Fastener + Fixing Technology #6 by Fastener + Fixing Magazine

I ss u e 6 J u l - S ep 2012

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editorial After a successful launch of the first European edition of Fastener + Fixing Technology at Fastener Fair Hannover, the past three months seem to have zipped by.

s well as constantly re-defining the readership and magazine we have been concentrating on what are currently the key fastener application issues. In this edition there is a feature dedicated to lightweight applications. The feature focuses on how integrating Will Lowry - Editor specific fastening technologies into the design process can help reduce weight leading to in-place cost reduction, improvement in the production process, as well as safety and performance enhancement – key topics in todays economic climate. There is also a special feature focused on the developments and capabilities of key fastener suppliers to the sheet metal industry. Articles focus on the optimisation of automatic blind riveting; providing prevailing torque thread lock; the repeat assembly of thin sheet metal; as well as company previews for the upcoming EuroBLECH 2012 – the international sheet metal working technology exhibition. Other subjects covered in this issue include the latest advancements in rail fastening technology; an insight into Italian manufacturer Ambrovit Srl and its commitment to provide the best fasteners for customers’ applications; as well as how the challenges in the design of wind turbines are increasing the demands on the fasteners used. All this, as well as the latest news and reports on fastening technology, underline why Fastener + Fixing Technology is a unique resource for finding out what is happening in the fastener world. To get in touch tweet @fastfixtech, connect on LinkedIn or via Facebook, or simply visit www.fastfixtechnology.com. We’ll be updating all these media feeds with the latest fastener related news, so stay connected with Fastener + Fixing Technology.

Contents Industry News Latest fastener industry news.......................................... 6-10

12-13

Exhibitions A report from Fastener Fair Hannover........................... 24-25 Sheet Metal Fastening EuroBLECH - “For a sustainable future”............................. 26 Sala Punzoni - High quality tools......................................... 26 WAFIOS to present latest novelties..................................... 26 Making the difference........................................................... 28 Wide range of innovative products..................................... 28 Innovative Soyer stud welding equipment......................... 28 Unique assembly technologies............................................ 30 High precision key................................................................. 30 Leading the field in distribution of rivets............................ 30 Cut assembly costs and simplify maintenance.................. 32 Specialist fastening solutions.............................................. 32 Your global partner in bolting solutions............................. 32 Optimisation, acceleration and automation of processes.... 34 EJOT SHEETtracs ®................................................................ 35

14-16

Features Trifast goes from strength to strength........................... 36-37 WindMade in HUSUM........................................................... 38 New challenges in the design of wind turbines............ 40-41 Rail InnoTrans is approacing....................................................... 42 New large diameter high strength fasteners...................... 42 On the right track................................................................... 42 Star performer....................................................................... 44 Product News Latest fastener product news.........................................46-50 Advertisers Index.................................................................. 50

4 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

Tel: +44 (0) 1727 814 400 Fax: +44 (0) 1727 831 033 www.fastfixtechnology.com Group Publishing Director Jamie Mitchell info@fastfixtechnology.com Editor Will Lowry editor@fastfixtechnology.com Executive Editor Phil Matten Senior Advertising Executive Harry Whyte sales@fastfixtechnology.com Senior Advertising Executive Claire Lake sales@fastfixtechnology.com Advertising Executive Emiliano Pagliaroli sales@fastfixtechnology.com Production Manager Andy Clow

Disclaimer

Cover Story Ambrovit - Beside you in the fastening world................12-13 Lightweight applications Almac™ - The coating of choice for aluminium .................14 The growth of lightweight composite materials........... 16-18 Two new topcoats at the O&S.............................................. 20 Fastener curing with Loctite MAX2..................................... 22 Hetal-Werke tests Arnold ATP studs................................... 22

Part of the Mack Brooks Group Romeland House, Romeland Hill, St Albans, Hertfordshire, AL3 4ET, UK

26-35

The Publisher cannot be held responsible or, in any way, liable for errors or omissions, during input or printing of any material supplied or contained herein although the utmost care is taken to ensure that information contained is accurate and up to date. The Publisher also cannot be held liable for any claims made by advertisers or in contributions from individuals or companies submitted for inclusion within this publication. The opinions expressed are not necessarily those of the Editor or Fastener Fairs Limited.

Copyright Entire contents copyright © Fastener Fairs Limited 2012. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means without the prior permission of the publisher.

CONNECTING QUALITY & FLEXIBILITY

as: rmerly known Stafa Group fo D I GOPAK I NEOFAST AN STAFA HOLL

STAFA GROUP: CONNECTED IN TRUSTED QUALITY Stafa Group: a new name for a trusted partnership. Stafa Group has the best answer to any question in the broad area of fasteners. Always. With maximum flexibility and quality and an approach that is as enterprising as it is personal. Just as you have been accustomed to with us over the past thirty-five years. ALWAYS ASSURED OF THE BEST Under the strong umbrella of the Stafa Group, Stafa Trading (formerly Stafa Holland), Stafa Assembly (formerly Gopak) and Stafa Direct (formerly Neofast) are combining their expert forces even more effectively. Whether we efficiently take over

your entire logistics system for fasteners, provide the smartest packaging method or arrange your imports under the most favourable conditions: you are always assured of quality and service. THE STRENGTH OF THE CONNECTION That is the strength of our connection. A connection that we as the Stafa Group share with each other, with our suppliers, with the global market and - above all - with you. STAFA GROUP: WE CONNECT QUALITY & FLEXIBILITY

www.stafa.nl

Fastener industry news

STAFA wins Graydon Award STAFA is celebrating affirmation that, even in times of economic decline, the Group has its business financially well organised. On 21st June 2012 at STAFA’s office in Maarheeze, George van Gool, general manager and founder of the STAFA Group, received the Graydon Award from Graydons Martijn Utermark.

eorge van Gool commented: “We are proud to receive this award. With Graydon’s ‘Financially Healthy’ certificate we can show that we are a reliable partner to do business with. In times of financial uncertainty that is a must. Our current and prospective customers can indeed rely on a financial healthy Stafa. After 35 years of hard work, a huge achievement.” To receive Graydon’s ‘Financially Healthy’ certificate, an organisation needs to meet certain selection criteria, such as a positive credit rating over a long period of time and satisfactory payment procedures. Further information consists of revenue data, annual and accurate figures, creditworthiness and a sound overall business worthy situation.

Graydon is a leading financial service provider in credit management, providing business information crucial to every company that wants to perform better in order to take a competitive advantage and able to look for suitable partners to do business with. Graydon rates companies on their creditworthiness and financial situation. STAFA Group is the collective name of STAFA Trading, STAFA Assembly and STAFA Direct. George van Gool describes them as: “Three independent companies that can provide the management of an entire logistic chain for fasteners, the best possible packaging methods, and the most favourable import conditions and terms. Opting for the STAFA Group means you are opting for a guaranteed service and quality.” www.stafa.nl

CAN-ENG contracted to design new system CAN-ENG Furnaces International Ltd has recently been contracted to design and commission a Continuous Mesh Belt Austempering System for installation in Mexico.

his Tier One automotive supplier of automobile transmissions selected CAN-ENG Furnaces International as its supplier of choice because of extensive experience developing state-of-the-art continuous mesh belt heat treatment systems that provides tight tolerances to characteristics found on complex shaped parts. CAN-ENG points out that its Continuous Mesh Belt System minimises part distortion, provides repeatable carbon potential control, produces predictable metallurgical properties, integrates zero part mixing strategies and conforms to CQI-9 quality initiatives. These attributes played a significant role in CAN-ENG being selected as a repeat supplier of its Continuous Mesh Belt Heat Treatment System. The automated system includes a computerised loading system, mesh belt furnace, molten salt quench conveyor system, conveyorised wash and dryer system, salt holding tank and integrated endothermic gas generator. This project represents one of a number of new mesh belt installations that CAN-ENG is currently commissioning for manufacturers around the world.

Gris Decoupage makes German acquisition Gris Decoupage has demonstrated commitment to its business motto by acquiring a die-cut engineered parts manufacturer based in Herscheid, Germany.

ris Decoupage expects the growth strategy to create significant new business opportunities by giving it greater access to the German carmaker market, which is already serviced by the new acquisition. Gris Decoupage was founded in 1984 and is based in Lesménils, France. It specialises in the manufacture of mechanical components and flat or conical diecut washers in medium or large runs. Seventy-five per cent of its output is for the automotive sector and the company is a first-tier supplier to many of the world’s leading vehicle manufacturers. Currently 35 percent of revenue comes from exports, half of this emanating from Germany, which is where its major European competitors are based. To break through, what it describes as, the economic patriotism of German manufacturers,

6 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

Gris Decoupage made the strategic decision to buy Knipping Umformtechnik GmbH from the LISI Automotive Group with effect from 1st June 2012. Now renamed Gris Umformtechnik GmbH the acquisition has 10 million euros annual sales and employs 50 people to supply parts to Volkswagen, Audi, BMW, MAN, ZF and Daimler, amongst others. The acquisition extends Gris’ product range by offering GUT’s knowledge and manufacturing skills in engineered washers and mechanical components to complement the Group’s existing capabilities. The Group says it is also pursuing an organic growth strategy in France, having committed 5 million euros to extend its premises and install a new ultra-high-power transfer press at the end of this year.

Fastener industry news

Anixter A-LAB fully commissioned Anixter Fasteners has announced that its testing laboratory ‘A-LAB’ in Gloucester, UK, is now fully commissioned. Independently audited by UKAS and accredited to UKAS/ISO17025, the facility offers a comprehensive range of fastener testing and failure investigation capabilities.

ommenting on the new laboratory, costing over £450,000 to establish, Richard Hawker, vice president of technical services, said: “One of Anixter’s core values is quality and our culture is focused to deliver a zero defects standard, whilst supplying over 14 billion components annually, worldwide. As part of this commitment we have invested heavily in our technical capability. Our UKAS accredited laboratory not only tests products that we supply, but also provides an independent investigation and product verification service.” The services offered at A-LAB fall under five headings; metallurgical, mechanical, chemical, failure investigation and product finish testing. Specialist equipment includes optical emission spectrometers as well as the capability to carry out salt spray testing. Specialists at the laboratory seek to verify properties of engineering components as well as checking conformity and determining suitability of materials. Metallurgist, Lee

Pugh explains: “At A-LAB we offer over 25 different tests to scrutinise the integrity of a huge array of components. We work to the most exacting standards of a broad range of industries, covering the specifications of BS, ISO, ASTM and Ford.” The rigour with which A-LAB performs tests is proportional to the criticality of the purpose of the components according to Richard Hawker: “We support the largest OEMs, including a large proportion of the automotive industry. The fasteners and components that we supply are therefore often application critical, for example in chassis build or construction of braking assemblies. We take our responsibility to our customers very seriously and feel our duty to their customers just as keenly. The testing work done at A-LAB is therefore an essential part of how we deliver an exceptional standard of quality, consistency and reliability.” Anixter has 15 fully equipped regional quality laboratories globally, with ten technical centres across North America, three in Europe and one in China.

NORM Civata wins Ford ‘Supplier of the Year’ award Norm Civata has another award for supplier excellence. The global fasteners supplier based in Izmir, Turkey, has been recognised as a Ford Otosan’s ‘Supplier of the Year’.

he award was presented to nine companies in Gold, Silver and Bronze Star categories. Norm was presented with the Silver Star award for outstanding performance during 2011 at an event held in Istanbul. According to a statement from Ford Otosan, it had gathered its producers who had contributed to Ford Otosan becoming a commercial vehicle production base, achieving great success as a global player in the world market and producing the best-selling brand in Turkey. Norm Group companies including bolt, screw and nut production, tooling and plating facilities, as well as the distribution centres Standart Civata, Norm Bursa, Best Kale and Vissart Europe. The company also has an R&D centre already giving an integrated service to automotive, machinery, white goods and construction industries.

