Abstract: A mandrel assembly has a mandrel, a biasing member, and a outer member. The biasing member biasly maintains the outer member in a first position, which corresponds to a contoured portion of the mandrel, when the outer member is either on the access or the blind side of a workpiece. The biasing member is compressible to allow the outer member to move into a second position as the outer member is moved through an opening in the workpiece. In the first position, the outer member includes a maximum outer circumference that is larger than the opening of the structural workpiece. In the second position, the outer member includes a maximum outer circumference that fits within the opening of the structural workpiece.

Abstract: This disclosure relates to a pre-assembled fastener assembly having a retainer, a nut member, and a cold expansion mandrel that is forcibly removable after the assembly is installed into an opening of a structural workpiece. The mandrel is captured between a portion of a retainer and a portion of a nut member. The forced removal of the mandrel expands the retainer into the opening, securing the fastener assembly therein. The assembly may also include a cap coupled to the retainer to seal the opening in the structural workpiece. The nut member can be fixed or free-floating with respect to the retainer. In addition, the nut member can be threaded to receive a fastener. The mandrel is recyclable or disposable.

Abstract: At least one embodiment of the invention generally relates to a bushing kit (102) and method of installing the same with a mandrel (300) having a tapered region (304). The bushing kit comprises an inner member (110) and an outer bushing (108). The inner member may include an inner surface (126) having an engagement portion, such as a coating, plating, and/or lining, such as a self-lubricating coating. The method of installing the bushing kit (102) includes passing the tapered portion of the mandrel through the outer bushing (108) to radially expand the outer bushing into the structural workpiece (104) and possibly induce some amount of residual compressive stress in the structural workpiece (104). Contemporaneously, the inner member (110) is passed into the radially-expanded outer bushing (108) before the outer bushing is permitted to radially inwardly rebound or spring back. The outer bushing (108) is then permitted to radially contract onto the inner member to form an interference fit therewith.

Abstract: An alignment device is located on a mandrel of an installation tool and is used to align a structural member in an opening of a workpiece while seating a radial flange of the structural member against a first surface of the workpiece. The alignment device comprises a disk-shaped device having an outer surface, an inner surface forming an opening through the alignment device, and where the opening is sized to be at least slightly smaller than a major diameter of an expansion portion of the mandrel. In one embodiment, the alignment is nylon to allow the inner surface of the alignment device to be repeatedly, radially expanded and yet the opening formed by the inner surface returns to its original size.

Abstract: A fitting (58) is inserted into an opening (56) in a wall (50). The fitting (58) includes a ring portion (64) where it extends through the opening (56). It also includes one or two end portions (66, 68) that extend axially outwardly from the ring portion (64). The ring portion (64) has an inside diameter (76) that is smaller than the inside diameters of the end portion or portions (66, 68). The fitting (58) is positioned within the wall opening (56). Then, an expansion tool is moved through the interior of fitting (58) for the purpose of expanding the ring portion (64). The ring portion (64) is expanded to such an extent that it makes a tight fit with the opening (56). Also, the degree of expansion may result in a cold working of the wall material surrounding the opening (56). The expansion tooling only expands the ring portion (64) and does not exert a substantial expanding force on the end portions (66, 68).

Abstract: At least one embodiment generally relates to an installation assembly for an opening in a workpiece that includes a swaged collar, an inner member, and an outer member. The swaged collar has a first end, a second end, and a main body extending between the first end and the second end. The main body includes an inner surface defining a passageway through the collar. The inner member has a mandrel section for expanding the outer member. The inner member is used to expand the outer member and to keep the outer member in an expanded state.

Abstract: A mandrel assembly has a mandrel, a biasing member, and a outer member. The biasing member biasly maintains the outer member in a first position, which corresponds to a contoured portion of the mandrel, when the outer member is either on the access or the blind side of a workpiece. The biasing member is compressible to allow the outer member to move into a second position as the outer member is moved through an opening in the workpiece. In the first position, the outer member includes a maximum outer circumference that is larger than the opening of the structural workpiece. In the second position, the outer member includes a maximum outer circumference that fits within the opening of the structural workpiece.

