(Reduced Expansion).....................................................................................................................A1
Appendix B Specification for Split Sleeve Cold Expansion of Low Elongation Materials
(Close-Tolerance Reduced Expansion) ......................................................................................... B1
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SECTION 1
General and Technical Information
82054-REV L / FTI-8101 NON-PROPRIETARY 1
1.0 GENERAL INFORMATION
1.1 Purpose
The purpose of this specification is to define a uniform system of tooling and process parameters necessary for
proper Split Sleeve Cold Expansion (SsCx ) of holes in aluminum, titanium and high-strength steel. When
used in accordance with this specification, the Fatigue Technology (FTI) Split Sleeve Cold Expansion process
has been shown by test and in-service experience to significantly extend the fatigue life and damage tolerance of
the structure in which the cold expanded holes are located.
1.2 Scope
This specification defines the critical tooling dimensions and starting hole diameters and configurations for
Split Sleeve Cold Expansion of holes in aluminum, mild steel, titanium, and high-strength steel (240 ksi
maximum, reference Section 5.2) for hole diameters ranging from 0.125 to 1.0 inch. All critical dimensions are
specified in both British (inches) and Metric (mm) units. Also defined are the method and tooling requirements
for cold expanding countersunk holes in aluminum alloys up to 9/16 inch in diameter.
This specification provides engineering, manufacturing and quality assurance guidelines for the use of the
process in both new production and rework environments. Post cold expansion final hole size (after final ream)
and fastener fit are not controlled by this specification. A detailed description of the tooling and non-critical
dimensions can be found in the FTI Tooling Catalog.
1.3 Process Description
Split Sleeve Cold Expansion is accomplished by pulling a tapered mandrel, pre-fitted with a lubricated split
sleeve, through a hole as illustrated in Figure 1.3-1. The function of the disposable split sleeve is to reduce
mandrel pull force, ensure correct radial expansion of the hole, preclude damage to the hole, and allow one-
sided processing.
Nosecap Assembly Lubricated Flared

Split Sleeve
Mandrel
Puller Unit Workpiece
Figure 1.3-1
Split Sleeve Cold Expansion
The applied expansion of the hole by the mandrel and sleeve is nominally 4.0 percent of the hole diameter for
aluminum and mild steels, and 5.5 percent for high-strength metals. The desired finished hole diameter is
normally obtained by reaming the cold expanded hole.
2 NON-PROPRIETARY 82054-REV L / FTI-8101
1.4 Process Benefits
The action of drawing the mandrel through the starting hole causes a radial plastic flow of material and results
in an annular zone of residual compressive stresses that extend up to one diameter beyond the edge of the hole
as shown in Figure 1.4-1.
The residual stresses created by cold expansion significantly increase fatigue life by reducing the stress intensity
factor and crack growth life by reducing the applied stress ratio at the hole. The magnitude of the peak residual
compressive circumferential stress is about equal to the compressive yield stress for the material. The
compressive stress zone spans one radius to one diameter from the edge of the hole, for diameters up to 1/2 inch
for most materials. A balancing zone of tensile stresses lies beyond the circumferential compressive stress zone.
+ Te n s io n
1 0 -1 5 % Te n s ile
Y ie ld S tre n g th
D is ta n c e F ro m H o le
- C o m p re s s io n
R e s id u a l C o m p re s s io n Z o n e
A p p ro x im a te ly C o m p re s s iv e
Y ie ld S tre n g th
Figure 1.4-1
Residual Stresses Induced by Cold Expansion
1.5 Definitions
Applied Expansion (Ia): The total expansion of a hole expressed as a percentage of the starting hole diameter.
Cold Expansion/Cold Work (Cx): The process used to provide residual compressive stresses around the
diameter of a hole.
Cold Expanded Hole Diameter (CxD): The diameter of a hole after cold expansion.
Critical Tooling Dimensions: Any tooling dimension that either contributes to the applied expansion of a hole
or to a related quality assurance inspection.
Edge Margin or e/D: The ratio of the distance between the center of the hole and the edge of the part (e) to the
nominal finished hole diameter (D).
Existing Hole Diameter (EHD): The diameter of a hole prior to reaming, cold expansion or any other operation
associated with cold expansion.
Fastener Interference: The difference, expressed in inches or millimeters, between the shank diameter of the
fastener and the hole in which it is installed.
Final Hole Diameter (FHD): The diameter of a hole prior to installing a fastener.
Hole Spacing: The distance between the centerline of two adjacent holes, usually expressed as the number of
hole diameters between hole centerlines.
Material Stackup Length: The combined thickness of a structure through which a hole is located; also the total
depth of a hole.
Shear Discontinuity: A small, non-fatigue critical anomaly that occurs at the edge of a hole adjacent to the axial
ridge caused by the split in the sleeve.
Sleeve Ridge: The slightly raised axial ridge corresponding to the sleeve split found on the inside of a cold
expanded hole.
Standard Tool Diameter Number (STDN): The tool code used to identify specific size tooling.
Starting Hole Diameter (SHD): The specified hole diameter before cold expansion.
Surface Upset: The out-of-plane deformation that occurs just around and adjacent to the perimeter of the hole
as a result of axial material movement during cold expansion.
1.6 Applicable Documents
MIL-Q-9858A “Quality Program Requirement”
MIL-STD-105 “Inspection Sampling Procedure”
MIL-STD-109 “Quality Assurance Terms and Definitions”
MIL-I-45208A “Inspection System Requirement”
FTI-29786 FTI Conformance Document, “Requirements for Pre-Lubricated, Stainless

Steel Sleeves Used in FTI’s Split Sleeve Cold Expansion Process”
FTI-30882 FTI Conformance Document, “Requirements for Gage and Check Fixtures
Used in FTI’s Split Sleeve Cold Expansion Process”
ANSI/ASME B46.1-1985 “Surface Texture (Surface Roughness, Waviness, and Lay)”
1.7 Patent Information
The Split Sleeve Cold Expansion Method and Apparatus described in this Specification was covered under
United States Patent Number 3,566,662. Most of the tooling provided by Fatigue Technology is manufactured
under United States Patent Number 4,187,708. The CsCx nosecap assembly and related method is covered by
United States Patent Numbers 4,423,619 and 4,425,780 (Foreign patents are pending). The United States
Government does not have a Royalty Free License.
1.8 Operator and Inspector Training Recommendations
Training is recommended for all personnel involved in cold expanding holes or who perform inspections of cold
expanded holes. Training should be provided by qualified training personnel only.
Proper training in the cold expansion processes is necessary to ensure that the operator understands the process
and carries it out correctly, thereby realizing the fatigue life enhancement benefits. FTI offers certified on-site
training designed for engineers, mechanics/technicians, quality assurance and other production liaison
personnel.
SECTION 2
Split Sleeve Cold Expansion

Process Steps for Standard Tooling
2.0 TOOLING SELECTION AND PROCESS PROCEDURE
2.1 Cold Expansion Process Overview
An overview of the process steps for the Split Sleeve Cold Expansion process is shown in Figure 2.1-1. Each of
these steps is explained in detail in Paragraph 2.2. These basic steps must be followed whether cold expanding
aluminum, steel, titanium or countersink holes to ensure proper process integrity.
Proper applied expansion is critical to overall performance of the cold expansion process. The three key
dimensions which determine applied expansion are starting hole diameter, mandrel major diameter and sleeve
thickness. The specified expansion is assured by selection of the proper tooling and by verification of these key
dimensions. These dimensions are specified in the Standard Tooling Diameter Number (STDN) Tables.
Determining the proper STDN is important for determining the proper tools for the application. STDN
selection is explained in detail in Paragraph 2.3.
The Split Sleeve Cold Expansion Process
Figure 2.1-1
Cold Expansion Process Steps Using Standard Nosecap
2.2 Detailed Split Sleeve Cold Expansion Process Steps
The basic steps for cold expanding holes are shown in detail in the following paragraphs. These steps must be
followed whether cold expanding aluminum, steel, titanium or countersink holes to ensure proper process
integrity.
2.2.1 Drill and Ream Starting Hole
The starting holes must be drilled or reamed to

Starting Drill
dimensions specified for the Standard Tool Diameter
Number. Bell mouthing, ovality, or barreling of the
starting holes are acceptable provided they do not
exceed the tolerance limits of Tables 4.0-1 and 5.0-1
(Metric Tables 4.0-2 and 5.0-2). The starting hole Starting Reamer
requirements for countersunk holes are generally the
same as for straight holes. Refer to Paragraph 3.15
and Section 7.0 for information on countersunk holes. Figure 2.2.1-1
Starting Hole Preparation
The starting hole and post reamed holes must have a
surface roughness of 125 micro inches or smoother, as
defined in ANSI/ASME B46.1-1985. Reaming of starting holes is not required if the drill unit is capable of
producing the surface finish within the specified limits. Holes must be normal, within 2°, to the surface
that is in contact with the nosecap. Backside normality should not exceed 10°. See Figure 2.2.1-1.
The choice of cutting fluid can be dependent on the material type, but in general, residue free cutting fluids
are recommended for drilling and reaming operations. Excessive lubricant residue left in the hole must be
removed in order to preclude axial slippage of the sleeve in the hole during the cold expansion process.
2.2.2 Check Starting Hole
Verify the starting hole diameter using the applicable Cx

combination gage as shown in Figures 2.2.2-1 and 2.2.2-2, or other Combination Gage
suitable flat (blade) Go/No-Go gage. In deep holes and in multi-
material stackups such as steel/aluminum, care must be taken to
verify that the entire length of the hole is within the hole diameter
tolerance specified in the tables for each Standard Tool Diameter Figure 2.2.2-1
Number. Starting hole diameters may also be verified using an Starting Hole Diameter
inspection pin (certified to .0002 inch or better accuracy), or a Verification
suitable hole measuring tool (certified to .0001 inch or better
accuracy).
Accept Reject
Figure 2.2.2-2
Verifying the Starting Hole Diameter
2.2.3 Inspect Mandrel
During normal use, the mandrel major diameter should be

periodically checked using the mandrel check fixture (see Mandrel Check Fixture
Figure 2.2.3-1). The mandrel should also be inspected at the
start and finish of each work shift. When working with
titanium or high-strength steel materials, inspection should be
more frequent. Because the mandrel major diameter is critical
for proper cold expansion of a hole, the mandrel should be
checked as often as practical. The mandrel major diameter is
Figure 2.2.3-1
allowed to wear to the minimum mandrel diameter as specified
Mandrel Check Fixture
in the Standard Diameter Tooling Number (STDN) Tables.
Mandrels that have worn to, or below, this limit must be
replaced to ensure process integrity. See Figure 2.2.3-2.
Mandrel major diameters can also be inspected using a micrometer, or snap gage. Refer to the STDN
Tables for specified minimum allowable diameters when using a micrometer or snap gage.
Mandrel Check
Accept Reject and Discard Mandrel
Figure 2.2.3-2
Inspecting the Mandrel Major Diameter
2.2.4 Cold Expand a Hole
To cold expand a hole, first slide the sleeve over the

mandrel until it is up against the nosecap. The sleeve
should have a very slight gap and fit snugly on the minor
diameter of the mandrel.
Next, slide the mandrel and sleeve combination into the

starting hole.
Place the nosecap firmly against the workpiece.
Withdraw the mandrel through the sleeve which is retained

in the workpiece by depressing the trigger on the puller
unit. Continue holding the trigger until the mandrel is
through the workpiece. Remove the puller and release the
trigger after the mandrel is clear of the structure. The
puller will automatically return the mandrel to accept the
next sleeve.
Remove the used sleeve from the hole and discard. Refer
to Figure 2.2.4-1. NOTE: Sleeves are only used once.
Figure 2.2.4-1
Cold Expansion Process
2.2.5 Check Cold Expanded Hole Diameter
Verify that proper cold expansion has been

