Abstract: A method of forming a fastener may include inserting a blank precursor into a bore of a forming die having an enlarged bore portion. The method may further include applying a first axial compression force to the blank precursor, and forming a cold-worked head section and an enlarged shank portion on the blank precursor corresponding to the enlarged bore portion. The enlarged shank portion may have a nominal shank portion extending therefrom. The method may additionally include inserting the nominal shank portion into a bore of a final reduction die, applying a second axial compression force to the enlarged shank portion, and urging the enlarged shank portion into the bore of the final reduction die. The method may also include reducing a cross-sectional area of the enlarged shank portion by approximately 2 to 5 percent to form a cold-worked shank section.

Abstract: A fastener suitable for use in airplane manufacture or repair that is coated with a pre-mixed moisture cure sealant. The sealant layer is coated with a frangible moisture barrier that will break apart when the fastener is installed, thus exposing the sealant to atmospheric moisture. Once exposed to moisture, the sealant will begin to cure. Preferred embodiments also provide a moisture indicator that provides a visual indication that the outer moisture resistant layer has been damaged.

Abstract: A fastener has a cold-worked head section, a cold-worked shank section, and a ductile shank section extending from the cold-worked shank section to a tail end portion of the fastener.

Abstract: A connecting element for forming a punch-riveted connection of at least two component sections is proposed, wherein a foot section has at its free end a foot base with a basic shape which is cylindrical or at least approximated to the cylindrical shape. According to the invention, an annular circumferential elevated portion is formed in the foot section between the foot base and the shaft section.

Abstract: A fastener (2) such as a rivet, and a method of manufacture of such, wherein the fastener (2) is formed with helical (16) and annular grooves on the shell (4), such that when the fastener (2) is installed into a workpiece (24), a bulb (30) having a lobed blindside footprint (36) is produced on the blindside of the workpiece (24), the helical grooves (16) having an increasing depth towards the head end (12) of the shell (4) to promote formation of the bulb (30) initially towards the head end (12).

Abstract: An aligner and a method for its use in staking a fastener. More specifically, the aligner guides a tip of a staking tool in some portion of a staking operation properly into alignment with a clinch portion of a staked fastener. As a result, the clinch portion is shaped into a head of a generally higher quality than would otherwise occur.

Abstract: A sheet metal rivet, a body with a centerline and first side and second sides oppositely disposed with respect to the centerline; at least one first protrusion extending from the first side of the body and having a first width; and at least one second protrusion extending from the second side of the body and having a second width. The first and second widths are different or the at least one first and second protrusions are at least partially misaligned in a direction orthogonal to the centerline. In one embodiment, the at least one first and second protrusions include first and second pluralities of protrusions, respectively.

Abstract: A blind rivet assembly is provided. In another aspect of the present invention, a blind rivet has ends that are received within countersinks in one or more workpieces and a mandrel head is completely pulled through the rivet without being severed from a mandrel stem. A further aspect of the present invention includes a mandrel with one or more ribs located on an outwardly tapering shoulder.

Abstract: A fastening device such as a rivet collar that includes a retention element is disclosed. The retention element enhances the retention of a fastener within the fastening device by frictionally engaging the fastener. The retention element comprises a heat resistant base polymer, such as a reactive hot melt, an ethylene acrylic acid copolymer, or a polyethylene polymer blend, that does not melt or become tacky even at high temperatures, and therefore has high stability even under extreme storage conditions. Also disclosed is a method of forming such retention element on a fastening device.

Abstract: A connector includes a body having a first portion and a second portion integrally formed with the first portion. The first portion has a first hardness and the second portion has a second different hardness. In an embodiment, the first portion has a first hardness of at least 40 Rockwell C and the second portion has a second hardness that is less than the first hardness. In another embodiment, the second portion has a hardness of 30 Rockwell C or less and the first portion has a greater hardness than the hardness of the second portion. The connector is made using a method including the steps of forming a body having first and second portions, and induction hardening the first portion to a hardness of at least 40 Rockwell C or the second portion to a hardness of 30 Rockwell C or less.

