Abstract: A method for directing electrical current to prevent sparking from the interaction between a composite structure and lightning or static electrical charge, the method including the steps of forming a hole in a composite structure; and positioning a bushing into the hole to create an interference fit between the bushing and the composite structure, wherein the bushing is formed of a material that has a coefficient of thermal expansion close to the coefficient of thermal expansion of the composite structure and the bushing provides an electrical path between a fastener disposed in the bushing and the composite structure.

Abstract: Threads are formed in situ throughout a bore of a sleeve inserted into a corresponding hole a substrate. A sleeve having a bore is inserted into a corresponding hole of a substrate. A mandrel is rotated through the sleeve. The mandrel has a threaded ended; the threaded end rotating throughout the bore of the sleeve forms threads throughout the bore. Prior to inserting the sleeve into the corresponding hole of the substrate, the sleeve can be placed onto the mandrel. In this case, the mandrel has an increasing diameter at the threaded end thereof, such that the sleeve rests on the mandrel towards the threaded end thereof where the bore has a smaller diameter than the mandrel. The mandrel is then rotated out of the sleeve in a direction opposite the direction in which the sleeve has been inserted into the corresponding hole of the substrate.

Abstract: In a state where the expanded protruding portion of the heat-exchanging tube, which has been expanded inside a grip portion of a chucking sleeve whose diameter has been reduced by a clamp bushing, is gripped by the grip portion, a tube expanding billet is inserted into a yet-unexpanded part of the heat-exchanging tube to cause tube expansion. When doing so, a guide portion, which is formed on a flare punch and has the same diameter as the maximum outer diameter of the tube expanding billet, is inserted inside the expanded protruding portion of the heat-exchanging tube gripped by the grip portion.

Abstract: A mandrel usable for expanding a medical device is disclosed. The mandrel includes a first tube portion having a first lumen and a first tube diameter. A second tube portion extends from the first tube portion; the second tube portion is configured to receive a medical device. A second tube diameter is smaller than the first tube diameter. A plurality of tube segments are separated by a plurality of slots formed in the mandrel, while a second lumen is in communication with the first lumen. At least a portion of the plurality of tube segments is moveable outwardly to expand the medical device.

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: The invention comprises a device for expanding tubular members to a controlled diameter and its method of fabrication. The device includes an expandable bladder held in a convoluted form. After the device is inserted into a cylindrical tube to be evenly expanded, the bladder is expanded by hydraulic pressure to a controlled maximum diameter. It is then deflated so the device can then be moved to another location and reused. The bladder is formed from a flexible impervious material having integral reinforcing fibers. It is initially formed in a fully expanded configuration over a convoluted mandrel and a removable cylindrical shell. When the shell is removed vacuum or external pressure draws the bladder against the mandrel. The bladder is overmolded with a resilient cover to hold it in reduced form until pressurized. The bladder cover prevents the bladder from kinking during the expansion.

Abstract: A method prevents a cylindrical body from buckling in externally curling edges of both side portions by pressing curling dies in an axial direction after molding the cylindrical body having a drop portion whose outer diameter is small and two side portions whose outer diameter is large by enlarging a cylindrical material made of aluminum alloy by electromagnetic molding. In curling the edges of the side portions, a buckling preventing die restrains an outer periphery of the drop portion of the cylindrical body. Because the buckling preventing die receives the axial compression force of the curling dies, it can prevent the cylindrical body from buckling and deforming. The buckling preventing die is what a split die disposed on the side of an outer periphery of the cylindrical material in the electromagnetic molding is used as.

Abstract: A lined conduit formed by decorrugating a corrugated liner conduit inside a first conduit is described. A method and apparatus for forming the lined conduit are also described. The corrugated liner conduit may be positioned inside the first conduit. Each end portion of the corrugated liner conduit may be coupled to a hydraulic expander. Each hydraulic expander may include a hydraulic cylinder. Each hydraulic cylinder may include a piston rod with an opening along the length of the piston rod. The corrugated liner conduit may be evacuated through a valve assembly coupled to the passageway in one of the piston rods. The evacuated corrugated liner conduit may be pressurized with fluid from a fluid source coupled to the valve assembly. Pressurizing the corrugated liner conduit may expand corrugations in the corrugated liner conduit to form a decorrugated liner in the first conduit.

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 coldwork tool assembly including an outer housing and an inner housing in telescopic arrangement with each other and a retaining collar configured to accommodate a plurality of mandrel configurations. One of a plurality of various mandrels is removably coupled to the inner housing using the retaining collar to secure the mandrel to the inner housing as the inner housing moves between a contracted and an expanded position relative to the outer housing.

