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2021
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 editorial

A future with clever bolts

“Imagine a future with clever bolts that communicate when tensioned?” This was
a phrase spoken at a wind-power conference years ago, long before the digital
wind farms of today, many of which are remotely connected and monitored to
ensure optimal performance. It was before the popularity of “smart” tools and the
industrialization of the internet-of-things (IoT).
One utility-scale wind turbine has thousands of different-sized bolts. Correct
tensioning is critical as one loose bolt could trigger a domino effect, resulting in
damage to the entire structure. The idea of bolts that could “communicate” was
groundbreaking at the time — and a potential game-changer for several industries.
Think of the anchors securing concrete beams or the fasteners in the suspension
or brake system of an automobile. The ability to check on the fasteners in an assembly
could ensure the long-term structural security of the application.
The initial “clever bolt” concept included a simple mechanism inside each fastener
that worked as an indicator of the actual load or tension at the time of installation.
Since that conference, several smart tools have hit the market, offering combinations
of precise torque monitoring, digital calibrations, and tool traceability.
However, the concept of connected fasteners that truly “communicate” wirelessly
has been slower to develop. A few companies are changing that.
For example, German-based Sensorise SmartScrew System offers new
technology for the continuous monitoring of dynamically loaded screws and bolts,
such as for wind turbines. The system includes Sensorise SmartScrews, which install
like any other screw but offer built-in sensors that measure the temperature and static
loads on the screws and bolts. It collects this data for processing and analytics, and to
remotely verify proper operation.
Hilti, a global power-tool company, has launched Tracefast, which leverages the
IoT. These smart fasteners have a laser-print data matrix code, which is similar to a QR
code, making each one identifiable and traceable. By using the Hilti Connect app on a
smartphone, users can simply scan the code to view a fastener’s details, including the
proper methods for installation method or its installed date.
In many cases, there’s no way to look at an installed fastener and have access
to its full history. Smart, connected components are providing historical insight and
quality assurance, which can lead to greater productivity and safety. Certainly, it
could be argued that not every assembly requires such diligence. But it’s nice to have
options and, particularly, for critical assemblies.
In this year’s annual Fastener Engineering Handbook, we cover fastener basics
and advancements in adhesives, welding, and tools. We enjoy learning about and
sharing the latest innovations. Thank you for reading!

DESIGN WORLD www.fastenerengineering.com December 2021 1

Engineering
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 Contents 12 • 2021 • fastenerengineering.com

4 _ADHESIVES: Tapes 28 _RINGS

When are adhesives and tapes What are the technical factors to
the ideal choice for an application? consider before choosing retaining
rings for an assembly?
8 _ADHESIVES: Threadlocker
How to choose the ideal 32 _RIVETS
threadlocker for an application? What are the typical riveting faults and
how can they be avoided?
10 _ASSEMBLY: Fasteners
How do I know which threaded 36 _SCREWS: Duplex Screws
fastener is right for my application? What is the difference between Duplex
Nails and Screws?
12 _ASSEMBLY: Methods
What methods are available to bond 38 _SCREWS: Security Screws
dissimilar metals for use in critical What are tamper-proof seal screws
applications? and when should you use them?

14 _BOLTS 40 _SUPPLY CHAIN

When does an application warrant How to ensure a successful fastener
the use of a bolt instead of a screw? supply chain?

16 _COUPLINGS 42 _TRAINING: Courses

How to avoid coupling failures? Why is fastener training important?

18 _LATCHES 44 _TRAINING: FAQs

What are the different types of latches What are some critical structural
available for secure enclosures? fastener facts you should know?

20 _MANUFACTURING 46 _TOOLS
How fasteners can affect What are the best practices for
product testing and manufacturing? tool and equipment preventive
maintenance?
22 _MATERIALS
What type of plastic is ideal for high- 50 _WASHERS
performance fasteners? How do flat and lock washers differ?

24 _NUTS 52 _WELDING: Joints

What are twin nuts and how do they When do joints need to be pre-heated
function? before welding?

58 _PROFILES
26 _PINS 54 _WELDING: Materials
64 _AD INDEX How to select the proper pin What advances in welding address
for an application? material variations?

DESIGN WORLD www.fastenerengineering.com December 2021 3

 Reese Weber
Senior Application Engineer
3M Industrial Adhesives and Tapes Division
ADhesives: tapes

A design engineer
applying tape
for an industrial
application.

When are adhesives and tapes

the ideal choice for an application?
Today’s design engineers have an For certain applications, more than
abundance of attachment options to one option can help a designer better
choose from — which is likely a blessing achieve his or her bonding objectives.
and a curse. Undoubtedly, identifying the To this end, tapes and adhesives
ideal adhesive or bonding solution for are rapidly gaining acceptance in
an application can be a challenge. This several markets. Their ease-of-use,
is particularly true given the factors that durability, and ability to bond and seal
typically affect a project, such as costs, simultaneously offer end-users flexibility
reliability, labor, and efficiency. when creating their design.

4 December 2021 www.fastenerengineering.com DESIGN WORLD

 This could include a combination • Design or geometry of the joint – • Acrylics:
of mechanical fasteners and adhesives. consider how the substrates will join. o Cures and builds strength at a
What’s imperative, however, is to first For example, is the bond area flat, much faster rate than other
understand the design attributes of each curved, or multi-dimensional? structural adhesives
attachment option before weighing • The environment – think about the o High tolerances for unprepared
the pros and cons. What works for one conditions where the final assembly bonding surfaces
application might not work for another. be placed (how hot, humid, cold, or o Available in low-odor options
wet, etc.?).
Liquid adhesives versus tapes • Epoxies:
Liquid adhesives are applied in liquid Liquid-applied structural adhesives o Highest bond strength and
form and rely on chemical reactions to Structural adhesives are one of the overall performance
occur to gain strength over time. This strongest adhesives available and their o Strongest durability in harsh
is typically referred to as the cure time. strength in bonding comes closest to environments
These types of adhesives are available that of welds. Once cured, structural o Typically require more surface
in several chemistries, with varying adhesives have overlap shear strengths preparation than acrylics
advantages and disadvantages. between 1,000 and 5,000 psi (6.9 and
Tapes are a different type of 34.5 MPa). This means they’re extremely
adhesive. They’re already cured or in a resistant to changes in the environment. Under equal stress conditions, metal
solid state yet are still tacky (or sticky) Two of the most common types panels bonded with acrylic foam tape (left)
enough to adhere to certain substrates. of structural adhesives are acrylics show no visible sign of stress compared to
Tapes can be single-sided (like a gift- and epoxies, which have a number of those with mechanical fasteners (right).
wrapping tape) or double-sided and are distinct attributes.
either removable or permanent.
There are two categories of
adhesives that are most commonly used
for industrial attachment:

1. Liquid-applied structural adhesives

2. Acrylic foam tapes The substrate
Common mechanical attachments, such as welding or using screws or rivets,
Both bonding options are incredibly
can potentially damage assembled substrates. Screws and rivets puncture
durable and proven to last the life of the
through the substrate, while the extreme temperature levels of welding can
bond. However, they differ significantly
cause thermal distortion to the surrounding material.
when it comes to process flexibility,
Adhesives inherently interact or react with only the surfaces of the
surface preparation, stress-resistance
substrates that they adhere to and bond. Keeping the original substrates intact
capability, and a few other features.
offers several advantages, including:
It’s important to consider each one
within a holistic view of the attachment
• Leak reduction. The puncturing of substrates can lead to water ingress and
process to identify the ideal method for
damage, which should be avoided.
an application.
• Smooth aesthetic. By ensuring no punctures or thermal distortions, the
For example, consider the:
substrate maintains its original smoothness. In the case of low modulus
liquid adhesives or adhesive tapes, shrinkage is also avoided.
• Substrates to be bonded – joining
• Lightweighting. Thinner gauge materials can be used with adhesives,
two pieces of aluminum will likely call
which reduces end-product costs and weight.
for a different solution than bonding
• Uniform stress distribution. Adhesives distribute stresses across the entire
polypropylene to thermoplastic
bond line, which reduces stress concentration typical of screw or rivet
because of how readily adhesives
points.
adhere to these substrates.
• Attaching dissimilar materials. Adhesives prevent galvanic corrosion
• Stresses acting on the bond –
between dissimilar metals. Plus, flexible adhesives can move with
does the attachment have specific
differential thermal expansion and contraction.
strength requirements or industry
certifications it needs to pass?

DESIGN WORLD www.fastenerengineering.com December 2021 5

 ADhesives: tapes

Structural adhesives have far greater

strength than acrylic foam tapes, but A structural adhesive is
they have a set work life (the duration applied to a stiffener prior to
between the dispensing and the fixture panel attachment. Stiffeners
of the second part). are attached to thinner-gauge
metal panels to add rigidity.
Once fixtured, adhesives gain
strength relatively quickly, typically
reaching handling strength (>50 psi
(345 kPa)) in under an hour, with a
longer time needed to reach a full cure.
However, these time constraints and
fixture requirements can create logistical
challenges because the parts must be
staged and sit idle before they achieve
handling strength and a full cure.

Acrylic foam tapes

Acrylic foam tapes (AFT) were invented
in 1980 and are considered one of the
newer bonding solutions. General foam
tapes are typically made from laminating
thin “skins” of adhesive onto the face
sides of a commercially available foam.
AFTs offer an adhesive foam core
(one that’s 100% adhesive throughout),
which allows for bonding and sealing
to take place simultaneously. This on the bonding surface, the application
viscoelastic adhesive core also excels of a primer. But a fully cured state allows
at dissipating stresses and absorbing for immediate handling strength, with no
energy, providing further unique bonding clamping or fixturing necessary.
properties including the following: Once pressure has been applied
to both sides of the tape, the bond is
• Dynamic loading strength. Offers instantly at 30 to 40% of its final bond
greater dynamic loading strengths strength. This immediate strength
than general foam tapes, commonly lets end-users move an application
demonstrating an ultimate tensile anywhere, instantly, without the need for
and shear strength of between 60 a staging area to allow it to cure.
and 100 psi (410 and 690 kPa). AFTs provide the greatest process
• Noise and vibration reduction. The flexibility through ease of use, immediate
viscoelastic adhesive core absorbs handling strength, and aesthetically
and dissipates energy to reduce pleasing results. On the other hand,
noise and vibration. structural adhesives have more
• Part movement. AFT can withstand complicated and less efficient processes,
300% shear strain, so it can move but provide the greatest shear strength
with large parts that are expanding performance needed for an application.
and contracting at different rates In sum, the entire application
process, including labor, cost, aesthetics,
Acrylic foam tapes are also one of the and load performance should be taken
easiest formulas to apply of all of the into consideration to determine the
bonding solutions. The tape requires appropriate attachment solution for each
moderate levels of surface preparation. application. Knowing there are options
This includes cleaning and, depending allows for design flexibility.

6
December 2021 www.makepartsfast.com DESIGN WORLD

EE-DW Fastner Hdbk K-Blog_SS_Robotics12-21p.indd 1 11/1/21 11:40 AM
 Simla Ay
Technical Marketing Writer
Hernon Manufacturing
ADhesives: threadlocker

How to choose the ideal

threadlocker for an application?
applied to the threads of fasteners
to prevent them from loosening. It
fills the gap between the threads of a
nut and bolt, significantly increasing
the area of contact, and forming a
bonded thermoset plastic seal. This
seal ensures unwelcome liquids stay
out of the threads and prohibit any
penetration of the bolt hole.
The use of threadlocker also
increases the area of friction between
the mated surfaces. Typically, there’s
a range of about 15% metal-to-metal
contact between the two (and this is
where friction occurs), but the remaining
85% of the threads are not in contact.
In addition to holding the assembly
in place, the cured thermoset plastic
provides some flexibility to tolerate
thermal and cycling while offering
an inert barrier that resists galvanic
corrosion.
Several different types of Only a small drop of threadlocker
threadlockers are available for use, is required for most applications,
depending on the bolt materials and which is applied near the end of the
requirements of the application. For male threads and away from the bolt
example, blue threadlocker is used Threadlockers are recommended for head. As a bolt is screwed into a nut or
for medium-strength assemblies use anytime a threaded fastener will be retaining piece, the adhesive will coat
and critical joints that only rarely exposed to vibration, repeated impacts, the female threads. Once the fastener
need disassembly. or when it’s imperative to maintain a is fully tightened, the threads will
product’s structure and function. This bear down on one another, leaving a
is because nuts and bolts often loosen small amount of liquid threadlocker as
due to thermal expansion, vibration, or oxygen is pushed out.
improper torque. This creates an anaerobic
Although conventional mechanical environment, given the absence of free
fasteners, such as nuts or washers, are oxygen, which triggers threadlocker
commonly used to keep the threads curing and the threaded assemblies then
secure, mechanical devices are subject lock into place.
to loosening or failure over time. When choosing a threadlocker,
A chemical threadlocker is a thin, the most important considerations
mainly anaerobic adhesive that’s are the:

8
December 2021 www.fastenerengineering.com DESIGN WORLD

1. Strength of the adhesive (which is • A low-strength threadlocker is ideal Custom formulas
denoted by the color) for fasteners that are less than one- In rare cases, off-the-shelf threadlockers
2. Fastener size quarter inch in diameter, such as are not ideal for an application. This
3. Application methods calibration screws or gauges. is typical when temperature extremes
• Medium-strength formulations lock are a concern, such as with cryogenic
1. The strength fasteners up to three-quarters of an products. It can also occur if the nut and
Threadlockers are available in a variety inch in diameter, such as those used bolt substrates for an application are
of strengths, colors, and grades. The in pumps or compressors. made of atypical materials or have an
strength is usually denoted by a color. • High-strength threadlockers unusual shape or coating that will not
For example: are most often used on fasteners bond to conventional threadlockers.
between three-quarters of an inch, In such cases, it’s possible to have
• Purple = low strength. Low-strength up to one inch in diameter. Typically, a custom formula designed for the
bonds can be disassembled using these are used for heavy-equipment application. An experienced adhesive
hand tools. This is important when applications. manufacturer can recommend an
disassembly of an application is ideal solution.
a routine occurrence, such as for 3. The application
maintenance reasons. If a threadlocker
• Blue = medium strength. Medium- is applied during
strength assemblies require power the assembly of an
tools for disassembly. They’re used application, either The benefits of threadlocker
for critical joints that only rarely need
disassembly.
low, medium, or high-
strength grades are used.
over mechanical locking
• Red = high strength. High-strength However, if a project • Locks mating threads to prevent
threadlocker is only used for requires a threadlocker loosening from vibration or shock
permanent bonds. Disassembly is not for parts that are already • Seals against moisture and fluids
easy and requires a combination of assembled, wicking • Protects against corrosion
high heat and power tools. grades avoid the need • Prevents fastener galling and seizing
to disassemble and • Reduces maintenance
2. The size reassemble all the
A fastener’s size is an important fasteners.
consideration when choosing the A wicking threadlocker
ideal strength and viscosity of the is a low-viscosity liquid for
threadlocker required. penetrating and locking pre-assembled
parts. It moves between fastened threads
by capillary action.
Wicking grades, Wicking is associated with the color
which are green to differentiate it from the other
typically green,
strengths available. Localized heating and
are available
hand tools are needed for disassembly. It
to penetrate
is the go-to threadlocker when fastener
pre-assembled
fasteners. disassembly is not an option.
Pre-applied threadlockers are
also available. They incorporate
a chemical activator through a
process called microencapsulation.
Microencapsulation is a method in
which tiny amounts of an activating
agent are stored within a shell or bead.
The activating material is isolated
during storage and released during the
assembly process, as shearing the treads
burst the beads.

