ENGINEERING PRODUCTIVITY KIT Fastening,joining,assembly
Coming: optimized robotics welding
Columbus, OH--1996 showed a 25%
increase over 1995 in the number of arc welding robots ordered from robot
manufacturers in the U.S., a sign that the use of robots in welding applications
continues to increase, according to the Robotic Industries Association (Ann
Arbor, MI). Most of these robots use gas metal arc welding (GMAW) and flux cored
arc welding (FCAW). The reason: these processes have simple torches, good
disposition rates, and tolerance to part fit-up. But they could work even
Robotic welding offers many advantages: repeatability, high productivity, and
better quality. However, many robot welding technicians lack a thorough
understanding of arc-welding fundamentals and, as a result, fail to fully
optimize the robot's capabilities, according to Dennis Harwig, senior research
engineer at the Edison Welding Institute (EWI). This, in turn, leads to
inappropriate selection of consumables and non-optimized weld parameters. The
result: higher defect rates, and lower production rates and quality.
Over the last few years, EWI has developed a way to rapidly characterize and
optimize arc welding processes. Now, the Institute has undertaken a project to
develop a comprehensive welding-parameter database for fillet welds designed to
simplify the parameter-selection process and enable assessment of process
By 1999, the project will develop welding parameter relationships and
productivity windows for selected process-consumable combinations over a range
of fillet weld sizes. Processes such as GMAW and FCAW will be compared using
several consumables for each fillet welding application.
By the project's end, some 50 process-consumable combinations will be
evaulated. The yield: considerable cost savings through a minimized need for
added parameter development and optimized deposition rates, says EMI's Harwig.
For more information about the high-productivity robotic arc welding project,
contact Dennis Harwig, Edison Welding Institute, 1250 Arthur E. Adams Dr.,
Columbus, OH 43221; ph: (614) 688-5132; FAX: (614) 688-5001; e-mail: email@example.com
Coating conquers airframe rivet problems
Long Beach, CA--The U.S. Air Force
touts a new kind of rivet--or, more precisely, a new rivet coating--as a
The coating, recently introduced by the Military Transport Aircraft division
of McDonnell Douglas and suppliers Hi Shear Corp. (Torrance, CA) and Aerospace
Rivet Manufacturing Corp. (Santa Fe Springs, CA), should cut costs, reduce
rework dramatically, and prevent fatigue, while improving airframe quality, says
Jeff Behnke, project manager at McDonnell Douglas.
The pre-coated dry sealant for titanium pins and aluminum rivets allows
mechanics to work faster and cleaner--and do better work, say its developers.
McDonnell Douglas C-17 program accountants predict it will save $2.2 million as
each new Globemaster III comes down the assembly line.
Each C-17 military cargo jet has more than 1.4 million fasteners which, until
now, had to be installed "wet" using a sealant that costs more to dispose of
than purchase because of its hazardous waste condition. "The pre-coated
fasteners improve the quality of work life for our mechanics," adds Nick
Peralta, senior manager at McDonnell Douglas.
The fasteners also improve the quality of the product, according to Jose
Jimenez, team leader in the Drivmatic area. "We get better squeeze on the
fastener and avoid problems where the rivets don't fill the hole tightly. Also,
if you have to remove a titanium pin, it won't seize up because there is more
lubricity." Jimenez explains that the old wet sealant used to clog up the
The patented technology, which uses an aluminum-pigmented resin with
corrosion inhibitors, reduces the process variability factor in installing a
C-17's 590,000 titanium pins and 733,000 rivets. And the sealant ensures
corrosion protection at each hole.
"We expect a 1.1 million-hour savings in phase 2 of implementation," says
Behnke. Phase 1, which began with aircraft P-33, and Phase 2 combined should
save 2.3 million labor hours. Behnke expects other military and commercial
programs will adopt the technology as well.
Self-tapping screws improve production, cut costs
Palm Coast, FL--When Pete Castellano
joined ABB Ceag Power Supplies as principal mechanical design engineer, his
primary objective was to create more cost-efficient designs. He quickly realized
the process of fastening power supply parts offered such an opportunity.
ABB Ceag's power supply casting requires 50 fasteners to hold it together.
Originally, the company used a nut in a three-step process--drilling, tapping,
and fastening. Switching to Parker-Kalon® Swageform® thread-forming screws
reduced costs significantly by combining the tapping and fastening steps into
The Swageform screws have external threads that tap, or form, their own
mating internal threads when driven into existing holes. The swaging of the
screw thread does not remove material around the hole, but displaces it around
the mating threads, making them stronger.
The result: the screws have a higher resistance to backout and vibration, and
don't produce cutting chips of metal as they are driven into the casting.
"Our units are tested with high voltage to pass UL qualifications. If a metal
chip has fallen into the unit, pc boards or semiconductors will burn and must be
discarded. We can't tolerate a single metallic chip within the unit," explains
Castellano. "We haven't had a problem since we started using Parker-Kalon
fasteners," he adds.
The new fastening system has increased productivity, cut labor, enhanced
quality, and cut costs on piece parts. The cost per hole on extrusions: five
cents now, compared with 15 cents previously. For ABB Ceag, that adds up to a
savings of $5.00 on every main power supply casting.