accomplished by using the verification Go/No-Go
plug gage or the FTI combination gage. The plug
gage diameter (and also the non-cutting pilot
diameter of the gage finish reamer) is sized such
Go-No-Go Gage
that it will fit into a cold expanded hole, but will Go/No-Go
not fit into a non-cold expanded hole. The FTI
plug gage has two flats along the surface. It may
be necessary to align one of the flats with the
ridge to properly inspect the cold expanded hole.
See Figure 2.2.5-1.
Gage Finish Reamer
Figure 2.2.5-1
Verification of Cold Expansion
If the plug gage does not fit (rejected condition), use the following steps to determine the cause of the
rejected condition.
1. Ensure that the correct cold expansion tooling was selected and used.
2. Check the mandrel for wear using the mandrel check fixture.
3. Check the sleeve for signs of break up during cold expansion.
Rejected holes should be re-cold expanded. If re-cold expanding with the correct tooling still gives a
rejected hole, contact FTI. Refer to the Standard Tooling Diameter Number Tables for the correct plug
gage and pilot diameters. Figure 2.2.5-2 shows a cold-expanded hole.
Note: Using tooling designed for cold expanding aluminum or mild steel (CB tooling) may not adequately
cold expand high-strength steel or titanium, and therefore the gage may not enter the hole as described.
Combination Gage Gage Finish Reamer
or Hole has been

cold expanded.
or Hole has not been

cold expanded.
Figure 2.2.5-2
Inspecting Final Hole Diameter
2.2.6 Post Reaming the Hole
After cold expansion, the holes may be

reamed up to a particular diameter for the
desired fastener fit. The typical ream
allowance for sizing to a nominal diameter is
provided in the STDN selection tables under
Columns 1A and 1B. The actual ream Finish Reamer
allowance will be dependent on the amount
of interference or clearance specified for
your application. For an open hole, the cold
expanded hole can be left in the as cold Figure 2.2.6-1
expanded (un-reamed) condition or reamed Final Reaming Operation
to any diameter less than the maximum hole
diameter specified in the last column of the
STDN selection table. Figure 2.2.6-1 shows
the final reaming operation.
2.2.7 Install Fastener
Fasteners may be installed into cold expanded, post-reamed holes using any
approved method. The cold expansion process may work harden the material
sufficiently to make installation of interference fit fasteners a bit more
difficult. In most cases, fasteners are just as easy to install into cold
expanded holes as non-cold expanded holes. Figure 2.2.7-1 shows the
fastener installation.
Figure 2.2.7-1
Fastener Installation
2.3 Standard Tooling Diameter Number Selection
Selecting the proper Standard Tooling Diameter Number (STDN) is very important for process effectiveness.
The STDN is a tool code that is used to identify tooling required for cold expanding a specific hole diameter in
a particular material. To select the STDN for the application, follow the steps below:
1. Select from the list below the appropriate Section that corresponds with the material or hole configuration to
be cold expanded.
Part 2: Tooling Selection Tables for the Split Sleeve Cold Expansion Process of Aluminum Alloys and
Mild Steel
Part 3: Tooling Selection Tables for the Split Sleeve Cold Expansion Process of Titanium and High-
Strength Steel
Part 4: Split Sleeve Cold Expansion of Aluminum Using the Countersink Cold Expansion System
2. Using the STDN selection table found in the appropriate Part listed above, scroll down the Reference
Fastener Diameter column to find the fastener diameter or final hole diameter required. Note: This column
refers to either the fastener diameter or final hole diameter required after cold expansion and final ream.
3. The STDN is specified in the column adjacent to the fastener or final hole diameter column.
2.4 Tooling Selection
After the STDN has been determined, selection of all associated tooling required for cold expansion can be
made. For maximum process effectiveness, the complete system of tooling should be used. The tooling
includes:
Starting Drill Mandrel

Starting Reamer Gage Finish Reamer
Combination Gage Nosecap
Split Sleeve Mandrel Check Fixture
To select the proper tooling for the application, follow these steps:
1. Identify the Standard Tooling Diameter Number (STDN).
2. Locate the Standard Tooling List Table further on in the same section where the STDN was selected.
3. Select the model numbers of the individual tools associated with the appropriate STDN found in the left
hand column.
2.5 Split Sleeve Cold Expansion Tool Use Guidelines
2.5.1 Safety Precautions
Split Sleeve Cold Expansion tooling requires use of very high hydraulic and air pressure. For operator
safety, the following precautions must be followed:
Wear safety glasses at all time during the cold expansion process.
Disconnect the air supply whenever the PowerPak is not in use, the hydraulic hose is disconnected
from the pump, or when maintenance is being performed.
In the event of a ruptured or leaking hydraulic hose, immediately release the trigger and disconnect the
air line from the PowerPak at the air input. Never use your hands to grasp a leaking hose under
pressure. The force of escaping hydraulic fluid can cause serious injury.
Periodically inspect the hose for wear or damage which could cause failure of the hose and possibly
result in injury.
2.5.2 Instructions for Safe and Effective Use of Tooling
Improper use of cold expansion tooling can damage the structure, injure the operator and/or provide
insufficient fatigue life improvement. In order to ensure the effectiveness of the process, the following
precautions must be followed:
Do not attempt to disconnect the hydraulic hose while the PowerPak is running.
Do not expose hoses to potential hazards such as extreme heat or cold, sharp surfaces, heavy impact,
vehicular traffic, toxic materials or paints.
Do not allow hoses to kink, twist, curl or bend so tightly that the oil flow within the hose is blocked or
reduced.
Do not mix this tooling with tooling from other manufacturers. Always use the complete set of
compatible FTI tooling including mandrel check fixtures and verification pins.
SECTION 3
Technical Information about the Standard

Split Sleeve Cold Expansion Process
3.0 TECHNICAL REQUIREMENTS
3.1 Applicable Materials
Most aluminum, mild steel, steel, titanium and nickel based alloys can be cold expanded successfully. Any
material that strain-hardens should develop the proper residual compressive stress necessary for life
improvement.
With the introduction of more advanced materials and large single-piece machined structures, it is important to
review and consider the material properties associated with holes drilled in different planes, i.e., material
properties relative to the grain direction into which the hole is drilled.
In any material, it is important that the percent failure strain (percent elongation) of the material be greater than
the percent applied expansion induced by the Cx process. For this reason, grain directions in some material
alloys should not be cold expanded with Table 4.0-1 or 5.0-1 applied expansion levels. Cracks, or shear tears,
radiating from the hole have been observed at these levels of cold expansion in a few materials. In most cases
the cracks originate at the shear discontinuity associated with the sleeve split. For these cases, the maximum
applied expansion can be modified for specific alloys, and the sleeve gap orientation specified. Some aluminum
alloy materials found to be sensitive to applied expansion and sleeve gap orientation, particularly in holes
drilled normal to the short transverse (ST) plane, include 7050/7010, 7178 (extrusions) and 2124 alloys.
Despite the fact that shear tears or cracks have been found in these materials, FTI has been able to adapt its
process specifications/procedures to successfully cold expand these materials. Investigation of some aluminum
lithium alloys has also shown a propensity to develop cracks/shear tears during cold expansion due to low
elongation properties in certain grain directions.
If you have a question about the applicability of Split Sleeve Cold Expansion to any alloy or grain direction,
please contact FTI for assistance.
3.2 Minimum Material Thickness
Split Sleeve Cold Expansion of holes in thin, single sheets may cause buckling of the material around the hole
with a consequent reduction in fatigue performance. The minimum material thickness should generally not be
less than 1/5 of the diameter of the hole being cold expanded. Buckling or oil canning is acceptable only if the
hole is filled with a fastener installed with sufficient clamp-up to mechanically remove the buckling, or if the
buckling does not create a static load or fit-up problem. Buckling can be reduced in both straight and
countersunk holes by using backup blocks, described in Paragraphs 3.16 and 7.8, or by reducing the applied
expansion. FTI can assist with any specific application.
3.3 Multi-Material Stackups
Cold expansion of holes in multi-material stackups (aluminum with titanium, aluminum with steel, etc.) is
acceptable. The applied expansion range (Table 4.0-1 or 5.0-1) should be selected based upon the material in
the stackup that requires the greatest fatigue improvement. For stackups that contain titanium or high-strength
steel, it is advisable to use a V2 mandrel material. The V2 material ensures that mandrel major diameter is
maintained under the high expansion forces generated in these higher yield strength materials.
Note: The final hole diameter after cold expansion will not be the same in each material (e.g., when cold
expanding aluminum alloy and titanium with CB [aluminum] Cx tooling, the Cx verification gage may not pass
through the titanium because it will “spring back” further after Cx).
As a general rule, do not cold expand material stackups that include composite material. Disassemble the stack
and cold expand only the metallic components. The amount of interference imparted during cold expansion of
the metallic parts may damage the composite materials. Investigation of some aluminum lithium alloys has also
shown a propensity to develop cracks/shear tears during cold expansion due to low elongation properties in
certain grain directions.
3.4 Edge Margin Requirement
An edge margin of 1.75 or greater is generally recommended. Edge margin is D

defined as a ratio of the length from the center of the hole to the edge (e) over the
diameter of the hole (D). See Figure 3.4-1. Testing has shown that e/D less than or
equal to one (1.0) may be satisfactorily cold expanded at the nominal applied e
expansion levels. Some bulging of the edge will be evident at low e/D conditions.
In general, orient the sleeve gap away from the free edge.
Figure 3.4-1
Edge Margin Requirement
3.5 Hole Spacing Requirement
Hole spacing should be a minimum of three times the hole

diameter (3D) between adjacent holes. For holes less than
three hole diameters (3D) apart, insert a pin with .0005 to
.002 inch clearance into one of the adjacent holes and cold 3 D (min)
expand the non-pinned hole. See Figure 3.5-1. Remove the
pin and repeat the sequence by installing a pin with similar
clearance into the cold expanded hole.
It is important when dealing with closely spaced holes that all

holes in the region be similarly cold expanded. A closely spaced hole Figure 3.5-1
near a non-cold expanded hole will probably have residual tensile Hole Spacing Requirement
stress at the edge of the hole, which could lead to premature fatigue
cracking under in-service loads.
3.6 Applied Expansion
The optimal applied expansion of a hole is determined primarily from the mechanical properties of the material
and the hole diameter. Applied expansion is also influenced by engineering trade-offs relating to surface upset,
standardization of tooling, and allowance for expected manufacturing variables.
Applied Expansion (Ia) is given by the following formula:
Ia = (D + 2t - SHD) 100%
SHD
Where:
D = Major Mandrel Diameter

t = Sleeve Thickness
SHD = Starting Hole Diameter
For typical fastener hole diameters in aluminum and mild steel (80 ksi Fty maximum), the applied expansion
ranges from 3 to 6 percent. The 4.5 to 6.7 percent range of applied expansion applies to titanium and high-
strength steels (240 ksi maximum, reference Section 5.2). The range of applied expansion is due to starting hole
and tooling tolerances.
The standardized system of starting hole diameters, mandrel diameters, and sleeve dimensions for producing the
required applied expansions are specified in Table 4.0-1 (aluminum/mild steel) and Table 5.0-1 (titanium/high-
strength steel).
3.7 Estimated Pull Forces
A reasonable estimation of the pull force expected for typical cold expansion applications is shown in Figure
3.7-1. These estimated pull forces are based on data reported in Technical Report AFML-TR-74-10, “Sleeve
Cold Working Fastener Holes,” J.L. Phillips, February 1974, and should be used as a guide only for selecting
the required puller unit. The maximum pull force for a stackup of materials is governed by the individual
material and/or thickness that provides the greatest pull force. Contact FTI for more specific information on a
range of different materials and parameters.
90,000
All diameters inches