DESIGN WORLD www.fastenerengineering.com December 2021 9

 Robert Taylor
Product Line Manager
ARaymond
A S S E M B LY: F A S T E N E R S

How do I know which

threaded fastener
is right for my
application?
There’s no mathematical equation that
will give you the answer to if and when
a threaded fastener should be used in an U-nuts are self-retaining
fasteners that provide an
application, but there are guidelines to
easy and fast attachment
follow for an educated decision.
of mating panels. They
Threaded fasteners can be used in will not turn as the screw
any application where a threaded joint is driven into place or
is deemed necessary for the proper freeze on screw threads.
assembly or continued safe use of a
product.
When selecting the ideal threaded
fastener for an application, one must
consider the:
The fasteners and load expectations are these instances, self-retaining threaded
• Loading expectations typically determined by a manufacturer’s fasteners are the ideal choice over
• Vibration R&D department and based on the end conventional nuts and bolts.
• Risk of failure product. In some cases, the expected
• Serviceability loading is small or the risk of failure The benefits of self-retaining threaded
• Assembly environment so little that threaded fasteners are fasteners
• Number of required fastener unnecessary. A non-threaded joint would • Available in options to meet loading
assemblies then be sufficient. expectations
However, when the loading of an • Reduce assembly time
application is great and the risk of failure • Reduce floor space in an assembly plant
is high, standard nuts and bolts are • Can be installed as part of an assembly
required. • Serviceable
But what about for the millions
of applications used in high-speed To choose the proper self-retaining
assembly environments or that are in the threaded fasteners for an application,
mid-loading range? For example, these consider the following.
are applications that require bolt sizes
between #6 screws, 3.5mm in nominal The assembly environment
diameter, to M12s or 1/2-inch screws. In In assembly-line or sub-assembly

10
December 2021 www.fastenerengineering.com DESIGN WORLD

stations, one of the threaded-fastener another, have sufficient thickness to Expansion nuts
components should be fixed, and this withstand loading, and can have two An expansion nut can be used if the
fixed component eliminates the need for concentric holes punched into them. components for assembly are parallel to
two hands or two operators to assemble However, the panel size and material one another, have sufficient thickness
the component. must be robust enough to handle the to withstand loading, and can have one
The pre-assembled threaded fastener loading and vibration. rectangular-shaped hole co-centric with
to the fixed component prevents the All u-nuts have a recommended a round hole. Like with the u-nut, the
need to go behind the panel, maximizing minimum-to-maximum panel range. If panel size and material must be durable
the assembly floor space. Additionally, the panel is near the high end, insertion enough for the loading and vibration.
because the fixed nut is superior in screw- efforts will be higher, but the retention The panel thickness is important.
holding strength, it reduces strip-outs will be greater. If the panel is near the low If the part is over the high end, the clip
when threading directly into panels. end, the insertion efforts are reduced. will not engage. If the panel is too thin,
Self-retained fasteners can also expedite The throat depth is a critical the part will rattle. It’s common for the
assembly in the field. consideration when choosing a u-nut. panel thickness to be decided upon after
It’s defined as the distance from the the expansion nut is chosen to “design
The thread type edge of the panel to the centerline of the around the part.” However, the size of the
The thread type is largely dependent on hole and is typically 2 mm shorter than hole must meet the drawing specification
the selected screw size. the distance from the inside edge of the for the part to work properly.
Some considerations: u-bend to the centerline of the screw Following a few simple guidelines
receiving feature. If the throat depth is when choosing the proper nut to
• Machine screws generally use a too small, the u-nut will not engage. If secure a bolt can ensure a solid, reliable
tapped barrel or nut retainers it’s too long, the u-nut will hang too far assembly. It can also minimize the
• Coarse thread screws primarily use over the edge. assembly time and maximize profits.
u-shaped speed nuts
• Common screw sizes, such as the
M6x1.0, 1/4-20, and #8 (ST 4.2)
screws are available in both types

Nuts with prevailing (as opposed to

non-prevailing) torque are preferred
for most joints, particularly when using
plastic components or in high-vibration
applications. Non-prevailing torque nuts
are recommended for joints that have
less vibration and loading, or that require
frequent disassembly.

The orientation
Component orientation is a key
determinant when selecting a
product family. After considering the
screw size, thread type options, and
Expansion nuts can provide
assembly environment, a designer a fast and vibration-
must determine the orientation of the resistant solution when
components for assembly. attaching components
Every fastener has specific to blind or center-panel
requirements, and some features are more locations where only one
critical, depending on the family selected. side is accessible. They
easily snap into rectangular
U-nuts holes and are self-retaining
A u-nut can be used if the components by spring legs.
for assembly are parallel to one

DESIGN WORLD www.fastenerengineering.com December 2021 11

 Jed Bothell
Vice President
Atlas UHV
A S S E M B LY: m e t h o d s

What methods are available to

bond dissimilar metals for use
in critical applications?
Bimetal components do not
require bolting or the use of
an adhesive. Advanced joining
technologies enable engineers to
reliably apply the ideal properties
of one metal with those of another,
offering an advantage in several
industries, including the vacuum,
cryogenic, and semiconductor
sectors, and others.

Where many applications might allow Additionally, the process of joining

for the use of mechanical bolting or certain materials, such as aluminum to
an adhesive or sealant to bond two other metals, is challenging. Its tenacious
dissimilar metals, high-performance oxide surface protects it from rust-like
applications in aerospace, medical, oxidation, which is visible on iron and steel,
cryogenic, and vacuum often require preventing close metal-to-metal contact.
greater strength and longevity. Fortunately, there are alternative
Mechanical fasteners are ideal for methods for bonding dissimilar metals
several applications but are subject to that ensure a solid bond.
cracking or corrosion, depending on The two most recognized methods
the environment, and add weight to an are explosion bonding (or explosion
assembly. Adhesives provide a solid bond welding) and diffusion bonding. Each
at the beginning of use, but they typically one offers benefits and drawbacks,
degrade over time. depending on the application. But both

12 December 2021 www.fastenerengineering.com DESIGN WORLD

 the final application. For example, a
copper substrate will add an electrically
conductive layer to the end product.
Diffusion bonding is a process by
which different metals are placed together
at an extremely high pressure and heated
to an elevated temperature for a specific
duration. Bonding occurs in stages.
First, the materials yield and creep
in a way that the frictional force pushes
waves of the now plastically deformed
materials into a larger area of contact.
Atoms that are in the contact area,
then, diffuse and rearrange the grain
boundaries of the two materials in such
a way that it eliminates the original pores
in the bonded area.
Finally, this diffusion dominates
the area, forming a bond. It’s critical,
however, that surface oxides are
removed or displaced, which typically
necessitates a vacuum environment.
is formed between the plates, moving It’s also important to note that
ahead of the collision point and stripping diffusion bonding has machine
In the explosion bonding
electrons from the two bonding surfaces. limitations. This type of bonding
process, the EXW bond line
separates the aluminum portion of The electron-hungry metals are then depends on the strict control
a component from the stainless- thrust together at extreme pressures, of bonding pressure, bonding
steel part, as shown above. forming an electron-sharing bond. temperature, the atmosphere, and the
Metals — such as copper, titanium, holding time. These conditions vary for
high-nickel alloys, and stainless steel — bonding different materials. Aluminum
can easily be bonded through the EXW stainless bonds are particularly
process. Typically, aluminum and stainless challenging as a result of the formation
methods produce a molecular bond that steel are incompatible and unable to of brittle intermetallic compounds,
outperforms mechanical bolting and bond directly, because of the formation of which can weaken the bond.
adhesive bonding, which typically require brittle intermetallic compounds. Additionally, thickness restrictions
upkeep and maintenance. However, technology is solving based on a machine’s size might create
Explosion bonding or welding this challenge. One solution exploits part size limitations. The joining of
(EXW) is a solid-state process by which the metallurgical compatibility from a dissimilar metal parts requires a unique
dissimilar metals can be joined together multi-layered composition consisting set of skills to properly machine the
at an atomic level. Preparation for of 316L stainless steel, copper, titanium, joined materials into a useable assembly.
bonding requires that two plates lay flat and 6061 T6 aluminum to provide a part So, it’s important to work with reputable
against one another — a flyer plate on with maximum hermeticity (or airtight), engineers or experts in the field.
top of a base plate, separated by a small ductility, and an ability to cycle from A benefit of reliably bonded
gap. An explosive charge is placed on the cryogenic to high temperatures. bimetallic joints is that these assemblies
flyer plate and detonated from a point at EXW is not always ideal. It depends can be used to combine corrosion
the edge of the plates. on the final application. Depending resistance, higher thermal conductivity,
A controlled progressive ignition on the bonding materials, explosive and several other properties not found
travels across the flyer plate much bonding typically requires a metal layer in just one metal. With bimetallic
like ripples in a pond. The explosion between the two primary metals, such joints, engineers can make a metallic
accelerates the plates together with as copper. This layer must be evaluated composite material that enables them
impact velocities of 1800 to 2200 m/sec. when producing a part because it also to attain the highest performance and
As a result, a high-energy surface plasma has characteristics that might affect maximum value.

DESIGN WORLD www.fastenerengineering.com December 2021 13

 bolts

When does an application warrant

the use of a bolt instead of a screw?
Screws and bolts are the most fastener is one that can tap its own
commonly used mechanical fasteners. hole as it is driven into the material.
Although similar and sometimes Screws (if self-tapping) are designed
referred to interchangeably, screws and to be installed in a pre-drilled or pilot
bolts offer unique features and are ideal hole, or (if self-drilling) can tap their
for different applications. own hole during installation — thanks to
A screw is an externally threaded a sharp, drill-bit point and full threading.
fastener, typically used to assemble Most significantly, screws do not use
objects with threads. A bolt, on the a nut to retain the assembly. For this
other hand, is used to assemble reason, they’re shorter than the width of
unthreaded objects and usually with the fastened part and do not protrude
the use of a nut. Unlike some screws, through to the other side. It’s the
bolts are not self-tapping and are friction at the threads, which is the force
only partially threaded. A self-tapping that keeps the parts securely fastened.

The most common type

of bolt is the hex bolt. It
has a hexagonally shaped
head, providing a flat
surface for tools to apply
torque during fastening.

14
December 2021 www.fastenerengineering.com DESIGN WORLD

 Bolts are slightly different in the way
they fasten an assembly. The hole for
a bolt is untapped. Instead, the bolt is
pushed through the hole and fastened
using a nut at the back of the assembled
part. Therefore, a bolt is longer than the
width of this part and protrudes for the
nut to screw onto the other side.
The unthreaded portion of the bolt
remains unseen and in the assembled part.
It’s what provides an advantage over most
screws. Typically, bolts are selected for an
application because they add strength,
making the assembled parts more resistant
to shear forces when compared to fully
threaded screws. Compared to screws,
they offer far more holding power.
A washer is also often used with a Bolts are graded according to
their strength, using two numbers
bolt and nut to spread the load over a
separated by a point, that are
larger surface area, thereby reducing
stamped onto the bolt head. The
stress and wear and tear that might first number before the point
otherwise loosen the bolt over time. is the ultimate tensile strength
Bolts are installed or removed using a to either side of the fastened material. This (UTS) in MPa, divided by 100. The
handheld or pneumatic wrench (screws, tension, or compression force, is referred second number is the ratio of yield
of course, use a screwdriver or drill bit). to as the bolt preload. Preload is important strength to the UTS. Common
The benefit of a pneumatic wrench is that because a properly installed bolt assembly classes are 5.8, 8.8, and 10.9. For
it provides more torque than a handheld can withstand a much heavier load example, a grade 8.8 bolt has a
tool, which makes the task easier. without the risk of fastener failure. UTS, the load at which it would
There are a few ways to ensure fail, of 800 MPa and will yield at
80% of this value (640 MPa).
Banking on bolts bolt preload. For example, there are
Generally, screws are used when basic or preload-indicating washers that spin until
medium-holding power is required, such a certain amount of load is applied to
as for sheet metal, plywood, drywall, them. When the washer stops spinning, be referred to and serve to indicate
pressboard, deck planks, etc. The the preload has been met. There are also the minimum acceptable standard of
reliability of screws is moderate. direct tension indicating washers, which mechanical properties or performance
Bolts are the go-to choice for heavy- have tiny, raised bumps that flatten when that the fastener must meet. Higher
duty applications and are a reliable choice the preload has been achieved grades offer greater mechanical strength.
for use with concrete, beams, and studs. Torque is also significant. A quality For commonly used ASTM and
This is because the nut and bolt assembly torque wrench can also indicate the SAE steel grades, there are grade
creates a high clamping force, keeping optimal torque, which should typically be identification tables for the commonly
two parts fastened under compression. in close range to the ideal preload. used grades (ASTM and SAE), which
When a load is placed solely on a specify the minimum acceptable values
bolt, it’s limited to the amount that it can Getting the grade of proof, tensile, and yield strength, etc.
handle before failing. However, when a Much like any fastener, bolts and nuts are In summary, bolts are used for
bolt is tightened against the material of available in a variety of sizes, types, and fastening unthreaded parts whereas
the part to be fastened, it distributes the material options. Steel bolts are the most screws are used for threaded parts. Bolts
force throughout the part. This means common. The ideal choice will depend provide a much greater holding strength
the bolt only holds a portion of the on the application. First assess the type and are preferred for use in high, load-
load — which is important with heavy of material to be joined, its thickness, and bearing applications. However, this also
applications, otherwise, the bolt might fail. the weight and strength requirements. means bolts typically cost more and
Essentially, the threads of the nut Bolt grade markings, which typically require a nut (and usually a washer) for
work with those of the bolt to apply force appear on the head of the bolt, should secure fastening.

DESIGN WORLD www.fastenerengineering.com   December 2021 15

 William Hewitson
President
Ruland Manufacturing Co., Inc.
couplings

How to avoid coupling failures?

