Cold-Expansion Processes:

Extreme Material and Geometry

Challenges and Solutions
Aircraft Airworthiness and Sustainment
Conference
April 1, 2015
Keith Hitchman (presenting)
Joy Ransom

OUTLINE

Processes overview and things to remember

Solving geometric challenges
Solving material challenges
Solutions for challenges posed by unique
features
Conclusion
Questions/Comments

DM#708994

Processes Overview
Split Sleeve Cold Expansion (SsCx)
The classic
Multiple options: i.e., to size, countersink
specific

Bushings, Liners, and Fittings

ForceMate (FmCx) Cold Expanded Bushings
ForceMate2 (Fm2Cx) Cold Expanded
Bushings with Liners
FlexMate (FlCx) Cold Expanded Fittings
GromEx Cold Expanded Grommets

Nut Products
ForceTec
Tukloc
ForceLoc
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Cold Expansion Basics

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FTI Processes Things to Remember

Plastic Deformation of Structure
Required for bare hole cold expansion to work properly (SsCx)
May or may not occur for insert cold expansion processes (FmCx,
FtCx)
Need sufficient elastically deformed structure to provide
compression

Plastic Deformation of Insert

Required for insert cold expansion processes
Plastic deformation of insert is typically higher than for the parent
structure
If a non-expandable material insert is required, consider ForceMate2

Expansion is Critical Parameter; Direct Relationship with:

Magnitude of tensile and residual stress/strain (larger compressive zone size)

Insert interference (direct, but non-linear relationship with expansion)
Magnitude of transient and residual tensile stress and strain
Applied (transient) vs. retained (residual) expansion
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Solving Geometric Challenges

Short Edge Margin (e/D < 1.5)
Parent Structure Features

Designed non-round holes

Pad ups
Webs
Countersinks
Counterbores
Multiple lug locations
Proximate features often pose challenges in
the form of access restrictions, in
addition to stress/strain/displacement
challenges.

Thin Materials (t/D < 0.4) and/or

Damaged Holes
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Challenges Presented by Short Edge

Margin
Reduction in FLI
Edge Deformation
Unwanted Residual
Tensile Stress at Free
Edge
free edge

FLI at all tested e/D is

better with cold working
than without.
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FTI Solutions for Short Edge Margin

Challenges
Possible Solutions for
Short Edge Margin

Solution Applicable
to
Split
Sleeve
Cold
Expansion

Cold
Expanded
Inserts

Adjust Applied Expansion

Adjust Sleeve Gap
Orientation
Insert Geometry Changes
Insert Material Changes

DM#708994

Example Solution: Point Design for

ForceTec
Optimize Design for Low e/D

Thin aluminum with short edge

margin and request for minimum
part count
Optimized expansion and part to
minimize hole size and required
underflush installations for some
hole locations
Tested worst case

LLT: Cycles to 0.010 inch

(0.25mm) crack

Results

Improved time to crack initiation for

all e/D for both ZLT and LLT
Reduced crack propagation rate
Shifted critical flaw location from
hole to free edge of short ligament

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Challenges Presented by Proximate

Features
Tensile stresses in non-optimal
locations
Non-uniform residual stress
Proximate feature deformation
Access restrictions, including
multiple lug locations

Residual Stress
Distribution

Sleev
e Gap

Plastic Strain
Distribution

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FTI Solutions for Proximate Feature

Challenges
Possible Solutions for
Proximate Features

Solution Applicable
to

Split
Sleeve
Cold
Expansion

Cold
Expanded
Inserts

Adjust Applied Expansion

Adjust Sleeve Gap
Orientation
Geometry Changes
(pre- or post-cold
expansion)
Material Changes
Tooling Design
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Example Solutions: Oval Hole Cold

Expansion
Productio
Rework
n

Some stress relief is expected;

residual stress is highest at
radii.
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Example Solutions: Non-Round Holes

Critical
Area

P
Critical Area

Non-Cold Expanded vs. Cold

Expanded
Based on Minimum Cycles to
Failure

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Example Solutions: Access

Restrictions
Multiple lug FmCx
using support
fixtures
Offset and tight
clearance tooling
designs

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Challenges of Thin Material and