50,000 25,000 1- 1/2
80,000
70,000
40,000 20,000
60,000
50,000 30,000 15,000

1
Mandrel
Force
(lb) 40,000
30,000
_ 20,000 10,000
3/4
20,000
10,000 5,000 1/2
10,000
3/8
7,000
300M Ti-6Al-4V 2024-T851

1/4 1/2 3/4 1 1 - 1/4 1 - 1/2
Steel Titanium Aluminum
Stack Thickness (in.)
Figure 3.7-1
Estimated Pull Forces for Different Materials and Hole Diameters
Use or disclosure of this data is subject to the restrictions on the title pages
Fatigue Technology. 401 Andover Park East Seattle WA USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886
82054 / FTI-8101 19
3.8 Cold Expanded Hole Geometry
3.8.1 General Shape
The cold expanded hole can be characterized as having a slight hourglass shape. The end of the hole
corresponding to the nosecap is usually larger in diameter than the mandrel entry end of the hole. The cold
expanded hole diameter, excluding the height of ridge, varies by no more than 0.0015 inch along the entire
length of the hole for typical fastener hole diameters.
The cold expanded hole diameter is primarily determined by the starting hole diameter, the applied
expansion provided by the mandrel and sleeve, and the elasticity of the material.
3.8.2 Axial Ridge
An axial ridge, which Ridge

corresponds to the position of (not to scale)
the split in the sleeve, is left in

the bore of the hole during the
cold expansion process. This Surface Upset
ridge is typically reamed out
when final sizing the hole. The
presence of the ridge has been
thoroughly tested and does not
adversely effect the fatigue
performance of a cold expanded
hole. See Figure 3.8.2-1.
As a general rule, the sleeve gap

which forms the axial ridge Figure 3.8.2-1
should be located away from free Axial Ridge
edges, away from the end of lugs
(i.e. oriented towards the thickest part of the structure), and positioned at 0 or 90 to the weakest grain
direction of low failure strain material.
3.8.3 Shear Discontinuity
This surface phenomenon, caused by the split in the Shear Discontinuity
sleeve during cold expansion, is generally very shallow

and normally only occurs in high-strength aluminum
Ridge
alloys. Extensive fatigue tests have shown that this non-
critical anomaly does not adversely affect the fatigue Hole
performance of a cold expanded hole. Shear

discontinuities are considered a visual anomaly and are
not cause for rejection of a cold worked hole. See Figure 3.8.3-1
Figure 3.8.3-1. If, however, a crack or shear tear is Shear Discontinuity
indicated after the final ream then the hole must be
rejected and dispositioned by the proper Engineering
Authority (reference Section 3.1 for information on applicable materials).
20 NON-PROPRIETARY 82054 –REV L/ FTI-8101
3.9 Surface Upset
The cold expansion process produces an out-of-plane distortion, as shown in Figure 3.9-1, just around and
adjacent to the perimeter of the hole. This deformation does not affect the fatigue life improvement imparted by
the cold expansion. The surface upset ranges from 0.002-inch for steels up to 0.010-inch for aluminum. The
surface upset may be machined off; however, it is not normally called for or required. Because surface upset is
localized at the hole edge, most of it is removed during the final reaming procedure. Surface upset is acceptable
so long as the installed fastener meets the requirements of the fastener installation specifications. Surface upset
on the mandrel exit side of the hole is slighter larger than the entry side of the hole.
surface upset - mandrel exit side
surface upset
mandrel entry side
mandrel direction of travel
Figure 3.9-1
Surface Upset
3.10 Faying Surface Separation
A stackup of material must be securely clamped to ensure faying surface contact during starting hole
preparation, hole cold expansion, and final sizing. There may be some separation of the faying surface after
cold expansion. This effect is directly associated with the surface upset described in Paragraph 3.9. Separation
is typically allowed provided that a 0.005-inch (.125-mm) thick shim cannot be made to contact the fastener at
the hole edge after installation of the fastener. See Figure 3.10-1. It is not normally necessary to breakdown
and clean up the surfaces of a joint after cold expansion of holes.
minor faying surface separation

must be less than 0.005 inches
Figure 3.10-1
Faying Surface Separation
Normal use of faying surface sealant or wet assembly of joints is acceptable for Split Sleeve Cold Expansion of
holes. Pressure-leak tests have been conducted to show that the cold expansion process will not affect the
integrity of a sealed joint.
3.11 Ream Allowance
The Split Sleeve Cold Expansion system defined in this specification allows for a nominal range of final
reaming after cold expansion to achieve range fastener installation fits. Holes may be further oversized within
the maximum limits defined without impacting the predicted fatigue life benefits from the residual compressive
stress around the hole.
The maximum hole diameter, or ream allowance, after cold expansion for each diameter is specified in the
Standard Tooling Diameter Number Tables.
3.12 Post Sizing of Cold Expanded Holes for Fastener Fit
The diameter of cold expanded holes specified in STDN tables are designed to be smaller than the desired
fastener diameter. Post sizing is required in order to size the hole for the desired fastener fit. Post sizing of
open holes is generally not required.
The maximum metal removal is limited to about 20 percent of the starting hole diameter or 0.065 inch (1.64
mm), whichever is less. In general, the larger the hole, cold expanded at nominal levels, the higher the ream
allowance. Post sizing within this limit does not significantly reduce fatigue performance. The maximum
allowable finish hole diameters that may be used without re-cold expansion are specified in Tables 4.0-1 and
5.0-1. Should it be necessary to post size a hole beyond the limits specified, re-cold expansion of the hole will
be required. This is accomplished by using the next oversize STDN system of tooling.
3.13 Fastener Interference
Fastener interference is controlled by final sizing the cold expanded hole to the specified fastener diameter
using a gage finish reamer. Interferences for fastener diameters of 3/16 to 3/8 inch typically range from 0.001 to
0.005 inch. Consult the appropriate Engineering authority or drawing for the correct hole diameter for the
fastener fit.
3.14 Deburring, Chamfering, and Radiusing
Cold expanded holes may be deburred, chamfered or radiused using conventional methods. The maximum ream
allowance specified in the Standard Tooling Diameter Tables for the cold expanded hole size should be used as
a guide for determining the maximum diameter of the chamfer or radius.
Fatigue testing at FTI on countersink holes shows that significant fatigue life can be obtained even when the
countersink diameter is much greater than the maximum hole diameter after cold expansion. These results can
be extrapolated for chamfers or radii that are beyond the limits of the STDN tables, but each instance should be
carefully evaluated. Finishing operations, such as chamfering or radiusing should be accomplished after the
hole has been cold expanded. De-stacking of multi-material stackups for deburring purposes is not generally
required. Contact FTI for any questions you have on this subject.
3.15 Countersunk Holes
Many applications of the Split Sleeve Cold Expansion process involve countersunk holes. A cold expanded
countersunk hole may be produced by three methods.
The first is to cold expand a straight hole then machine the countersink afterward. This approach is typically
used in thin gage materials where a knife edge condition exists. When used for new production, this method
provides the highest fatigue life improvement.
The second method is to cold expand the countersunk hole using FTI’s patented countersink (CsCx) nosecap.
The action of the mandrel and nosecap combination simultaneously cold expands the bore of the hole and the
countersink portion. This is the preferred method of cold expansion for existing countersunk holes. It is used
primarily in rework applications, but is also useful in new production. In thin materials, the CsCx nosecap may
require the use of a backup block described in Paragraphs 3.16 and 7.8.
The third method, and one that is not generally recommended because of the lower fatigue life, is to enlarge the
hole by approximately 3/64 inch to remove most of the countersink portion of the hole and then cold expand the
remaining straight portion of the hole. This method can be used in AOG situations where getting the aircraft
back into service is a priority. It is also sometimes not practical because it removes a large amount of good
material and requires a large oversize fastener to be installed.
These three options are described in the paragraphs that follow:
3.15.1 Countersinking Holes After Cold Expanding Straight Hole
Machining of countersinks can be performed after cold expanding a straight hole. This method provides
the maximum amount of compressive residual stress in the countersink area and subsequently the highest
fatigue life. Cold expansion of the straight hole can be performed with standard CB, CA or Cx2s tooling.
3.15.2 Cold Expansion of Countersink Holes Using the CsCx Nosecap Assembly
Split Sleeve Cold Expansion of a countersunk hole using the CsCx nosecap is similar, in process
application, to the Cx process. This process is described in Section 4, Paragraphs 7.1 through 7.8.
3.15.3 Rework of Previously Countersunk Holes
It is recommended that previously countersunk holes be processed using the CsCx process per Section 4,
Paragraph 7.5.
To obtain satisfactory fatigue improvement using standard extension or flush nosecaps, it is necessary to
remove part of the existing countersink prior to cold expansion of the hole. Satisfactory results have been
achieved by increasing the fastener hole diameter 3/64 inch (1.1 mm) prior to cold expansion and
subsequent countersinking (nominal 3/16 to 3/8 inch or 5 to 10 mm fastener sizes).
An extension nosecap used on the countersink side of the material may mar the surface finish of the
countersink. It is generally advisable to either use a flush nosecap on the countersink side or to cold
expand from the back side of the hole using either an extension or flush nosecap.
3.16 Backup Block Usage
A Backup Block is a piece of material that is used in the cold expansion process to provide either a higher pull
force or in-plane stability to thin structure. The backup block must be made from a material with a modulus and
yield strength equal to or higher than the structure being cold expanded. A starting hole equal to the starting
hole of the structure is typically machined into the block.
For cold expanding countersink holes in thin structure using the CsCx nosecap, a backup block is placed on the
side opposite the countersink to provide a higher pull force. The higher pull force increases the action of the
nosecap on the countersink, which leads to increased fatigue life improvement. Backup blocks for countersink
holes are necessary where the countersink is close to a knife edge condition. This is described more fully in
Paragraph 7.8.
For straight holes in thin structure (D\t 5, where D = hole diameter, t = component thickness), a backup block
can be used on both sides of the hole to minimize out-of-plane buckling that may result from the cold expansion
process. Minimizing the buckling ensures the hole is radially expanded and improves the fatigue life and load
carrying capability of the structure.
3.17 Sleeves
One of the system critical components is the lubricated split sleeve. Split sleeves provide four important
functions during the cold expansion process:
Allows for a one-sided operation for nominal diameters
Provides total lubrication for the cold expansion process
Ensures radial expansion of the hole
Protects the workpiece from damage during cold expansion and increases durability of mandrels
Sleeves are available in both flared and straight configurations. The appropriate sleeve configuration is
determined by the application and the tooling. There are few, but important rules to follow when using the
sleeves.
Sleeve length must be at least 1/32 inch (.75 mm) longer than the material stack thickness. Sleeves must also
protrude by the same amount through backup blocks.
Sleeves cannot be reused due to distortion and loss of lubricity which results from the process application.
Sleeves should not be coated with any additional lubricants on either the inside or outside diameters. This
will result in higher pull forces and slippage which is detrimental to fatigue life performance.
Sleeves must not slide nor be damaged during cold expansion (e.g., sleeves breaking at the flare end). If,
during the process, axial slippage of the sleeve occurs such that the opposite end of the sleeve enters the
hole or if the sleeve breaks up, then the hole must be re-cold expanded. If the hole is not damaged beyond
the final ream, it may be re-cold expanded with the same tool set and a new sleeve. A hole may be re-cold
expanded using the same size tooling with no adverse effects to the fatigue life improvement (do not use the
same sleeve).
3.17.1 Sleeve Orientation
Process performance is not affected by the orientation of the split sleeve in the hole, except in the case of
edge margins less than 1.75 e/D where it is recommended that the sleeve split be oriented away from the
narrow edge.
Note: Some materials, such as 7010 or 7050 aluminum alloy in the short transverse grain direction may
require special sleeve gap orientations and reduced applied expansion levels. Contact FTI for assistance.
In most cases FTI will recommend orientation of the sleeve split normal to the longitudinal grain direction
to minimize the possibility of generating shear tears or cracks associated with the shear discontinuity (see
Sections 3.1 and 3.8.3).
3.17.2 Sleeve Stacking
FTI manufactures sleeves to cover hole diameters from around 1/8 inch to over 4-1/2 inches and in lengths
from about 1/4 inch to 6-1/2 inches depending on hole size. Single length sleeves are preferred for cold
expansion, especially in deep holes. However, if a single length sleeve is not available, stacking sleeves is
an acceptable practice for cold expanding deep holes. For ease of removal after cold expansion, ensure
that the sleeve splits are aligned with each other. Select sleeve lengths so as to ensure that there is no
sleeve joint that is less than one hole diameter from the back of the hole. The total sleeve length must
protrude 1/32 inch from the back of the hole. Sleeve joints should not occur within 1/32 inch of faying
surfaces in multi-material stackups. Refer to Figure 3.17.2-1.
UNACCEPTABLE UNACCEPTABLE
Reason: Length must be Reason: Sleeve splits are
1/32-inch longer than not aligned
material stack thickness
Min. Dim. = 1/32-inch
UNACCEPTABLE ACCEPTABLE
Reason: Sleeve joint less
than one hole diameter
from back surface
Figure 3.17.2-1
Sleeve Stacking
PART 2
Tooling Tables for the Split Sleeve Cold Expansion Process of