Mechanical couplings have a principal
use in the connection of rotating shafts
for the transfer of rotary motion and
torque. As with all mechanical devices,
a coupling must match its intended
purpose and application parameters
including various performance,
environmental, use, and service factors.
When selected with these design
parameters in mind — and when installed At work and working
and maintained correctly — a coupling properly: three types
should have no failure issues over of Ruland couplings
on shafts (from top
its lifetime. However, if these design
to bottom): bellows,
parameters are not adequately met,
beam, and Oldham
a coupling can fail prematurely. The
couplings.
result might be negligible and a small
inconvenience; or it might be far more
significant and include financial loss or
personal injury so due diligence is critical.
Here are a few of the primary
reasons why couplings perform poorly or
unsuccessfully, along with the steps that
can be taken to minimize failure risk.

Coupling errors carefully review how it’s stated and if there where the shafts are not in the same
Ideally, a coupling must fit its intended are other service factors to consider. Jaw- horizontal or vertical planes.
application, meeting the required type couplings are typically expressed with These are important distinctions, and
performance factors. However, a design an operating and peak torque to account the proper selection of a coupling cannot
engineer must also consider additional for use in start/stop applications. But this be made correctly without an overview of
criteria and address issues relating differs from beam couplings, which are the application and an understanding of the
to the application environment (for usually expressed using static torque and misalignment issue being addressed in the
example, heat, cold, vibration, humidity, derated based on use. system. The goal of ensuring alignment is to
debris, etc.), serviceability, and potential A designer must fully understand increase the reliability of rotating machinery.
maintenance requirements. these specifications and the design
One key is to think ahead. The criteria for the system or application Consequences
availability of a new coupling for future under review to select the ideal A mismatched coupling for a given
replacement if or when necessary should coupling. Another common mistake application can have several consequences.
be planned for in advance. Preparation is is mismatching the coupling to the When one or more of the design criteria
critical as downtime can seriously affect equipment’s misalignment condition. The and overall system attributes are not met, a
many processes, leading to lost uptime goal of shaft alignment is to increase the coupling is likely to fail. Coupling failure can
and revenue. reliability of rotating machinery. However, lead to equipment downtime, unplanned
A common mistake in design misalignment is not uncommon. maintenance, financial loss, or more
selection is an incomplete understanding For example, with parallel serious human injury.
of what the manufacturers’ product misalignment, the center lines of both Mechanical couplings are typically
specifications mean. For instance, when shafts are parallel, but they are offset. used for connecting rotating equipment
the manufacturer provides torque data, Angular misalignment is the opposite, shafts for the transfer of motion and

16
December 2021 www.fastenerengineering.com DESIGN WORLD

torque. A coupling choice that does
not accurately account for the torque
requirements, including the starting
and stopping torque as in servo-motor
applications, can result in failure and application assembly is regularly • Does the coupling need to be fail-safe?
potentially harmful consequences. maintained so that the design parameters • What speed and temperature will the
When shaft misalignment is a design are up to par. It’s important that no coupling be operating at?
factor, a beam coupling is usually a good system component or coupling wear, • What is the maximum torque that will
performance and economic choice. Beam contamination, or other detrimental factors be applied to the coupling?
couplings are ideal for handling angular have been introduced into the assembly. • Are there other environmental factors
misalignment and axial motion. However, to consider for the application?
failure may occur in applications with How to maximize production and
parallel misalignment. This is because the minimize coupling failures? Far too often motion control couplings are
single beam must bend in two different When specifying and installing a selected exceedingly late in the application
directions simultaneously, creating larger coupling, ask these questions… design process. Yet, these components are
stresses in the coupling. critical to successful system performance.
When excessive parallel misalignment • What are the accuracy requirements? Early selection will reduce errors along with
exists in the application other types of • Does the application require high the potential for premature coupling failure.
couplings should be considered, such torsional stiffness? The keys to avoiding coupling failure
as bellows and Oldham, subject to the • Is dampening or shock absorption are correct coupling selection based on
system design criteria. necessary? What about electrical the design parameters, proper installation,
isolation? and periodic system maintenance.
Choosing wisely • How much misalignment is present
Choosing a coupling for an application in the design? Is it angular, parallel, To learn more, go to tinyurl.com/
can be a complex process but should axial, and/or complex? MechanicalCouplings
not be overly time-consuming. The best
advice is to carefully consider all of the
system design criteria.
Typically, these include: torque,
shaft misalignment, stiffness, rpm, inertia,
space requirements, shaft mounting, and
there are others.
Selecting the ideal coupling is not
the end of the job. It’s equally important
to install it properly, verifying that the
design considerations were followed and
correct for the application. For example,
there might be a greater or lesser degree
of misalignment than originally specified.
Additionally, ensure that the

A beam coupling has

failed near the center,
representing what can
occur in a torque-
overload condition.

DESIGN WORLD www.fastenerengineering.com   December 2021 17

 Jonathan Coulter
Commercial Product Manager
Southco, Inc.
latches

Latches, such as this C2 Lever

Compression Latch, can offer
a streamlined look that’s easy
to install and operate while
ensuring a secure and sealed fit.

What are the different types of latches

available for secure enclosures?
A latch is a mechanical device that joins • Actuation method is closed, the cam rotates behind the
two objects together while allowing for • Ease of access fixed panel to secure the moving panel
regular separation or autonomy. For • Desired mounting style or door. The cam lever is actuated by a
example, these two objects can be a • Security requirements simple twisting or turning motion, either
moving panel or door, and a non-moving • Environmental considerations by hand or tool.
or fixed panel.
A latch typically holds these objects Design engineers should carefully Compression latch – nearly identical
together to protect the contents of consider these factors when deciding in functionality to a cam latch in that
an enclosure, granting regular access which type of latch to select for their a compression latch is composed of a
when needed — such as a metal latch specific application. body and a cam lever that rotates when
that might hold a gate closed when not actuated by hand or tool. However,
in use. Choosing the ideal latch, which Types of latches with a compression latch, the cam
appropriately manages access to an The following latch types can be used to creates a clamping force between the
enclosure, is an important consideration manage access to enclosures. two surfaces.
during the design process. This force between the panels
Latches range greatly in Cam latch – consists of a body that’s helps prevent vibration or rattling. It
complexity, depending on the purpose typically attached to a moving panel or can also compress a gasket to provide
of an intended application. There are door, which incorporates a cam lever adequate sealing for protection
several factors affecting latch selection, that can be rotated to engage a non- against environmental factors, such as
including the: moving or fixed panel. Once the door dust or moisture.

18 December 2021 www.fastenerengineering.com DESIGN WORLD

 Today, there are several
latch options that offer
quick accessibility,
smooth operation,
and vibration-resistant
its ability to resist damage if the door or
fastening — and in a
variety of styles including
panel is slammed shut. Unlike many other
hand-actuated, tool- latches, the handle requires no turning for
actuated, or key-locking. the latch to engage.
For example, the E5
Cam Latch series from Sliding latch – made up of a sliding or
Southco provides rotating body that’s attached to one
quick access with just a surface and a stationary keeper that’s
quarter-turn. Its modular attached to the other surface. The two
design is ideal for several surfaces become secure when the sliding
different actuation and
or rotating mechanism moves behind the
door dimensions.
more stable part. Slide latches can also be
designed to resist vibration and rattling.

Draw latch – provides compression by materials, such as stainless steel, and Visible or hidden latches – choosing a
pulling two surfaces securely together in offer sophisticated locking mechanisms hidden or visible latch will depend on the
the same plane while reducing vibration or designed for better security. end user’s requirements and operating
rattling. A draw latch is typically made up environment.
of two parts. The first is attached to one Push-to-close or slam latch – holds Visible latches are important when
panel and acts as an operating mechanism. doors or panels securely, allowing a user must view the latch to actuate it.
The second panel has a mounted securing closure by simply pushing the door Hidden latches are generally required
part or mechanism, which acts as a keeper. closed. This type of latch, when attached for security reasons, in which case
Tension is, then, created when the lever is to a swinging door or panel, consists of they can be concealed behind a door
hooked to the keeper. a body and a cam that’s spring-loaded. or panel. Hidden latches also allow for
When the panel or door is closed, the clean, uninterrupted surfaces, which can
Outdoor latching – have stricter cam is either pushed in against a mating improve the appearance of a product or
requirements compared to indoor surface or it hooks around a striker. piece of equipment.
latches. This is because engineers have Then, the cam will spring back out Ideally, evaluate an application’s
to account for environmental factors behind the mating surface or lock around requirements, features, and
and weather events when designing the striker to secure the panel or door in environmental considerations early in the
outdoor latches, such as cold weather, place. The push-to-close is sometimes design process to ensure the best latch
ice, or heat and high humidity. referred to as a “slam latch” because of for the job.
Depending on the application,
corrosion resistance and material
degradation might also be necessary
Draw latches should offer a tight latch
design considerations. Latches used in
grip and additional clamping force for
electrical and food equipment often need doors and panels in challenging outdoor
to meet specific industry requirements for operating conditions. Southco’s 37
design, construction, or sealing. Lever-Assist Latch features a long handle
It may be necessary to meet certain for added leverage and built-in detents to
specifications, such as with the National prevent accidental opening due to
Electrical Manufacturers Association (or shock or vibration.
NEMA, which designs standards in North
America for electrical enclosures) and
the Underwriters Laboratories (or UL, a
global safety certification company), or
other organizations.
When a latch is installed outdoors,
security risks increase depending
on the location and its interior
contents. Typically, outdoor latches
are constructed of strong or durable

DESIGN WORLD www.fastenerengineering.com December 2021 19

 Article courtesy of UC Components
manufacturing

Vacuum chambers must

remain clean and free of
contaminants and volatile
materials that could lead to
contamination of the entire

How fasteners can affect

system — and this includes the
fasteners used in its assembly.

product testing and manufacturing?

Manufacturers in a range of industries These chambers must remain
rely on vacuum chambers for different clean and free of contaminants and
phases of product development, volatile materials that would disrupt the
testing, and final manufacturing. entire system. Cleanliness is incredibly
Vacuum chambers work by removing important. Anything that exists within a
air and gases from a vessel or chamber vacuum system that hurts or inhibits its
through a vacuum pump — creating a proper function is a contaminant and
space (or vacuum) that’s completely must be addressed. This can include
devoid of matter. the fasteners.

20 December 2021 www.fastenerengineering.com DESIGN WORLD

 In fact, O-rings are most often the to the surface, machining, tooling for All types of packaging can also
primary source of contamination in drawing, rolling, and heading. impart contamination to the parts
any vacuum system. An unprocessed For example, the material that the contained within. Even handling a
O-ring contains a great deal of water, fasteners are manufactured from, or coated properly cleaned part with bare hands
which is chemically formed during the with, can potentially release lightweight can impart skin oils that will also outgas
manufacturing process. molecules that can interfere with the and drag a system down, emphasizing
Additionally, the materials used for vacuum process. This is also true for the need for gloved hands and the
any of the fasteners — including during materials that are not normally considered proper handling of a cleaned fastener.
post-fabrication treatments — are absorbent, such as metals and glass.
vital, particularly if the fastener will be Mild steel parts are often chrome- How to address contamination problems?
exposed to corrosive elements, extreme plated or black-oxide-coated to prevent Vented screws (also known as vacuum,
temperatures, extreme pressure, or high rusting. These types of rust or corrosion- ventilation, or hollow screws) and/or
levels of physical strain. preventing methods should be carefully vacuum baking are two methods that can
High and ultra-high vacuum vetted for their appropriateness for address potential contamination issues.
applications require parts that are free vacuum service. A vented screw features a hollow core,
from volatile materials that would lead to Particles are another, more direct which is specifically designed to allow
contamination of the vacuum system. form of surface contamination and the release of gases, contaminants, and
Types of contamination issues include should be factored in when choosing pressure through the fastener. These types
the type, coating, and use specifications. of screws are widely used within vacuum
• Imbedded and surface water
• Surface particulate
• Volatile organics Vented screws feature a hollow core, which rapidly
• Hydrocarbons eliminates trapped air volumes from the base of
• And other types of debris the screw during pump-down when used within a
vacuum system, ensuring a clean environment. Learn
All of these can lead to virtual leaks, more in this video: tinyurl.com/VentedScrews
outgassing, and other catastrophic
issues within a sealed, vacuum system.
Similar problems can also occur if using
improper or misspecified fasteners.

What are the sources of vacuum

contamination from fasteners?
Fasteners can lead to several
contamination issues due to:

• The materials they’re made from Plastics, elastomers, porous metals, systems and allow for the quick evacuation
• Secondary treatments, such as ceramics, and lubricants are some of the of trapped pockets of air and surface
coatings or use of lubricants worst sources of material outgassing. contaminants from blind-tapped holes.
• Improper cleaning and/or incorrect Vapor pressure and the rate of chemical Vacuum baking provides the
packaging of the fastener(s) reactions at higher temperatures can ultimate level of contamination control
• Mishandling, such as carrying also cause outgassing. for fasteners in extremely critical process
fastener(s) by hand after cleaning Hydrocarbon-based lubricants can environments. The vacuum baking cycle
• Using the wrong type of fastener in a also be a major source of contamination can be monitored and certified with a
blind-tapped hole and are difficult to remove. Secondary residual gas analyzer, which provides
• And others hydrocarbon-based lubricants (such control and monitoring to ensure a
as oils and grease) can be major and contaminate-free product.
Surface contamination in a vacuum destructive forms of contamination in Overall, careful selection of the
system can come from a variety of vacuum systems because they have a low fasteners, as well as proper cleaning,
sources — starting with the original metal vapor pressure and will spread throughout packaging, and handling of fasteners
the fasteners were made from. This a tool quickly, requiring lengthy and costly after cleaning, will ultimately offer the
includes any wire or lubricants added cleaning to remove properly. best product for your vacuum system.

DESIGN WORLD www.fastenerengineering.com December 2021 21

 Barbara Gerard
CEO
Craftech Industries, Inc.
materials

What type of plastic is ideal for

high-performance fasteners?
POM is a thermoplastic material
also known as acetal. It’s a molecule
Polyoxymethylene (POM) containing the functional group of
is supplied in a granulated
carbon bonded to two –OR groups
form and, with heat and
and was first discovered by a German
pressure, can be molded into
the desired shape. It offers chemist, Hermann Staudinger, who won
strength and hardness, making the 1953 Nobel Prize in Chemistry.
POM plastic an ideal choice Staudinger had studied this
for many fastener applications. material in the 1920s but found it to
be thermally unstable. This thermal
instability meant the material was not
useful, at least not commercially.
Eventually, however, a heat-stable
POM homopolymer was discovered by
the chemist, Dal Nagore. He realized
that by reacting the hemiacetal ends
with acetic anhydride, he could readily
depolymerize hemiacetal into a
thermally stable and melt-processable
thermoplastic.
Soon after, the chemical company
DuPont synthesized a version and
filed for patent protection of the
homopolymer. In 1960, it built a
manufacturing plant to produce
Metal has long been the material wear and tear. PVC is often ideal when Delrin — its version of the POM
of choice for mechanical fasteners. corrosion and weather-resistance homopolymer, which is still offered
However, it’s no longer the go-to option are required. For high-performance, today. Around the same time,
for all design engineers. Depending however, you’ll want to consider POM. the chemical company Celanese
on the application, the use of plastic completed its study of the copolymer
is gaining popularity and offers several Precision parts and started production of Celcon.
material advantages including strength, Polyoxymethylene is an engineering Other manufacturers soon followed
longevity, and cost-effectiveness. material used in parts that require with their versions of this material.
Plastic fasteners are now more precision. Applications for POM include
frequently used in high-pressure and high-performance components, such as The process
critical environments. Much like with fasteners (screws, nuts, washers, etc.). It’s important to note that different
metals, plastics offer different properties The material is ideal for parts manufacturing processes are used to
and options — such as nylon, polyvinyl that require high strength, stability, produce the homopolymer and the
chloride (PVC), polyoxymethylene (POM), durability, and low friction. It’s also copolymer versions of POM. To make the
and others. The choice should be based used in a variety of other applications, homopolymer, first anhydrous formaldehyde
on the demands of the application and its such as for zippers, ski bindings, insulin is necessary. The formaldehyde is then
environment. pens, coffee spigots, and even as a polymerized by anionic catalysis and the
For example, nylon is a popular solvent for perfumes and as a synthetic resulting polymer is stabilized by the reaction
choice and works fine for everyday flavoring ingredient. to acetic anhydride.