Putting a spring in your step Smalley flat wire wave springs from TFC Ltd are used by shoe manufacturers for cushioning in the soles of both athletic and casual shoes.

ave springs are used because of their space saving abilities and lightweight design compared to conventional coil springs. TFC Ltd explains that wave springs, which typically operate at half the height of conventional coil springs, provide an accurate repeatable load in both the heel and ball of shoes. A single Crest-to-Crest wave spring in the heel and two parallel wave springs in the ball of the shoe absorb the impact associated with athletic activities, reducing stress on joints. TFC Ltd highlights that the springs, manufactured in corrosion resistant 17-7 stainless steel, were specifically designed to handle the extensive cycle life that is associated with the wear of the shoes. Smalley wave springs offer accurate, repeatable loads for the duration of the spring life, which is designed to outlast the life of the shoe itself. Using the same unique method of manufacture, TFC Spirolox retaining rings offer an ideal space saving alternative to conventional circlips. By ‘edge-coiling’ rectangular section material to exact dimensions (rather than using the die-stamping process that is used to produce conventional circlips). Spirolox retaining rings have a uniform cross-section without lugs to interfere with the assembly and are free of burrs. “With a wide range of sizes and materials to choose from Spirolox rings can be found in thousands of mechanical products throughout the world.” www.thefastenercentre.com

8 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

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Fastener industry news

Coal mining shearers use RotaBolt technology Caterpillar is using RotaBolt measurement technology on special versions of its longwall mining shearers that are used in very challenging underground environments where vibration is a constant factor.

he shearers have a reputation for maximum structural integrity and service life and the performance of RotaBolt fasteners has been helping Caterpillar to not only assure integrity but also improve maintenance checking. The shearers can cut and load more than 5,000 tonnes an hour and feature a one-piece mainframe design. Special versions of the shearers with split mainframes are available wherever there are underground conditions that limit transportation. The mainframe is split into three separate units and RotaBolts up to 6 metres in length are being used to join the sections together. The technical team at James Walker RotaBolt have worked closely with Caterpillar over the last five years evolving mainly M64 and M80 fasteners that have ranged from 1 metre in length to over 6 metres. In joining sections of the mainframes together, the fasteners are operating as mechanical jack tensioners, accurately measuring the correct tension, with loads of up to 250 tonnes. “Feedback from operational teams in mines across Asia and Europe has been very positive, reporting enhanced underground assembly and disassembly as well as ongoing assured structural integrity.”

EL 2000 longwall mining shearer from Caterpillar

New high performance topcoats With the aim of expanding its topcoat range (PLUS®, DACROLUB®), NOF METAL COATINGS GROUP recently launched its new GEOKOTE® line of topcoats.

ike other topcoats it is applied onto GEOMET® 321 or 500 zinc flake coatings, thus enabling the increase, with a very thin layer, of the anti-corrosion performance of coated parts while providing new features. The new features of the GEOKOTE ® range includes resistance to chemicals, controlled tribological properties, as well as additional anti-corrosion and abrasion performance. The GEOKOTE ® topcoat is also particularly well adapted for manufacturers and users of fasteners (screws, nuts, tightening clips) by providing them optimal strength and mount-ability properties. The GEOKOTE ® topcoat also helps to avoid the stick-slip effect when tightening.

MGI COUTIER selects the GEOKOTE® topcoat

MGI COUTIER manufactures and assembles parts for the automotive industry, such as door check straps that are

highly stressed. The company wanted to develop a very high performing anti-corrosion solution, even after very harsh use simulated by various test cycles. Two solutions were chosen - the application of a GEOMET® 321 coat and a clear or black GEOKOTE ® topcoat. Mr Sébastien Leclerc, project manager at MGI COUTIER explains: “We wanted a new coating combining both a strong corrosion and mechanical resistance. The GEOMET® 321 zinc flake coating with a GEOKOTE ® topcoat provides us with the compromise sought regarding the preservation of the corrosion performance after the numerous mechanical stresses exerted on parts. From the tests performed we have selected two options: a black topcoat and a clear topcoat.” The whole range of GEOKOTE® topcoats is available worldwide. It can be used with dip or spray processes on the lines of NOF METAL COATINGS GROUP’s global applicators network.

Saint-Gobain launches SolarBond® ReadyFrame To help module manufacturers remain competitive in today’s highly volatile solar market, Saint-Gobain Solar recently launched its SolarBond® ReadyFrame solution for cost effective module framing.

olarBond ® ReadyFrame is a custom tape-in-frame solution designed to streamline the module framing process by removing the extra steps needed to add a sealant or a tape to the frame. Saint-Gobain states that this will help manufacturers boost cost-savings, operational efficiency and sustainability on the line. “We created SolarBond ® ReadyFrame to provide small-tomedium module manufacturers with a cost-effective framing solution that delivers a high-quality product quickly, easily and without making changes to their existing production line,” said Geoffrey King, market manager, renewable energy,

10 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

Saint-Gobain Solar. In addition to SolarBond ® ReadyFrame, Saint-Gobain Solar also has other offerings from its SolarBond ® portfolio. SolarBond ® InFrame, an intelligent, innovative and instant solution for solar module manufacturing, is a unique foamable material, which is applied warm in a single continuous motion, ensuring both accuracy and high bonding strength immediately after contact with the frame. SolarBond ® Frame Tapes provide a UL listed and TÜV certified solution to reducing labour costs, material waste and the downtime associated with curing silicone sealants.

21st and 22 nd November 2012 Expo Center Norte Sao Paulo - Brazil Fastener Fair Brasil is a highly focused exhibition, exclusively dedicated to fastener and

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13.01.2012 11:56:21 Uhr

www.fastenerfair.br.com Demonstrate your products and services

Organization 111229_E25_Verschluß_92x134.indd 1

• Electronic and electrical goods • General engineering – light / heavy • HVAC (Heating / Ventilation / Air) • Energy and power generation • Communication technology • Furniture manufacturing • Sanitary ware and plumbing • Installation

E-mail: brasil@fastenerfair.com

cover story

Beside you in the fastening world

In May 1997 two managers, already with several years experience of fastener production and distribution, founded a company in Garlasco, 25 kilometres south-west of Milan. Today Ambrovit makes a powerful claim to provide a benchmark in fastener supply, to both the Italian and wider European markets.

he company grew up quickly. In 1997 it started with a 900 square metre warehouse; by 2001 that had grown to 3,200 square metres, enlarged again in 2006 by the rental of a further 2,000 square metres of external warehouse space. In mid-2009 Ambrovit relocated entirely to its new and current corporate headquarters. For Ambrovit high quality, customer care and advanced technologies are essential features in meeting the requirements of all their markets so this sustained progression in size combined with investments in advanced logistics, product packaging and a state- of-the-art IT system have all aroused considerable interest from its customers. Today, Ambrovit’s facility in Garlasco extends over a total area of 12,000 square metres, of which 6,000 is buildings. The company recently installed a new automatic warehouse: 28 metres high with a storage capacity of 22,000 pallet places it currently handles some 1,400 order lines during each shift and despatches around 165 shipments every day. An advanced automatic packing line, supplied by Bilwinco, has daily capacity of 22,000 boxes. Ambrovit also has a quality laboratory which is equipped with the

latest generation of quality control instruments co - ordinated through sophisticated statistical software. The quality laboratory includes a metallographic micro cutting machine, pneumatic mounting press machine, automatic polisher grinding machine, Rockwell hardness tester, Vickers micro -hardness tester, stereoscopic microscopes, coating thickness tester and drilling testing machine. In November 2011 Ambrovit certified its quality system according to the requirements of UN EN ISO 9001:2008, for which it received certification from TÜV Italia. The company is currently working towards achieving CE UNI EN 14592:2009 certification. Thanks to the previous experience in the production field of Ambrovit’s founders the company has established and strengthened, over the years, supplier relationships that ensure reliability of both product quality and availability. The management continue to periodically visit worldwide suppliers checking and verifying their capabilities and establishing both stronger existing and new business relationships. Ambrovit constantly updates its product range and is committed to offer products that are both technically advanced and commercially competitive. Today it boasts a very large number of items for different application sectors, which includes hex lag screws, chipboard screws, drywall screws, recently launched PVC window screws,

12 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

concrete screws, dome and euro screws, machine screws, nuts, washers, bolts and threaded rods, tapping screws, drilling screws and A 2 stainless steel screws. Sizes range from 2mm to 30mm in diameter with lengths from 4mm to 400mm. Key application sectors include: the furniture industry, door and window shutters, mechanical industries, carpentry and woodworking, civil and industrial construction, plasterboard, do -it-yourself and hardware shops, as well as gazebos and garden structures. In all, Ambrovit now holds stocks of about 9,000 items. In Italy Ambrovit currently delivers to more than 1,500 customers. The sales network in Italy, which is divided into different regions, covers the entire country. Relationships with area agents are managed by Ambrovit’s commercial department, which informs them of problems and opportunities so that they can solve them in real time. This wide sales network also provides the way for

Ambrovit to constantly update its products range and ensure it meets its customers’ requirements. The new logistics facility, constructed in 2009, enabled improved control of stocks, storage of high quantities of material and prompt delivery of customer orders. Coupled with Ambrovit’s participation in major fairs, including Fastener Fair Stuttgart and most recently Fastener Fair Hannover (pictured below), it has enabled Ambrovit to become one of the trade leaders and substantially widen the countries to which it sells its products and promotes its ever developing product range. Ambrovit has been able to extend its business to countries throughout Europe including: Germany, France, England, Spain, Portugal, Greece, Belgium, Russia, Slovenia, Croatia, Hungary, Romania, Bulgaria, Slovakia, the Czech Republic, Ukraine, Poland,

Estonia, Latvia, Lithuania, Albania, Macedonia, Finland, Sweden and Denmark. This growth across Europe has seen a significant increase in export sales, which now represent over 25% of total sales. Central to the Ambrovit business philosophy is a deep desire to serve customers and to provide them with the best fastener for their applications. All of the development and investments made by the company have always been clearly targeted to achieve these goals. At every internal stage the company carries out constant check controls on random samples, analysing the critical stages in order to solve immediately any issues that may arise, which could cause an interruption in the managerial and logistical processes. Thanks to its quality control laboratory, Ambrovit has precision tools for checking the quality of incoming products. In addition to stringent dimensional checks this now includes using a drilling machine test to simulate screw performance in application. The introduction of these technologies and advanced quality management structures have made the company’s confidence in its vision for the future even more concrete, linked as it is to the constant development pinpointed by the management. Ambrovit is also

confident that, for global markets, it will continue to break down commercial barriers, implement specific skills and strengthen its trade position: a future Ambrovit believes will be marketed by constant seriousness and professionalism. Ambrovit tries always to improve its service level in order to reinforce its presence and respond to the new challenges in both national and international markets - above all to live up to its motto “we are always beside you in the fastener world”. www.ambrovit.it

“ Central to the Ambrovit business philosophy is a deep desire to serve customers and to provide them with the best fastener for their application.” www.fastfixtechnology.com

lightweight applications

Almac™ - The coating of choice for aluminium By Alan Gardner, global marketing manager, MacDermid Industrial Solutions The use of aluminium is growing in automotive car production. This metal allows manufacturers to reduce fuel consumption by reducing vehicle weight. One particular application is the use of aluminium body panels, which are fastened using high tensile steel self-piercing rivets (SPR). Examples of automotive manufacturers using this technology include Audi, BMW, Daimler and Jaguar.

he coating of choice for these rivets must perform four important functions: 1. Protect the steel rivet substrate. 2. Have galvanic compatibility with the aluminium sheet. 3. Not induce hydrogen embrittlement in the fastener. 4. Allow adhesion of a subsequent organic coating.

A coating technology which has been proven to meet these criteria is Almac™ zinc-aluminium, applied by a mechanical plating process.

Protecting the steel rivet

Corrosion is an electrochemical process that leads to the oxidation (rusting) of steel. Rusting occurs as a result of the chemical reaction between steel and oxygen, in the presence of water. This galvanic reaction may be prevented by the application of a sacrificial coating, a special alloy, which protects the underlying steel substrate. Metals such as zinc and aluminium, which are more electronegative (more reactive) than steel in the galvanic series do this by corroding preferentially (see Table 1). In contact with aluminium sheet, a 12µm of Almac coating will typically protect the steel rivet for more than 500 hours to base metal corrosion.