Aluminum Alloys and Mild Steel
4.0 TOOLING SELECTION
The applicable STDN for most hole diameters can be found in either Table 4.0-1 or Table 4.0-2 (metric
conversion).
4.1 General
After the proper STDN has been determined, selection of all associated tooling required for cold expansion is
easily accomplished. The fatigue life improvement imparted to the structure relies on proper selection and use
of the complete and compatible system of tooling. Process quality is certified using the gages and checking
fixtures specified.
The applicable STDN for most hole diameters can be found in either Table 4.0-1 or Table 4.0-2 (metric
conversion). The STDN for CB tools is set such that the first digit calls out the fastener diameter in 1/32-inch
increments. The second number, preceded by a dash, specifies the number of 1/64-inch oversize increments
from nominal.
For example, an STDN of 8-1-N is used to cold expand holes that accommodate a first oversize fastener from
1/4 inch; a 17/64 inch fastener. A 10-2-N STDN calls out tools used to install an 11/32-inch fastener; second
oversize from 5/16-inch nominal.
The “CB” STDN selection tables are set up to provide the user a choice of two final ream allowances after cold
expansion. Since the process provides a large zone of residual compressive stress, either ream amount can be
selected without impacting the fatigue life of the structure. Columns 1A and 1B in Table 4.0-1 give the average
ream allowance using the nominal fastener diameter, based on cold expansion parameters of 2024-T3
aluminum. The higher ream allowance in Column 1B removes more of the surface upset and shear
discontinuity at the hole. This may be desirable for holes in multi-material stackups, or where non-destructive
inspection picks up a signal from the shear discontinuity.
If the higher ream option is selected (Column 1B) then the STDN convention changes. Using the example from
above, an 8-1-N STDN (using column 1B ream allowance) can be used to install a second oversize fastener with
more final ream allowance. To install a nominal 1/4-inch fastener, 6-3-N tooling would be selected. The
Column 1B ream allowance should be used for high interference fasteners and other situations where more final
ream allowance is desired than that provided by Column 1A.
After the proper STDN has been selected, use Table 4.0-3 to select the appropriate system of tooling to perform
the cold expansion operation.
Most aluminum and mild steel alloys with a yield strength less than 80 ksi Fty can be cold expanded
successfully with CB tooling. There are some alloys and stackups that should be cold expanded with caution.
These are specified in Chapters 3.1 and 3.3. To cold expand higher strength steels or titanium, refer to Part 3,
Section 5.0.
Table 4.0-1
High Interference Cold Expansion Requirements
Aluminum and Mild Steel
Tooling Selection
1A. 1B. Standard Starting
Reference Fastener Reference Fastener Tool Hole Mandrel Diameters Maximum Finished
Diameter Av. Ream Diameter Av. Ream Diameter Diameter Minor Major Sleeve Gage Diameters (7) Hole Diameter
(1) Allow. (2) (1) Allow. (2) Number Min. Max. (3) Nom. (4) Min. (5) Thickness (6) A B C Not to Exceed (8)
1/8 .007 1/8 .007 4-0-N .113 .115 .0970 .1070 .1064 .0060 .1130 .1150 .1160 .1370
9/64 .007 9/64 .007 4-1-N .128 .130 .1120 .1230 .1224 .0060 .1280 .1300 .1310 .1560
5/32 .006 5/32 .006 4-2-N .144 .146 .1260 .1400 .1394 .0060 .1440 .1460 .1470 .1760
11/64 .006 11/64 .006 4-3-N .160 .162 .1420 .1560 .1554 .0060 .1600 .1620 .1630 .1920
3/16 (9) --- 3/16 .012 4-4-N .169 .171 .1520 .1654 .1648 .0060 .1690 .1710 .1720 .2026
3/16 .003 13/64 .019 6-0-N .177 .180 .1610 .1740 .1734 .0060 .1770 .1800 .1810 .2130
13/64 .004 7/32 .019 6-1-N .192 .195 .1766 .1895 .1889 .0060 .1920 .1950 .1970 .2300
7/32 .002 15/64 .018 6-2-N .209 .212 .1920 .2070 .2064 .0060 .2090 .2120 .2130 .2490
15/64 .002 1/4 .017 6-3-N .225 .228 .2080 .2230 .2224 .0060 .2250 .2280 .2290 .2650
1/4 .006 17/64 .022 8-0-N .235 .238 .2150 .2300 .2294 .0080 .2350 .2380 .2390 .2790
17/64 .006 9/32 .022 8-1-N .251 .254 .2311 .2460 .2454 .0080 .2510 .2540 .2550 .2950
9/32 .006 19/64 .022 8-2-N .266 .269 .2442 .2617 .2611 .0080 .2660 .2690 .2700 .3128
19/64 .005 5/16 .021 8-3-N .283 .286 .2614 .2789 .2783 .0080 .2830 .2860 .2870 .3306
5/16 .006 21/64 .021 10-0-N .297 .300 .2755 .2940 .2930 .0080 .2970 .3000 .3010 .3490
21/64 .006 11/32 .021 10-1-N .313 .316 .2916 .3100 .3090 .0080 .3130 .3160 .3170 .3650
11/32 .005 23/64 .021 10-2-N .328 .331 .3028 .3223 .3213 .0100 .3280 .3310 .3330 .3852
23/64 .005 3/8 .021 10-3-N .344 .347 .3184 .3379 .3369 .0100 .3440 .3470 .3490 .3996
3/8 .005 25/64 .021 12-0-N .359 .362 .3335 .3540 .3530 .0100 .3590 .3620 .3645 .4190
25/64 .005 13/32 .020 12-1-N .375 .378 .3496 .3700 .3690 .0100 .3750 .3780 .3800 .4350
13/32 .004 27/64 .019 12-2-N .391 .394 .3652 .3867 .3857 .0100 .3910 .3940 .3985 .4538
27/64 .004 7/16 .020 12-3-N .406 .409 .3809 .4024 .4014 .0100 .4060 .4090 .4120 .4710
Notes:
(1) Selected reference fastener diameter to provide the average ream allowance for that STDN.
(2) Average ream allowance is determined using the nominal fastener diameter and is based upon 2024-T3 aluminum. Materials with higher yield strengths will produce a minimal
increase in the ream allowance due to a smaller cold expanded hole diameter.
(3) Tolerance +/- .0005 inch.
(4) Manufacturing tolerance +/- 0.0002 inch.
(5) Minimum allowable diameter, mandrel gage diameter +0.0002/-0.0001 inch.
(6) Source inspected before lubricant applied; tolerance +0.0004/-0.0002 inch.
(7) A = Starting hole gage “GO” diameter; tolerance +0.0000/-0.0002 inch. B = Starting hole gage “NO-GO” diameter; tolerance +0.0002/-0.0000 inch.
C = Cx verification diameter; applies to gage finish reamer pilot (tolerance +0.0000/-0.0005 inch) and post Cx verification gage pin (tolerance +0.0002/-0.0000 inch).
(8) Cold expanded holes may be enlarged to the diameters listed without re-cold expanding.
(9) Use 4-4-N or 6-0-N tooling for 3/16-inch diameter final fasteners, depending on amount of desired final ream allowance.
Table 4.0-1 (Continued)

Tooling Selection
1A. 1B. Standard Starting
Reference Fastener Reference Fastener Tool Hole Mandrel Diameters Maximum Finished
7/16 .004 29/64 .020 14-0-N .421 .424 .3950 .4180 .4170 .0100 .4210 .4240 .4280 .4860
29/64 .004 15/32 .019 14-1-N .437 .440 .4111 .4340 .4330 .0100 .4370 .4400 .4440 .5020
15/32 .006 31/64 .021 14-2-N .450 .453 .4242 .4482 .4472 .0100 .4500 .4530 .4580 .5150
31/64 .006 1/2 .022 14-3-N .465 .468 .4394 .4634 .4624 .0100 .4650 .4680 .4735 .5300
1/2 .012 33/64 .027 16-0-N .474 .477 .4445 .4695 .4685 .0120 .4740 .4770 .4825 .5390
33/64 .012 17/32 .028 16-1-N .490 .493 .4601 .4850 .4840 .0120 .4900 .4930 .4980 .5550
17/32 .012 35/64 .027 16-2-N .505 .508 .4752 .5012 .5002 .0120 .5050 .5080 .5135 .5700
35/64 .012 9/16 .027 16-3-N .521 .524 .4908 .5168 .5158 .0120 .5210 .5240 .5285 .5860
9/16 .010 37/64 .026 18-0-N .537 .540 .5070 .5340 .5330 .0120 .5370 .5400 .5460 .6020
37/64 .011 19/32 .026 18-1-N .553 .556 .5226 .5495 .5485 .0120 .5530 .5560 .5615 .6180
19/32 .010 39/64 .026 18-2-N .568 .571 .5377 .5657 .5647 .0120 .5680 .5710 .5780 .6330
39/64 .010 5/8 .026 18-3-N .583 .586 .5533 .5813 .5803 .0120 .5830 .5860 .5940 .6480
5/8 .011 41/64 .026 20-0-N .597 .600 .5610 .5915 .5898 .0150 .5970 .6000 .6080 .6620
41/64 .011 21/32 .026 20-1-N .613 .616 .5766 .6070 .6053 .0150 .6130 .6160 .6235 .6780
21/32 .008 43/64 .023 20-2-N .631 .634 .5942 .6257 .6240 .0150 .6310 .6340 .6410 .6960
43/64 .008 11/16 .024 20-3-N .646 .649 .6098 .6413 .6396 .0150 .6460 .6490 .6565 .7110
11/16 .010 45/64 .025 22-0-N .659 .662 .6230 .6555 .6538 .0150 .6590 .6620 .6710 .7240
45/64 .010 23/32 .025 22-1-N .675 .678 .6386 .6710 .6693 .0150 .6750 .6780 .6865 .7400
23/32 .010 47/64 .025 22-2-N .690 .693 .6537 .6872 .6855 .0150 .6900 .6930 .7025 .7550
47/64 .010 3/4 .025 22-3-N .706 .709 .6693 .7028 .7011 .0150 .7060 .7090 .7150 .7710
Notes:
(9) Use 4-4-N or 6-0-N tooling for 3/16-inch diameter final fasteners, depending on amount of desired final ream allowance.

Tooling Selection
1A. 1B. Standard Starting - Maximum
Reference Fastener Reference Fastener Tool Hole Mandrel Diameters Finished
3/4 .012 49/64 .027 24-0-N .718 .721 .6820 .7165 .7148 .0150 .7180 .7210 .7270 .7830
49/64 .012 25/32 .028 24-1-N .734 .737 .6976 .7320 .7303 .0150 .7340 .7370 .7430 .7990
25/32 .012 51/64 .027 24-2-N .749 .752 .7062 .7422 .7405 .0180 .7490 .7520 .7580 .8140
51/64 .012 13/16 .027 24-3-N .765 .768 .7218 .7578 .7561 .0180 .7650 .7680 .7740 .8300
13/16 .009 53/64 .025 26-0-N .782 .785 .7390 .7760 .7743 .0180 .7820 .7850 .7910 .8470
53/64 .010 27/32 .025 26-1-N .798 .801 .7546 .7915 .7898 .0180 .7980 .8010 .8070 .8630
27/32 .011 55/64 .027 26-2-N .811 .814 .7677 .8057 .8040 .0180 .8110 .8140 .8200 .8760
55/64 .011 7/8 .027 26-3-N .826 .829 .7833 .8213 .8196 .0180 .8260 .8290 .8350 .8910
7/8 .012 57/64 .027 28-0-N .841 .844 .7980 .8370 .8353 .0180 .8410 .8440 .8500 .9060
57/64 .012 29/32 .028 28-1-N .857 .860 .8130 .8520 .8503 .0180 .8570 .8600 .8660 .9220
29/32 .004 59/64 .020 28-2-N .879 .882 .8357 .8757 .8740 .0180 .8790 .8820 .8880 .9440
59/64 .005 15/16 .020 28-3-N .894 .897 .8513 .8913 .8896 .0180 .8940 .8970 .9060 .9590
15/16 .013 61/64 .028 30-0-N .901 .904 .8580 .8990 .8973 .0180 .9010 .9040 .9130 .9660
61/64 .013 31/32 .029 30-1-N .917 .920 .8736 .9145 .9128 .0180 .9170 .9200 .9290 .9820
31/32 .012 63/64 .028 30-2-N .933 .936 .8920 .9310 .9293 .0180 .9330 .9360 .9450 .9980
63/64 .012 1 .028 30-3-N .949 .952 .9080 .9465 .9448 .0180 .9490 .9520 .9610 1.0140
(10) 1 .009 1 1/64 .025 32-0-N .965 .968 .9200 .9655 .9638 .0180 .9650 .9680 .9780 1.0300
Greater Contact Fatigue Technology for technical assistance.
than 1
Maximum
Notes:
(9) Use 4-4-N or 6-0-N tooling for 3/16 inch diameter final fasteners, depending on amount of desired final ream allowance.
(10) For one-sided operation the starting hole is .9690/9720 inches, use starting reamer CXSR-.9690/.9355-1 (1189-079) and combination gage CXG-.9690/.9720/.9750 (2072-621)
(A=.9690, B=.9720, C=.9750 inch). Remaining tool list does not change.
Table 4.0-2
Cold Expansion Process—Metric (All Dimensions in mm)
Tooling Selection Standard Max. Finished