Damaged Holes
Possible out of plane
deformation
Reduced effectiveness of cold
expansion
Reduced effectiveness of cold
expanded inserts (grip length
limits)
Need sufficient material for
countersink or other features
Typical thickness-to-diameter
ratio (t/D) > 0.20, as per
FTI-8101J

FLI can be realized even for thin sheet

materials.
Results Shown Above
2024-T3 0.040 inch thick specimens
with
blind rivets, R=0.05

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FTI Solutions for Thin Material and/or

Damaged Hole Challenges
Possible Solutions for
Thin Materials and/or
Damaged Holes

Solution Applicable
to
Split
Sleeve
Cold
Expansion

Cold
Expanded
Inserts

Adjust Applied Expansion

Geometry Changes
Tooling Design

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Example Solution: Panel Repair with

ForceMate2
Regular removal and
Regular removal and
Proposed for countersunk
replacement of access
panels may cause
fastener holes that require a
fastener through-holes
to become damaged
large starting hole with
over time.
respect to both fastener size
and structure thickness
Clean up of excessive damage
Based on ForceMate2
Panel Repaired with Panel Repair
technology
Method
Metals and composites
Repaired Hole

Installed Bushing Configuration

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Example Panel Repair

Unserviceable Panel Restored to Service

2. Clean hole is
countersunk to accept
repair bushings

1. Clean up damaged
hole using alignment
fixture

3. Repaired
hole

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Solving Material Challenges

Parent or Insert Material Strength
High strength parent may reduce residual stress
zone size
High strength materials may result in high process
loads

Parent or Insert Material Elongation

Non-Metallics
No plastic deformation
FLI is often not a primary concern

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Challenges Presented by Materials

Low Elongation Materials (Parent and Insert)
Low elongation poses a challenge for cold expansion
Standard cold expansion design may require elongation of
up to five percent, in absence of special features

Non-Metallics
For composites, design emphasis remains on ensuring
adequate performance (retention, strength) without
damaging parent structure
For composites, emphasis is on hole reinforcement and
protecting composite from damage, as opposed to FLI
Non-metallic inserts can be useful, but require special
installation technique

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FTI Solutions for Material Challenges

Possible Solutions for

Material Concerns

Solution Applicable
to
Split
Sleeve
Cold
Expansion

Cold
Expanded
Inserts

Adjust Applied Expansion

Sleeve Orientation
Insert Design
Material Selection

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Example Solution: ForceMate2

The ForceMate2 process simultaneously
installs:
A ForceMate outer bushing with typical ForceMate
attributes
Fatigue life and strength improvement
Increased resistance to rotation/migration
Increased corrosion resistance
An inner bushing or specialty liner
Not expanded
Maintenance free liners
Non-metallic liners (KAron, Teflon)
Sacrificial wear bushings
High temperature bushings

ForceMate bushing
Liner / inner bushing
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Solutions for Composites: A Balancing

Act
Performance

175
150
125
100

19.7
16.9
14.1
11.3

75
50
25
0

8.4
5.6
2.8
0.0

Torque (in-lb)

28.2
25.4
22.6

Applied Expansion to Hole (%)

Torque (Nm)

250
225
200

Lamina
te
Integri
ty
Limit

Laminate Integrity

Torque
Requirem
ent

Variables

Part configuration
Tolerance stack-up
Nominal applied expansion Process parameters
Tool configuration
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Example Solution: GromEx

Fasteners Can Be Removed and Replaced

No degradation of interference level
No increase in installation forces
0.002 to 0.003 inch (0.05 to 0.08 mm) interference

Improved Fatigue Performance

Expanded grommets increased fatigue performance
over bare holes with clearance fit fasteners
Interference fit fasteners better than clearance fit
fasteners in joint with expanded grommets
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Force (lbf)

8897
6673

1000 Fastener Test inside of Grommet

4448
(GromEx did not move)
500
2224
Removal Force
Installation Force
0
0
0.0015
0.0020
0.0025
0.0030
Interference (in)

Force (N)

1500

0.076
11121

12

Legend
57.8
Baseline
Interference GromEx
53.4
Clearance GromEx

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48.9

10

44.5

40.0

13
Test Parameters:
Parent Material: CRFP
Thickness: 9.53 mm (0.375 inch)
Fastener Type: EN6114T6-12
Fastener Dia.: 9.53 mm (0.375 inch)