Table 1 – Electrochemical series using a calomel reference electrode/sea water

Noble (cathodic)

Active (anodic)

Metal

Electrochemical potential V

2xxx series aluminium

-0.60

Steel

-0.70

1,3,5 xxx series aluminium

-0.75

Cast aluminium

-0.80

Cadmium plate

-0.80

Zinc plate

-1.10

Magnesium

-1.60

Galvanic compatibility

Galvanic corrosion can occur if dissimilar metals are in contact and exposed to damp conditions. In any bi-metallic couple, the more noble (cathode) metal will not be corroded, whereas the less noble (anode) metal will be attacked, at a rate dependent on the environment and the electrical potential between the metals. Even though zinc is anodic to aluminium, it is not recommended that it be in contact (with aluminium) due to the high rate of corrosion of zinc in salt water environments. Corrosion of the zinc plate will locally raise the pH, increasing the rate of aluminium corrosion.

14 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

For this reason an alloy of zinc-aluminium is recommended. It combines the advantage of sacrificial corrosion for the steel fastener, with galvanic compatibility in contact with aluminium. The preferred alloy composition is between 6% – 11% aluminium. Levels at less than this increase the potential for galvanic corrosion. More than this prevents uniform deposition of the alloy coating by the mechanical plating method due to the hardness of the aluminium metal powder.

Freedom from hydrogen embrittlement

With high tensile steel rivets, hydrogen embrittlement is a critical factor as well. It is generally accepted that steels having a hardness above Rockwell C-40 are susceptible to hydrogen embrittlement. High tensile steel rivets are typically above C-50. For this reason, rivets are coated using a mechanically applied process rather than traditional electroplating. In the mechanical plating process, the zinc and aluminium metals are present as a fine dust. Deposition is by a cold welding process. Impact energy is transferred through glass beads to the metal dust. This impacts the zinc-aluminium mixture against the steel substrate. The resulting coating is deposited without introducing hydrogen embrittlement into the part.

Adhesion of the organic layer

Finally, as the rivets are used at the body panel assembly stage, the rivets need to be coated in an organic primer and final topcoat. The surface topography of the final Almac coating ensures that the painted layers adhere as well to the coated rivets as to the aluminium body panels.

Summary

With the increased use of aluminum in automotive applications, the need for coatings which protect steel fasteners without galvanic corrosion are required. One such coating is zinc-aluminium ‘Almac’, which is extensively used to protect high tensile self-piercing rivets. In this application, the steel is protected to more than 500 hours in neutral salt spray while the aluminium is also protected against galvanic corrosion. On high tensile substrates, the coating must not cause hydrogen embrittlement in the fastener, so it is applied by a mechanical plating method. Once plated, the rivet can be subsequently treated by an organic coating in the same finishing line as the main car body. Almac coatings, along with other mechanically applied zinc/zinc alloy finishes can be applied to most steel fastening systems and is particularly suited to high tensile steels and those used in safety critical applications. www.macdermid.com

Enviralloy Ni 12-15 & Almac MacDermid Zinc Alloy Systems

Fastener Finishes Which Minimise Galvanic Corrosion The use of light metals is growing, allowing manufacturers to reduce weight in order to boost fuel economy. However, the mechanical fastening of light metals presents the engineer with the problem of galvanic corrosion Traditionally, cadmium or zinc plate is applied to protect the fastener. However, the use of cadmium is being restricted, due to toxicity issues, and traditional zinc has poor galvanic compatibility with aluminium. The solution...? Enviralloy Ni 12-15 zinc nickel alloy for threaded fasteners and Almac zinc aluminium for rivets. Both coatings have galvanic potentials close to aluminium, so they not only protect the steel fastener, but minimise the contact corrosion of the aluminium substrate. When it comes to protecting fastening systems trust MacDermid.

Key Features

• Minimises galvanic corrosion • Excellent corrosion protection • Production proven systems • Specified by major automotive manufactures • Free of hexavalent chromium

Anti-Corrosion • ZinKlad • TriPass • Torque ‘n’Tension • Enviralloy • Envirozin • Kenlevel For more information, please contact us at: fasteners@macdermid.com © 2012 MacDermid, Inc. All rights reserved.

lightweight applications

The growth of lightweight composite materials Here bigHead Bonding Fasteners Ltd, based in Dorset, UK, looks at the development of lightweight composite materials and how they are contributing to the growth of bonding fasteners.

he development of composites and plastics and their migration into applications habitually dominated by traditional materials such as wood and metal has been significant. Lighter, stronger, versatile and more mechanically stable, modern composite materials have found a home in almost every industrial sector. The issue of reducing weight or ‘light-weighting’ has become central to innovation in the automotive sector. High oil prices and increasing regulatory pressure to reduce carbon emissions will only enhance this trend. Initially, lightweight composite materials such as carbon fibre were only used in very high end applications such as aerospace and super cars, as costs were very high and production processes slow. Increasingly, major car makers are introducing carbon fibre into their luxury models and many are examining ways to replace structural elements traditionally made in heavier metal with lightweight carbon fibre. As the volumes of carbon fibre production increases, the costs will fall and the number of applications in premium and standard car models will increase. The expansion of carbon fibre and other lightweight composite materials presents challenges as well as opportunities. One of the key challenges is how to securely fasten to such materials. Traditional fastening systems designed for sheet metal, such as rivets, bolts and clinched fixings are incompatible with carbon fibre. Increasingly therefore, design engineers are turning to bonding and bonding fasteners as a solution. Interestingly, this is exactly how design engineers solved the same problem in the 1970s when GRP became a popular material.

The development of the bonding fastener

Bonding fasteners were invented by bigHead in 1966 to solve a fastening problem that traditional fasteners could not; how to achieve a strong mechanical fastening in a composite material, such as GRP. bigHead came up with the unique bigHead bonding fastener design; a fixing, such as a threaded stud or collar, is welded to a flat perforated head which is embedded in the composite material. The perforated head helps spread the load directly into the composite material while the welding process means there is an almost infinite variety of fixings that can be used. Like all the best inventions it was simple and effective but also versatile in solving a problem. In its 45 year history bigHead has made over 5,000 types of bigHead bonding fasteners for specific customer applications, and customers show no sign of diminishing their need for flexible design. Since the 1960s bigHead bonding fasteners have become a trusted solution for design engineers working with composite materials. bigHead is still as relevant and useful for design engineers using innovative materials such as carbon fibre today as it was 40 years ago with the first applications of GRP. Over

16 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

that time bigHead has amassed significant experience across an enormous range of industries and applications. The growth in performance and acceptance of adhesives has gone hand in glove with the growth of bonding fasteners. Whereas the original bonding fasteners were embedded in the GRP when laid up or formed, most manufacturers today surface bond bigHead fasteners with adhesive. The perforated head allows the adhesive to flow through and lock the fastener in position when cured. A substrate like carbon fibre is left undamaged and the load continues to be effectively spread through the perforated head and adhesive to the substrate. The expansion and refinement of adhesives continues to broaden the scope and range of bonding fasteners across many industries.

From prototype to production

The phrase “time is money” has never been truer, whether for the assembly of a car or the construction of a building. Streamlining a production process has therefore become a critical factor for success. bigHead typically supplies Tier 1 and Tier 2 sub-assembly manufacturers who provide completed modules to their customers for final assembly. By integrating the bonding fasteners within their module, Tier 1 and 2 suppliers help their customers streamline final assembly. In this streamlined process simple product design and reliability have become even more critical. As bonding fasteners become integral to the product they are bonded to, the strength and reliability of the welding technology that forms the bigHead is of central importance. The bigHead welding technology also enables an enormous range of different bigHead fasteners to be made quickly and reliably, and often in small runs to support customer prototyping and testing. bigHead can test fasteners for specific applications and provide customers with critical data to help them optimise design and performance. bigHead’s automated welding technology is designed to ensure a perfect weld every time. By utilising multiple high energy cyclic pulses together with a high compression force for each weld bigHead can guarantee maximum fusion occurs, all within a fully controlled environment. Each weld is very closely monitored during the production process to ensure all set parameters are met and the optimum weld is achieved, resulting in a low stress, crack-free crystalline structure to the finished weld. A standard measure used to assess the control and consistency of bigHead’s weld is the number of bigHeads per million that were shipped with a defective weld. The average PPM rate since 2009 has been 1.33ppm. To support this high level of consistency bigHead is committed to continuous improvement and Lean Manufacturing. Data is analysed to streamline operations and reduce inefficiency. This ensures the service to customers is accurate, responsive and flexible.

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lightweight applications Growth markets and industries

bigHead has enjoyed considerable success across diverse industries such as automotive, mass transport, marine, construction, general industry and signage. The bigHead website contains over 40 case studies and a number of recent projects on which bigHead is working with customers.

Automotive bigHeads are used in cabin panels, interior trim, external cladding, bumpers, moulded panels, light clusters, seating, anchor points, and many other applications. They are used in many of the world’s leading automotive companies such as Aston Martin, Bentley, Lotus, McLaren, Ford, Audi, VW, Mercedes, Jaguar Land Rover and JCB, as well as numerous kit car manufacturers and enthusiasts. bigHead is a BMW approved supplier to Rolls Royce Motors. As the automotive market is investing particularly heavily in lightweight materials, bigHead is continuing to see an extension of demand from supercars to premium and luxury cars as lightweight materials such as carbon fibre extend their penetration.

Sandwich panels Manufacturers everywhere, from mass transportation to construction continue to increase their use of composite sandwich panels. The desire to reduce weight while maintaining strength continues to drive this trend. As the applications for these panels grow, so do the fastening challenges. Fastening solutions that worked for more substantial structures in steel, wood, stone and concrete may not be effective. The photo above shows a panel made up with a range of bigHead fasteners that provide a high strength but discrete mechanical fastening.

Marine bigHeads are used to secure cabin panels, engine room insulation, interior furnishings, deck fixings, light clusters, and in

18 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

many other applications. Made of 316 stainless steel, bigHeads are ideally suited to provide high load bearing fixings to GRP, carbon fibre and other composite materials in the most severe marine environments. For many years bigHeads have been found in many of the world’s leading boats such as Sunseeker Yachts, Lasers and RNLI Lifeboats. bigHead has also seen an increase in the use of bonding as an alternative to welding in marine environments as welding can lead to weakness through corrosion. Offshore oil and gas platforms for example have started to implement adhesive bonding as an effective alternative to welding.

Construction bigHeads are used to secure interior panels, exterior cladding, moulded panels, light clusters, seating, anchor points, and in many other applications. bigHeads are particularly good for discretely fixing thin panels where traditional drilled fixings are incompatible. Product tests show that bigHead fasteners withstand very high loads. When Chelsea Artisans installed lightweight stone cladding

to the London atrium of a financial institution there were a number of technical issues to overcome. The existing wall could not accept the loading of traditional limestone blocks 75mm thick. Using a proprietary aluminium support framework, Diamond Ultralite panels were installed in panel sizes up to 2.20m x 1.10m. To ensure the panels were securely anchored into position Chelsea Artisans commissioned tensile (pull-out) load testing on the bigHead fasteners recommended. The TwinDisk exceeded expectations in withstanding a 330kg tensile load.

Made in UK bigHead fasteners are made in the UK, at the factory in Bournemouth, Dorset. This ensures total control of product and process quality and a flexible service to customers. It is many manufacturers’ experience that low cost imports and overseas copies can actually increase production costs, with inconsistent quality leading to costly re-work and dissatisfied customers. bigHead continues to invest in process improvement and Lean Manufacturing but also in innovation. bigHead is working with MAS, Bath University and UWE on several projects to ensure its product and designs solutions remain innovative and relevant. bigHead is also working with world leading partners in composites and adhesives, such as ITW Plexus and 3M, to ensure that customers receive the best guidance and ultimately the best solution to their fastening challenges. www.bighead.co.uk

lightweight applications

Two new topcoats at the O&S Two new top coats for specific applications were recently presented at the O&S - International Trade Fair for Surface Treatments and Coatings in Stuttgart, Germany, by Dörken MKS-Systeme GmbH & Co KG.

ith Delta-Protekt ® VH 301.1 GZ the company presented a further development of the silicon sealing with integrated lubricant. Dörken highlights that this offers optimised fastening properties for assembling with aluminium components or against e-coat surfaces and sets new standards as far as the fulfilment of the highest requirements of German automobile manufacturers for the surfaces of screws in car body and engine construction is concerned. Also presented in Stuttgart, Delta-Lube® 10 is a lubricant specially tailored to the MKS system with multifunctional properties for large dimension threaded components in commercial vehicle construction.