22 December 2021 www.fastenerengineering.com DESIGN WORLD

 The water that’s produced must What’s more is metal parts tend to There are drawbacks to the use of POM,
be removed from the reaction. The weigh more than plastic parts, which can depending on the application. Although
homopolymer has excellent creep make it more difficult to transport and this material offers high heat resistance,
resistance. For example, DuPont’s Delrin install when compared to plastic. it’s unavailable in a flame-retardant
is typically made this way. However, the Polyoxymethylene demonstrates the grade. It also has poor resistance to acids
copolymer of POM requires that the following properties: and a high shrinkage rate.
formaldehyde is converted to trioxane, The key is to choose the right material
which can be done by acid catalysis. This • High stiffness for your fastener application. Fortunately,
is followed by purification of the trioxane • Low coefficient of friction there is more than one type of plastic
by distillation or extraction to remove • Hardness and durability available — some can be machined,
the water and other active impurities • High abrasion resistance others molded, and some are as strong as
containing hydrogen. • High heat resistance stainless steel. The type selected is critical
• Low water absorption because it will affect the function, longevity,
Thermoplastic benefits • Good electrical and dielectric appearance, and cost of the project.
The benefits of thermoplastic parts properties As with any important purchase,
include an ability to provide strength and • Excellent dimensional stability choosing a knowledgeable supplier
corrosion resistance, typically lowering • More creep resistance than nylon for plastic components is critical. Look
maintenance and repair costs and • Low smoke emissions for one with insight into the different
extending longevity. This is why design • A high-gloss surface materials available for fasteners that can
engineers are now often choosing • Highly crystalline offer strong technical support.
plastics over metal parts.
Plastic is more resistant to
normal weather conditions and some
extreme environments, resulting in less
maintenance and fatigue over the long
run. Not only will plastic fasteners last
longer, for example, but they also offer
higher-temperature thresholds, are less
subject to vibration, and provide enhanced
operational efficiency and reliability.

Whether it’s extreme temperatures,

vibration, or chemicals, it’s
important to consider the elements
fasteners will be exposed to before
choosing the ideal type and material
that works best for an application.
For example, POM is commonly
used in the consumer electronics
and automotive industries.

DESIGN WORLD www.fastenerengineering.com   December 2021 23

 NUTS

What are twin

nuts and how do
they function?

A nut is a mechanical fastener with

A twin nut is a unique type threaded shaft where there’s no access
of fastener that can be split
a threaded hole. It’s used with a bolt, to the other end of the part. Installation
into two halves for quick
screw, or stud to provide a clamping on a bolt, rod, or shaft can be done
assembly or adjustments of
force and prevent axial movement. without the disassembly of these
an application. Typically, a bolt is inserted through fasteners.
two parts with aligned holes and a The split feature of the twin nut
nut is then screwed onto the bolt. means it splits into two, identical halves
The shaft of the bolt prevents radial along a plane that passes through the
movement of the parts while both the axis of rotation. This allows the female
head of the bolt and the nut prevent thread to be opened and placed around
axial movement. the male thread. It can, then, be used to
The most common type of nut is insert the nut onto a leadscrew, which
the hex nut. It has a hexagonal outer has no accessible end.
shape for the faces of tools to apply Alternatively, this allows the nut
torque when fastening. to be opened so that it can move
TWIN OR SPLIT NUTS ARE The hex nut is typically axially along a screw without any
a good go-to option for relative rotation — and then closed

IDEAL FOR APPLICATIONS THAT many basic assemblies.

However, there are
at a new position (so that the screw
actuation can resume). This can be
also several types of nuts useful in positioning applications,
REQUIRE THE ADDITION OF A available to suit the needs such as the leadscrew of a lathe,
of different applications. allowing a quick, rough setting before
STRUCTURAL NUT TO ANY BOLT, One such option is the final adjustments are made.
the twin nut, which is Split nuts used in these types of
ROD, OR THREADED SHAFT a type of split nut that positioning applications are usually
resembles a regular made with machined parts and have
WHERE THERE’S NO ACCESS TO hex nut that’s cut into additional mounting interfaces for
two pieces for quick secure attachment. They typically have
THE OTHER END OF THE PART. assembly and rapid threads cut to match the leadscrew
adjustment. The two of the machine. For this reason,
halves lock together these fasteners can be more costly to
so that they can function as a typical manufacture.
nut. To secure the nut to a bolt, it’s The ability to separate the nut and
typically fitted with a conical washer. place it at an arbitrary location and
Twin or split nuts are ideal for along a long, threaded shaft can be
applications that require the addition particularly useful for clamping and
of a structural nut to any bolt, rod, or tooling adjustment operations.

24 December 2021 www.fastenerengineering.com DESIGN WORLD

Advantages of twin (split) nuts:
• Easy to install
• Disassembly of the bolt or shaft is not
required
• Greater inherent strength
• Improved thread load distribution
• Reduced tensile bending stress and
The simple installation of a wing
bending at the thread root
nut — no tools are required.

The term, “twin nuts,” can also refer

to the combination of a jam or half
nut that’s used with a regular nut and
as a form of friction (like a lock nut).
A jam nut is typically used when it’s
necessary to lock a nut into place
without clamping to another object.
It’s used to resist loosening under
vibration and torque.

Take your pick

Nuts are the mating part in the assembly of a bolt and Coupling nut: an elongated nut that allows two
are used in many different applications, from basic threaded shafts to be joined coaxially.
furniture assembly to complex automotive or aerospace
requirements and many others. Flange nut: has a wide flange at one end, which
There are several types of nuts available, serves as an integrated washer to prevent
including specialty options, depending on the movement. Serrated flanges work to distribute
application. Consult with your fastener supplier to force or pressure on the nut over the part being
determine the ideal choice for your application. Here secured and ensure a locking action.
are a few options:
Keps or k-nut: designed to make assembly easier, it
Barrel or dowel nut: has a cylindrical shape that can includes an attached free-spinning, lock washer.
be inserted into a hole, which runs perpendicular to
the axis of the bolt. Knurled nut: has a large textured (or “knurled”)
diameter and is designed to be hand-tightened.
Cage nut: a type of captive nut that can be attached
to thin materials, such as sheet metal, allowing bolts Square nut: a four-sided (square) nut that may be
to be fastened in inaccessible spaces. flat or beveled on top, providing a greater surface
contact area — which offers greater resistance to
Cap nut: also called an acorn nut (because of its loosening.
shape), it has a domed top to prevent contact with
external threads. T-nut: used to fasten wood or particle board, it has a
thin body with a flange at one end that resembles a “T.”
Castellated nut: works as a locking device that’s
resistant to movement and vibration and can be Wing nut: has two “wings” on each side, which
readily removed. Also called a castle or slotted nut, it’s allow it to be easily tightened and loosened by hand
typically used with cotter pins to prevent loosening. without tools.

DESIGN WORLD www.fastenerengineering.com December 2021 25

 Jeff Greenwood
Product Sales Engineer
SPIROL International Corporation
PINS

COILED SPRING PIN

SLOTTED SPRING PIN HEADED, BARBED
SOLID PIN

How to select the proper pin

for an application?
Fasteners are some of the most There are two general categories of
important parts of an assembly as press-fit pins: solid and spring pins.
they hold all of the parts together and Solid pins either have a smooth,
facilitate any interaction between the uninterrupted surface (such as dowels) or
components. Ideally, the selected are designed with retention features (such
fasteners are simple to install, provide as knurls, grooves, and barbs). All solid pins
a quality product for the are retained by displacing the host material.
lifetime of the assembly, Conversely, spring pins are self-
TYPICAL PIN FUNCTIONS and yield the overall lowest retained by exerting a radial force (tension)
cost given the entire against the hole wall after installation.
Coiled pin Slotted pin Solid pin manufacturing process. There are two different types of spring
Press-fit pins are one pins: slotted spring and coiled spring pins.
Hinge (free fit) X X X
of the most common Slotted spring pins are general-purpose
Hinge (friction fit) X
types of pins used in fasteners typically recommended for non-
Hub/shaft X X X modern manufacturing. critical assemblies. Oftentimes, these pins are
Alignment X X X The fasteners are typically used in applications where they’re manually
Stop X X X easy to install and let installed into mild or hardened steel
manufacturers avoid components. They have a gap designed for
Joining X X X
soldering, such as when the pin to flex during installation, which lets it
Serviceable X X absorb the varying hole tolerance.
assembling electronics.

26
December 2021 www.fastenerengineering.com DESIGN WORLD

 Coiled spring pins are available in Coiled spring pins are superior for
light, standard, and heavy-duty options, assemblies that are subject to dynamic
so a designer can choose the optimum loading. This is because these pins offer
combination of strength, flexibility, and a unique combination of strength and
diameter suited for varying host materials flexibility, which allows them to dampen
and performance requirements. These forces and vibration, preventing hole
pins have two, 1/4-coils of material, damage and prolonging the assembly life.
allowing them to flex during and after Each type of press-fit pin serves
installation. The flex supports varying a purpose for manufacturers. The
hole tolerances, helps dampen shock Features and benefits table compares
and vibration, and prevents hole damage. the common features, advantages, and
benefits for each type of pin.
Common functions
Although there are several ways to use
FEATURES AND BENEFITS
pins, the most common are shown in
the Typical pin functions table. These
guidelines apply the majority of the time, Coiled pin Slotted pin Solid pin
but each application should be evaluated
Flexes to prevent hole damange during X X
for which pin type is most appropriate.
installation

Choosing right Allows for wide hole tolerances X X

These are some of the many
Superior combination of strength and X
considerations when determining the
flexibility
proper pin for an application:
Superior performance in static applications X X X
• What’s the pin’s function?
Superior performance in dynamic X
• What are the strength requirements
applications (absorbs shock loads)
of the pin?
• What is the material of the component Superior resistance to axial load (push- X
in which the pin will be used? out/pull-out)
• What environment will the pin be
Tamper-resistant X
exposed to?
• What’s the intended product lifetime Performance in soft materials under static X X
or the number of cycles? loading (with aluminum, plastic, etc.)
• How will the pin be installed?
Provides positive stop/location X X X

Spring pins are typically preferred over

solid pins because of their flexibility,
lower insertion forces, and ability to Designers can optimize the
accommodate wider hole tolerances. performance and total manufactured
However, there are exceptions. cost of an assembly by selecting the
Solid pins are the ideal choice when proper pin for an application. To do so,
precise hole locations must be maintained, the fastener options must be considered
it’s necessary to manually align several early in the design stage of a project.
clearance holes, a hollow pin is unsuitable, One of the most important steps
or increased bending or shear strength is in selecting the ideal pin is to fully
required. Solid pins are also favored when a evaluate and establish the performance
smooth, uninterrupted surface is preferred requirements of the intended
(such as when used in conjunction with an applications. The design team should
angular component) or the head is required also test and validate the fasteners in
for a positive stop or to retain a thinner part prototype assemblies before a final
to a thicker section of an assembly. decision is made.

DESIGN WORLD www.fastenerengineering.com   December 2021 27

 Article courtesy of Rotor Clip
RINGS

What are the technical

factors to consider
before choosing retaining
rings for an assembly?

It’s challenging to develop economical Here are some factors to consider

designs that reduce weight, size, raw before choosing a retaining ring for an
Much like a screw requires
a correctly tapped hole,
materials, labor, and costs. Retaining assembly.
retaining rings need properly rings hold components in place while
cut grooves for high-quality accomplishing these goals. Groove depth and preparation
performance. Both grooved Retaining rings are metal fasteners Retaining rings are installed into a groove
walls should be parallel and that secure components or assemblies on a shaft or bore and, therefore, should
perpendicular to the axis of onto a shaft or in a housing or bore. fit the specific grooves to perform as
the shaft or housing. Essentially, these devices keep parts designed. The grooved walls should be
in place using a compact design that parallel to one another, yet perpendicular
requires fewer machining operations to the axis of the shaft or housing.
than other fastening techniques. When a load is applied, it creates a
Like most fasteners, retaining rings lever action against the loaded, grooved
can range in size (from 1 mm to 1 m in wall. Under extreme loads, this can lead
diameter) and are available in different to a deflection of the ring and, ultimately,
combinations of size, shape, style, and failure. Failure is far more likely to occur if the
material. However, knowing which incorrect ring is used for the application.
ring is ideal for an application will
contribute to the overall effectiveness Standard or inverted lugs
and economy of the design. Before settling on a retaining ring style,

28 December 2021 www.fastenerengineering.com DESIGN WORLD

 Inverted retaining ring
designs mean the lugs
do not stick out from
the shaft, allowing for
greater clearance.

it’s important to assess the demands

Beveled retaining rings offer the cost-saving of the application. For example, if the
benefits of conventional rings with an added loading conditions of an application
advantage: they compensate for accumulated call for maximum groove engagement,
tolerances or wear in the retained parts and standard retaining rings are generally an
provide rigid endplay take-up in the assembly. ideal choice.
However, if the force or load of
an application is not a critical factor,
preference should be given to inverted
rings — and particularly when lug
protrusion might cause an interference
challenge. The lug is the part that
protrudes from the ring, often containing
lug holes, which are used for installation
and removal. Since they protrude, the
lugs can get in the way.
But this is no problem for inverted
lugs as they allow for greater clearance.
Inverted ring designs are also often used
in low-load capacity applications where
aesthetics or compatibility are the main
criteria. Otherwise, these two styles are
interchangeable as far as the groove
dimension is concerned.