Reference Fastener (1A) Reference Fastener (1B) Tool Starting Hole Mandrel Diameters Sleeve Hole Diameter
Diameter (1) Diameter Av. Ream Diameter (1) Diameter Av. Ream Diameter Diameter Minor Major Thickness Gage Diameter (7) Not to Exceed
Metric (U.S.) Allow. (2) Metric (U.S.) Allow. (2) Number Min. Max. (3) Nom. (4) Min. (5) (6) A B C (8)
3.175 1/8 0.178 3.175 1/8 0.178 4-0-N 2.870 2.921 2.464 2.718 2.703 0.152 2.870 2.921 2.946 3.480
3.572 9/64 0.178 3.572 9/64 0.178 4-1-N 3.251 3.302 2.845 3.124 3.109 0.152 3.251 3.302 3.327 3.962
3.969 5/32 0.152 3.969 5/32 0.152 4-2-N 3.658 3.708 3.200 3.556 3.541 0.152 3.658 3.708 3.734 4.470
4.366 11/64 0.152 4.366 11/64 0.152 4-3-N 4.064 4.115 3.607 3.962 3.947 0.152 4.064 4.115 4.140 4.877
4.763 (9) 3/16 --- 4.763 3/16 0.305 4-4-N 4.293 4.343 3.861 4.201 4.186 0.152 4.293 4.343 4.369 5.146
4.763 3/16 0.076 5.159 13/64 0.483 6-0-N 4.496 4.572 4.089 4.420 4.404 0.152 4.496 4.572 4.597 5.410
5.159 13/64 0.102 5.556 7/32 0.483 6-1-N 4.877 4.953 4.486 4.813 4.798 0.152 4.877 4.953 5.004 5.842
5.556 7/32 0.051 5.953 15/64 0.457 6-2-N 5.309 5.385 4.877 5.258 5.243 0.152 5.309 5.385 5.410 6.325
5.953 15/64 0.051 6.350 1/4 0.432 6-3-N 5.715 5.791 5.283 5.664 5.649 0.152 5.715 5.791 5.817 6.731
6.350 1/4 0.152 6.747 17/64 0.559 8-0-N 5.969 6.045 5.461 5.842 5.827 0.203 5.969 6.045 6.071 7.087
6.747 17/64 0.152 7.144 9/32 0.559 8-1-N 6.375 6.452 5.870 6.248 6.233 0.203 6.375 6.452 6.477 7.493
7.144 9/32 0.152 7.541 19/64 0.559 8-2-N 6.756 6.833 6.203 6.647 6.632 0.203 6.756 6.833 6.858 7.945
7.541 19/64 0.127 7.938 5/16 0.533 8-3-N 7.188 7.264 6.640 7.084 7.069 0.203 7.188 7.264 7.290 8.397
7.938 5/16 0.152 8.334 21/64 0.533 10-0-N 7.544 7.620 6.998 7.468 7.442 0.203 7.544 7.620 7.645 8.865
8.334 21/64 0.152 8.731 11/32 0.533 10-1-N 7.950 8.026 7.407 7.874 7.849 0.203 7.950 8.026 8.052 9.271
8.731 11/32 0.127 9.128 23/64 0.533 10-2-N 8.331 8.407 7.691 8.186 8.161 0.254 8.331 8.407 8.458 9.784
9.128 23/64 0.127 9.525 3/8 0.533 10-3-N 8.738 8.814 8.087 8.583 8.557 0.254 8.738 8.814 8.865 10.150
9.525 3/8 0.127 9.922 25/64 0.533 12-0-N 9.119 9.195 8.471 8.992 8.966 0.254 9.119 9.195 9.258 10.643
9.922 25/64 0.127 10.319 13/32 0.508 12-1-N 9.525 9.601 8.880 9.398 9.373 0.254 9.525 9.601 9.652 11.049
10.319 13/32 0.102 10.716 27/64 0.483 12-2-N 9.931 10.008 9.276 9.822 9.797 0.254 9.931 10.008 10.122 11.527
10.716 27/64 0.102 11.113 7/16 0.508 12-3-N 10.312 10.389 9.675 10.221 10.196 0.254 10.312 10.389 10.465 11.963
(2) Average ream allowance is determined using the nominal fastener diameter and is based on 7075-T651 Aluminum.
Materials with higher yield strengths will produce a minimal increase in the ream allowance due to a smaller cold expanded hole diameter.
(3) Tolerance +/- 0.013mm.
(4) Manufacturing tolerance +/- 0.005mm.
(5) Minimum allowable diameter, mandrel gage diameter +0.005/-0.003mm.
(6) Source inspected before lubricant applied; tolerance +0.010/-0.005mm.
(7) A = Starting hole gage "GO" diameter; tolerance +0.000/-0.005mm. B = Starting hole gage "NO GO" diameter; tolerance +0.005/-0.000mm.
C = Cx verification diameter; applies to gage finish reamer pilot (tolerance +0.000/-0.013mm) and post Cx verification gage pin (tolerance +0.005/-0.000mm).
(9) Use 4-4-N or 6-0-N tooling for 4.763mm diameter final fasteners, depending on amount of desired final ream allowance.


11.113 7/16 0.102 11.509 29/64 0.508 14-0-N 10.693 10.770 10.033 10.617 10.592 0.254 10.693 10.770 10.871 12.344
11.509 29/64 0.102 11.906 15/32 0.483 14-1-N 11.100 11.176 10.442 11.024 10.998 0.254 11.100 11.176 11.278 12.751
11.906 15/32 0.152 12.303 31/64 0.533 14-2-N 11.430 11.506 10.775 11.384 11.359 0.254 11.430 11.506 11.633 13.081
12.303 31/64 0.152 12.700 1/2 0.559 14-3-N 11.811 11.887 11.161 11.770 11.745 0.254 11.811 11.887 12.027 13.462
12.700 1/2 0.305 13.097 33/64 0.686 16-0-N 12.040 12.116 11.290 11.925 11.900 0.305 12.040 12.116 12.256 13.691
13.097 33/64 0.305 13.494 17/32 0.711 16-1-N 12.446 12.522 11.687 12.319 12.294 0.305 12.446 12.522 12.649 14.097
13.494 17/32 0.305 13.891 35/64 0.686 16-2-N 12.827 12.903 12.070 12.730 12.705 0.305 12.827 12.903 13.043 14.478
13.891 35/64 0.305 14.288 9/16 0.686 16-3-N 13.233 13.310 12.466 13.127 13.101 0.305 13.233 13.310 13.424 14.884
14.288 9/16 0.254 14.684 37/64 0.660 18-0-N 13.640 13.716 12.878 13.564 13.538 0.305 13.640 13.716 13.868 15.291
14.684 37/64 0.279 15.081 19/32 0.660 18-1-N 14.046 14.122 13.274 13.957 13.932 0.305 14.046 14.122 14.262 15.697
15.081 19/32 0.254 15.478 39/64 0.660 18-2-N 14.427 14.503 13.658 14.369 14.343 0.305 14.427 14.503 14.681 16.078
15.478 39/64 0.254 15.875 5/8 0.660 18-3-N 14.808 14.884 14.054 14.765 14.740 0.305 14.808 14.884 15.088 16.459
15.875 5/8 0.279 16.272 41/64 0.660 20-0-N 15.164 15.240 14.249 15.024 14.981 0.381 15.164 15.240 15.443 16.815
16.272 41/64 0.279 16.669 21/32 0.660 20-1-N 15.570 15.646 14.646 15.418 15.375 0.381 15.570 15.646 15.837 17.221
16.669 21/32 0.203 17.066 43/64 0.584 20-2-N 16.027 16.104 15.093 15.893 15.850 0.381 16.027 16.104 16.281 17.678
17.066 43/64 0.203 17.463 11/16 0.610 20-3-N 16.408 16.485 15.489 16.289 16.246 0.381 16.408 16.485 16.675 18.059
17.463 11/16 0.254 17.859 45/64 0.635 22-0-N 16.739 16.815 15.824 16.650 16.607 0.381 16.739 16.815 17.043 18.390
17.859 45/64 0.254 18.256 23/32 0.635 22-1-N 17.145 17.221 16.220 17.043 17.000 0.381 17.145 17.221 17.437 18.796
18.256 23/32 0.254 18.653 47/64 0.635 22-2-N 17.526 17.602 16.604 17.455 17.412 0.381 17.526 17.602 17.844 19.177
18.653 47/64 0.254 19.050 3/4 0.635 22-3-N 17.932 18.009 17.000 17.851 17.808 0.381 17.932 18.009 18.161 19.583


19.050 3/4 0.305 19.447 49/64 0.686 24-0-N 18.237 18.313 17.323 18.199 18.156 0.381 18.237 18.313 18.466 19.888
19.447 49/64 0.305 19.844 25/32 0.711 24-1-N 18.644 18.720 17.719 18.593 18.550 0.381 18.644 18.720 18.872 20.295
19.844 25/32 0.305 20.241 51/64 0.686 24-2-N 19.025 19.101 17.937 18.852 18.809 0.457 19.025 19.101 19.253 20.676
20.241 51/64 0.305 20.638 13/16 0.686 24-3-N 19.431 19.507 18.334 19.248 19.205 0.457 19.431 19.507 19.660 21.082
20.638 13/16 0.229 21.034 53/64 0.635 26-0-N 19.863 19.939 18.771 19.710 19.667 0.457 19.863 19.939 20.091 21.514
21.034 53/64 0.254 21.431 27/32 0.635 26-1-N 20.269 20.345 19.167 20.104 20.061 0.457 20.269 20.345 20.498 21.920
21.431 27/32 0.279 21.828 55/64 0.686 26-2-N 20.599 20.676 19.500 20.465 20.422 0.457 20.599 20.676 20.828 22.250
21.828 55/64 0.279 22.225 7/8 0.686 26-3-N 20.980 21.057 19.896 20.861 20.818 0.457 20.980 21.057 21.209 22.631
22.225 7/8 0.305 22.622 57/64 0.686 28-0-N 21.361 21.438 20.269 21.260 21.217 0.457 21.361 21.438 21.590 23.012
22.622 57/64 0.305 23.019 29/32 0.711 28-1-N 21.768 21.844 20.650 21.641 21.598 0.457 21.768 21.844 21.996 23.419
23.019 29/32 0.102 23.416 59/64 0.508 28-2-N 22.327 22.403 21.227 22.243 22.200 0.457 22.327 22.403 22.555 23.978
23.416 59/64 0.127 23.813 15/16 0.508 28-3-N 22.708 22.784 21.623 22.639 22.596 0.457 22.708 22.784 23.012 24.359
23.813 15/16 0.330 24.209 61/64 0.711 30-0-N 22.885 22.962 21.793 22.835 22.791 0.457 22.885 22.962 23.190 24.536
24.209 61/64 0.330 24.606 31/32 0.737 30-1-N 23.292 23.368 22.189 23.228 23.185 0.457 23.292 23.368 23.597 24.943
24.606 31/32 0.305 25.003 63/64 0.711 30-2-N 23.698 23.774 22.657 23.647 23.604 0.457 23.698 23.774 24.003 25.349
25.003 63/64 0.305 25.400 1 0.711 30-3-N 24.105 24.181 23.063 24.041 23.998 0.457 24.105 24.181 24.409 25.756
25.400 1 0.229 25.797 1 1/64 0.635 32-0-N 24.511 24.587 23.368 24.524 24.481 0.457 24.511 24.587 24.994 26.162
Greater than Contact Fatigue Technology Inc. for technical assistance.
25.4mm
Notes:
Table 4.0-3
Standard Tooling List
I II III IV V VI VII VIII IX