No chance for stick-slip effect In the past, the change from chromium (VI)-based to chromium (VI)-free surfaces led to problems when installed against e-coat surfaces, as documented in test specification VDA 235-203 and the surfaces approved therein. These so-called stick-slip effects can currently only be observed in particularly difficult applications. These include, for example, fastening elements with extreme outer supports. A further problem is caused by the increasing demand for weight reduction in vehicle construction. This results in increasing amounts of lightweight metals such as aluminium and magnesium being utilised. For under-head plates for screwed fasteners the range extends from milled to polished backings. In the thread area screwing depths in tapped holes with triple diameter can be accommodated. Here high coefficients of friction at torque/angle of rotation tightening lead to high tightening torque levels, which exceed the control limits and even the capacity of the power screwdriver employed. Dörken points out that the new topcoat Delta-Protekt ® VH 301.1 GZ was developed specifically for these scenarios. In particularly difficult applications sealing with integrated lubricant prevents stick-slip effects when installing chromium (VI)-free surfaces against e-coat surfaces and also satisfies requirements for loosening under high temperatures. The new top coat can also be screwed against aluminium without problems and satisfies the requirements of the new VW standard 1131-1/2, such as double tightening in the yield point against aluminium or five times fastening with e-coat surfaces. The new surface has been employed in various installation areas with both lightweight constructions and the difficult applications stated and has proved itself capable of solving the installation problems there.

20 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

Delta-Lube® 10

Smooth as silk With Delta-Lube® 10 Dörken MKS-Systeme also presented a new lubricant with multifunctional properties at the O&S. The water-based inorganic material was designed specifically for large-dimensioned threaded components assembled with automatic screwing systems. The main area of use is in the field of commercial vehicles and here it was soon specified in plant standard 183 by MAN Truck & Bus AG. Relubrication provides for a dry, non-slip lubricating layer and permits consistent overall coefficients of friction µg with a VDA-based value between 0.09 and 0.14. For the user, this means: calculable fitting results with reproducible tightening torque and clamping force, with shorter fitting times. The topcoat is applied using dip spin or spin coating methods and then dried for 15 to 20 minutes at 50°C to 60°C. www.doerken-mks.com

The topcoat Delta-Protekt ® VH 301.1 GZ can be screwed to aluminium without problems and in particularly difficult applications prevents stickslip effects when installing chromium (VI)-free surfaces against e-coat surfaces

Naturally – you demand the best. At NORMA Group we guarantee that you have the widest range of products to choose from. Our products will fit every customer’s connection technology needs. We are continuously improving our solutions and services so that we we will always be your first choice

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lightweight applications

Faster curing with Loctite MAX2 With lightweighting in mind, automotive manufacturers are using more and more parts made from carbon fibre or glass fibre composites. This is why Henkel has developed a polyurethane-based composite matrix resin that cures faster than the traditional epoxy resins.

omposites based on carbon fibre or glass fibre are gaining momentum in various application areas due to the opportunity for enormous weight savings over traditional part construction, with no loss in mechanical performance. Starting in aerospace where pre-impregnated fibres (prepregs) are manually laid up and then baked into composites, many different applications are now penetrating into the automotive industry. New manufacturing methods like resin transfer molding enable economic processes that are suited for high volume automotive production. For the resin transfer molding process, Henkel has developed a new composite matrix resin based on polyurethane that enables improved economics and throughput in processing. Compared to standard epoxy matrix resins, Henkel says the new Loctite MAX2 cures significantly faster. During injection it also enables more efficient impregnation without stressing the fibres due to the lower viscosity of the resin. “The composite properties of Loctite MAX2 were specially developed to provide more flexibility as well as much higher impact resistance than traditional epoxy resins. We are confident that this new generation of polyurethane matrix resins deliver significant benefits for fast and efficient manufacturing.”

Hetal-Werke tests Arnold ATP studs The automotive division of Hetal-Werke, located in Alpirsbach, Germany, is intensively looking for alternatives to conventional joint technologies. In the future, ATP® TriPress fasteners from Arnold Umformtechnik are expected to be used in place of conventional weld-on studs.

hese press-in studs match the requirements profile of the company, which specialises in the full scope of kinematic sub-assemblies and hinges in the passenger car seating area. According to Reinhard Gruber, sales manager of the automotive division of Alpirsbach based Hetal-Werke: “The anticipated use of lighter materials, such as magnesium, fibrereinforced composites such as carbon, or high-strength steel in car construction requires fastener systems that ideally provide better joint quality at lower cost.” With their triangular shape, Arnold Umformtechnik says that its TriPress press-in studs provide the answer to this cost/benefit dilemma. They are polygonal fastassembly components that can be pressed into plastic and light metal materials. The cost savings result from the process. The number of manufacturing operations is dramatically reduced compared to the welded-stud option, and cycle times are shortened. The triangular shank and longitudinal

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knurling provide high resistance to fastener stripping in permanent joints, such as for seat rail adapters. Circumferential locking grooves on the shank also provide a high pull-out strength. Arnold Umformtechnik points out that eliminating the thermal stresses resulting from stud welding reduces the effort necessary for material inspections, which yields cost savings of around 50 percent for this cost item alone. The environmental impact, such as noise and vapour emissions, is also reduced, along with the associated protective measures. In addition, the reject rate in production is sustainably lower due to the purely mechanical nature of the process. “Experience from the use of ATP ® TriPress fasteners indicates potential cost savings of around 80 percent compared with using weld-on studs. At the same time, joint quality is improved and the process allows different types of materials to be assembled quickly and economically. These are all convincing arguments for the specialists at Hetal-Werke.”

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exhibitions

First Fastener Fair Hannover showed good potential The first Fastener Fair Hannover, launched as an event for the fastener and fixings industry with a particular focus on an end-user audience, attracted a total of 400 exhibitors from 31 countries and 4,500 visitors from 75 countries. Fastener Fair Hannover, held from 24th - 26th April 2012 in hall 21 at the Hannover Exhibition Grounds, was co-located with Hannover Messe, internationally renowned as the world’s most comprehensive industry fair for technological innovation.

xhibiting companies at Fastener Fair Hannover put a wide range of industrial fasteners, construction fixings, assembly and installation systems as well as manufacturing technology on display and their highly attractive stands added to the professional flair of the show. Fastener Fair Hannover was a very international event. The majority of exhibiting companies were European with Germany and Italy being the largest European exhibitor countries. Other important exhibitor countries were China, France, Great Britain, the Netherlands, Taiwan and Turkey. The event welcomed a total of 4,500 visitors from 75 countries. Almost half of the visitors (46%) were visitors from outside Germany. Top ten visitor countries after Germany were the

Netherlands, Italy, Great Britain, Poland, the Czech Republic, France, Turkey, Austria, Switzerland and Belgium. The exhibition survey showed that 38% of the visitors were end-users; the remainder were distributors and suppliers, trade and wholesale as well as fastener and fixings manufacturers. Fastener Fair Hannover 2012 attracted industry specialists at all levels, with 74% having managerial responsibility and/or direct purchasing responsibility. Major industry sectors the visitors belonged to were the automotive industry, distribution, engineering, hardware/DIY retailing and electrical and electronics equipment. The exhibitor survey showed that 85% of the exhibitors had fully or partly achieved their aims at the first Fastener Fair Hannover. While 61% of

24 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

the exhibitors rated the visitor quality as excellent or good, the exhibitors were less happy about the visitor numbers at their stands; 57% of the exhibitors rated the visitor quantity as good. “The first Fastener Fair Hannover was a successful launch and we are pleased with the outcome. The exhibition survey clearly showed that for many companies the event was thoroughly successful. More than 80% of the exhibitors had a positive overall impression of the event. However, we now have to further analyse how we can attract more visitors and improve the experience for all of the exhibiting companies,” explains Susanne Rauberger, exhibition director Fastener Fair, on behalf of the organisers, Mack Brooks Exhibitions. www.fastenerfair.com

“ We are very happy with Fastener Fair Hannover. We showcased the strength of our ST clamp on the stand by inviting visitors to try and break the product, with no–one succeeding. Overall we received 80+ contacts from the show with the visitors being a 50 - 50 split between trade (distributors) and end users (OEMs).” Dániel Szedlacskó, MPC Industries

“ We invited a lot of our customers who were based around Hannover to the show so our stand was constantly busy. We also had some new customers visit our stand who were interested in the products we were showcasing.” Heinz Soyer GmbH

“ The first two days of the show we hardly had 10 minutes to ourselves, with visitors constantly coming onto our stand wanting to find out more about our Tension Control Bolts and innovative Shear Wrench system. We are very happy with our first Fastener Fair show.” Tension Control Bolts Ltd www.fastfixtechnology.com

sheet metal fastening

EuroBLECH “For a sustainable future” EuroBLECH is the world’s largest exhibition for the sheet metal working industry. The event is renowned as the leading international trade exhibition and a trend barometer for this industry sector. With this year’s theme “For a sustainable future”, EuroBLECH puts a special focus on energy efficient technology, environmentally friendly manufacturing processes and intelligent use of material.

urrently, a total of 1,340 exhibitors from 37 countries have booked their stands at EuroBLECH 2012, from 23rd – 27th October 2012 in Hannover, Germany, covering a net exhibition space of more than 84,000 square metres. This is an increase in floor space of more than 6% compared with the previous show. “This thoroughly positive outlook for this year’s EuroBLECH reflects a further recovery of the sheet metal working industry; and it also shows that the industry sector is inspired by overall trends such as sustainability, awareness of resources, energy efficiency and mobility. Major developments in sheet metal working focus upon lightweight construction, intelligent use of material, processing of hybrid structures, as well as new applications of established production processes,” says Nicola Hamann, exhibition director EuroBLECH, on behalf of the organisers, Mack Brooks Exhibitions. “Visitors to the exhibition can look forward to discovering a

Sala Punzoni High quality tools The Italian company Sala Punzoni Srl has been manufacturing high quality tools for more than 40 years.

large number of machine demonstrations throughout the eight exhibition halls, as live presentation of innovative machinery and systems is traditionally a major focus for participating companies at EuroBLECH,” adds Nicola Hamann. International attendance, a further characteristic of EuroBLECH, is, once again, very high at this year’s exhibition. Almost 48% of the companies that have already booked their stands come from outside Germany, with Italy, Turkey, China, Switzerland, the Netherlands and Spain being the biggest exhibitor countries after Germany. EuroBLECH 2012 will occupy halls 11, 12, 13, 14, 15, 16, 17 and 27 at the Hannover Exhibition Grounds. The exhibition profile represents the entire sheet metal working technology chain: sheet metal, semi-finished and finished products, handling, separation, forming, flexible sheet metal working, joining, welding, surface treatment, processing of hybrid structures, tools, quality control, CAD/CAM systems and R&D. www.euroblech.com

WAFIOS to present latest novelties 13.G67

ala Punzoni specialises in the production of special punches according to customers’ drawing in high speed steel and carbide for sheet metal piercing, forming and cupping and for wire deformation. Over the years the company has evolved both from a technological and a technical point of view. The technological development comes from its long experience and from its constant skill in researching new raw materials, new and better heat treatments and in developing more and more suitable TiN coating in order to improve its products’ quality.

WAFIOS, a leading manufacturer of wire and tube processing machinery, will present numerous novelties at EuroBLECH 2012.

15.M06

he RBV 60, for example, is the first fully electronic CNC tube bending machine for processing tubes and solid material exhibited by WAFIOS. Moreover, a tube bending version of the WAFIOS CNC wire bending machine BM 40 will be presented together with a newly designed pay-off unit. A recent addition to the WAFIOS product range is the B3 CNC wire bending machine - an economical solution for the production of two- and three-dimensional bent parts.