Basic versus heavy-duty

To ensure reliability in applications with
significant loads, a reinforced retaining
ring will typically outperform a non-
heavy type. This is because of the larger
section, lug shape, and thickness of the

DESIGN WORLD www.fastenerengineering.com December 2021 29

 RINGS

reinforced ring, which is better able to any accumulated tolerances or wear

Self-locking or push-on remedy instances of fatigue failure. in an assembly and can exert pressure
retaining rings offer easy For radially installed retaining rings, between and against retained parts.
installation and security where space is at a premium and loads Bowed rings, for instance, can
in one solution. They’re are small, a crescent C-ring is usually flatten under specified loads and will
suitable for devices with the best choice. return to their original height when
shaft or housing diameters E-clips are a kind of shaft-mounted the application’s load is decreased
of one inch or less that retaining ring, which are ideal for use and removed. When the ring is flat,
require low thrust loads. with higher loads as they offer a larger it exerts a counter-load much like a
abutment area for retaining. Reinforced spring, offering endplay take-up and
E-rings function best in applications producing a compressive force that
characterized by high vibration, or with reduces chatter and vibration.
RPM and cyclic loads. In many assemblies, dimensional
tolerances in ring thickness, groove
Bowed and beveled retaining rings location, or the overall length of the
Retaining rings can offer multiple components being retained add up to
advantages, depending on the type. a degree of clearance — or endplay —
They can be used to compensate for between the abutting surfaces of the
ring and retained part. The endplay
IN MANY ASSEMBLIES, DIMENSIONAL can sometimes be eliminated by
shims, washers, or similar components

TOLERANCES IN RING THICKNESS, GROOVE

by “selective assembly” in which the
parts (with plus or minus tolerances)
are carefully matched to provide the
LOCATION, OR THE OVERALL LENGTH OF THE desired tight fit.
In high-speed production, however,
COMPONENTS BEING RETAINED ADD UP TO A such alternatives can be prohibitively
costly. In such cases, manufacturers have
DEGREE OF CLEARANCE — OR ENDPLAY — benefitted from substituting beveled
retaining rings, which offer unique spring
BETWEEN THE ABUTTING SURFACES OF THE characteristics. The 15-degree bevel
on the grooved side of the ring acts
RING AND RETAINED PART. as a wedge between the grooved wall

30 December 2021 www.makepartsfast.com DESIGN WORLD

and the retained part, which then locks These single-use rings can only
securely. This is unlike the bowed ring, be installed in one direction and are
which may deflect while under the load. destroyed upon removal. An external
Although bowed rings offer greater grip ring can move in either direction
endplay take-up than beveled retainers, and its position can be adjusted after
beveled rings offer rigid endplay take- installation. This style is more suitable
up and should be considered where for applications where components
cyclic loads occur. An additional may have to be disassembled for repair
consideration: high rotational speeds do or maintenance.
not work well with beveled circlips. Whatever the requirement,
there is a retaining ring to meet
Applications without grooves it. When choosing the ideal
Self-locking rings are used on shafts or component, consider the application’s
within bores without grooves and have a requirements, including its force or
flat rim that supports moderate static loads. load, the frequency with which the
Its prongs or teeth resist any counter- rings will be installed or removed, and
pressure by digging lightly into the shaft. the installation method.

HEX SOCKET SET SCREWS

SOCKET, FLAT & BUTTON HEAD CAP SCREWS

SQUARE HEAD SET SCREWS

SHOULDER BOLTS

HEX & TORX KEYS

ZINC PLATED SOCKETS

SPECIALS, STANDARDS & SECONDARIES

300 North Klick St.,

Hampshire, IL 60140
630.800.6377 / [email protected]

DESIGN WORLD www.makepartsfast.com   December 2021 31

 Rosa E Hearn
CFS, Product Manager — Proferred Rivets
Brighton-Best International
rivets

What are the

typical riveting
faults and
how can they
be avoided?

To select the correct length

for a rivet, measure from the
underside of the head to the tip
of the stem. The head itself is not
included in this measurement.
First…the basics when only one side of an assembly is
A rivet is a permanent, non-threaded accessible (making them “blind” to the
mechanical fastener typically made opposite side). They’re mostly tubular
of steel or aluminum. It has a head on with a mandrel through the center.
“These rivets are faulty” or “These one end and a cylindrical stem (the When inserted into drilled holes, a tool
rivets don’t seem to work with this “mandrel”) on the other, which looks like is used to draw the mandrel through
rivet gun” are phrases you might have a metal pin. The mandrel deforms during the body of the rivet, which expands
heard (or said before) if working in the installation, expanding to securely hold and deforms the back of the body. The
construction or fastener industry. Even the rivet in place. mandrel then snaps off, leaving a clean,
the best of the best rivet distributors Riveting is ideal for the quick, cost- finished-looking application.
must deal with inexperienced end-users, effective yet durable fastening of plastic On the other hand, solid rivets are
buyers, and newbies. or metal and, particularly, when the one of the oldest, most commonly
Product knowledge and experience are assembly remains permanently affixed or used fasteners and require access
invaluable. If you’ve never affixed a rivet, ask if access is limited. to both sides of an application for
your fastener supplier to show you how to The type of rivet and tool used installation. They’re ideal for important
pull a rivet and hold a rivet gun. With strong depends on the application, and there structural joints and are often used
product knowledge, you’re better equipped are several choices available. in several critical industries. During
to safely and effectively get the job done — As one example, blind rivets use the installation process, the rivet
or teach others how to get the job done! a clamping force and are ideal for use flattens against the back of the hold so

32
December 2021 www.fastenerengineering.com DESIGN WORLD

that it can never unscrew. However, Within those options, there are choices
these fasteners can be removed or related to ergonomics, power rating, It’s important to ensure your
uninstalled with a drill. and battery life. Ultimately, the ideal rivet tool is perpendicular to
These are only two options. There choice comes down to the assembly avoid improper alignment and
are several types of rivets with different requirements. This should include to minimize the occurrence
features — such as those that are an assessment of the clearance to of unsuitable hole conditions.
waterproof and sealed or split (which determine if the tool will fit a given space
are ideal for wood assemblies). There to be used correctly.
are also rivet nuts that are threaded and
add strength to an application. Common riveting failures
Additionally, there are several types Typically, the rivets or tools are not
of rivet guns for installations, including: to blame for riveting failures. In most
cases, the operator holds the tool
• Hand riveters are a manually operated incorrectly when drilling the hole —
tool used to install blind rivets. They and often perpendicularly, creating an
have a simple lever and use a squeeze oversized or irregular hole. As a result,
technique to work. a blind rivet will not perform properly.
• Pneumatic rivet guns are powered by If the mandrel breaks off above the
compressed air, with a built-in catch, rivet face, leaving a portion that sticks
to quickly install blind rivets. These out of the rivet, this is called a high
tools require a hosed, compressed- mandrel break.
air connection. There is more than one potential
• Battery-powered rivet guns offer root cause, including that the:
more maneuverability and versatility,
since there’s no cord, and work with • Assembly material for riveting is too
the push of a button. There are two thin or soft
main tool types: the first one pulls • Grip thickness is below the minimum
mandrels into a mandrel holder recommended amount
so a user only has to empty the • Hole diameter is over or under-sized
catch; the second one spits out the • Hole conditions are improper and not
mandrels from the front of the tool. ideal, such as if there’s an:
o Excessive variation in size
o Improper alignment of the tooling
for an application
Calipers are a good way to
If the mandrel head of the rivet pops
determine your proper grip range to
avoid grip thickness — whether over out, this is called a pull-thru or partial
the maximum or under the minimum. pull-thru.
The cause could be because the:

• Body length is too short

• Grip range is above the maximum
recommendation
• Hole diameter is oversized or above
the maximum recommended size
• Assembly or hole conditions are not
ideal. Examples include:
o An excessive variation in hole size
o A non-circular or a tapered hole
o Burrs or sharp edges (can occur
when drilling and should be
removed before riveting)

DESIGN WORLD www.fastenerengineering.com   December 2021 33

 rivets

o The assembly material for riveting Depending on the problem, you’ll want o The wrong nosepiece used for
is too soft or there’s a gap to check for if the: tooling
between the material thickness o An insufficient secondary side
o Improper alignment of tooling to • Grip thickness is above the clearance
application and the use of a non- maximum or below the minimum
perpendicular set recommended amounts A rivet supplier should be able to
o The wrong nosepiece used for • Hole diameter is below the minimum help you determine the cause of any
tooling recommended size installation problems and suggest the
• Assembly or hole conditions are not ideal rivets and tools for use, depending
Some other potential riveting challenges ideal. Examples include: on the application. It’s important to work
or failures are less common but can o An excessive variation in hole size with a company that has experience and
occur, including if: o A non-circular or a tapered hole genuine confidence in its product lines.
o Burrs or sharp edges (can occur If you’re a supplier, when you focus
• A rivet’s head unexpectedly pops off when drilling and should be on selling solutions instead of products,
(the “head popper” problem) removed before riveting) your customer interactions will be much
• A tool experiences a loose set o The assembly material for riveting more successful.
• The rivet length is insufficient, not is too soft or there’s a gap
allowing for the proper formation between the material thickness
of a secondary head at the back o Improper alignment of tooling to
of the application (the “sheared” application and the use of a non-
secondary head) perpendicular set

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 Pam Berry
Owner | VP of Marketing
Advance Components
SCREWS: Duplex screws

What is the
difference between
Duplex Nails and
Screws?
Studies show that Duplex
Screws can be installed as
fast as 45 screws per minute
compared to Duplex Nails
at 24 per minute.

Duplex Nails and Screws are flanged-

head or double-headed fasteners that
are often used to build temporary
structures such as braces, scaffolding,
and concrete formwork. They’re
designed to be removed with ease, so
they do not completely go into the
wood during installation.

First came the nail

Duplex Nails are as strong as regular nails,
but the double head makes them easier to
remove with a claw hammer or crowbar.
Workers drive the nail until the lower
flange is flush with the material. With a pull
bar or the reverse end of a claw hammer,
the nails pull out after the job is complete.
Depending on the application, if a lot
of force or bending is necessary to remove
the nails, they might not be reusable.
William Arthur Collings of Missouri
received a patent for the Duplex Nail in
1917. His description detailed how the
double-headed nail was ideal for use
on concrete forms because it was easy
to remove compared to regular nails,
without damaging the forms.

36 December 2021 www.fastenerengineering.com DESIGN WORLD

 Duplex Screws outperformed Duplex
Nails in timed comparison studies.

Collings wrote: “After the concrete

has set sufficiently, the forms are
removed, but due to the fact that the
heads of the nails are driven into the
wood, it’s extremely difficult to remove
the nails without damage being done to
the forms, which frequently have to be
broken and even smashed to pieces in
their removal, thus causing a considerable
waste of material and loss of time.”
Today, there are several available
styles and sizes of Duplex Nails, which
are made by manufacturers worldwide.

Then came the screw

Duplex Screws feature a double-hex
head, which accepts a variety of driving
tools — including a pile driver or hex-
head screwdriver — for installation and
removal after use. The driver drills the
orange hex-head screw until the stop
flange is flush with the material, and can
easily remove it by reversing the drill.
Since there’s no need to force the
removal, the screw maintains its shape
and can be reused multiple times
Duplex Screws were patented in 2007
by Daniel Carrillo Sr. and Hector Carrillo of
California, and the patent was assigned to wide margin. During three workdays, a and mishaps or injuries are rare.
Removerite Inc. in 2013. In their application, pair of concrete-form setters built a 50 According to recent reports from the
the Carrillos said that the Duplex Screw is x 50 lineal-foot form. One worker used National Safety Council and the Bureau of
ideal for concrete formwork and better than only Duplex Nails and the other worker Labor Statistics, the average hand injury
double-headed nails. used Duplex Screws. The Duplex Screw claim can cost from $540 to $26,000 per
The Carrillos wrote: “Removal of user outperformed the Duplex Nail driver patient. Lost-time workers’ compensation
the double-headed nail from poured in setting and form stripping, completing claims for hand injuries can exceed
concrete has proven difficult. When the task in six compared to eight hours. $7,500. A badly broken finger or thumb
removing the forms with a hammer or In another study, crews were timed can result in more than a month off work
pry bar, substantial pressure is placed on for one minute to see how many screws and can leave lasting disabilities.
the forms, which can break the edge of and nails could be installed in the same
the freshly poured cement.” amount of time. The results showed a 47% To hammer or drill?
difference, with 45 Duplex Screws drilled in It all comes down to convenience, cost,
Timed tests versus 24 Duplex Nails hammered in. and performance. Duplex Nails are readily
In timed comparison studies, Duplex available in a multitude of styles and sizes
Screws outperformed Duplex Nails by a Job safety and are sold everywhere. Duplex Screws
Safety on the job site is always a big are only available from select distributors,
consideration. Hammers are notorious come in sizes 1-1/4, 1-5/8, 1-3/4, and 2-3/4
for causing hand injuries and are among inches. They cost more than Duplex Nails.
Duplex Screws and Nails are ideal the top four causes of injury in the However, Duplex Screws outperform
fasteners for temporary structures construction industry. Most injuries involve Duplex Nails and are reusable. All of
that must be erected quickly and broken or badly bruised thumbs and these factors that must be weighed
removed with little effort. fingers. Although some power drills can be when deciding on what fastener is the
quite heavy, they’re generally easier to use right one for the job.

DESIGN WORLD www.fastenerengineering.com December 2021 37

 Kim Keating
Director of Customer Success
ZAGO Manufacturing Co.
SCREWS: security screws

Security or tamper-proof seal

screws — such as the six-lobe flat
head seal screw (left) and the six-
lobe button head seal screw (right)
— prevent unauthorized removal,
thanks to a pin in the center of each
drive. A rubber O-ring also forms a
360-degree, leak-proof seal.