Fastener reduces cross threading
Dean Lamb, Mgr. of Mktg. Communications Camcar Textron;
On the assembly line, cross threading can result in significant down time,
poor productivity, scrap, and rework. Cross threading occurs when misalignment
between the fastener and nut member due to off-center or off-angle driving
causes a wedging action in the hole.
To help alleviate the problem, Camcar Textron has introduced the
AcupointTM anti-cross-threading fastener. The Acupoint features a
spherical point that enables the fastener to self-align from off-angle and
off-center positions. The point design allows quick engagement into the hole,
and thread engagement only when the fastener is properly aligned. When compared
to other anti-cross-thread designs, the Acupoint has a shorter point length to
During lab testing under controlled conditions, the Acupoint showed a 97%
starting rate at an off angle of 30 degrees. A machine screw showed only a 55%
starting rate at a 7-degree off angle.
In the off-center position, the Acupoint design showed a good start 100% of
the time at 2.40 mm off center, while a machine screw demonstrated a 73%
starting rate at 2.40 mm.
The Acupoint fastener comes in M4, M6, and M8 sizes. Other sizes are
currently under development.
For details contact Camcar Textron, 516 Eighteenth Ave., Rockford, IL
61104-5181; ph: (800) 544-6117; www.camcar.textron.com; FAX: (815)
Standoffs thread ultra-thin sheets
New self-clinching threaded standoffs provide permanent threads in ultra-thin
aluminum or steel sheets to enable stacking or spacing of pc boards and other
The PEM® Type TSOTM, TSOSTM, and TSOATM
standoffs install in sheets as thin as 0.025 inch (0.63 mm) and deliver high
push-out and torque-out resistances, says Michael Rossi, corporate
communications supervisor at Penn Engineering.
Installation involves inserting the standoffs into punched or drilled holes
and applying a squeezing force. The fasteners become a permanent part of the
assembly, while the head remains flush with the mounting sheet.
Type TSOTM (steel), TSOSTM (stainless steel), and
TSOATM (aluminum) fasteners come in both standard and metric sizes in
For more information contact Michael J. Rossi, Penn Engineering &
Manufacturing, Box 1000, Danboro, PA 18916; ph: (800) 237-4736; FAX: (215)
766-0143; e-mail: firstname.lastname@example.org; visit http://www.pemnet.com
Adhesive withstands oil and contamination
Loctite® 243 single-component, removable, anaerobic, threadlocking adhesive
stands up to oil and other contaminates. As a result, fasteners require no
additional cleaning or preparation before the threadlocker is applied, says
manufacturer Loctite Corp. (Rocky Hill, CT).
The adhesive cures without air when applied between close fitting metal parts
such as nuts and bolts, while protecting fastener threads from rust and
corrosion. Suited for threaded fasteners up to 3/4 inch (20 mm), the
threadlocker works on stainless steel, plated finishes, and other substrates.
Threaded fasteners treated with the adhesive can be disassembled using simple
Loctite 243 is NSF/ANSI 61 certified for use in potable water systems, and
can be applied manually or with semi- or fully automatic dispensing equipment.
Packaging ranges from a 0.5-ml tube to a 1 liter bottle.
For more information contact Loctite Corp., 1001 Trout Brook Crossing, Rocky
Hill, CT 06067; ph: (800) 323-5106 x67; FAX: (860) 571-5465.
How EWI does it
Most fillet-welding applications involve consumable electrode processes that
use constant-voltage power supplies. The primary parameters of these processes
include wire-feed speed, voltage or arc length, and travel speed. Current
becomes a function of the wire-feed speed, type, diameter, and extension from
The parameter development methodology in use at EWI yields the voltage as a
function of wire-feed-speed curves for each process-consumable combination. Once
this relationship is determined, a welding productivity window that relates heat
input as a function of deposition rate is developed. The boundaries of the
welding productivity window are established by bead shape geometry and weld pool
stability criteria. The welding productivity window assesses both productivity
Welding technology replaces aircraft rivets
Wichita, KS-based PACMIG Inc. has developed a new pressurized, air-cooled,
metal inert gas (PAC-MIG) welding gun technology that may soon replace heavier
rivet fasteners in commercial airframes. In preliminary, third-party fatigue
tests, butt joint welds using the MIG technique were then shot-peened. The
joints showed twice the fatigue life of comparable three-row, flush-riveted lap
joints like those used by Boeing transports, says PACMIG President Joseph
Cusick. The patented technology uses compressed air to cool the welding
appliance and then vents it to the atmosphere. According to Cusick, PACMIG is
lighter, simpler, and more economical to use than comparable rivet systems.
Additional details, contact PACMIG, 311 Laura, Wichita, KS 67211, ph: (316)
Forum offers fastening solutions
Looking for a place where fastener manufacturers and distributors can gather
with OEM engineers and purchasing agents to exchange information, go back to
"school," and solve fastener application problems? The Fastening Design and
Application Engineering Expo and Technical Conference is just the ticket, say
Taking place October 23-24, 1997 at the Novi Expo Center in Detroit, MI, the
event features educational seminars, hands-on demonstrations, workshops, and
discussion groups that will address questions and concerns in fastener
application, design, and engineering. Participating companies will feature
products for the aerospace, automotive, utilities, appliance, and shipbuilding
industries, among others.
For more information on exhibiting or attending, contact FDAE, 5008-34 Pine
Creek Dr., Westerville, OH 43081; ph: (614) 895-8348; FAX: (614) 895-3466; see