Standard Cx Mandrel
Tool Diameter Starting Starting Combination Flared Nosecap Check
Number Drill Reamer Gage Split Sleeve (1) Mandrel (3) Gage Reamer (2) Assembly (3) Fixture
4-0-N CBSD-4-0-N-1 CBSR-4-0-N-1 CBG-4-0-N-1 CBS-4-0-N-16F CBM-4-0-N-1-30-V1 CBR-4-0-N-1-.XXXX MEN-14A-0401F CBMG-4-0-N
14-0-N CBSD-14-0-N-1 CBSR-14-0-N-1 CBG-14-0-N-1 CBS-14-0-N-16F CBM-14-0-N-1-40-V1 CBR-14-0-N-1-.XXXX MEN-14B-1401F CBMG-14-0-N
Notes:
(1) Sleeve length in 1/16 inch (-12, -16, -20, -23F, -24S); sleeve length must be at least 1/32 inch greater than hole depth (F = flared, S = straight sleeve). For material thickness 1.41 to 1.97 inches, use a -16F
flared sleeve and a -16S straight sleeve or a single -32F sleeve, reference FTI tooling catalog for assistance.
(2) .XXXX = Specified reamer diameter (inches); MX.XXX = specified reamer diameter (millimeters).
(3) Flush nosecap assemblies and associated mandrels are equivalent substitutes.
These are recommended standards, but if deviation or more information is required, reference the FTI Tooling Catalog or contact FTI.
Pullers: LB-20, Hydraulic Puller
HP-20, Mechanical Puller
PowerPak: FT-200, FT-20, or equivalent


Standard Cx Mandrel
20-2-N CBSD-20-2-N-1 CBSR-20-2-N-1 CBG-20-2-N-1 CBS-20-2-N-16F CBM-20-2-N-2-60-V1 CBR-20-2-N-1-.XXXX MEN-26C-2023F CBMG-20-2-N
30-2-N CBSD-30-2-N-1 CBSR-30-2-N-1 CBG-30-2-N-1 CBS-30-2-N-16F CBM-30-2-N-5-60-V1 CBR-30-2-N-1-.XXXX MEN-26D-3023F CBMG-30-2-N
30-3-N CBSD-30-3-N-1 CBSR-30-3-N-1 CBG-30-3-N-1 CBS-30-3-N-16F CBM-30-3-N-5-60-V1 CBR-30-3-N-1-.XXXX MEN-26D-3023F CBMG-30-3-N
Notes:
(1) Sleeve length in 1/16 inch (-12, -16, -20, -23F, -24S); sleeve length must be at least 1/32 inch greater than hole depth (F = flared, S = straight sleeve). For material thickness 1.41 to 1.97 inches, use a -16F
flared sleeve and a -16S straight sleeve or a single -32F sleeve, reference FTI tooling catalog for assistance.
(2) .XXXX = Specified reamer diameter (inches); MX.XXX = specified reamer diameter (millimeters).
Pullers: MB-30, Hydraulic Puller
PART 3
Tooling Tables for the Split Sleeve Cold Expansion Process of

Titanium and High-Strength Steel
5.0 TOOLING SELECTION
For steel, titanium, and nickel based alloys with yield strengths greater than 80 ksi but not exceeding 240 ksi
(reference Section 5.2), the “CA” system of tooling in Table 5.0-1 or 5.0-2 (metric conversion) should be used.
5.1 General
After the proper STDN has been determined, selection of all associated tooling required for cold expansion can
be done easily. The fatigue life improvement imparted to the structure relies on proper selection and use of the
complete and compatible system of tooling. Process quality is certified by using the gages and checking fixtures
specified.
For steel, titanium, and nickel-based alloys with yield strengths greater than 80 ksi but not exceeding 240 ksi
(reference Section 5.2), the “CA” system of tooling in Table 5.0-1 or 5.0-2 (metric conversion) should be used.
This table does not provide for a selection in final ream allowance as the fatigue life is sensitive to ream
amount. The STDN is given by a two- or three-digit number. The first one or two digit(s) give(s) the nominal
diameter in 1/16-inch increments. The last number specifies the number of 1/64-inch oversize increments from
nominal.
For example, an STDN of “40” is used to cold expand holes that accommodate a nominal ¼-inch fastener. A
“101” STDN calls out tools used to install a 41/64-inch fastener; first oversize from 5/8-inch nominal.
Due to the higher strength of the parent materials, the CA system of tooling differs from the CB system of
tooling. The CA standard system incorporates cutting tools made of cobalt material, which may be designated
by a “-C” suffix in the tooling model number. Carbide cutting tools may also be specified by the customer, and
will be designated by a “-CBD” suffix in the tool model number. The CA standard system of tooling also
incorporates a higher strength and wear mandrel material. This mandrel material is designated by a “-V2”
suffix in the mandrel model number.
Most steel, titanium, and nickel-based alloys can be cold expanded successfully. Any material that strain
hardens should develop the proper residual stress necessary for life improvement. For materials with yield
strengths greater than 160 ksi, capability is dependent on the diameter and material thickness contact FTI.
If composites or alloys with lower yield strength are present in a multi-material stackup, refer to Sections 3.1
and 3.3 for guidelines.
Table 5.0-1
Reference Standard Tool Starting Hole Mandrel Diameters Maximum Finished

Fastener Diameter Diameter Minor Major Sleeve Gage Diameters (6) Hole Diameter
Diameter Number (1) Min. Max. (2) Nom. (3) Min. (4) Thickness (5) A B C Not to Exceed (7)
1/8 20 .110 .112 .0950 .1045 .1039 .0060 .1100 .1120 .1125 .1331
9/64 21 .125 .127 .1100 .1201 .1195 .0060 .1250 .1270 .1275 .1513
5/32 22 .140 .142 .1250 .1356 .1350 .0060 .1400 .1420 .1425 .1694
11/64 23 .156 .158 .1360 .1481 .1475 .0080 .1560 .1580 .1585 .1888
3/16 30 .170 .172 .1500 .1627 .1621 .0080 .1700 .1720 .1725 .2040
13/64 31 .185 .187 .1650 .1782 .1776 .0080 .1850 .1870 .1875 .2220
7/32 32 .200 .202 .1800 .1938 .1932 .0080 .2000 .2020 .2025 .2400
15/64 33 .216 .218 .1910 .2063 .2057 .0100 .2160 .2180 .2185 .2592
1/4 40 .231 .234 .2060 .2251 .2245 .0100 .2310 .2340 .2350 .2726
17/64 41 .246 .249 .2210 .2408 .2402 .0100 .2460 .2490 .2500 .2903
9/32 42 .261 .264 .2360 .2565 .2559 .0100 .2610 .2640 .2650 .3080
19/64 43 .277 .280 .2520 .2732 .2726 .0100 .2770 .2800 .2810 .3269
5/16 50 .287 .290 .2570 .2800 .2790 .0120 .2870 .2900 .2920 .3358
21/64 51 .302 .305 .2720 .2957 .2947 .0120 .3020 .3050 .3070 .3533
11/32 52 .318 .321 .2880 .3124 .3114 .0120 .3180 .3210 .3230 .3721
23/64 53 .333 .336 .3030 .3281 .3271 .0120 .3330 .3360 .3380 .3896
Notes:
(1) The STDN has been selected to provide a 0.010-inch to 0.015-inch ream allowance between the cold expanded hole diameter and the interference fastener diameter.
(3) Manufacturing tolerance: + 0.0002 / - 0.0000 inch for STDNs 20-33
+/- 0.0002 inch for STDNs 40-111
(4) Minimum allowable diameter, mandrel gage diameter +.0002/-0.0001 inch.
(6) A = Starting hole gage “GO” diameter; tolerance +.0000/-0.0002 inch. B = Starting hole gage “NO-GO” diameter; tolerance +0.0002/-0.0000 inch.


3/8 60 .348 .351 .3180 .3438 .3428 .0120 .3480 .3510 .3530 .4037
25/64 61 .363 .366 .3330 .3595 .3585 .0120 .3630 .3660 .3680 .4211
13/32 62 .379 .382 .3420 .3702 .3692 .0150 .3790 .3820 .3840 .4396
27/64 63 .394 .397 .3570 .3859 .3849 .0150 .3940 .3970 .3990 .4570
7/16 70 .409 .412 .3720 .4015 .4005 .0150 .4090 .4120 .4160 .4740
29/64 71 .424 .427 .3870 .4172 .4162 .0150 .4240 .4270 .4310 .4890
15/32 72 .440 .443 .4030 .4339 .4329 .0150 .4400 .4430 .4480 .5050
31/64 73 .455 .458 .4180 .4496 .4486 .0150 .4550 .4580 .4630 .5200
1/2 80 .470 .473 .4330 .4653 .4643 .0150 .4700 .4730 .4780 .5350
33/64 81 .486 .489 .4490 .4820 .4810 .0150 .4860 .4890 .4940 .5510
17/32 82 .501 .504 .4630 .4977 .4967 .0150 .5010 .5040 .5090 .5660
35/64 83 .516 .519 .4710 .5074 .5064 .0180 .5160 .5190 .5240 .5810
9/16 90 .531 .534 .4860 .5230 .5220 .0180 .5310 .5340 .5390 .5960
37/64 91 .547 .550 .5020 .5397 .5387 .0180 .5470 .5500 .5550 .6120
19/32 92 .562 .565 .5170 .5554 .5544 .0180 .5620 .5650 .5710 .6270
39/64 93 .577 .580 .5320 .5711 .5701 .0180 .5770 .5800 .5860 .6420
Notes:
+/- 0.0002 inch for STDNs 40-111


5/8 100 .592 .595 .5470 .5875 .5858 .0180 .5920 .5950 .6020 .6570
41/64 101 .608 .611 .5630 .6042 .6025 .0180 .6080 .6110 .6180 6730
21/32 102 .623 .626 .5780 .6199 .6182 .0180 .6230 .6260 .6330 .6880
43/64 103 .638 .641 .5930 .6355 .6338 .0180 .6380 .6410 .6490 .7030
11/16 110 .653 .656 .6080 .6512 .6495 .0180 .6530 .6560 .6630 .7180
45/64 111 .669 .672 .6240 .6679 .6662 .0180 .6690 .6720 .6800 .7340
Greater than Contact Fatigue Technology for assistance.
45/64 inch
Notes:
+/- 0.0002 inch for STDNs 40-111
Table 5.0-2
Cold Expansion Process—Metric
Applicable Standard
Fastener Tool Mandrel Diameters Maximum Finished
Range (1) Diameter Starting Hole Diameter Minor Major Sleeve Gage Diameters (6) Hole Diameter
Min. Max. Number Min. Max. (2) Nom. (3) Min. (4) Thickness (5) A B C Note to Exceed (7)
3.14 - 3.28 20 2.79 2.84 2.413 2.654 2.639 .152 2.794 2.845 2.858 3.381
3.54 - 3.71 21 3.18 3.23 2.794 3.051 3.035 .152 3.175 3.226 3.239 3.843
3.93 - 4.17 22 3.56 3.61 3.175 3.444 3.429 .152 3.556 3.607 3.620 4.303
4.35 - 4.65 23 3.96 4.01 3.454 3.762 3.746 .203 3.962 4.013 4.026 4.796
4.75 - 5.05 30 4.32 4.37 3.810 4.133 4.117 .203 4.318 4.369 4.382 5.182
5.11 - 5.49 31 4.70 4.75 4.191 4.526 4.511 .203 4.699 4.750 4.763 5.639
5.51 - 5.94 32 5.08 5.13 4.572 4.922 4.907 .203 5.080 5.131 5.144 6.096
5.93 - 6.43 33 5.49 5.54 4.851 5.240 5.225 .254 5.486 5.537 5.550 6.584
6.33 - 6.86 40 5.87 5.94 5.232 5.718 5.702 .254 5.867 5.944 5.969 6.924
7.11 - 7.32 41 6.25 6.32 5.613 6.116 6.101 .254 6.248 6.325 6.350 7.374
7.11 - 7.75 42 6.63 6.71 5.994 6.515 6.500 .254 6.629 6.706 6.731 7.823
7.54 - 8.23 43 7.04 7.11 6.401 6.939 6.924 .254 7.036 7.112 7.137 8.303
7.80 - 8.53 50 7.29 7.37 6.528 7.112 7.087 .305 7.290 7.366 7.417 8.529
8.19 - 8.97 51 7.67 7.75 6.909 7.511 7.485 .305 7.671 7.747 7.798 8.974
8.61 - 9.45 52 8.08 8.15 7.315 7.935 7.910 .305 8.077 8.153 8.204 9.451
9.01 - 9.91 53 8.46 8.53 7.696 8.334 8.308 .305 8.458 8.534 8.585 9.896
Notes:
(1) Select largest applicable fastener range, which includes the desired fastener diameter, i.e., select 33 tooling for use with 6.2 fastener.
(2) Tolerance +/-.013 mm.
(3) Manufacturing tolerances: +/-0.005 mm for STDNs 40-111
+0.005 / -0.000 mm for STDNs 20-33
(4) Minimum allowable diameter, mandrel gage diameter +.005/-.002 mm.
(5) Source inspected before lubricant applied; tolerance +0.010 / -.005 mm for all STDNs.
(6) A = Starting hole gage “GO” diameter; tolerance + 0.000 / - 0.005 mm. B = Starting hole gage “NO-GO” diameter; tolerance + 0.005 / - 0.000 mm.
C = Cx verification diameter; applies to gage finish reamer pilot (tolerance +0.000/-0.012 mm) and post Cx verification gage pin (tolerance + 0.005 / - 0.000 mm).
(7) Cold expanded holes may be enlarged to the diameter listed without re-cold expanding.