WAFIOS B3 CNC wire bending machine

26 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

22nd International Sheet Metal Working Technology Exhibition

For a

e r u t u F e l b a n i a t s u S e of material

Intelligent us

nology

Efficient tech

riendly Environment-f g processes manufacturin

23 – 27 October 2012  Hanover, Germany Sheet metal, Tube, Section  Handling  Forming  Finished products, Parts, Assemblies  Separation Flexible sheet metal working  Machine elements  Tube / Section working  Composites  Joining, Welding Surface treatment  Tools, Dies  Safety at work  Controlling, Regulating, Measuring, Inspection Data capture / processing  Quality control  Factory and warehouse equipment Environment protection, Recycling  Research and development  CAD/CAM systems

www.euroblech.com

sheet metal fastening

Making the difference Since 1948 SACMA MACCHINE PER LAMIERA, based in Crosio Della Valle (VA), Italy, says it has made the difference with its range of slitters, sheet metal precision straightening machines and levellers, as well as cut to length machines with more than 380 references worldwide.

27.J53

ACMA points out that it is able to create complete turnkey plants for various materials including hot and cold rolled sheets and plates, stainless steel, electromagnetic sheets, galvanised and pre-painted steel, as well as aluminium. SACMA’s machines can handle coils up to a weight of 40 tonnes and a width of 2,100mm. The material thickness can go up to 15mm.

Wide range of innovative products Avdel®, a producer of mechanical fastening technology, is able to offer customers blind rivet and self-pierce rivet technology, engineered threaded products, installation tools and assembly stations.

13.C26

vdel ® has a wide range of innovative products including NeoSpeed ® which Avdel says is the first multi-grip Speed Fastening ® system. Due to the wide grip range NeoSpeed ® is able to replace several standard grip fasteners. Another new product is the new eRiv ® battery tool which combines lightweight with robust construction to provide dependable riveting in all situations and locations - 100% portable riveting. Finally, there is the new Infalok ® lockbolts - heavy duty steel fasteners that are available in diameters from 12.7mm to 28.6mm (1/2 inch to 11/8 inch) and designed to provide exceptionally high strength and secure assembly. Suitable placing equipment has also been designed with the new 734 AV™ tool range.

Innovative Soyer stud welding equipment The search for unique selling points continues to drive Heinz Soyer Bolzenschweißtechnik GmbH, a German specialist for fastening and joining technology, towards the development of product innovations.

he idea of developing a stud welding device with a gun which can be used to identify important operating conditions was realised in the form of the innovative BMS-9 stud welding device and the corresponding PS-9 stud welding gun. Thanks to the multi-coloured traffic light LED display system on the welding gun, the operator is now able to identify at a glance when the stud welding system is ready for operation and when there is a problem. Furthermore the PS-9 welding gun is equipped with an innovative and adjustment-free stud chuck (patent application: DE 102010 001 629.2). For the first time there is no need to change chucks when using different stud lengths from 6mm - 40mm. “Besides improving the welding quality of welded joints, the new BMS-9 stud welding equipment also helps users to save time and work more efficiently.” www.soyer.com

28 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

13.E08

Your Stud Welding Specialist

& No Riveting – Self-piercing Hardened Self-Clinching Fasteners

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● Press Nuts ● Binding screws ● Rivet Bushes ● Prestincerts ● Eccentric studs ● Floating Nuts RoHS Compliant

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Hannover, Oct. 23rd - 27th Hall 013, Booth E08 Come & see us!

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20.06.2012 09:59:50

sheet metal fastening

Unique assembly technologies

13.A18

Emhart Teknologies is a designer and manufacturer of unique assembly technologies from concept through installation. mhart highlights that its technology based assembly products and systems deliver innovative, integrated system solutions to virtually any manufacturing challenge around the world. “From aerospace to automotive, computers to appliances, Emhart products are sold worldwide to solve customers’ assembly and fastening needs.” A Stanley Black & Decker Inc Company, Emhart Teknologies employs over 3,000 people in 24 operating facilities worldwide.

High precision key Schmeck Verbindungstechnik GmbH, based in Lüdenscheid, Germany, manufacturers screws and studs for a wide range of applications and technologies.

chmeck says that the highest precision and profitability are determining factors in the manufacture of its products, which include: • Welding studs (capacitor discharge, short cycle welding, drawn arc welding). • Weld screws. • Friction welding studs. • Special cold-formed parts to customers’ specifications.

13.B78

Schmeck’s customers include manufacturers of prototypes, machines and electrical equipment, automotive suppliers, as well as major commercial enterprises dealing with connectors. “Whether for prototypes, large or small series – we are the right contact partner for you in all cases.”

Leading the field in distribution of rivets Bralo UK is an entirely owned subsidiary of Bralo SA, a Spanish blind rivet manufacturer. Established in Wednesbury, West Midlands, in 2000, Bralo UK has premises of more than 12,000 square foot, with the company stocking over 4,000 different product lines of blind fastenings.

ralo UK says that it has grown into one of the UK’s foremost rivet, rivetnut and tooling manufacturers/distributors, with an assortment of products including a wide variety of sizes and designs of blind rivets and rivetnuts in aluminium, steel, stainless and copper, as well as for special applications – with the aforementioned products supplemented by a series of manual and pneumatic tools. The Bralo Group is certified to ISO 9001 and ISO/TS 16949 with accreditation to the majority of the automotive sector. Bralo’s willingness to continually improve its products and services leads it to be more and more stringent in the pursuit of a better and more demanding quality control, priding itself on the quality of the products it manufactures and sells and aimed at the distribution sector, major manufacturers and first tier suppliers. Richard Turner, managing director, comments: “Our aim is to provide a constant level of excellent service at a competitive rate. We offer the same quality service whether we are supplying minimum quantities or large scale usage. To meet customers’ requirements we offer a next day delivery service anywhere in the UK.” He adds: “The constant search for solutions for our customers allow us to progress, continually improving our competitiveness as well as the capacity to react against specific problems, with delivery times according to their requirements.” The Bralo team in the UK consists of eight employees, all of them experienced and able to give expert advice on any enquiries and help customers in any way needed. “The success of Bralo UK is due to our close-knit team and back-up and support from our head office situated in Madrid,” adds Richard Turner. “Our staff are all more than happy to go above and beyond to meet our customers’ requirements.” www.bralo.com

30 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

sheet metal fastening

Cut assembly costs and simplify maintenance

13.D24 Böllhoff GmbH states that whilst TORX® or hexalobular drives are well established in production as an efficient drive form, there are some applications in which it is still to make its mark.

his is especially the case where connections have to be able to be released again, for maintenance or repair for example. The argument that fitters do not always have access to hexalobular tools or that the hexalobular socket head becomes clogged with dirt has tended to discourage its use in assembly. FLEXIDRIVE® is not a single product but rather a product family. So a wide variety of drive combinations are possible, such as a hexalobular drive with a hexagonal head or a slotted hexalobular drive. As far as screw geometries, thread types, materials and surface finishes are concerned, all technically feasible options are available as each solution is custom-made. The efficient hexalobular drive is used for assembly. A variety of tools can then be used for maintenance purposes. If the hexalobular drive becomes clogged with dirt, for example, or the right bit is not available, then there are other options such as an external drive for unfastening the threaded connection. Example applications:

Motor assembly/attachment of mounted parts Previous solution: FLEXIDRIVE® solution:

Hexagon socket fasteners/Hexagon head fasteners. Hexagon head-hexalobular drive flange bolt.

Lamp mounting Previous solution: FLEXIDRIVE® solution:

Crosshead screws. Pentagonal thread-rolling screw with serrated flange and slotted hexalobular.

Screw fastening of heat exchanger components Previous solution: Slotted screws. FLEXIDRIVE® solution: Trilobular thread-rolling screw with slotted hexalobular drive. Böllhoff advises its customers about the best technical and most cost-effective solution and then it delivers in accordance with specific requirements. Drawings for individual FLEXIDRIVE® solutions can also be prepared by Böllhoff. Key benefits of FLEXIDRIVE® include: • Shorter assembly time through the use of hexalobular drives. • Use of standard tools for maintenance and repair work. • Fewer tools required. • Longer tool lifetime. • Technical advice. • Procurement, stocking and supply of customers’ FLEXIDRIVE® product. www.boellhoff.com

32 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

Specialist fastening solutions

13.A66

HEYMAN®, a specialist in the field of access and fastening solutions, says that its mission is to improve the competitive position of its customers by means of using its knowledge, service and creativity in order to improve the quality of customers’ products and/or improve the efficiency of their production and assembly processes.

hroughout the years HEYMAN ® says it has established an excellent reputation for high-quality fastening and access systems, which are sourced from the world market leaders. Its product range includes latches, hinges, handles, telescopic slides, gas springs, blind rivet nuts and studs, rivets, tools as well as cable accessories.

Your global partner in bolting solutions The Nord-Lock Group is a world 27.E77 leader in bolt securing systems, offering a unique combination of bolting expertise and a wide product range, including wedgelocking solutions and Superbolt® tensioners.

ord-Lock states that its mission is to safeguard human lives and customer investments by securing the world’s most demanding applications. Nord-Lock products have documented success in every major industry and hold several certificates from independent institutes including AbP, DIBt, DNV and TÜV. “We share our experience, knowledge and creativity to help our clients achieve outstanding results. The Nord-Lock Group looks forward to being your partner in bolt optimisation.”

Joining together! – our company vision.

A vision that inspires our company culture

For four generations, courage, fairness and

and daily life.

loyality have been the cornerstones of our

This inspiration drives our product program

business culture. The foundation on which

in the world of fastening and assembly

we have built success for our company, our

technology. “Joining together” is much

customers, our business partners and our

more than just a neat slogan. It is also a

employees.

business vision that puts people first. Because it is people who put the vision

Böllhoff Group · Archimedesstr. 1–4

into practice and build the solid foundation

33649 Bielefeld · Germany

of our success today and in the future.

www.boellhoff.com · info@boellhoff.com

Böllhoff is exhibitor at the InnoTrans 2012. We are looking forward to meet you in hall 8.2, stand 137.

Joining together!

sheet metal fastening

Optimisation, acceleration and automation of processes GESIPA®’s automatic blind riveting unit GAV 7000 was recently adapted to GAV 8000 eco, electronic and HF versions for better optimisation, acceleration and automation of processes in blind riveting applications.

ESIPA® has been catering to varied industries including white goods, ladder manufacturing and most importantly the automotive industry with its automatic blind riveting units. Recently, it announced three new versions to its GAV series, including GAV 8000 eco without the process control monitoring, GAV 8000 electronic with process control monitoring - widely used in automotive production lines, and lastly GAV HF used to set high-strength blind rivets. GESIPA®’s head of R&D Richard Gärtner explains: “These fully automatic blind riveting units for industrial applications are capable of setting 40 rivets per minute increasing the productivity, saving time and cost by approximately 50% compared to conventional blind riveting tools. This all is possible due to the automatic loading of blind rivets into the gun’s working position. With no skilled staff required, it has a capability of integrating into full automatic production lines and can be flexibly tailored to the specific production requirements of each customer.” Factors such as workstation layout, production type, application, securing of reproducible and safe working processes, adaptation to the industrial environment, as well as process documentation, can be realised using combinations of different pistol versions, lengths of tubing (up to 25 metres), special accessories for

GAV HF

34 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

13.F40

GAV 8000 electronic

different rivet dimensions and production requirements. In addition to that, all GAV versions can be equipped with three different versions of setting pistols for ideal adaptation to the workstation and for best access to the rivet locations. Used as part of a complete production system or in self-sustained configuration, the system can be quickly and easily adapted to the new conditions in case of change of the application. Both versions of GAV 8000 can also be integrated in robotic systems and can be programmed on most different courses of movement efficiently adapting to riveting tasks in combination with the GESIPA® riveting technique. Explaining the different setting ranges for GAV 8000 eco, electronic and HF, Mr Gärtner comments: “The GAV 8000 eco and electronic sets blind rivets from 2.4mm diameter to 6.4mm diameter aluminium and copper, blind rivets up to 6mm diameter steel and up to 5mm diameter stainless steel as well as blind rivets up to a head diameter of 11.4mm, and they offer a setting force over 11,000N at 6 - 7 bar air pressure. With a GAV HF you can set blind rivets from 4.8mm up to 8mm diameter all materials, rivet shaft lengths up to 35mm, setting head diameter up to 19mm, rivet mandrels up to 5.5mm diameter and it offers a setting force up to 25,000N at 5 bar air pressure.” GESIPA® points out that using a fully automatic GAV combined with a multi axial robot within a regulated, fast and safe production process offers advantages like high precision, economic efficiency, short cycle times and high flexibility to the industrial customers. “If you are interested in any information about GESIPA®’s fully automatic blind riveting units or GESIPA® in general please visit us at our stand F40 in hall 13 at this year’s EuroBLECH,” adds Mr Gärtner. www.gesipa.com