What are tamper-proof seal screws and

when should you use them?
Security or tamper-proof seal screws After the screw is torqued, the
are vital for securing indoor and O-ring is sealed and will not break
outdoor, high-asset machinery and the or crack. This ensures the fastener is
sophisticated components within them, impervious to contaminants that may
such as 3D cameras and sensors. seep into and damage equipment or leak
These specialty seal screws prevent out into the environment, including:
contaminants from leaking in or out of
equipment. They also contain a locking • Liquids • Oil
mechanism that will not break or open • Moisture • Gas
without proper tooling, effectively • Precipitation • Disinfectants
deterring vandalism and tampering. • Saltwater • Dust or dirt

The seal difference Security seal screws are designed

While security or tamper-proof seal for indoor and outdoor use and
screws may resemble standard security can withstand harsh weather, high
screws — and are all inordinately difficult atmospheric pressure, and extreme
to remove — there is one significant and temperatures (hot and cold). They’re
visible difference. Security seal screws also vibration and corrosion-resistant,
feature a custom groove under the head and pollutant-free.
of the screw and are engineered with a These screws often provide
360-degree rubber O-ring that, when a more convenient alternative to
tightened, squeezes outwardly to form a permanently fastening or welding
360-degree hermetic seal. parts together. This is because

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December 2021 www.fastenerengineering.com DESIGN WORLD

critical equipment often requires
fastening, with the option to open • Advanced manufacturing (3D printers)
or disassemble at a later date for • Electronics and enclosures
maintenance. • Energy generation and utilities
• Marine (3D cameras)
Applications • Medical devices
Increasingly, security and tamper- • Military and aerospace
proof seal screws are used to protect • Telecommunications
automated machinery from wear and • Transportation
tear or malfunction. They can also
protect the fragile sensors that capture, What’s ideal for certain applications is Materials
store, and transmit sensitive data from that security or tamper-proof seal screws Security and tamper-proof seal screws
physical disruption or cyberattacks. can be removed and reused multiple come in six-lobe pin, socket pin,
These fasteners are often used when times for maintenance purposes (with spanner, as well as one-way slotted
LiDAR (or Light Detection and Ranging, the rubber O-ring intact). However, they and corrosion-resistant metals, such as
which is a remote-sensing method that will not unscrew without the proper stainless steel and steel alloys.
uses light to measure variable distances) tooling to remove the pin. A variety of rubber O-rings are
is employed, including for autonomous Adding this feature prevents also available, and the ideal choice
vehicles, robots and co-bots, and drones unauthorized users, including customers, depends on the equipment application
whether aerial, ground, or underwater. from removing screws and attempting and environmental exposure (such
A few of the industries and maintenance that should only be as moisture or heat). Options include
equipment applications that rely on performed by skilled or trained personnel silicone, fluorosilicone (a variation of
security seal screws to protect hardware — such as with portable medical devices silicone rubber that maintains high
and components from tampering and (including heart monitors or dialysis temperature), Buna (Nitrile rubber), Viton,
contamination are: machines) or automotive software. neoprene, and others.

Security or tamper-proof seal

screws with rubber O-ring
technology protect automated
machinery, such as robots and
co-bots, from contaminants,
as well as sensitive electronic
components from tampering.

DESIGN WORLD www.fastenerengineering.com   December 2021 39

 Caia Baker
VP of Procurement
Fasteners Direct
s u p p ly c h a i n

How to ensure a successful

fastener supply chain?
Whether it’s a buyer of copious quantities many, perseverance was the only option,
of fasteners for ongoing projects or a one- which meant generating and adopting
time consumer assembling a work-from- new ways of conducting business.
home desk, it’s important to recognize the This required flexibility and
value of a buyer and supplier interaction modifications, such as investments in a
within the supply chain. Treating this more secure online presence and remote
exchange as a relationship — and a accessibility for customers and employees.
potential long-term partnership — rather For example, collaborative platforms
than a transaction is one key to long-term such as Microsoft Teams, Dropbox, or
Post-pandemic success for both parties. Smartsheet let users transmit data in
wholesalers are The global pandemic emphasized real-time with the ability to connect, do
maintaining stock in the significance of supply-chain partners business, and track orders digitally. For
efforts to prevent any for several in the fastener industry. Frantic essential-service manufacturers and
unforeseen delays. This purchases, frequented stockouts, shipping suppliers, it also meant re-distributing the
warehouse has added its delays, and skeletal workforces highlighted workforce for a period of time to meet
most frequented items to how prepared (or ill-prepared) many distancing regulations in an effort to fulfill
ensure no stockouts.
companies were to handle the sudden customer demands.
changes and restrictions. The changes and challenges over
However, it has been said that the last couple of years also likely
challenges bring opportunities. If 2020 strengthened many supplier-buyer
offered nothing else, it forced companies to relationships. It quickly became evident
re-evaluate their systems for doing business which companies could meet the
to identify faults and ensure resilience. For challenges and remain dependable.

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December 2021 www.fastenerengineering.com DESIGN WORLD

 Knowledge is power. There are many relationships. Trust goes a long way in
options in the fastener industry. securing good partnerships. Be honest,
Consumers may be unaware of their keep your word, and be kind.
choices when it comes to new or full One best practice is to seek
product line capabilities. Suggesting a non-compete supplier. A non-
options or providing professional compete agreement offers assurance
installation tips adds quality incentives. that vendors will not sell to or
A specialized customer-service team provide a service to the client’s direct
who can share insightful product and competitors or disclose trusted insight
assembly knowledge is highly attractive. or private information.
Material test reports and certificates As a buyer, don’t be shy about a
of compliance are also wise additions manufacturer or supplier’s values and
to provide consumers with product standards. Ensure what you’re paying
sourcing knowledge. for also offers peace of mind, security,
and confidence.
Inventory management is a Expect competition. The emergence of
critical link in any supply chain.
Amazon Prime has added a new level of Go with the flow. The supply chain is
Ensure you continually track
competition for certain manufacturers continuously evolving. If nothing else,
what products you have in
stock, what’s typically required and suppliers. Often suppliers will offer you can expect challenges and changes
(and when), the costs, and unique components or smaller quantities over time, which are an important part of
delivery times to ensure you’re on third-party sites, such as Amazon. development. Flexibility is important.
optimizing your revenue and With e-commerce becoming more Remember, it’s always possible to
supply-chain relationships. popular, particularly since the pandemic, grow and there are several strategies to
it’s worth surveying the online presence improve the bottom line. Don’t be shy
of potential vendor(s) as the heavy-hitters when it comes to advancing business
Despite the disruptions from the will take advantage of several platforms. practices, trying new digital platforms, or
pandemic, however, some things A stronger online presence might also be reaching out to new customers.
never change when it comes to good something that could serve your company.
business relationships. Whether you’re Know your customers — and
a manufacturer, supplier, or buyer in the your potential new customers.
industry, here are some tips to ensure a
good relationship with your customers. Exceed expectations.
There are basic factors that
It starts with communication. A wise consumers require from
person once said, “communication suppliers. And ironically, it’s
is key.” Within the supply chain, not simply better pricing, even
communication is imperative. This is no though this is typically one
time for modesty or timidity. Be clear component. When suppliers
about what you want and truthful about meet or exceed consumers’
you can offer or budget for. expectations, it’s considered a
Moreover, prioritize those stakeholder win-win for all parties involved.
relationships and keep in contact regularly. If expectations are unmet,
If you’re a manufacturer or supplier, keep this typically means the stage
customers appraised of your products and has not been properly set
offerings. Offer options and good service. and better communication (or listening
Beyond mass emails or e-newsletters, skills) is required. A good rule-of- Identifying supplier
it’s worth reaching out to customers thumb: under-promise and over-deliver. relationships that align with
personally to maintain a strong bond. your business goals can lead
Stick to a code. In the fastener industry, to increased efficiencies and
If you’re a buyer, form a good
reduce the costs associated with
relationship with your suppliers, so they standards are critically important to
establishing new partnerships.
clearly understand your needs and can ensure safe assemblies. A code of ethics
then consistently meet them. should also be followed in supply-chain

DESIGN WORLD www.fastenerengineering.com   December 2021 41

 training: courses

Why is
fastener
training
important?

The Fastener Training Institute is

once again offering in-person classes
throughout the U.S. and has live,
monthly online webinars. Review their
2022 classes at fastenertraining.org.

The significance of choosing the right “The vast majority of fastener-related • Material properties
assembly method might not become problems arise from improper selection, • Temperature (minimums and
obvious until an application fails, and specification, misuse, or installation,” shares maximums)
the fasteners are to blame. Granted, it’s John Wachman, managing director of the • Environmental conditions (humidity,
one thing if a few books fall off of loose Fastener Training Institute (FTI), a non-profit moisture, gas, debris, etc.)
shelving. But when it’s a vehicle with launched by experienced industry professionals • Application stressors (vibration,
loose tire lug nuts or a pressurized bolted to provide fastener product training and dynamic loads, shock, etc.).
flange joint assembly that begins to leak, continuing education. “But regardless of the
the outcome might result in a major cause, a fastener or joint failure can cost lives at It’s advisable to choose fasteners that are
safety hazard. worst or simply be a costly inconvenience.” made of higher quality than the parts that
Fasteners and bolted joints are critical When designing, manufacturing, or they will hold together. However, there
to the safe operation of many types of installing the larger assembly, it’s important are more questions to ask.
equipment in applications including to avoid overlooking the smaller, critical For example: How many fasteners are
power generation, manufacturing, mining, components that hold it together. required for a given application — and to
and transportation. However, fasteners “Fasteners can be simple ensure the expected product life? What size,
are typically one of the lowest cost items components,” says Wachman. “Their style, and equipment or tools are needed
in any structure and are often the most complexity relates to the vast options that for proper assembly? Will the application
neglected or last considered. design engineers have when choosing the need to be serviced and how often?
This is, perhaps, one reason fastener ideal components for an assembly.” “There are many fastener options,
training is of low priority in most design The wrong choice can lead to shorter such as the size, as well as the diameter
and engineering programs. In some ways, product lifespan, poorer performance and length, head style, drive, material,
this makes sense. Fastener manufacturing or failures, and increased labor costs for coatings, plus any quality requirements,”
is a mature industry, and the majority of repairs or replacements. Wachman points out. “The fastener
producers supply high-volume parts with To ensure fastener reliability and industry is also innovative and without
single-digit defects. Only rarely are the integrity, there are several factors to current knowledge or training, a superior
fasteners at fault for failures. consider, including the: fastener solution might be missed.”

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December 2021 www.fastenerengineering.com DESIGN WORLD

 This means that to ensure the safest, organizations — such as the Industrial PennEngineering is offering an
most productive, and cost-effective Fasteners Institute (IFI), the American opportunity to learn from the leading
products and applications, updated and Society of Mechanical Engineers (ASME), experts in fastening technology via
ongoing fastener education is essential. the Occupational Safety and Health FastenerClass — and at no charge.
Administration (OSHA), etc. Here are a few The customized training sessions are
Training options other options... designed to give attendees actionable
Training that enhances the level of insights from industry experts who
technical understanding and expertise Fastener Training Institute (FTI). FTI cover theory, best practices for fastener
of individuals in the industry is critical provides beginner and advanced training selection, application examples, and more.
for a successful industry. on fastener products, standards, and Participants will also learn how to test
Look for a program that: specifications, with full-day and week- and confirm fastening designs with support
long classes (FTI’s Fastener Training Week from PennEngineering’s PEMedge services,
• Fully covers fastener products, is an industry mainstay). which supports exploring and testing
standards, and specifications “FTI’s core purpose is to enhance alternative fastening solutions available
• Teaches proper fastener selection fastener use, reliability, and safety by to design engineers. The aim is to find
and installation methods to prevent providing fastener product and technical innovative ways to improve cost, assembly
unnecessary faults and failures training at all levels,” says Wachman. time, strength, weight, and aesthetics.
• Is hosted by recognized industry They also offer live webinars and have an info.pemnet.com/fastener-class
experts with years of experience extensive On-Line Training Library. FTI
• Offers hands-on training, when possible often partners with IFI for its training events. The HYTORC Bolting Institute (HBI).
fastenertraining.org HBI has the goal of educating all of
Many fastener manufacturers will offer those engaged in industrial bolting to
online or in-person training sessions FastenerClass. A global manufacturer significantly improve the safety, quality,
for customers, as do most standards’ of mechanically attached fasteners, and efficiency of bolting operations.
HBI regularly delivers technical
certificate training classes for a variety
of job functions — from operators and
technicians to managers and engineers.
HBI also offers regularly scheduled
online public short classes, which are
brief, non-certificate classes. HYTORC
partners with ASME and OSHA to provide
standardized technical training that
maximizes the educational value.
hytorc.com/training

The Würth Fastener Academy. This

Academy is tailored specifically for its
audience. Würth provides in-person
training at a company’s facility, with an
engineering team that offers real-world
experience and insights. Attendees will
learn answers to the complex questions
that often come up when dealing with
the broad spectrum of fasteners, as well
as cost-savings methods and options.
Würth Knowing YouTube Series was inspired by the company’s Course objectives include torque-
Fastener Academy training. The online series dives into topics related tension, corrosion and fastener finishes,
to fastener engineering, bolted joint design, and proper assembly — manufacturing processes, fastener
covering basic to complex concepts, including a funny story or two. materials and mechanical properties,
Check it out at youtube.com/wurthindustrynorthamerica.
thread inspection, standards, and more.
tinyurl.com/WurthTraining

DESIGN WORLD www.fastenerengineering.com December 2021 43

 Article courtesy of the Fastener Training Institute
training: faqs

It’s important to know your

fastener facts and standards
to ensure a high level of safety
and accuracy when assembling
structural buildings or applications.

What are some critical structural

fastener facts you should know?
The late Joe Greenslade, an icon in applications together. It’s extremely are mostly related to structural bolts,
the fastener industry, once wrote: “The important to specify and choose fasteners materials, and related standards.
technology of mechanical fasteners is wisely and install them correctly.
much more complex and varied than most Greenslade taught mechanical What are the four most commonly
people understand until they embark on a fastener technology for 45 years, used structural bolt material
career where they either supply or specify publishing more than 300 informational standards and what material
the use of mechanical fasteners.” articles. He also served eight years as the strength levels are they associated
Those with a career in the industry director of Engineering & Technology with?
can most certainly attest to the accuracy at the Industrial Fasteners Institute, a The most commonly used structural bolt
of this statement. Those who are in trade organization for North American material standards are ASTM A325 and
the process of training or upgrading mechanical fastener manufacturers. F1852, which are 120 ksi tensile strength,
their skills can also likely relate to the In 2015, Greenslade compiled a list and A490 and F2280, which are 150
importance of learning about the of his most frequently asked questions ksi tensile strength. These grades are
different fastener types, materials, tools, with answers that cover the specifying, covered in the ASTM F3125.
and assembly methods available. inspecting, and installing of mechanical
After all, these components are fasteners — and more. What is the difference between Type 1
responsible for holding or joining Here are a few of his answers that and Type 3 structural bolts?