Abstract: A blind rivet formed with a tubular shell, and a mandrel extending through the shell. The shell has an outwardly extending flange at one end forming a rivet head, and having a first set of radial indentations arranged around the periphery of the shell at a first distance from the rivet head, and a second set of radial indentations arranged around the periphery of the shell at a second distance from the rivet head. Each of the radial indentations are formed by crimping them in the rivet shell after the shell has been positioned around the mandrel with the end of the shell remote from the rivet head defining the blind end of the rivet shell. Lastly, the mandrel having a head formed at one end to abut against the blind end of the shell, and the stem extending from the head having a point of weakness part way along the length thereof disposed within the shell.

Abstract: A component of a multi-gear, manual transmission, in particular, an idler gear shaft support which supports one end of a relatively short idler gear shaft within a transmission housing. The idler gear shaft has an idler gear mounted thereon, the idler gear being rotatable about a bearing, usually a needle bearing, relative to the idler gear shaft in order to provide a reverse output to the reverse gear on the output shaft of the transmission. More specifically, the idler gear shaft support of the present invention includes an offset bolt slot for securing the idler gear shaft to the transmission housing, and a non-symmetrical mass apportionment of the support on either side of the bolt slot with a larger portion thereof accommodating the maximum thrust load of the idler gear shaft.

Abstract: An apparatus and method are provided for angularly extruding a workpiece through a die to form blanks and articles having refined grain structure. The die is also used to form the workpiece to a desired shape, such as a cylinder. The angular extrusion method can be used in place of some heat treatments, thereby lowering the cost and time for manufacturing articles. The method is compatible with materials with high strength-to-weight ratios such as aluminum, titanium, and alloys thereof. The blanks can be used to form articles having favorable mechanical properties such as strength, toughness, formability, and resistance to fatigue, corrosion, and thermal stresses.

Abstract: A threaded locking beam nut having a plurality of locking beams configured such that the inside edge surface of each locking beam has a radially inwardly angled surface thereby forming substantially a V-shaped channel between adjacent beams.

Abstract: A method of forming a tubular member with longitudinal slots along part of its wall, comprising the steps of: firstly, forming longitudinal zones of weakness along part of the wall of the tubular member, and secondly, expanding the said part of the tubular member radially to cause fracture of the wall of the member along the longitudinal zones, thereby to form longitudinal slots.

Abstract: The present invention comprises aluminum solid rivets and methods of manufacturing aluminum solid rivets for aircraft and other demanding applications to provide rivets with high strength and excellent driveabiltity while improving the rivets resistance to fatigue and stress corrosion cracking. In accordance with the method, an aluminum rivet blank approximately the same diameter as the head of the finished rivet is used. This rivet blank is forced into a die to extrude the tapered region and the shank of the finished rivet. The fabrication process provides more uniform cold working at the junction of the shank and the tapered region of the rivet, and better orients the flow lines in this region. The process also can provide a superior surface finish, and may be suitable for use in wet wing fabrication without further processing for improved surface finish. Alternate embodiments are disclosed.

Abstract: A metal rod (20) having a conical or pyramidal cut extremity (20a) is used to make a mandrel for blind rivets. The rod is held in place between a pair of die segments (11) such that its end (26) of a preset length, including the tip protrudes from an upper surface (14) of the segments. Subsequently, a free intermediate portion of the swageable end (26) is axially compressed to form a mandrel head (27) by a punch (12) which has a lower face (17) parallel to the upper surface (14) of the segments with a conical or pyramidal recess (18) formed on the end. The free intermediate portion of the swageable end (26) swells radially outward to form the head (27) having a flat flange (31) from which the tip intrudes. The mandrel, which has the head formed uniformly without any eccentricity about the longitudinal axis of a mandrel body, can be produced inexpensively using a prior art nail manufacturing apparatus.

Abstract: A method of making an elongated mandrel having an end integral with a drill section, with the method including the steps of subjecting a single columnar piece of material to the heading process so as to make a blank N composed of the mandrel, a short stem having one end integral with the end of the mandrel and having a diameter D greater than a diameter of the mandrel, and a flange formed integral with the other end of the stem. The short stem is then cold forged to produce the drill section having end edges (7a) and (7b) facing the flange, and, subsequently, the drill section is trimmed so as to remove the flange together with a scrap resulting from the cold forging of the stem, in such a manner that the mandrel having the integral drill section can be mass produced from the single piece of raw material, efficiently at a reduced cost.