8
102

Max Force (N)

2000

Interference (mm)
0.051
0.064

Max Force (kip)

0.038
2500

62.3

103

104

105 106
Cycles

107

35.6
108
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Solving Unique Feature Challenges

Special Insert Features (threads, grooves, ports)

Lubrication features
Through-holes and ports
Complex thin-wall cross-sections
Threaded features
Unique bushing flanges

Threaded Inserts and Other Special Challenges

Tie-downs (wire bundles, cable, conduit)
Nut replacements
Spherical bearings

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The Challenge of Special Insert

Features
May include grooves on inner or
outer diameter of bushing
May include bushing through-holes
May include o-ring gland features
May include threaded grease ports
All of these
features can act
as stress/strain
hot spots!

May result in nonuniform interference!

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FTI Solutions for Special Insert

Feature Challenges

Possible Solutions for

Special Insert Features

Solution Applicable
to
Split
Sleeve
Cold
Expansion

Cold
Expanded
Inserts

Adjust Applied Expansion

Material Selection
Insert and Feature
Design Optimization

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Example Solution: Lubrication

Features

FEA and Physical Tests Used to Inform:

Adjustments to applied expansion

Dimensional changes to lubrication features while retaining
original level of performance (tribology, strength, migration)
Positional changes to lubrication features
Geometry based
hotspot exceeds 10%
strain

Peak
strain
~4%

Typical Analysis Result

Showing Grooved Insert Strains
during Installation
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Example Solution: Bringing Concepts

Together for a ForceMate Application

Repair of Bushing that

Needed Two Areas
Expanded
The bushing was the
bottom cup area
The top required a
special mandrel process
for second operation

Area
before
Repair

2nd
Process
(unique
ForceMat
e
1st
process)
Process
(similar to
standard
ForceMat
e)

Repair
Bushing

Area
after
Repair

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Example Solution: FleXmate

Bulkhead fitting installed using
FTI cold expansion
Radial expansion using handheld
tooling at room temperature
Yields fitting and surrounding
bulkhead material and results in
precise interference fit
Residual stresses are beneficial
to structural longevity
Fuel-tight without sealant;
redundant seal when sealant
applied
Contributes to weight and labor
savings

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Example Solution: FleXmate

Grease Fitting Example #1
Customer was able to eliminate tapping holes
in fatigue critical titanium structure
Customer avoided costly redesign
Analyzed as an open hole versus a threaded hole

Testing requirements
Exceed 1,300 lbs of force
Simulate hydraulic pressure during grease insertion
Test Results requirement exceeded

Grease Fitting Example #2

Reduced skin pad up thickness
Saved weight

Eliminated cold working step

Faster installations
Part count reduction
Reduced costs
Must seal
Lock wire included

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Threaded Insert Challenges

Maintain dimensional tolerances
Maintain or exceed performance
standard of non-cold expanded
threaded inserts
Mechanical

Fatigue life
Torque-out
Push-out
Thread locking
Reusability
Sealing

Electrical (conductivity)
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FTI Solutions for Threaded Insert

Challenges
Possible Solutions for
Threaded Insert
Features

Solution Applicable
to
Split
Sleeve
Cold
Expansion

Cold
Expanded
Inserts

Adjust Applied Expansion

Material Selection
Insert and Feature
Design Optimization

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Example Solution: ForceLoc

ForceLoc is an adaptable,
blind-installation threaded
insert
Axial/tensile/torque performance
Electrical conductivity
Bushing material, coating/plating,
expansion level, wall thickness
Bushing flange geometry (none,
countersink, square)
Nut or stud material, interference
range

2024-T351, open hole

dogbone
25ksi gross stress;
R=+0.05, 10Hz
size

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Conclusion

FTIs Cold Expansion

Processes Adaptable
Effective
Fatigue Life
Improvement
Production Easement
Rework and Sustainment
High Interference
Resistant to Fretting
Resistant to Migration
Resistant to Rotation
Hole Reinforcement and
Repair
Laminate Integrity

Production or
Rework
Applied Expansion
Interference Level
Insert Material
Insert Geometry
Iteration via FEA
Iteration via Testing

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Questions?

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