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December 2021 www.fastenerengineering.com DESIGN WORLD

Type 1 structural fasteners are made What should be the relationship of
from carbon or carbon-alloy steels an assembled bolt end be to the top
and require coating and/or painting surface of a nut in structural bolting?
to avoid rusting. Type 3 structural An assembled bolt end should be at
fasteners are made from “weathering least flush to the top surface of a nut in
steel” that oxidizes to a point and stops, structural bolting.
eliminating the need to coat or paint to
avoid further rusting. The rotational capacity (ROCAP) test:
how is it performed and what is its
What is the dimensional standard primary purpose?
covering inch structural bolts? A “ROCAP” test is performed using exact
ASME B18.2.6 is the dimensional standard bolts, nuts, and washers tightened in a The late Joe
that covers inch structural bolts. Skidmore (hydraulic) tester, tightening the Greenslade, who
nut to 10% of the target bolt tension. Then, was an industry
What are the two styles of structural rotate the nut the number of degrees expert in the
fastener sector.
bolts, and which is the most popular? designated in the ASTM F3125 standard.
The two styles of structural bolts are Heavy The bolts must not break and once
Hex and Tension Control (TC). TC is the the nut is broken loose, the nut must
most popular structural bolt because of unscrew by hand. washers on the job site will assemble
faster assembly and visual inspection. The primary purpose of a ROCAP properly when constructing the structure
test is to determine if adequate nut prior to actual assembly starting. It must
What is the applicable washer standard lubrication is present to enable proper be performed and documented by the
for structural bolting? fastener tightening without failure. assembly crew doing the installation.
ASTM F436 is the applicable washer According to ASTM F3125 (Table 3, Note
standard for structural bolting. A), the ROCAP testing of galvanized What is the specification that governs
assemblies is mandatory. Testing may be structural steel assembly?
required by the purchaser by specifying Research Council on Structural
“Supplementary Requirement S.4” at the Connections (RCSC) is the specification
time of inquiry and order for plain or that governs structural steel assembly.
assemblies having other coatings.
The test must be conducted using What are the three things that can be
the exact lots of bolts, nuts, and washers, tried to stop the galling of stainless bolt
if any, that will be used on a job site. and nut threads?
Three things that can be tried to stop
Why should all of the exact fastening the galling of stainless bolts and nuts are
components be shipped to the job site using a different grade of stainless for the
by the same supplier? mating components, slowing down the
According to the RCSC standard, installation RPMs, and lubricating the bolt
when performing a ROCAP test, all of and/or nut with thread lubricant.
the fastening components should be
shipped to the job site by the same To read additional FAQs from
supplier to assure the exact mating parts Greenslade, go to https://tinyurl.com/
Meeting standards is critical will work on the job site. FastenerFacts.
to ensure a safe and reliable
assembly. Organizations, such What is a pre-installation test and why
as the American Society of is it required?
Mechanical Engineers (ASME) A “pre-installation test” is a test
and ASTM International, support performed on a job site using the exact
the industry with the latest components and assembly technique
codes and standards for testing, specified for the structure.
materials, and engineering.
The pre-installation test is required
to demonstrate that the bolts, nuts, and

DESIGN WORLD www.fastenerengineering.com   December 2021 45

 Deanna Postlethwaite, Sr.
Director Program Management
STANLEY Industrial
TOOLS

Reducing downtime is one key to a successful

preventive maintenance program for tool and
equipment use. Ensure the correct tools are in
place, plan ahead for replacement parts, and
always ensure workers are properly trained.

What are the best practices for

tool and equipment
preventive maintenance?
Reducing or eliminating the risk of PM program is the first step but • Extended tool and equipment
unplanned downtime, manufacturing implementing preventive maintenance lifecycles by eliminating breakdowns
interruptions, and missing repair stock is in a way that’s flexible and manageable or failures
an issue every manufacturer addresses at is critical to ensure that downtime and • Increased tool and equipment
some point. One effective way to achieve interruption risks are avoided. It’s not product quality
best practices is to work on implementing just saying it, it’s doing it. • Decreased high-dollar expediting
a service preventive maintenance (PM) fees and spare-part costs by planning
program to maximize manufacturing time What are the key drivers for success? out PM schedules
and extend product quality and machine life. A manufacturer can begin the PM • Decreased cost of additional
Gaining a commitment within journey by defining what they want to workforce required to run or verify
one’s organization to set up a regular achieve, such as: backup processes

46
December 2021 www.fastenerengineering.com DESIGN WORLD

To create a comprehensive plan: support, and knowledge can help
develop the correct processes and habits
Gather tool and equipment from the start to support the team — and
manufacturer (OEM) information on to keep the program active.
the tools and equipment Once the assessment of and
Evaluate, with the OEM, the usage planning for the program are complete,
and PM guidelines from the factory the PM implementation team will depend THE IDEAL LEADER
— based on your application usage, on the size and complexity of the facility.
create a baseline plan for preventive Typically, this team is relatively small. FOR ANY GIVEN PM
maintenance and repair The focus should be on the rollout,
Plan a PM program (some areas of acceptance, and results of the program PROGRAM IS THE
the plant may be different based on with the extended teams.
applications and use of the tools and MAINTENANCE TEAM.
equipment) How can success be measured?
Ensure the proper supplies and spare When the program is implemented, success
parts are on hand and a re-order can be measured and celebrated with the
plan is in place once the parts are team involved after any ongoing challenges
consumed to ensure the necessary or problems are resolved.
inventory is always on hand Depending on the tools, equipment,
Establish checklists for each area and the type of application, some of
Audit the plan and implement changes the performance indicators to measure
based on successes or failures success are:

Who drives success?

The ideal leader for any given PM
program is the maintenance team. Along A successful maintenance program
means decreasing the likelihood of
with possessing the correct skills, they’re
tool or equipment breakdowns and
experienced practitioners of the product
failures. Invest in quality products
workflow and are responsible for the and follow the manufacturer’s
high-quality output. guidelines for use and care.

In addition:

• Engage the service and repair teams

(internal and/or external) in the
planning and ask for feedback
• Involve the quality team to implement
the process as part of the standard
operating procedure
• Lean on OEMs and/or your
distribution partners who can provide
sales and servicing support
• Manufacturing and operations teams
must buy-in and commit to the plan
to rotate tools and equipment for
preventive maintenance to ensure a
quality PM program

The lack of expertise and acceptance

from the team is the primary reason PM
programs may fail.
Accessing the proper assistance,

DESIGN WORLD www.fastenerengineering.com   December 2021 47

 TOOLS

• Improved system uptime maintenance and repairs, and supporting • Reduce the chances of complete
• Reduced system lifecycle costs the team with the necessary information breakdowns
• Planned maintenance percentage to excel. The team can and should • Recognize the problems earlier
– the time spent on planned versus identify this when the goals of the through a preventive maintenance plan
unplanned maintenance program are created and evaluated. • Reduce the chance of emergency repair
• Preventive maintenance compliance calls and overtime to resolve issues
rate – how many scheduled PM work Summary • Reduce downtime for bringing in and
orders are completed within a set There are several reasons why it’s expediting spare parts
amount of time important to implement a preventive • Reduce the potential of unnecessary
• Critical scheduled maintenance maintenance program and, over time, repairs
percentage – the impact of late the program will pay for itself.
planned maintenance work Avoid waiting for the high cost
• Downtime analysis for root cause of downtime and failure, or losing on
and resolution timing – downtime investments, before implementing such
resolution and timing a strategy.

With any program, there are Implementing a PM program will:

opportunities to enhance and
supplement the program with digital • Ensure continued uptime, while
tools to assist in collecting data, tracking reducing downtime

Structural Adhesives to Your total solutions provider in specialty chemicals & application equipment.

Replace Traditional Fasteners 800.888.0698 | ellsworth.com | [email protected]

Let our team of experts help you

make the switch to adhesives.

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48
December 2021 www.makepartsfast.com DESIGN WORLD

800-WASHERS
 Article courtesy of NBK
WASHERS

Washers are available in a variety

of types, sizes, and materials. Steel
and stainless steel are the most
common, but other metals and
plastics are also used, depending
on the application. Regardless of
the washer chosen, installing with
the proper torque is the best way
to ensure a reliable hold.

How do flat and lock washers differ?

Generally, washers are used to distribute by absorbing the compression forces of choosing the ideal one depends on the
a fastener’s load, reducing friction and the bolt as it’s driven into the application. application. For example, they might
preventing loosening. A washer is a plate A washer is positioned at the top of the be sprung to prevent vibration and
with a hole, which lets a fastener pass bolt’s shaft where it meets the head and loosening or to indicate the correct
through it. The most common shape is a slides into the mounting hole, preventing preload. They might be serrated
flat disk with a concentric hole. the bolt head and nut from scratching or or tabbed to prevent unscrewing.
Before a threaded fastener, such indenting the surfaces of the two fastened Regardless of which washer is chosen,
as a bolt, is driven into an application’s parts. tightening with the proper torque is the
surface, a washer is often placed Otherwise, without the washer, this best way to ensure a reliable hold.
through the end for greater protection could damage the application’s surface By far, the most common is the
during installation and over time. This is and eventually loosen the fastener. So, flat (or plain) washer. Its purpose is to
because threaded fasteners stress the washers often offer greater reliability. distribute a fastener’s load while reducing
material in which they’re used. There are several types of washers heat and friction during the installation
During installation, the washer works available and, as with any fastener, process.

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December 2021 www.fastenerengineering.com DESIGN WORLD

 Since flat washers are generally
manufactured by pressing metal, one
side has rounded corners and one side
has burrs. There’s no fixed rule about
which side should be placed up or down
but placing the burred side facing down
is typically ideal, particularly if surface
pressure is a concern.
Bear in mind that these burrs can
also mark the surface of the fastened
object during tightening so, for certain
applications, it may be better to put
the rounded side down to avoid plate
peeling. It’s also worth noting that flat
Captive spring washers
washers are sometimes used as spacers,
are installed under the
which is common in industrial and head of a screw to ensure
domestic applications. locking and prevent falling
Lock washers are also quite out. They’re ideal for
common and designed to secure semiconductor and food-
fasteners that might otherwise rotate or the torque applied by the nut, preventing related applications.
lose friction, such as in high-vibration it from unscrewing or separating.
applications. In other words, these Regardless of the type, lock
washers are solely designed to “lock,” washers are designed for the same
keeping nuts and bolts from coming purpose: to exert a load, partially
loose. There are several types of lock deform, and lock a fastener in place.
washers and each is designed for use However, the sharp hold from lock
with a particular fastener or application. washers can leave the application’s
For example, spring washers are surface scratched, which is not ideal
a type of lock washer made by cutting for repeated installation or removal.
out part of a flat washer so that it can For this reason, in some
form a twisted shape. This results in a applications, lock washers (mainly,
spring action or an elastic force. Unlike spring washers) are deployed along with
flat washers, which are placed on both a flat washer to distribute the load more
the bolt and nut sides, spring washers evenly without deforming the assembly
only go on the nut side of the fastener to that the fastener is secured to.
establish a bond. Essentially, the cut part There’s also an alternative to
“bites” into the bearing’s surface. conventional lock washers. Eccentric
This locking effect due to “biting” lock washers can be combined with
is limited to applications in which the commercially available hex nuts to prevent
material of the fastened object is softer screw loosening. They consist of a bearing
than the metal washer. Spring washers washer and an eccentric washer. When the
have proven useful for anti-loosening, eccentric washer is wedged into a bolt, the
especially in the semiconductor sector bearing washer changes the commercially
due to the heat cycles and the material’s available hex nut into an anti-loosening
thermal expansion coefficient. nut. The added bonus is that no tools are
External-tooth lock washers, also required for installation.
known as “star” washers, have teeth Overall, washers benefit threaded
located on the outside of the washer fasteners in many applications. Washers
ring, which are designed to offer a protect the surface from damage
stronger hold and tend to be used with during installation, evenly distribute
larger fastener heads. Star washers pressure, and prevent the fastener from
increase the locking force by resisting moving or corroding.

DESIGN WORLD www.fastenerengineering.com   December 2021 51

 welding: joints

Welding pre-heat is commonly used

before welding steel or steel alloy
materials that are one-inch thick or
more. Typically, thicker components
require pre-heat, but it depends on
the materials and assembly goals.

When do joints
need to be
pre-heated
before
welding?

Welding is a fabrication process that an ideal bond with less heat during the
joins materials — typically metals welding process. Thicker material means
or thermoplastics — by using high that more of it, including the surrounding
heat to melt the parts together and material, will act as a heat sink when
then allowing them to cool to cause welded. This leads the weld to cool more
fusion. Welding is distinct from lower- rapidly after the energy source is removed.
temperature, metal-joining techniques Although thicker components
such as brazing and soldering, which do (usually one inch or thicker) are more
not melt the base metal. likely to require or benefit from pre-
Pre-heating components before heating, there are several criteria to
welding can reduce the rate of cooling consider beforehand.
and result in stronger and more reliable To accurately assess if a welding
welds. The process can involve heating assembly requires pre-heat first
the area around the weld joint or the consider the type and thickness of the
entire part to a specified temperature base material. Although it’s difficult to
before welding. provide simple rules for the material
When thicker components are pre- thickness at which pre-heating is ideal,
heated, it’s typically possible to achieve there are rules-of-thumb and different

52 December 2021 www.fastenerengineering.com DESIGN WORLD

 The advantages When an ideal option, pre-heating
The rapid heating and cooling of the can be achieved using different heat
base metal during routine welding can sources. For smaller components, a
put heavy stresses into the parts, creating furnace or oven can be used, and this
hard structures that are susceptible to may provide the best process control.
hydrogen embrittlement. For larger components, options include:
Hydrogen embrittlement is a
permanent loss of ductility in a metal or • Arrays of torches
alloy caused by hydrogen in combination • Electrical resistance heaters
with stress. Pre-heating reduces the • Induction heaters
cooling rate of the weld and drives out • Radiation heaters
moisture. A slower cooling process
provides more time for hydrogen to Process control is extremely important
defuse from the weld-affected zone, when pre-heating, to ensure the material
which reduces the risk of cracking. is heated to the correct temperature
Additionally, slower cooling and that it remains within the required
produces microstructures in the weld temperature tolerance throughout the
metal and the heat-affected zone, which welding process.
are more ductile and provide a greater This involves three key process
resistance to cracking. Shrinkage stresses parameters:
are also less likely to occur.
Residual hydrogen can become 1. Pre-heat temperature: the
trapped at different sites within temperature of the surfaces to be
the metal, so the technique and joined before welding begins
weld temperature are important 2. Maximum interpass temperature:
considerations that might require the maximum temperature at which
adjusting. Depending on the metals, subsequent weld runs are deposited,
welding with a longer contact-tip-to- affecting the microstructural
work distance can remove hydrogen development
from the weld area. A longer electrical 3. Minimum interpass temperature:
tip can create greater preheating of the minimum temperature at which
the wire, burning off more hydrogen subsequent weld runs are deposited,
before the parts weld. affecting hydrogen cracking —
However, it’s critical to follow the typically, this is similar to the pre-heat
considerations for different materials. recommended ranges for the material temperature
For example, with alloys, the to be bonded. Careful monitoring of
tensile and yield strength are significant the base metal’s temperature between The minimum interpass temperature
considerations. Tensile strength refers to weld passes is important to ensure the might need to be maintained for a
the breaking point of an alloy and yield material remains within the required specified period of time after the weld is
strength is the point at which stress or range, regardless of the technique used. deposited to ensure sufficient hydrogen
pressure causes an alloy to deform. Joint preparation is also critical diffusion. The temperatures can be
Typically, pre-heating is based on because dirt, rust, debris, coatings, monitored using temperature-indicating
the welding code that’s used for the or oils can introduce hydrogen into crayons, thermocouples, or contact
project. Welding codes are developed the weld. Ensure the joint is clean and thermometers.
and available from several organizations completely dry before welding. Several welding pre-heating
and set the requirements for approved Welding with restraint can methods are available, so it’s important
materials, design specifications, testing, generate additional residual stresses to understand the differences and pros
inspection, as well as the welding itself. in the weld, which may cause and cons of each in relation to your
The most commonly used codes are cracking. With each assembly, be project. The aim should be to choose
from the American Society of Mechanical mindful of how the parts for joining a method that optimizes efficiency and
Engineers (ASME | Section IX) and the are positioned and how the material costs while producing high-quality welds
American Welding Society (AWS | D1.1). reacts to welding. in your application.