Applicable Standard
Min. Max. Number Min. Max. (2) Nom. (3) Min. (4) Thickness (5) A B C Not to Exceed (7)
9.40 - 10.34 60 8.84 8.92 8.077 8.733 8.707 .305 8.839 8.915 8.966 10.254
9.79 - 10.80 61 9.22 9.30 8.458 9.131 9.106 .305 9.220 9.296 9.347 10.696
10.22 - 11.23 62 9.63 9.70 8.687 9.403 9.378 .381 9.627 9.703 9.754 11.166
10.61 - 11.61 63 10.01 10.08 9.068 9.802 9.777 .381 10.008 10.083 10.135 11.608
11.00 - 11.99 70 10.39 10.46 9.449 10.198 10.173 .381 10.389 10.465 10.566 12.040
11.40 - 12.34 71 10.77 10.85 9.830 10.597 10.572 .381 10.770 10.846 10.947 12.421
11.82 - 12.75 72 11.18 11.25 10.236 11.021 10.996 .381 11.176 11.252 11.379 12.827
12.21 - 13.16 73 11.56 11.63 10.617 11.420 11.394 .381 11.557 11.633 11.760 13.208
12.61 - 13.54 80 11.94 12.01 10.998 11.819 11.793 .381 11.938 12.014 12.141 13.589
13.02 - 13.94 81 12.34 12.42 11.405 12.243 12.217 .381 12.344 12.421 12.548 13.995
13.43 - 14.30 82 12.73 12.80 11.760 12.642 12.616 .381 12.725 12.802 12.929 14.376
13.82 - 14.68 83 13.11 13.18 11.963 12.888 12.863 .457 13.106 13.183 13.310 14.757
14.21 - 15.06 90 13.49 13.56 12.344 13.284 13.259 .457 13.487 13.564 13.691 15.138
14.63 - 15.47 91 13.89 13.97 12.751 13.708 13.683 .457 13.894 13.970 14.097 15.545
15.02 - 15.85 92 14.27 14.35 13.132 14.107 14.082 .457 14.275 14.351 14.503 15.926
15.42 - 16.23 93 14.66 14.73 13.513 14.506 14.481 .457 14.656 14.732 14.884 16.307
Notes:
(1) Select largest applicable fastener range which includes the desired fastener diameter, i.e., select 33 tooling for use with 6.2 fastener.
+0.005 / -0.000 mm for STDNs 20-33

Applicable Standard
Min. Max. Number Min. Max. (2) Nom. (3) Min. (4) Thickness (5) A B C Not to Exceed (7)
15.82 - 16.64 100 15.04 15.11 13.894 14.923 14.879 .457 15.037 15.113 15.291 16.688
16.23 - 17.02 101 15.44 15.52 14.300 15.347 15.304 .457 15.443 15.519 15.697 17.094
16.62 - 17.40 102 15.82 15.90 14.681 15.745 15.702 .457 15.824 15.900 16.078 17.475
17.03 - 17.78 103 16.21 16.28 15.062 16.142 16.099 .457 16.205 16.281 16.485 17.856
17.42 - 18.16 110 16.59 16.66 15.443 16.540 16.497 .457 16.586 16.662 16.840 18.237
17.83 - 18.57 111 16.99 17.07 15.820 16.965 16.921 .457 16.993 17.069 17.272 18.644
Greater than Contact Fatigue Technology for technical assistance.
17.86 mm
Notes:
(1) Select largest applicable fastener range which includes the desired fastener diameter, i.e., select 33 tooling for use with 6.2 fastener.
+0.005 / -0.000 mm for STDNs 20-33
Table 5.0-3
Standard Tooling List—Cold Expansion Process

Standard Cx Mandrel
20 CASD-20-1-C CASR-20-1-C CAG-20 CAS-20-16F CAM-20-1-30-V2 CAR-20-1-.XXXX-C MEN-14A-0401F CAMG-20
60 (4) CASD-60-1-C CASR-60-1-C CAG-60 CAS-60-16F CAM-60-2-60-V2 CAR-60-1-.XXXX-C MEN-26B-1201F CAMG-60
Notes:
(1) Sleeve length in 1/16 inch (-12, -16, -20, -23F, -24S); sleeve length must be at least 1/32 inch greater than hole depth (F = flared, S = straight sleeve). For material thickness 1.41 to
1.97 inches, use a -16F flared sleeve and a -16S straight sleeve, reference FTI tooling catalog for assistance.
(2) XXXX = Specified reamer diameter (inches); MX.XXX = specified reamer diameter (millimeters).
(4) A Medium Brute MB-30 puller may be required for this size and greater depending on material heat treat and thickness. Contact FTI for technical assistance.
HP-20, Mechanical Puller
PowerPak: FT-200. FT-20, or equivalent

Standard Tooling List—Cold Expansion Process

Standard
Tool Cx Mandrel
Diameter Starting Starting Combination Flared Nosecap Check
80 CASD-80-1-C CASR-80-1-C CAG-80 CAS-80-16F CAM-80-2-60-V2 CAR-80-1-.XXXX-C MEN-26B-1601F CAMG-80
102 CASD-102-1-C CASR-102-1-C CAG-102 CAS-102-16F CAM-102-2-60-V2 CAR-102-1-.XXXX-C MEN-26C-2023F CAMG-102
111 CASD-111-1-C CASR-111-1-C CAG-111 CAS-111-16F CAM-111-2-60-V2 CAR-111-1-.XXXX-C MEN-26C -2201F CAMG-111
Notes:
(1) Sleeve length in 1/16 inch (-12, -16, -20, -23F, -24S); sleeve length must be at least 1/32 inch greater than hole depth (F = flared, S = straight sleeve). For material thickness 1.41 to
1.97 inches, use a -16F flared sleeve and a -16S straight sleeve, reference FTI tooling catalog for assistance.
(2) XXXX = Specified reamer diameter (inches); MX.XXX = specified reamer diameter (millimeters).
PART 4
Split Sleeve Cold Expansion Using the

Countersink Cold Expansion Process
6.0 GENERAL
6.1 Purpose
This section describes the procedures and tooling necessary to cold expand countersink holes in aluminum
using FTI’s patented* Countersink Cold Expansion Process (CsCx). The CsCx process simultaneously cold
expands the countersink and straight portion of the hole. Use of the CsCx nosecap assembly eliminates the
requirement to machine countersinks subsequent to cold expansion as required by the Cx process.
* The CsCx nosecap and associated cold expansion method is covered by U.S. Patent Numbers 4,423,619
and 4,425,780 (foreign patents issued).
6.2 Process Description
The Split Sleeve Cold Expansion process for a countersunk hole is similar to the Cx process for straight holes.
The basic process steps are shown in Figure 6.2-2. The CsCx system components include a two jaw nosecap
assembly, a longer length, shallow taper mandrel and a straight (i.e. non-flared) split sleeve. The assembly of
these components is inserted into the countersunk hole, where the sleeve is passed through the outer jaw so
that it rests against the inner jaw as shown in Figure 6.2-1. The longer length of the mandrel taper and major
diameter increases mandrel pull force, which, in turn, ensures that applied expansion is imparted to the
countersink portion of the hole through the nosecap assembly. Activation of the puller unit simultaneously
cold expands both the countersunk and straight portion of the hole.
Cold expansion of the countersink will increase the diameter by about .003 inch. It will be necessary to do a
test plate to adjust the pre-cold expansion countersunk hole depth prior to cold expanding the actual
workpiece. Refer to Section 7.7. It is also recommended that the base of the countersink be chamfered to
accommodate the corresponding radius on the shank of the fastener.
The desired final hole diameter (straight portion of the hole) is obtained by final reaming the cold expanded
hole. The process can also be used with the Cold Expansion to Size (Cx2s) mandrels and sleeves to eliminate
a final reaming process. The Cx2s tooling is described in FTI Process Specification 8201.
Figure 6.2-1
Countersink Cold Expansion System Components
Figure 6.2-2
Countersink Cold Expansion Process Description
6.3 Countersink Cold Expansion Nosecap
The CsCx nosecap is different from a standard extension nosecap in that it has an inner and outer jaw. The
sleeve is restrained by the inner jaw, away from the countersunk hole surface. The pull force generated by the
process is reacted through the outer jaw to effectively “coin” the countersink. When the mandrel major
diameter passes through the outer jaw, it also slightly expands the countersink.
The CsCx nosecap assembly is identified according to the Standard Tool Diameter Numbers and part numbers
specified in Table 7.0-1. A unique CsCx nosecap assembly is required for each 1/64-inch fastener hole
diameter increment.
Note: Inner jaw is subject to wear and will periodically need to be replaced. Criteria for wear on jaw is
indicated by sleeves that are drawn inside the inner jaw during expansion.
Cap
Expanding Outer Jaw
Sleeve Restraining
Inner Jaw
Retainer
Figure 6.3-1
Countersink Cold Expansion Nosecap Assembly
6.4 Tooling Selection
After the proper STDN has been determined from Table 4.0-1 or 4.0-2 (metric conversion), selection of all
associated tooling required for cold expansion can be done easily using Table 7.0-1 or the FTI tooling catalog.
The fatigue life improvement imparted to the structure relies on proper selection and use of the complete and
compatible system of tooling. Process quality is certified by using the gages and checking fixtures specified.
Starting drills, starting reamers, mandrels, sleeves, and finish reamers are identified using the standard tool
diameter numbers specified in Table 4.0-1 and the part numbering system defined in Table 7.0-1.
7.0 TECHNICAL REQUIREMENTS
Refer to Table 7.0-1 for the standard tool list for countersunk cold expansion’
7.1 General
The technical requirements for the CsCx process are generally the same as those for the standard Split Sleeve
Cold Expansion system. These requirements are specified in Part 1, Section 3. It is important that all process
and inspection steps are followed as specified to ensure that the proper residual stresses are imparted to the
hole. Technical requirements in addition to those specified in Section 3 are provided in the following
paragraphs.
Countersunk holes in most aluminum alloys can be cold expanded successfully. There are some alloys and
stackups that should be cold expanded with caution. These are specified in Section 3.3. Multi-material
stackups may be cold expanded using the CsCx nosecap assembly provided that the countersink portion of the
hole is in the aluminum part of the stackup.
7.3 Starting Hole Requirements
The CsCx process cold expands 100° countersunk holes in aluminum alloys for hole diameters ranging from
3/16-inch through 27/64-inch. The starting hole tolerance is specified in the Standard Tooling Diameter
Number Tables for the appropriate process. For typical applications use the STDN tables found in Part 3.0.
For cold expansion to size applications, refer to the STDN tables in FTI Specification 8201.
7.4 Prelubricated Split Sleeves
Straight sleeves are required for use with the CsCx Nosecap Assembly due to its unique design. Because the
nosecap allows a portion of the sleeve to extend into the nosecap, sleeve lengths should be selected based on
either of the two following constraints:
1. When the sleeve, mandrel, and nosecap are assembled in the hole, the sleeve must protrude at least 5/32
inch (4 mm) beyond the backside of the hole; or
2. Sleeve length must be at least 1/4 inch (6.35 mm) greater than the maximum material thickness.
7.5 Rework of Previously Countersunk Holes
Split Sleeve Cold Expansion of a previously 100° countersunk hole should be accomplished using the CsCx
nosecap. The desired finish countersink diameter and finish hole diameter may be machined after cold
expansion. When fitting oversize fasteners with the same countersink head geometry as the existing fastener,
it is important to note that the countersink depth will increase as a result of cold expanding the countersink,
and that consideration should be given to countersink flushness requirements.
7.6 Minimum Material Thickness
Fatigue enhancement of the countersink requires that the countersink diameter be physically enlarged (.003 to
.006 inch) during the cold expansion process. Proper functioning of the CsCx nosecap requires sufficient
depth of the straight portion (S) of the hole to generate the reactive pull force necessary to lock the nosecap
into the countersink. The minimum allowable finish hole diameter to straight hole thickness ratio (S/D) is 1.0;
see Figure 7.6-1. Deep (“feather edge”) countersinks in thin structure cannot be successfully cold expanded
unless the straight portion of the hole is artificially lengthened through the use of a backup block described in
Paragraph 7.8.
100°+/-0° 30' 100° +/-0° 30'