EJOT SHEETtracs® The process capable assembly of pre-drilled, thin sheets has always presented a problem in the field of repeat assemblies. If a few years ago sheet metals with 1mm and more thickness were the rule, today the thickness is constantly being reduced due to cost saving potentials. Up until then the demands on the joint could sometimes still be realised with common sheet metal screws, more often though with the respective clip-on washer or preparation of the pressed hole.

onsidering this reduction in thickness of the sheet metal and the adherence to DIN 7975 for sheet metal joints at the same time, the problem occurs that the thickness of the components to be joined has to correspond to the pitch of the used sheet metal screw as a minimum requirement. A repeat assembly is still often at times not possible, since partly only one thread is engaged in the sheet metal. Therefore the so called thin sheet metal screws have been successful in the market place in recent years. These screws have a metric 60° thread and in most cases a conical tip. The advantage of this metric thread is the smaller pitch compared to sheet metal screws, which enables more thread engagement in the thin sheet metal. However, since most of the time the formed female thread - and not the screw - is the real weak spot of the joint, EJOT developed a thin sheet metal screw for a process capable

13.C72

assembly in thin sheet metal with a pre-hole. The EJOT SHEETtracs ® has a 45° (30°/15°) asymmetric flank angle and by that creates a more stable female thread in the sheet metal because of the lower material displacement. In this way the torque level of the joint is increased and a repeat assembly becomes possible. In the lower, conical part of the screw the flank angle is turned round and thus the extrusion is formed mainly in the screw-in direction. The non-circular thread forming zone enables an easy and centred application and the increased thread area secures a safe entering into the sheet metal. The circular cross section in the upper, bearing part of the thread results in a higher flank coverage in the sheet metal, compared to non-circular thread geometries. Thus the metric pitch of the SHEETtracs enables a trouble free replacement.

Visit us at the EuroBLECH 2012 (hall 13 / stand F40)

GAV 8000 electronic GAV HF GAV 8000 electronic, fullyautomatic blind rivet system for industrial production with setting process monitoring GAV HF, fully-automatic blind rivet system for high strength blind rivets For any information about GESIPA® blind rivet machines please contact us.

GESIPA blind rivet machines: fully-automatic – practical – reliable! GESIPA Blindniettechnik GmbH Nordendstraße 13-39 64546 Mörfelden-Walldorf Germany

T +49 (0) 6105 962 0 F +49 (0) 6105 962 287 info@gesipa.com www.gesipa.com

GAV 8000 electronic

GAV HF

The experts in blind riveting

fastener + fixing technology

Trifast goes from strength to strength Over the last three years Trifast plc has successfully restructured its operations in its European, Asian and USA businesses. The integration of Malaysian Group Power Steel and Electro-Plating Works in December 2011 has further enhanced its capacity and capabilities in the global fastenings industry, but it is the Asian automotive sector that has fuelled change.

n essential part of TR’s management growth strategy is to identify and selectively acquire profitable, self-managing bolt on businesses that either, extend its product range or offer niche opportunities as well as being earnings enhancing for the Group. Power Steel and Electro–Plating Works Sdn Bhd (PSEP) was acquired in December 2011 and is considered to be one of the most advanced fastener manufacturers in the Asia region, employing around 176 staff and producing 450 tonnes of products per month. PSEP was incorporated in

for competent manufacturers in the automotive sector in Asia is substantial. We believe this addition to the existing five TR manufacturing locations will further compliment that strategy and enhance what we are already doing following on from our success in this sector in Europe.” TR Fastenings, part of the Trifast Group, was traditionally known for its supply into the electronics and telecoms market places. This involved the supply of small diameter fasteners and components, with high specifications and the supply chain was usually managed on a VMI system. This sector contributed to the Group’s success in the

1972 by Mr Foo Poh Wah, the CEO and principal shareholder with an incredible 90% of its products sold into the existing automotive markets in Malaysia supplying companies such as Proton and Perodua. Trifast CEO Jim Barker spent many months working with Asia’s MD Thomas Tan to conclude this acquisition as it was strategically important to the future plans for the Group’s automotive strategy. Mr Barker says: “The growth potential

1980s and 1990s, and to the knowledge of managing these parts globally for companies with multiple sites across the three main continents. This became a particularly important part of TR’s supply strategy to major OEMs and the Contract Electronics Manufacturers (CEMs) that supported them, as these businesses transitioned their sites globally in search of lower cost manufacturing sites, in Asia particularly.

36 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

During this time TR acquired manufacturing sites in Singapore, Malaysia, Taiwan and China to further strengthen its product offering and compete in very challenging market conditions in the early 2000s. The Dotcom boom and bust saw a sizeable drop in the fortunes of many of these electronics groups and TR decided to diversify into other markets as a buffer, ensuring that it had no heavy dependence, again, on a specific industry. These different business silos include electronics/telecoms, audio and visual, marine and the automotive sector in particular which has seen unprecedented growth. No one sector exceeds 25% of the total turnover of the Group and this spread of industries has been instrumental in the success of TR in the three years since recession. From its background of smaller diameter fastenings, TR focussed on the interior of the car, supplying fasteners within the cockpit for the IP console, seating, air bag and trim. Having built up a good reputation for quality of product and supply of Lean Build systems and winning some prestigious customer awards, TR recognised the need to increase its product offering to Tier 1 and Tier 2 suppliers so that it provides a more holistic supply chain. TR Fastenings had a very strict AVL, controlling either its own manufacturing, e.g. SFE in Taiwan or other major global manufacturers it chose to work with. This list of vendors, however, only satisfied the supply of cockpit fasteners and not engine, steering or braking products. The acquisition of PSEP has addressed that shortcoming. Chris Black, group automotive manager for TR Fastenings is confident that this will see an increased level of interest now that the scope of supply has been enhanced. PSEP Malaysia, soon to be renamed

TR PSEP, has a lot to offer; a stable economy, natural resources, a skilled work force and reasonable labour costs. Charlie Foo, director of operations at the site is confident the output of the factory can be doubled without difficulty and sees being part of the TR family as an opportunity to grow to meet the Group’s needs. Both he and his team possess the in-depth technical knowledge required to drive the business forward and this has been amply demonstrated at the recent Asia meeting of the operational heads for TR Asia and the Trifast board at the conference hosted by Mr Foo and his team. PSEP previously had strong ties with Osaka Rashi Mfg Company in Japan and that influence extends to the way it operates today. For example, the steel PSEP uses is 80% Japanese because of its high quality and integrity. This is of particular importance as companies seek alternative sources of supply based on price with the high cost of the Yen. So Japanese quality at Malaysian prices is a winning formula. The multi die forged parts they produce in the TS16949 accredited facility are supplied to many blue chip companies already in Asia. PSEP’s second op facilities are not usually seen in conventional forging companies, which enables it to meet certain customers’ demanding expectations. PSEP’s niche is high strength, and complex parts, some examples are in the photographs to the right. The Trifast Group is presented with real business opportunities for future growth in Asia, at a time of worldwide recession. The networking opportunities for PSEP will ensure a successful future, no more so in the Chinese automotive market which is importing high strength grade fastenings to support its growing demands.

www.fastfixtechnology.com

fastener + fixing technology

WindMade in HUSUM

HUSUM WindEnergy, an international wind industry trade fair, takes place every two years in the North Frisian county town of Husum, Germany. This year’s exhibition will take place from 18th – 22nd September and is expected to attract 1,200 exhibitors and 36,000 trade visitors from around 90 countries at its 58,000 square metre showground.

USUM WindEnergy 2012 was recently awarded the WindMade label emphasising its commitment to the use of renewable energy. The WindMade label is granted by a nonprofit organisation solely to enterprises that draw a share of their power from renewable energy sources – and in the case of exhibitions and events this share must be 100% in order to carry the label. The 2012 show applied for the WindMade label so that it can clearly emphasise the fact that it practises what it preaches when it comes to running the fair itself. The WindMade label enables businesses and event organisers to communicate their commitment to renewable energy to the outside world and stand apart from the competition. “We are overjoyed that the 2012 fair has been awarded the WindMade label. The WindMade organisation corresponds excellently with our objective of making the use of wind and other renewable energy sources attractive for everybody. As the world’s most influential trade fair for wind power, HUSUM WindEnergy has such international charisma that it can also use the WindMade label as a message to other enterprises and events in the industry”, emphasises exhibition boss Peter Becker. WindMade’s CEO Henrik Kuffner added: “We are proud for HUSUM WindEnergy 2012 to carry the WindMade label and for it to spread the message that wind power has become the technology of choice for many electricity users. This includes event organisers, but also large and small companies from a great variety of sectors.” To the right is a selection of the fastener related exhibitors at the show. For a full list of exhibitors visit www.husumwindenergy.com

COMPANY Adolf Würth GmbH & Co KG alki-TECHNIK GmbH AMG Intellifast GmbH Atotech Deutschland GmbH August Friedberg GmbH Berdan Civata BUFAB Germany GmbH Dokka Fasteners A/S Dörken-MKS Systeme GmH & Co KG ERICO GmbH Flaig + Hommel GmbH GEDORE Tool Centre KG Graewe GmbH & Co KG HAZET-WERK - Hermann Zerver GmbH HellermannTyton GmbH Henkel AG ITH GmbH ITW WindGroup James Walker SPS Ltd Kleinsorge Verbindungstechnik GmbH Lösomat - Schraubtechnik Neef GmbH MÜTH Selbstklebetechnik GmbH & Co KG Navarra de Tecnicas de Soldadura y Fijacion S.L. Nord-Lock GmbH OBO Bettermann GmbH Optima Spanntechnik GmbH RAD Torque Systems New World Tech Inc Radolid Thiel GmbH REYHER F. Nchfg GmbH & Co KG SCHAAF GmbH Schatz AG Schraubenwerk Zerbst GmbH SNA Europe (Deutschland) STAHWILLE GmbH & Co KG Tentec Ltd tesa SE Total Wind A/S TVS Peiner Services GmbH WEICON GmbH & Co KG

38 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

COUNTRY Germany Germany Germany Germany Germany Turkey Germany Denmark Germany Germany Germany Germany Germany Germany Germany Germany Germany Denmark UK Germany Germany Germany Spain Germany Germany Germany Canada Germany Germany Germany Germany Germany Germany Germany UK Germany Denmark Germany Germany

STAND 1G13 7B01 1E20 3B05 7B08 3A05 2B09 5B01K-6 4D10 3D21 6A04 3E18 1C07 3A02 1D09 3C06 8B01 5C01H-2 3G11 3E23 3E18 3B10 4F15 1A06 3F20 3D04 3G01-A 7C11 1A01 3B09 6A19 8A16 1D25 7D06 8A14 3B10 6A14 4C07 5B04

fastener + fixing technology

New challenges in the design of wind turbines increase the demands on the fasteners Dr.-Ing. Selcuk Güres - August Friedberg GmbH - R & D, application engineering Dipl.-Ing. Carsten Stolle - August Friedberg GmbH - R & D, application engineering Beatrix Brand-August Friedberg GmbH - Marketing / GL The development and use of powerful wind turbine generators (WTGs), with capacities up to 7.5 megawatts, represent the ‘state of the art’ technology in the wind power industry.

or the best utilisation of the wind potential, high wind speeds require substantial hub heights up to 130m. To further capture the wind’s potential, optimal energy utilisation through special aerodynamic blades with lengths of up to 65m is favoured. Onshore WTGs have limitations that restrict how tall they are built and therefore not capturing the greatest wind potential. The best alternatives to onshore WTGs are through the construction of offshore WTGs. Offshore WTGs have their own set of significant challenges and design considerations. In addition to the extreme wind loads on offshore installations, the turbines are acted upon by forces of wave action, tidal stress and a highly corrosive environment. In contrast to onshore wind turbines with the same rotor blade diameters the hub heights could be significantly reduced and stresses on the connecting systems are also reduced significantly. Apart from the structural aspects of offshore WTGs, the intended useful life of at least 20 years must be assured. Since accessibility of offshore wind turbines is much more difficult than onshore, the low-maintenance design of fasteners in security-related areas is increasingly important. The inspection intervals must be reduced to a minimum or by the use of novel methods, such as remotely monitoring the fasteners preload which is becoming essential. Besides maintaining the fastener preload force, avoiding/delaying and monitoring corrosion is equally essential. Constructive and economical requirements for WTGs provide the engineers with increasing challenges regarding the design of fasteners in saline

atmospheres and extreme conditions of wind, temperature and service loads. The application of appropriate fasteners in security-related areas gains increased importance. Highstrength fastener connections with different types of corrosion protection, contribute to reliable operation of WTGs.