Abstract: A method and apparatus for coldworking holes using rotational mandrel. The apparatus uses a tubular seamless sleeve made of shape memory alloys having a superelasticity property, a mandrel having major and minor diameter portions, an end-cap to seat and restrain axial and rotational motion of said sleeve.

Abstract: A metal gas-feed tube for a head air bag automotive vehicle has a sleeve formed on a bent end thereof to fit onto a connecting fitting of a gas generator. That sleeve is formed in part from an unbent region of the tube by pressing a mandrel into the end of the tube which lies outside a die so that the rear end of the sleeve is formed from a bent portion while the free end is not subjected to bending deformation in the production of the bend.

Abstract: An improved machine for performing a swaging operation includes a mandrel and an expandable collet that are mounted to an actuator such as a conventional pneumatic gun. The mandrel includes a plurality of ramped planar engagement surfaces that are slidably engageable with a plurality of planar reaction surfaces on deflectable segments of the collet. The planar nature of the engagement surfaces and the reaction surfaces avoids unwanted deflection of the segments that would otherwise turn the segments into cutting tools, such as would occur if the surfaces were of certain other shapes. The mandrel is rotatably mounted to the pneumatic gun whereby the engagement surfaces are self-aligning with the reaction surfaces during an initial stage of a swaging operation.

Abstract: An elongated first tubular member has a mandrel receiving center passageway and a slotted outer end portion that comprises first axial fingers separated by first axial slots. An elongated second tubular member surrounds the first tubular member and has a slotted outer end portion that comprises second axial fingers separated by second axial slots. An elongated third tubular member surrounds the second tubular member and has a slotted outer end portion comprising third axial fingers separated by third axial slots. An elongated mandrel is positioned inside the center passageway. The first tubular member is extendable and retractable longitudinally of the second and third tubular members. A tubular sleeve is provided that has an inner end and a flange projecting radially outwardly from the sleeve at the inner end.

Abstract: A tubular fastener element is inserted into an opening in a wall until a flange at the trailing end of the fastener element is in contact with the wall. Then, an externally threaded end of a rod is inserted into a center opening in the fastener element from the flange side of the wall and is mated with internal threads in the fastener element beyond the second side of the wall. A tubular mandrel that surrounds the rod is moved into contact with the entrance portion of the center opening in the tubular fastener. The outside diameter of the mandrel is larger than the inside diameter of the center opening in the fastener element. The rod is retracted to cause a reduced thickness wall portion of the fastener element to collapse and form a second radial flange on the second side of the wall. The mandrel is forced axially into the center opening in the fastener element.

Abstract: A system and method for expanding, joining or securing a plurality of tubes by electromagnetic expansion to a plurality of sheets in a tubular heat transfer system. The system and method involve the automatic sensing and positioning of a electromagnetic coil in operative relationship with at least a portion of a tube and an inner wall of a sheet and then energizing the electromagnetic coil to expand the portion of the tube to engage the inner wall of the sheet, thereby securing the tube thereto. A tubular heat transfer system tube expander and method are also shown.

Abstract: A tubular fastener element (34) is inserted into an opening (44) in a wall (W) until a flange (40) at the trailing end of the fastener element (34) is in contact with the wall (W). Then, an externally threaded end (32) of a rod (28) is inserted into a center opening (56) in the fastener element (34) from the flange side (42) of the wall (W) and is mated with internal threads (52) in the fastener element (34) beyond the second side (50) of the wall (W). A tubular mandrel (24) that surrounds the rod (28) is moved into contact with the entrance portion of the center opening (56) in the tubular fastener (34). The outside diameter of the mandrel (24) is larger than the inside diameter (58) of the center opening (56) in the fastener element (34). The rod (28) is retracted to cause a reduced thickness wall portion (46) of the fastener element (34) to collapse and form a second radial flange (60) on the second side (50) of the wall (W).

Abstract: A tool for forming an armature guide eyelet. The tool having a body with a working end, a support end and at least one sizing rib disposed along a longitudinal axis. The at least one sizing rib has a perimeter having a first portion and a second portion. The first portion has a substantially constant distance Dc, from the longitudinal axis. The second portion has a varying distance Dv from the longitudinal axis. Also, a method for forming the armature guide eyelet with the tool. The method including aligning at least one non-uniform sizing rib and an armature guide eyelet having a constant inner diameter along a longitudinal axis and forming the constant inner diameter of the armature guide eyelet into a non-uniform inner diameter with the at least one non-uniform sizing rib.

Abstract: A method and apparatus for coldworking holes using a reusable tubular seamless sleeve made of shape memory alloys. The apparatus uses a pre-lubricated tubular seamless sleeve made of shape memory alloys having a superelasticity property, a mandrel having a major diameter portion, an end-cap with a rough surface, and an adapting-spacer having a rough complementary surface.