Abstract: A fitting is inserted into an opening in a wall. The fitting includes a ring portion where it extends through the opening. It also includes one or two end portions that extend axially outwardly from the ring portion. The ring portion has an inside diameter that is smaller than the inside diameters of the end portion or portions. The fitting is positioned within the wall openings. Then, an expansion tool is moved through the interior of fitting for the purpose of expanding the ring portion. The ring portion is expanded to such an extent that it makes a tight fit with the opening. Also, the degree of expansion may result in a cold working of the wall material surrounding the opening. The expansion tooling only expands the ring portion and does not exert a substantial expanding force on the end portions.

Abstract: An alignment assembly comprises an outer bushing received in an aperture of a work piece, and an eccentric bushing received in a passage of the inner bushing and rotated to align a passage of the eccentric bushing with passages of other work pieces and/or alignment assemblies. An alignment assembly comprises an outer bushing received in an aperture of a work piece, inner bushing received in a passage of the outer bushing, and an eccentric bushing received in a passage of the inner bushing and rotated to align a passage of the eccentric bushing with passages of other work pieces and/or alignment assemblies mounted in other work pieces. Flanges and/or ends may be machined to accommodate off-center passages. The bushings may be secured via cold work expansion.

Abstract: A dual bushing installation kit includes a first metal bushing and a second metal bushing. The first metal bushing can include a first body having first and second ends. The first and second ends are connected by a first outer surface having a first outer circumference and a first inner surface having a first inner circumference. The second metal bushing is defined by a second body having first and second ends. The first and second ends are connected by a second outer surface having a second outer circumference and a second inner surface having a second inner circumference. The second outer circumference is dimensioned to be substantially conforming with the first inner circumference such that the second bushing is closely receivable by a first opening of the first bushing. Both the second outer circumference and the first inner circumference can be expanded in an outwardly radial direction.

Abstract: Installation/processing tools may be used to install one or more expandable structures in a workpiece. An installation/processing tool may include an expansion mandrel, a processing tool, and an expansion assembly having an expansion jaw movable between a collapsed configuration and an expanded configuration. An expandable portion of the expansion jaw is sized to fit within a passageway of an expandable member. When the mandrel is moved through the expansion assembly, the expansion jaw is moved between the collapsed and expanded configurations to cause expansion of the expandable member. The installation/processing tool can also be used to cold work a workpiece.

Abstract: Self-aligning tools may be used to install and reposition an expandable structure in a workpiece. A self-aligning installation system may include an expansion mandrel, self-aligning nose cap assembly, and an installation tool for driving the mandrel. The expansion mandrel is sized to fit within a passageway of an expandable member such that the expandable member radially expands when the expansion mandrel is moved through the passageway. The self-aligning nose cap assembly moves relative to the installation tool and mandrel. A self-aligning seating system can be used to move the installed expandable member. The self-aligning seating system includes a seat backing, a seat base, and a pull rod coupled to the seat backing and extending through the seat base. The seat backing slidably engages the seat base to permit rotation of the pull rod.

Abstract: At least one embodiment generally relates to using an installation tool to pass an expansion mandrel through an elongated member to at least locally, radially expand at least a portion of the elongated member and achieve an interference fit with a radially expandable member located about an outer surface of the elongated member. In one embodiment, the elongated member is radially expanded over its entire length and may include a stepped feature so that only a portion of the elongated member achieves the interference fit with the radially expandable member. During the radial-expansion process, both the radially expandable member and the elongated member may be at the same or approximately the same temperature. Before the radial-expansion process, the radially expandable member may be assembled using press-fit techniques, shrink fit techniques, clearance fitting techniques, or combinations thereof.