‘Supporting each other’ Under this motto August Friedberg GmbH in Gelsenkirchen, Germany, produces engineered fastening solutions from M6 to M72. In close cooperation with wind turbine manufacturers, comprehensive solutions are designed and manufactured in safe production processes with full traceability and with the most experience in the industry. Subsequent performance tests guarantee a high quality level and predictable level of fastener performance. From the foundation anchors in the onshore area, through the most widely used ‘solid-wall’ tubular towers, up to the rotor blades and various parts in the engine/nacelle room, all different versions of high strength fasteners are used. Foundation fasteners are mostly galvanised threaded rods or anchor bolts up to M48 in diameter. These have to resist the resulting loads from impact. Here fasteners are used with a total length of 2 metres, or occasionally even longer. For the assembly joints in steel towers with planned preloaded ring flanges galvanised HV sets are exclusively provided. Hot dip galvanised HV sets have more than 50 years of experience in steel constructions throughout Europe. The standard

“ In close cooperation with wind turbine manufacturers comprehensive solutions are designed and manufactured.” 40 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

sizes of sets, depending on the type of turbine and depending on the position of the flange, are from diameter M30, for the top flange, up to M72, for the lowest flange. A bolt in M64 is statically designed to resist loads up to 200 tonnes. With a regulated and defined preload the required minimum pretension load is reliably introduced into the bolt and thus ensure the desired load capacity. According to the application in the nacelle, bolts or studs with non-electrolytically applied zinc flake coatings will be used. Such coating can reach a corrosion resistance of the ground material of more than 1,200 hours. Especially for the rotor blade fittings, high strength fasteners with appropriate surface protection systems are of high importance. Studs in sizes M30 to M42 in various designs, such as reduced and thin shaft, both hot dip galvanised and zinc flake are applied. The development of powerful onshore and offshore wind turbines is becoming increasingly important for energy reasons. Extreme welds from external forces increase the demands on the connection elements and provide simultaneously the planning engineers with new challenges. The requirements of appropriate customer-specific solutions are therefore of immense importance in addressing these tasks. August Friedberg GmbH will be exhibiting at the upcoming HUSUM WindEnergy 2012 fair, 18 th â&#x20AC;&#x201C; 22nd September 2012, at booth number 7B08. www.august-friedberg.com

FRIEDBERG WIND FASTENERS from tower base to rotor blade! FRIEDBERG is a pioneer in wind energy in a global context. In close cooperation with leading manufacturers, fastening systems have been developed, which are installed from base to tower in all decisive safety and stability interfaces. In this way, bolts from FRIEDBERG have become the supporting component of systems which are becoming higher and more powerful on both land and water.

GERMANY

USA

KOREA

BRAZIL

www.august-friedberg.com

rail technology

InnoTrans is approaching At the ninth InnoTrans, which takes place from 18th - 21st September 2012 in Berlin, Germany, the main emphasis will be on railway technology, railway infrastructure, tunnel construction, interiors and public transport.

nnoTrans, organised by Messe Berlin, is the world’s leading business meeting place for rail transport technology. More than 2,400 exhibitors from 47 countries will be presenting their innovative products and services at InnoTrans 2012. Organisers expect the show to attract some 100,000 trade visitors from more than 100 countries. The organisers have announced that all available space has been reserved at InnoTrans 2012 and the individual segments of the fair, including Railway Infrastructure, are expanding. As a result, exhibitors in the Railway Infrastructure segment are also represented in Hall 5.2 this year, and for the first time are occupying six halls at the fair. Compared with the previous occasion on which this trade fair was held, the overall display area set aside for Railway Infrastructure has increased from

25,000 to 30,000 square metres overall. This enables InnoTrans 2012 to provide exhibitors and trade visitors with an even more comprehensive and international overview of the market. Some 53 percent of those participating in Railway Infrastructure are coming from abroad. Fastener related exhibitors at InnoTrans include: Böllhoff GmbH, Click Bond Inc, DIRAK GmbH, DIV Group, EMKA Beschlagteile GmbH & Co KG, Ferdinand Gross GmbH, Flaig + Hommel GmbH, Growermetal Srl, Lederer GmbH, Max Mothes GmbH, Nord-Lock GmbH, Staytite Ltd and Vossloh AG. More details about InnoTrans and current developments in international transport technology are available at www.innotrans.com

On the right track DIV Group is specialised in processing, manufacturing and trading fasteners, other machine parts and products in south east Europe.

IV Group has a dedicated production site specialising in railway accessories such as: • Spike screws for wooden and conrete sleepers. • Coach screws. • Fishplate bolts and other bolts with various types of protection. • Elastic clips SKL1, SKL1A, SKL2, SKL12, SKL MD, K-clamps, flat ring washers, single and double spring washers.

DIV is also able to offers customers Fishplate for 60E1, 49E1, fishplates for isolation joints, Ribbed base plates for rails type 60E1 and 49E1: with or without inclination, Tram rails, crane rails, light rails, as well as rolling stock components - buffers, draw gears, truss rods, and light railway machinery. DIV Group points out that a newly constructed factory for concrete sleeper production in Svrljig, Serbia, will help strengthen its position in the railway track accessories production. The DIV Group portfolio also includes plants for hot and cold forming, sheet metal processing and other light constructions, as well as machined part processing. www.divgroup.eu

Avdel® introduces large diameter high strength fasteners For demanding assembly applications where welding is not practical or where conventional bolts struggle to provide a guaranteed and retained clamp load quickly and consistently, Avdel® has developed the new range of Infalok® lockbolts.

nfalok® lockbolts are large diameter, heavy duty, two piece structural steel fasteners designed to provide exceptionally high strength and secure assembly. Capable of delivering a joint clamp (pre-load) of over 250kN and a tensile strength of over 300kN, Infalok® lockbolts can be widely used in demanding engineering industries throughout the world including railways, commercial vehicles, construction, mining, bridge, crane building, renewable energy and many structural applications including maintenance/repair. Infalok® lockbolts offer a wide choice of bolt diameters from 12.7mm to 28.6mm (1/2 inch to 11/8 inch) and grip ranges from 6.35mm up to 152.4mm (0.25 inches up to 6 inches). They are available in two different head forms and various finishes. Infalok® lockbolts are tamper resistant and eliminate the risk of vibration loosening during fastened joint service. Joint clamp performance offered by Infalok® lockbolts compares to (or exceeds) equivalent sized Metric Property Class 8.8 threaded

42 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

fasteners. The controlled clamp loads provided by Infalok® delivers strong, robust joints. In parallel with the Infalok® fasteners, innovative new placing equipment has been designed by Avdel utilising the very latest technology available resulting in the launch of Avdel’s 734 AV™ installation tool system. The Avdel 734 AV™ tool range comprises a range of placing tool options to suit varied working environments. “Compact and ergonomic hand tools combined with powerful and robust Enerpac ® pump units offer a new range of highperformance high-speed installation systems enhanced with built-in features and reliability that exceed current industry levels. Less service, maintenance and down-time means more costeffective assembly.” The hydraulic pump units are available in voltages from 115/1PH to 480/3PH. Avdel’s 734 AV™ tools can place a variety of Avdel structural fasteners and Avseal® II sealing plugs.

on the right track DIV group is one of the group leaders in Europe specialized for production and sales of fastener goods, as well for the production and processing of various metal parts and products. The DIV Group portfolio includes plants for hot and cold forming, sheet metal processing and other light constructions, as well as machined part processing.

Manufacturing

• Railway track fastenings • Railway concrete sleepers • Railway stock components • Lightweight railway machinery • Steel products of various purpose • Bolts and nuts by the hot forging process

Most significant products • Lightweight railway machinery • Railway stock components • Baseplates and fishplates • Sleeper screws • Standard bolts • “T” bolts • Nuts

DIV Group

www.divgroup.eu e: div@divgroup.eu

Hall 26 Stand 334

rail technology

Star performer

Magna-Grip

Star Fasteners (UK) Ltd is a specialist in the fastener market and through successive years of growth has become a key distributor of Huck® fasteners.

uck ® fasteners can be found in every tough engineering situation - railcars, railway tracks, rolling stock, as well as various other industries including aerospace, automotive, construction and mining/quarrying. In fact anywhere that fastener failure is not an option. Huck ® fasteners have been designed to cope with extreme stress and vibration, providing strength and facilitating lighter, stronger, more durable structures. The heavy duty tamper resistant fasteners can be used for applications including bogies, chassis coupling mechanisms, cabs, sidewalls to chassis and sidewalls to roofs. The blind self-locking range is popular for installation on air conditioning units, door and window frames, luggage shelves, front and rear panels and brackets. Star Fasteners highlights that a key product in LockBolt evolution is the Bobtail ® fastener which combines rugged installation tools with a precisely engineered fastener range to deliver superior value and performance. The Huck ® Bobtail ® offers a safe and more efficient fastening method than more traditional procedures such as installing standard nuts and bolts, and welding. The installation process only takes two seconds, which, Star Fasteners says, is up to twice as fast as any other large diameter LockBolts on the market. The Bobtail ® also has the benefit of no pin-tail or pin-break; this reduces material waste and as there is no pin-break the fastener’s corrosion resistance is increased. Additionally the Bobtail ®, as with all Huck ® fasteners, is tamperproof and cannot be easily removed without specialist tooling. Other key benefits of using a Bobtail ® fastener include: • Permanent, mechanically locked fastener. • High clamp; no torque or re-torque required. • Consistent, high quality installation. • Installation process automatically provides fastener values. • Smooth, shock free installation sequence. • Easy visual inspection ensures correct installation. • High core strength values enables use of smaller diameter LockBolts without compromising strength. • The same tooling system can be used for installation and removal. Just a quick swap of the nose assembly (12mm - 20mm diameter only). • Unique helical lock groove (12mm - 20mm diameter only) holds pin and collar in place prior to installation.

