Abstract: A composite tube assembly and a method of making the same are provided. The composite tube assembly includes a composite tube and a fitting penetrating the composite tube. The fitting includes a reduced diameter section surrounded by a reduced diameter tube portion of the tube. A bolstering structure surrounds this reduced diameter tube portion. The method includes inserting the fitting into the composite tube, heating the tube portion surrounding the fitting to soften the same, radially compressing the tube portion onto the fitting reduced diameter section, and providing a bolstering structure surrounding the compressed tube portion.

Abstract: A force sensor rod for an aircraft actuator system. The force sensor rod is constructed from a tube and a force sensing transducer. The force sensing transducer has a body containing a force responsive primary element and electronic circuitry. The force sensing transducer is provided with a protruding end composed of a material relatively harder than the tube material. The threads on the protruding end terminate in a plurality of axially spaced grooves adjacent to the force sensing transducer body and normal to the axis of the force sensing transducer. The tube is threaded onto the protruding end of the force sensing transducer and swaged onto the protruding end by causing the tube material to flow into the grooves.

Abstract: A control rod for an aircraft actuator system. The control rod incorporates a swivel insert to create a rotatably connected rod end. The swivel insert comprises a longitudinal bore for introduction of a rod end shaft. The rod end shaft has a circumferential groove that aligns with radially extending bores in a threaded portion of the swivel insert. Ball bearings are placed into the radially extending bores and the swivel insert is threaded into a tube having an internally threaded bore and a counter bored entrance portion. Once the swivel insert is threaded into place, the ball bearings are captured in the radially extending bores between the counter bored entrance portion of the tube and the circumferential groove. The rod end is thus free to rotate but is rotatably attached to the control rod.