DESIGN WORLD www.fastenerengineering.com December 2021 53

 Tarick Walton
Global Product Manager
Ultrasonics, Branson Welding
and Assembly at Emerson
welding: materials

What advances in welding address

material variations?
Conventional ultrasonic welding — from miniaturization to increased
technology, using single-parameter electronic contents — require a new
weld modes, has enabled electronics range of assembly innovations.
manufacturers to achieve high levels of Fortunately, advanced technology is
assembly quality and reliability. This is offering just that and eliminating the need
particularly true for products built from for external measuring devices. This new,
rigid, molded plastic components. “dynamic mode” for ultrasonic welding
Ultrasonic welding creates a high-
frequency, heat-generating motion
between the components to be bonded.
It’s been used to join thermoplastics for
more than 70 years and has frequently
been chosen when parts were too
complex or costly to be molded in one
piece. Instead, they were molded in
multiple parts, which allowed for more
efficient and cost-effective welding.
This type of welding uses single,
weld-parameter modes such as
downforce, distance/collapse, depth,
time, or energy to manage weld
consistency and high repeatability.
However, controlling weld quality
with single-parameter modes becomes
more challenging when assembling
plastic parts that are:

• Compressible or contain
compressible elements
• Inserted into substrates that vary in can automatically adjust to respond
hardness to part-to-part variabilities and unique As next-generation
• Installed over or contain sensitive materials while avoiding the need to add electronic devices become
metal or electronic components external measurement or sensing devices. smaller and lighter, ultrasonic
This technique can safely weld techniques are evolving to
To assemble hard-to-handle or variable small, thin, or complex plastic parts onto create repeatable welds atop
parts, manufacturers have typically had plastic structures directly atop sensors or delicate components.
to add an external measuring device delicate electronics without damage. It
to the welder, which allows for the can also weld parts atop plastic assemblies
adaptation of a critical weld parameter. containing compressible internal elements,
This practice adds time, complexity, and such as elastomeric seals or cores.
cost to the process.
Manufacturers facing next- Working in dynamic mode
generation product assembly challenges The dynamic welding mode can monitor,

54
December 2021 www.fastenerengineering.com DESIGN WORLD

 welding: materials

recalculate, and adjust multiple weld

parameters in real-time to optimize weld
performance within a user-specified
target result. This provides users greater
versatility and more consistent results
by welding in accordance with a design
profile instead of a single parameter.
To do so, users must first select the
single-parameter weld mode that offers
the ideal application results, and then enter
two application-specific scores. These act
as limits for the dynamic mode activity.
The first score is a material density
score that characterizes the hardness
or resistance of the material that’s to
receive the welded, staked, or inserted
part. The second is a weld reactivity
score, which impacts the reaction time Before view: Staking application After view: Single recipe setting in
to achieve the desired density setting. with different number of metal dynamic mode used to weld both single
The dynamic mode then monitors each washers (single and double). and double washer staking applications.
weld cycle and optimizes it in response
to specific, part-to-part variabilities
throughout the production run.
Here are two examples of how the are embedded in a compressible core of These before-and-after views
dynamic mode weld cycle can overcome elastomeric plastic. The finished plugs show the flexibility of dynamic
the limitations of single-parameter weld- must be air and watertight, so the welded- mode in staking a pair of metal
mode controls. on lid compresses the elastomer around washers onto posts. By using
the inserted pins. A flat fit is essential the Branson GSX-E1, Elite
Precision+’s “dynamic mode,”
1. Sealing a watertight cover over for the lid, but the height of the plug’s
a consistent weld result was
electronics. In this example, a plastic elastomeric core may vary by up to 10%.
obtained (see image on the
cover must bond gap-free, watertight, The use of a single-parameter weld right), and even though the
and without the cover structure mode (downforce, distance/collapse application set-up was different
contacting or compressing the sensitive depth) risks producing unacceptable and based on the number of
electronics inside the lower component. variances in the lid height, which would metal washers being staked.
A single-parameter weld mode (the weld expose the length of connecting pins This is not possible using an
distance or collapse depth) could exert and could compromise the watertight alternative weld mode. The
too much pressure on the cover and sealing capability. dynamic mode stored the
damage internal device electronics. In the dynamic mode, however, material density and reactivity
By using a dynamic welding mode the materials density score allows for information, enabling it to
detect the completion of the
instead, a manufacturer can optimize the a weld-by-weld adjustment, which
stake and dynamically shut the
distance/collapse depth mode in each compensates for the varied consistency
weld down early.
cycle and enable the weld actuator to and height of the plug’s elastomer core.
produce enough collapse depth for a This mode requires that the actuator
watertight seal. At the same time, this mode “sense” or “feel” for the specified amount
detects and avoids a higher resistance that of resistance (so, the contact with the
could compress the cover and damage the harder material on the plug’s rim) before
electronics below the welded cover. beginning the lid weld.
As advances in electronics develop, so
2. Welding a sealed, elastomer-core do the assembly technologies that ensure
pin connector. The challenge is to a strong and reliable bond. Fortunately,
assemble an elastomer-filled, two-way plastic welding now offers more than one
pin connector so that the connecting pins way to meet new demands.

56 December 2021 www.makepartsfast.com DESIGN WORLD

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2021
A D V E R T I S E M E N T
Vendors in the fastener industry

NBK America
NBK’s historic past since 1560 has
allowed it to provide new value to customers
by constantly renewing itself. The NBK
brand stands for strong design, precise
manufacturing and sales of products based
upon the needs of its customers. NBK
provides high-precision, high-performance
specialty screws and machinery components
such as the following: Low Profile, Small
Head, Vacuum Ventilation, Seizing / Galling
Resistant, Specialty Metal (Inconel, Hastelloy,
etc.), Miniature, Captive, Clamping, Tamper
Resistant, Plastic, Loosening Resistant, Ball
Roller (Transfer), Roller Chain Bolts, Spring
Plungers, Knobs, and more. Furthermore,
NBK has Flexible Shaft Couplings, Wireless
Positioning Units, Clampers, and additional
products. We can customize these products
flexibly should the need arise.
NBK products are used in advanced
industries, such as manufacturing equipment
for automation, robotics, semiconductors,
and medical devices.

NBK America LLC

307 East Church Road, Suite 7
King of Prussia, PA 19406

Web: www.nbk1560.com
Phone: 484-685-7500
Fax: 484-685-7600
Email: [email protected]

58 December 2021 www.fastenerengineering.com DESIGN WORLD

2021
A D V E R T I S E M E N T
Vendors in the fastener industry

Pivot Point
Pivot Point is a designer and manufacturer
of Non-Threaded Fasteners - i.e. clevis pins,
cotter pins, quick-release pins/devices,
wire rope cable assemblies, and more. A
family-owned company, the Leitzke family’s
manufacturing heritage dates back to the
1920’s, and continues today in Pivot Point’s
line of classic, and unique, fastening solutions.
Wide stock selection and endless customization
options allow us to solve application challenges
on tight timelines, fixed budgets, and with
creative solutions. Pivot Point is known for our
inventive, original, fastening solutions like our
SLIC Pin™ (a quick-locking pin featuring a self-
contained cotter), Bow-Tie Locking Cotter,
Rue Ring Locking Cotter, U-Lock Nylon Tether
and others. Our state-of-the-art Wisconsin
manufacturing facility features in-house pin
design as well as automation capabilities,
making Pivot Point a powerhouse in fastening
solutions – at prices that can compete with
imports. Pivot Point is proud to offer digital,
and in-person, product training sessions. These
are live, interactive sessions that cover “Non-
Threaded Fastener Basics.” The training is
tailored to industries, teams and individuals, and
schedules. Full of application examples, product
comparisons, and best practices, the 1 hour
(or less) session is intended to round out the
knowledge of any design professional. Reach
out today and let us know how we can help!

Pivot Point, Inc.

PO Box 488
761 Industrial Lane
Hustisford, WI 53034
Phone: (800) 222-2231
Fax: (920) 349-3253
Email: [email protected]

DESIGN WORLD www.fastenerengineering.com December 2021 59

2021
A D V E R T I S E M E N T
Vendors in the fastener industry

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

Smalley
555 Oakwood Road
Lake Zurich, IL 60047

Phone: +1 847 719 5900

Email: [email protected]
smalley.com

60 December 2021 www.fastenerengineering.com DESIGN WORLD

 Selecting the Optimal Washer

Flat: Generally used for load disbursement

Tab/Lock: Designed to effectively lock an assembly into place

Finishing: Often found on consumer products

Wave: For obtaining loads when the load is static or the working range is small

Belleville: Delivers the highest load capacity of all the spring washers

Fender: Distributes a load evenly across a large surface area

Boker’s Inc.
Shim Stacks: Ideal for simple AND complex applications 3104 Snelling Avenue
Minneapolis, MN 55406-1937
Phone: 612-729-9365
TOLL-FREE: 800-927-4377
(in the US & Canada)

bokers.com

Structural Adhesives
For Specialty Trucks
and Trailers
Many truck and trailer manufacturers
are making the switch to adhesives instead of
traditional welding and fastening. Lowering
fuel cost, wind drag, and weight has become an important component
in manufacturing specialty vehicles. Several trial applications have
been performed, and results have shown that the bonds of structural
adhesives are stronger and more reliable. Ellsworth Adhesives offers a
variety of acrylic, epoxy, and urethane structural adhesives.

Structural adhesives can be used to configure work truck equipment, trailer assembly, Ellsworth Adhesives
and aftermarket upfitting. Applications can range from panel bonding for trailers, (877) 454-9224
installation of toolboxes in construction trucks, shelf hanging for delivery vehicles,
plumbing equipment for firetrucks, to electrical components in utility vehicles. Ellsworth.com

DESIGN WORLD www.fastenerengineering.com   December 2021 61

 J.W. Winco, Inc.

Spring Loaded Devices from JW Winco

When you need to align, hold, or latch different parts

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

Check out www.jwwinco.com to find out more!

J.W. Winco, Inc.

Phone: 800.877.8351
[email protected]
www.jwwinco.com

Keystone Electronics Corp.

A World Class Manufacturer of precision electronic
components & hardware for over 70 years. Keystone’s design
and engineering experts are fully integrated with their in-
house precision tool & die division supported by advanced
manufacturing systems to produce close tolerance Stamping,
Machining, Assembly, CNC and Injection Molded parts.
Keystone utilizes state-of-the-art software to support the
thousands of standard products found in their Product Design
Guide M70 and Keystone’s Dynamic Catalog on-line.

Product Overview: Battery Clips, Contacts & Holders; Fuse

Clips & Holders; Terminals & Test Points; Spacers & Standoffs;
Panel Hardware; Pins, Plugs, Jacks & Sockets; Multi-Purpose
Hardware.
As an ISO9001:2015 certified manufacturer, Keystone’s
quality control system, responsive customer service and custom
manufacturing division can meet your challenges with
a standard or custom design solution.
DESIGNERS & MANUFACTURERS Keystone Electronics
55 S. Denton Ave.
New Hyde Park, NY 11040

Tel: 1.800.221.5510
www.keyelco.com www.keyelco.com

62 December 2021 www.fastenerengineering.com DESIGN WORLD

 Custom Plastic
Machined & Molded
Fastener Components

ADAPTERS • BACKUP WASHERS • BOLTS •

COUPLINGS • CONNECTORS • HEX BOLTS •
INSULATORS • NUTS • SEALS • SET SCREWS •
SHOULDER BUSHINGS • PAN HEAD SCREWS •
PINS • SLEEVES • SLOTTED SET SCREWS •
SPACERS • WASHERS

Manufacturing Solutions Since 2001

Materials Utilized: ABS, Acetal, Acrylic, Delrin®, HDPE, KEL-F,
Phenolics (G10, G11, XXX, CE, LE), PEEK, PTFE, Polycarbonate,
Next Level Manufacturing
401 E. Edgewater Street
Polypropylene, PVC, PVDF, Torlon®, UHMW and Ultem® Portage, WI 53901

Please visit us at www.nextlevelmanufacturing.com [email protected]

(608) 975-7424

SET SCREWS • HEX KEYS • SHOULDER BOLTS • NYLON TIP

• SOCKET CAP SCREWS • STAINLESS • METRIC / INCH •
ZINC PLATED SOCKETS • SHORT ARM HEX KEYS • 6-LOBE
SOCKETS • BUTTON HEAD CAP SCREW • DOWEL PINS •
IMPORT / USA • BRASS TIP • STANDARDS / SEMI-STANDARDS
• SQUARE HEAD SET SCREWS • HEX JAM SCREWS •
LONG ARM HEX KEYS • NYLON PATCH • LOW HEADS 6-LOBE
(TORX) KEYS • BUTTON FLANGE CAP SCREWS
Setko Fasteners & Distribution
Please visit us at www.SetkoFasteners.com 300 N. Klick St. Unit A • Hampshire, IL 60140

[email protected]
setkofasteners.com
(630) 800-6377

DESIGN WORLD www.designworldonline.com December 2021 63

 AD INDEX

Able Electropolishing .......................... IBC SALES LEADERSHIP TEAM

Boker’s Inc. ................................................49 Ryan Ashdown Publisher

Ellsworth Adhesives ..............................48 [email protected] Mike Emich
216.316.6691 [email protected]
J.W. Winco, Inc. ......................................... 17 508.446.1823
Jami Brownlee @wtwh_memich
Keystone Electronics Corp ....................7 [email protected]
224.760.1055 Managing Director
NBK America LLC ...................................IFC Scott McCafferty
Mary Ann Cooke [email protected]
Next Level Manufacturing................... 34 [email protected] 310.279.3844
781.710.4659 @SMMcCafferty
Pivot Point Inc.......................................... 35
Jim Dempsey EVP
Setko Fasteners ...................................... 31 [email protected] Marshall Matheson
216.387.1916 [email protected]
Smalley Steel Ring ................................ BC 805.895.3609
Mike Francesconi @mmatheson
Würth Industry North America ..........55 [email protected]
630.488.9029

Jim Powers
[email protected]
312.925.7793
@jpowers_media

Courtney Nagle
[email protected]
NBK America LLC ...................................58 440.523.1685

Pivot Point Inc. .......................................59

@wtwh_CSeel

Smalley Steel Ring .................................60

1
December 202
ring.c om
neren ginee
www. faste

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64 December 2021 www.fastenerengineering.com DESIGN WORLD

 SIC K OF
R IN GS?
SNA P

We were too.

That’s why we are the only

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• Easy and Quick Install/Removal

• Interchangeable with Snap Rings
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