100°+/-0° 30'
D
S S S
B
D
D
Acceptable Unacceptable Acceptable
S greater than or equal to D S less than D S plus B greater than or
equal to D
Notes: S = Material stackup of straight portion of hole

D = (Ref.) Final Hole Diameter
B = Backup block thickness
Figure 7.6-1
Minimum S/D Ratio
7.7 Cutting Countersink Prior to Cold Expansion
Countersinks must be machined to an included angle of 100° 1/2°. The CsCx nosecap causes the countersink
diameter to expand approximately .003 to.006 inch. Consequently, the countersink cutting tool must be
adjusted such that the required countersink diameter and fastener flushness are achieved after the hole is cold
expanded. Figure 7.7-1 shows a flow diagram of the process by which the initial countersink depth is
determined.
Note: This procedure should be performed on a sample of material prior to countersinking holes on the
actual structure. The sample material must be the same alloy and temper as the structure being cold expanded.
Start
Drill / Ream Starting Hole
Countersink
Cx Using CsCx Nosecap Assembly
Install Fastener
Measure Flushness
Fastener Fastener
Protrudes How does too Deep
fastener fit?
Adjust Cutter Flushness Adjust Cutter

to increase Acceptable to decrease
Countersink Depth Countersink Depth
Proceed with CsCx
Figure 7.7-1
Procedure for Adjusting Countersink Depth
7.8 Backup Blocks
A Backup Block is a non-reusable, piece of material that is used in the cold expansion process to provide
either a higher pull force or in-plane stability to thin structure. The backup block must be made from a
material with a modulus and yield strength equal to or higher than the structure being cold expanded. A
starting hole equal to the starting hole of the structure is machined into the block. The width, height, or
outside diameter of the backup block should be at least five (5) times greater than the diameter of the hole
being cold expanded.
For cold expanding countersunk holes in thin structure using the CsCx nosecap, a backup block is placed on
the side opposite the countersink to a provide higher pull force. The thickness of the straight portion of the
hole combined with the thickness of the backup block must be greater than or equal to the finish hole
diameter. Figure 7.8-1 shows the backup block usage for a countersunk hole.
1. Install mandrel/sleeve/nosecap
assembly into countersunk
starting hole.
2. From backside of workpiece,

slide backup block over
mandrel and sleeve. Press
block firmly against back of workpiece.
Ensure sleeve protrudes through the
backup block by 5/32-inch
3. Puller actuation simultaneously

cold expands straight portion
of hole, countersink, and
backup block. Discard backup
block after use.
Figure 7.8-1
Backup Block Usage for Countersunk Holes
Table 7.0-1
Cold Expansion Process: Using the Countersink Cold Expansion Nosecap Assembly
NOTE: This table provides standard tooling requirements for the cold expansion of unrestricted countersink holes
with material stackups of 1.25 inches or less. For applications involving restricted access and material
thickness greater than 1.25, contact Fatigue Technology.

Standard Tool Cx CsCx Mandrel
Diameter Starting Starting Combination Straight CsCx Gage Nosecap Check
Number Drill Reamer Gage Split Sleeves Mandrel Finish Reamer (1) Assembly Fixture
4-0-N CBSD-4-0-N-1 CBSR-4-0-N-1 CBG-4-0-N-1 CBS-4-0-N-24S KBM-4-0-N-1-35-V1 CBR-4-0-N-1-.XXXX KBC-040-1A CBMG-4-0-N
Notes:
(1) .XXXX = Specified reamer diameter (inches); MX.XXX = specified reamer diameter (millimeters). For additional information, reference the FTI tooling catalog.


Cx Process: Using the Countersink Cold Expansion Nosecap Assembly
NOTE: This table provides standard tooling requirements for the cold expansion of unrestricted countersink holes
with material stackups of 1.25 inches or less. For applications involving restricted access and material
thickness greater than 1.25, contact Fatigue Technology.

Standard Tool Cx CsCx Mandrel
Diameter Starting Starting Combination Straight CsCx Gage Nosecap Check
Number Drill Reamer Gage Split Sleeves Mandrel Finish Reamer (1) Assembly Fixture
Notes:
(1) .XXXX = Specified reamer diameter (inches); MX.XXX = specified reamer diameter (millimeters). For additional information, reference FTI tooling catalog.

PART 5
Equivalent/Other Cold Expansion Specifications
8.0 EQUIVALENT/OTHER COLD EXPANSION SPECIFICATIONS
Table 8.0-1 lists other companies’ compatible Split Sleeve Cold Expansion specifications. In general, these
specifications are equivalent to FTI-8101 specifications; however, some may contain minor deviations based on
individual requirements. FTI provides customized cold expansion tooling to meet these customers specifications.
Table 8.0-1
Equivalent/Other Cold Expansion Specifications
Specification or
Company Document Number Title
Aerospatiale A/DET-0020 Cold Expansion of Holes in Wrought Aluminum Alloy
Bell Helicopter BPS-4542 Cold Expansion of Fatigue Critical Holes in Metals
Boeing Aircraft Co. BAC 5973 Sleeve Cold Working of Holes in Aluminum Structure
Boeing Defense & Space Group 5PTPBT28 Sleeve Cold Working of Holes in Metallic Structures
Bombardier/DeHavilland Canada PPS 2.36 Split Sleeve Cold Expansion of Fastener Holes
British Aerospace (Airbus) TS/1/0164 Cold Expansion and CCx
British Aerospace (Airbus) TS/1/0094 Cold Expansion, Basic Cx
British Aerospace (Airbus) ABP 1-2035 Cold Expansion of Holes
CASA I+D-P-209
Cessna Wallace Division CES 2180 Cold Expansion of Holes Using Split Sleeve System (Cx)
DASA (MBB) 80-T-32-2611
Douglas Aircraft Company DPS 3.67-74 Split Sleeve Cold Working- Holes and Countersinks
Grumman Aircraft Systems A-F302 Cold Working of Holes, Process for
IAI Ltd. P.S. 55.1180 Cold Working of Holes: Split Sleeve Method
Lockheed, Fort Worth FPS-3030 Split Sleeve Cold Working of Holes in Aluminum
Lockheed, Georgia LASC-51-20-01 Split Sleeve Cold Expansion of Fastener Holes
McDonnell Douglas Helicopter Co. HP 15-82 Cold Working Fastener Holes in Aluminum Parts, Processing
of (Split Sleeve Method)
McDonnell Douglas PS 19180 Cold Working Holes; Split Sleeve Method
Northrop Aircraft FH-56 Cold Working and Sizing of Fastener Holes
Northrop (A.S.D.) B-134 Cold Working of Fastener Holes
Panavia Aircraft GmbH PAN 1079 Cold Expansion of Holes
Sikorsky Aircraft SS No. 5098 Cold Expansion of Holes in Wrought, Heat Treatable
Aluminum Alloys
Rockwell International Corp. LA0103-023B Cold Working of Fastener Holes
Rolls-Royce Ltd. RPS.642 Split Sleeve Cold Expansion Process
Appendix A
Specification for Split Sleeve Cold Expansion of
Low Elongation Aluminum Using the CBL System of Tooling
(Reduced Expansion)
Contact FTI for appendix content. Content is releasable upon

execution of an FTI Non-Disclosure Agreement.
Fatigue Technology 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886
271727 PROPRIETARY RELEASABLE A1
Appendix B
Specification for Split Sleeve Cold Expansion of
Low Elongation Materials Using the CB3 System of Tooling
(Close-Tolerance Reduced Expansion)
Contact FTI for appendix content. Content is releasable upon

execution of an FTI Non-Disclosure Agreement.
Fatigue Technology 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886
B1 PROPRIETARY RELEASABLE 272760

Split Sleeve Cold Expansion (8101)

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Split Sleeve Cold Expansion (8101)

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UNCONTROLLED IF PRINTED

401 Andover Park East

FATIGUE TECHNOLOGY INC.

FTI Process Specification 8101

Cold Expansion of Holes Using the

July 29, 2019

RESTRICTION ON DISCLOSURE AND RELEASE

82054 REV L/ FTI-8101

Revision # Description By Date

1.0 GENERAL INFORMATION .......................................................................................................... 2

2.0 TOOLING SELECTION AND PROCESS PROCEDURE .......................................................... 7

3.0 TECHNICAL REQUIREMENTS................................................................................................. 16

3.15 Countersunk Holes............................................................................................................... 22

4.0 TOOLING SELECTION ............................................................................................................... 27

5.0 TOOLING SELECTION ............................................................................................................... 37

6.0 GENERAL ....................................................................................................................................... 47

7.0 TECHNICAL REQUIREMENTS................................................................................................. 50

8.0 EQUIVALENT/OTHER COLD EXPANSION SPECIFICATIONS ........................................ 56

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General and Technical Information

1.3 Process Description

Nosecap Assembly Lubricated Flared

Puller Unit Workpiece

1.6 Applicable Documents

MIL-Q-9858A “Quality Program Requirement”

MIL-STD-105 “Inspection Sampling Procedure”

MIL-STD-109 “Quality Assurance Terms and Definitions”

MIL-I-45208A “Inspection System Requirement”

FTI-29786 FTI Conformance Document, “Requirements for Pre-Lubricated, Stainless

ANSI/ASME B46.1-1985 “Surface Texture (Surface Roughness, Waviness, and Lay)”

1.8 Operator and Inspector Training Recommendations

Split Sleeve Cold Expansion

2.1 Cold Expansion Process Overview

2.2.1 Drill and Ream Starting Hole

The starting holes must be drilled or reamed to

2.2.2 Check Starting Hole

Verify the starting hole diameter using the applicable Cx

During normal use, the mandrel major diameter should be

Accept Reject and Discard Mandrel

To cold expand a hole, first slide the sleeve over the

Next, slide the mandrel and sleeve combination into the

Place the nosecap firmly against the workpiece.

Withdraw the mandrel through the sleeve which is retained

Verify that proper cold expansion has been

3. Check the sleeve for signs of break up during cold expansion.

Combination Gage Gage Finish Reamer

or Hole has been

or Hole has not been

2.2.6 Post Reaming the Hole

After cold expansion, the holes may be

2.4 Tooling Selection

Starting Drill Mandrel

1. Identify the Standard Tooling Diameter Number (STDN).

2.5 Split Sleeve Cold Expansion Tool Use Guidelines

2.5.1 Safety Precautions

2.5.2 Instructions for Safe and Effective Use of Tooling

Technical Information about the Standard

3.1 Applicable Materials

3.2 Minimum Material Thickness

3.3 Multi-Material Stackups

3.4 Edge Margin Requirement

An edge margin of 1.75 or greater is generally recommended. Edge margin is D

3.5 Hole Spacing Requirement