Another popular LockBolt in the Star Fastener range is the Magna-Grip. Its unique lock-groove design ensures a secure HuckLok ® vibration proof performance that can be used in both light and heavy duty applications. With a selection of diameters from 3/16 inch to 3/8 inch, a flush pin break every time, and a wide grip range allowing multi thickness capability, Magna-Grip can be used in a wide variety of industries. An additional Huck product available from Star Fasteners is the HuckLok ® - a unique blind high strength rivet offering a wide grip range. Its ingenious double-locking action clamps the assembly from both sides producing maximum joint integrity. The bulb-forming design significantly reduces pull-through when installed in thin or lightweight materials compared to other structural blind fasteners. HuckLok ® can be used on all types of metals, plastics and composites. Huck ® fasteners are identified by unique markings on their heads so are therefore fully traceable. This is especially pertinent following the rise of cheap copycat versions on the market, says Star, which in some instances have proven to be not anywhere near as reliable or long-lasting as the real article. Star Fasteners has evolved over twenty years to meet the changing needs of the market. An ever-wider range of products is stocked in response to customers increasing demands and requirements. These include rivets, threaded inserts, weld and self clinch studs, screws, insert bits and holders, and rivet bushes. Star is flexible enough to adapt to its customers needs and has the knowledge and experience to offer customers a combination of reliable service, technical help and support, quality products, delivered on time, on budget and without compromise. Star’s service includes the supply, hire and maintenance of a range of hand, hydraulic and pneumatic installation equipment. Customers can receive a quick, reliable and competitive repair service; with a wide range of tooling spares stocked as standard. Star Fasteners philosophy is based on principles of quality, service and continuous improvement; this has enabled it to achieve accreditation to BS ISO9001: 2008. “We can become an integral part of the customer’s service and maintenance system. Our documentation and data are controlled within a dedicated software system, and our stocking and distribution of industrial fasteners is supplied from quality assured sources giving us full traceability and ensuring quality.” www.starfasteners.co.uk

44 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

GISTE R RE FIRM

QUAL IT

Unit 3, Gallows Industrial Estate, Furnace Road, Ilkeston, Derbyshire DE7 5EP, UK T: +44 (0) 115 932 4939 F: +44 (0) 115 944 1278 E: sales@starfasteners.co.uk

99001:2008

ISO QUALITY SERVICES

- BS EN ISO -

product news

Future-oriented adhesive tapes tesa® says that it is taking the chemistry involved in tape production forward a generation with tesa® ACXplus, a future-oriented range of adhesive tapes that guarantee optimal strength for constructive bonding on materials with different surface characteristics.

esa ® ACXplus technology enables a new functional combination of the tapes’ chemical components to effectively withstand the dynamic and static stresses that constructive bonds are subject to, particularly in outdoor applications. During the life cycle of a component, static and dynamic forces act upon the constructive bond. In outdoor applications there will be temperature variations to contend with and often the effects of high wind loads, water, UV light or even exposure to chemicals. Dissimilar materials also show different elongations when temperatures change, creating extreme physical stresses that need to be dissipated for the bond to be durable. The ability that tesa ® ACXplus has to compensate for different thermal elongations and extreme conditions is ® based on its viscoelasticity; a • highest tensile strength material performance defined • minimize weight and space by both elastic and viscous • minimize costs characteristics. • strengthening threads for The elastic restoring forces new construction options • thread repair provide inner strength while the viscous part of the material behaviour leads to the relaxation of mechanical stresses. Due to the viscoelastic behaviour of the tape, arising stresses can be dissipated through relaxation of the tape and a secure, longterm bond achieved. tesa ® ® ACXplus employs a special acrylic adhesive system that • minimize space and combines both effects to weight of parent material provide excellent results. • thread reinforcement • very high tensile strength Jeremy Smith, marketing • high connection with manager of tesa UK, workpiece summarises the significance • thread restoration of this product in ensuring the strength of constructive bonds: “When two materials with different thermal elongations, for example aluminium on steel or deco glass on composite fibre, are bonded tesa ® ACXplus will deliver a consistent bond irrespective of the conditions in which the application is found. The special balance between elastic and viscous performance does not only secure an optimal wetting of different surfaces, it also allows absorption of BAER Company dynamic forces and vibrations Robert-Bosch-Str. 5 68542 Heddesheim/Germany and stress relief in the bonded Tel.: +49 (0)6203 40 48 790 joint.” Fax: +49 (0)6203 40 48 791

BaerCoil

BaerFix

strongest bolted connection for engineering: saves material, weight and costs

E-Mail: info@baercoil.com www.baercoil.com

Non-magnetic brass inserts Yardley Products Corporation, a manufacturer of threaded metal insert fasteners, has been producing non-magnetic brass inserts for use in MRI machines and sensitive electronics equipment for nearly five years.

n addition to being made in the USA, Yardley has reaffirmed its commitment to producing the highest quality non-magnetic metal inserts by upgrading to all new magnetoscope equipment used for testing and quality control of the products. “Standard brass inserts are actually slightly magnetic due to small traces (about 0.2% - 0.4%) of iron in the alloy”, said Tim Bailey, president at Yardley Products. “Our magnetoscope testing equipment allows us to perform a quality check that ensures absolutely zero magnetic material is present in our non-magnetic fasteners.” There are numerous applications that require the use of nonmagnetic inserts in order to minimise potential RF interference with sensitive electronics and prevent failure. Typical

applications include medical instruments like MRI machines, microwave and cell phone towers, semiconductor protection equipment and devices, aerospace vehicles, robotic assemblies, instrumentation devices, printers/plotters, and laboratory and test equipment. The non-magnetic characteristics (zero magnetic flux density) of the material used by Yardley produces inserts of the same high quality as those produced with magnetic materials. In addition, the full line of Yardley’s brass threaded metal inserts are available in the non-magnetic variety. Produced on a custom quote basis, Yardley non-magnetic threaded metal insert fasteners are available in a wide range of U.S. and metric sizes and thread configurations.

Unbrako fastener selector App Unbrako has announced the release of the Unbrako fastener selector guide smartphone App.

he smartphone App replaces the manual screw data, socket screw selector and fastener terminology guides which have been used by engineers over several decades. Unbrako says that its fastener selector guide App is an invaluable source of data for all engineers involved in fastener selection and joint design. The App provides easy access to product details, dimensional data and torque values

Hall: 2.2 Stand: 215

for standard applications. There is also a very useful section explaining fastener terminology as well as Unbrako part numbers and other data. “The iPhone/iPod/iPad versions are available to download right now from the App Store. Just search for ‘Unbrako’ in the App Store. Android and Blackberry versions of the App will become available shortly.”

product news

Ornit shows its strengths Proper sub-structures and accurate installations are key success factors in solar panels being a cost effective, resource saving, alternative energy supply. This means that effective fastening of solar panels is becoming of prime importance to installers and users.

rnit Blind Rivets offers a range of possible rivet based solutions to address this issue. Solar panels are attached onto metal frames and these frames are fixed onto roofs or on other weatherproof exposed surfaces made of various material types such as concrete, tiles or corrugated iron. As a result the joints require different performance characteristics from the fasteners, but it is essential that the fasteners create joints strong enough to resist the wind force. Ornit’s structural and multi-grip rivets are able to handle these strict joint requirements. Ornit’s solution for the steel frame structures are the high strength, structural rivets Stelock, Steelfix, Orlock, Super

Orlock, Or-Bolt and Ornilock – 4.8mm, 6.4mm, 6.5mm and 7.8mm. Ornit highlights that these powerful breakstem fasteners are ideal for this application due to their exceptional shear and tensile strengths, which create a vibration resistant joint. They are also available in a range of corrosive resistant materials - steel, stainless steel and aluminium, so the enduser may chose the material most suited to their roof type. In addition, Ornit’s peel rivet, TPR, designed especially for roof fixtures, is vibration resistant with enhanced shear values, making it suitable for fixing steel frames to corrugated-iron rooftops. Ornit’s extensive product range offers solutions for many application types and its R&D department is always looking to design and improve products for the end-user.

TR Fastenings launches new Plas-Fix 45 screw Further investment in product development for the thermoset and thermoplastic industries has enabled TR Fastenings to expand its screws for plastics range with the introduction of the Plas-Fix 45 screw.

he Plas-Fix 45 screw has a 45-degree angle and Tri-lobular thread form, which makes it ideal for harder plastics. TR also continues to offer the Plas-Tech 30 screw that has a 30-degree angle and is used extensively in softer plastics. The complete range offers a number of different head styles and thread sizes, ranging from 1.4mm up to 6mm. Both screws are available off-the-shelf in casehardened steel and offer superior screw performance with low torque drive and high pull out strengths. TR Fastenings’ range of products for plastics also includes a comprehensive selection of brass inserts. Consisting of sixteen different types, both headed and un-headed, these brass inserts are available in sizes ranging from M2 up to M10. The variety of styles offers a number of installation methods with

varying performance levels, allowing users to easily find the product to suit their individual application. TR says that its products for plastics meet virtually all assembly requirements within the thermoset and thermoplastic industries and can offer considerable time and cost-saving benefits. Additionally, they are designed for optimum performance and therefore can be used in a number of different industries, including electrical, telecommunications, sound and vision. TR Fastenings product specialist Steve Wallis says: “In recent months TR has invested heavily in its products for plastics ranges. We are confident that we now have a quality fastener to suit most applications and we welcome the opportunity to discuss requirements with manufacturers.”

Seam design makes coiled pin perfect for hinges Coiled spring pins are manufactured with a seam, which is much better for hinges than the gap or slot of slotted spring pins, says Michael Pasko, engineer at Spirol International.

he seam is inherent to coiled pins because they are rolled with more than one wrap of material. The coiled pin’s ‘duty’ will affect material thickness and the coil configuration but all coiled pins will possess a seam. Some assume that a coiled pin’s seam is raised above the surface of the pin. This is not the case. A coiled pin’s seam is actually ‘tucked’ or rolled to ensure the pin remains round. In addition, the seam is prepared with a bevelled edge to soften the transition into the ‘comma’ area. In fact, a key characteristic of a properly rolled coiled pin is that the diameter of the pin at the seam is equal to or less than the diameter adjacent to the seam. This prevents the edge of the material from contacting the inside diameter of the hole wall and prevent skiving when inserted. A large percentage of coiled pins are used in hinges and the unique seam configuration is essential to their proper function. Thus, when utilised in round holes, the seam should have

48 Faste ner + Fixing Technology • Issue 6 Jul - Sep 2012

absolutely no impact on performance. The coiled pin’s tucked seam will allow smooth, interferencefree rotation of hinge/axle components in the vast majority of assemblies. In most situations where the seam is problematic, it is typically the result of poor installation methods or improper implementation. If excessive compressive force is applied to one part of the pin and not another, seam deformation may occur. This sometimes happens when assemblies are designed such that they do not properly support the pin. Similarly, pins can be damaged during installation and this can lead to deformation at the seam. Improper installation technique, equipment, hole condition, or pin material and duty are typical causes. Designers have also attempted to use coiled pins and slotted pins in assemblies where a ‘pawl’ or lever must ride axially on the surface of the pin as it rotates. The geometry of these components sometimes causes them to catch or ‘hang up’ on the seam.

Fixed. And fastened. By Hopwood. In partnership with Ejot.

The original PT® screw

Available from stock at Hopwoods

Tel: +44

(0)845 519 6066

E-mail: sales@rhf.co.uk Hibbert Street • Whitehill Ind. Estate Stockport •United Kingdom SK4 1NS Leading the way in fastener distribution, quality and service

www.rhf.co.uk

RHF0072 Fastener Fixing Ad_92x135.indd 1

23/03/2012 11:32

product news

Optimum thread forming in plastic EFC International, a provider of specialty engineered fastener component parts, now has stock on the latest PT® screw development, the Delta PT®, which it says provides optimum thread forming in plastic without any material damage.

FC International explains that the Delta PT® screw provides better clamp loads and increased joint life in a wide range of plastic materials. It also offers improved vibrational safety, improved dynamic safety from new shear area, and high clamp load at smaller contact pressure from increased flank engagement. Stock sizes include 4mm to 6mm diameters and 12mm to 25mm lengths with round washer head. EFC also provides Delta PT® screws in 1.8mm to 10mm diameters and 3mm to 100mm lengths with any head style. EFC offers professional engineering support and samples. EFC is a US master distributor with facilities in Atlanta, St Louis, Chicago, Detroit and Toronto.

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Stand B72

American and British

inch sized screws USA - fasteners

Screw thread types:

Over 30 years experience in trading and in supplying customers with inch sized fastening items. Don´t hesitate to ask us – We shall be pleased to help you.

Peter Schröder GmbH Silcherstr. 38 • D-74172 Neckarsulm Telephone: +49 (0) 71 32/99 60-0 Facsimile: +49 (0) 71 32/99 60-60 info@schroederschrauben.de www.schroederschrauben.de

DELTA® protects surfaces.

AwArDS

Sustainably successful. Yet another panel has succumbed to our charms: Following its successes in the German Material Efficiency Prize and the Best Professional Supplier Award, Dörken MKS-Systeme has been put on the TOP-100 Innovators list for the third time. This is the best possible recognition for our know-how, creativity and passion, which we are constantly putting to use in developing new ideas to make our DELTA-MKS® products even better. To find out what else is new in Herdecke, go to: www.doerken-mks.com