Abstract: An alignment device is located on a mandrel of an installation tool and is used to align a structural member in an opening of a workpiece while seating a radial flange of the structural member against a first surface of the workpiece. The alignment device comprises a disk-shaped device having an outer surface, an inner surface forming an opening through the alignment device, and where the opening is sized to be at least slightly smaller than a major diameter of an expansion portion of the mandrel. In one embodiment, the alignment is nylon to allow the inner surface of the alignment device to be repeatedly, radially expanded and yet the opening formed by the inner surface returns to its original size.

Abstract: A bushing with wave relieving geometric features includes a unique geometric end feature such as a countersink or arcuate surface, which creates a pocket, volume, and/or reservoir, to receive an amount of material that is extruded in a longitudinal direction during radial expansion of the bushing. At the mandrel exit side of the bushing, the extruded material may be accumulated from a propagating wave of material preceding a radial-expansion mandrel. At the mandrel entry side of the bushing, the extruded material may be caused by the radial force of the expansion mandrel near the unrestrained end surface at the entry side of the bushing. The unique geometric end features of the bushing may also include a high portion on the end surface of the bushing to direct the fastener clamp-up loads through the radial flange of the bushing and into the workpiece.

Abstract: A mandrel assembly has a mandrel, a biasing member, and a outer member. The biasing member biasly maintains the outer member in a first position, which corresponds to a contoured portion of the mandrel, when the outer member is either on the access or the blind side of a workpiece. The biasing member is compressible to allow the outer member to move into a second position as the outer member is moved through an opening in the workpiece. In the first position, the outer member includes a maximum outer circumference that is larger than the opening of the structural workpiece. In the second position, the outer member includes a maximum outer circumference that fits within the opening of the structural workpiece.

Abstract: A structural assembly for use with a structural workpiece includes a bushing and a first member, such as a washer. The bushing is placed in an opening of the structural workpiece and the first member is placed on the bushing. A portion of the bushing within the opening of the structural workpiece is radially expanded (e.g., with a tapered mandrel) into the structural workpiece to achieve an interference fit therewith. An extended portion of the bushing is radially expanded to generate a swaged portion. The swaged portion mechanically captures and retains the first member on the bushing and against the structural workpiece. The combination of a radial flange on the bushing and the retained first member, on opposite surfaces of the structural workpiece, respectively, may operate as bearing surfaces for thrust loading in more than one direction.

Abstract: This disclosure relates to a pre-assembled fastener assembly having a retainer, a nut member, and a cold expansion mandrel that is forcibly removable after the assembly is installed into an opening of a structural workpiece. The mandrel is captured between a portion of a retainer and a portion of a nut member. The forced removal of the mandrel expands the retainer into the opening, securing the fastener assembly therein. The assembly may also include a cap coupled to the retainer to seal the opening in the structural workpiece. The nut member can be fixed or free-floating with respect to the retainer. In addition, the nut member can be threaded to receive a fastener. The mandrel is recyclable or disposable.

Abstract: A bushing (52) has two bushing parts (52, 58), each of which includes a tubular section (54, 60) and a radial flange section (56, 62) Tubular section (54) is inserted into an opening (38) in a work member (40), from one side of the work member (40). Tubular section (60) is inserted into tubular section (54) from the opposite side (44) of the work member (40). A mandrel (M) is moved through the interior of the tubular portion of the bushing to radially and circumferentially expand the tubular portion of the bushing and move the flange sections against the opposite sidewalls of the work member (40). The tubular portions (54, 60) of the bushing (52) is radially and circumferentially expanded an amount sufficient to introduce fatigue life enhancing compressive residual stresses in the work member (40) immediately around the opening (38) in the work member (40).

Abstract: A blind nut installed in a structural joint provides an interference fit and a fatigue enhancing benefit to the structural joint. A bolt can be inserted into the nut for additional shear strength and shear continuity. During installation in the structural joint, a first flange of the nut is seated against a first structural member, an installation tool is inserted into a passage in the nut, and the tool is operated to buckle a collapsible portion of the nut to form a second flange on a second structural member. Contemporaneously, an expandable portion of the nut is radially expanded into the structural joint. The installation process induces a high interference fit and may also induce a residual compressive stress in the structural joint.