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Wednesday, June 9, 2004 - 9:00 AM
WAJ3.2

Simplified Structural Joining Using an Advanced Design Rivetless Nut Plate System

L. Reid, Fatigue Technology,, Seattle, WA; J. Restis, Fatigue Technology, Inc., Seattle, WA

Aerospace structures incorporate a wide variety of fastening methods to facilitate the assembly of manufactured components and structural assemblies. The physical act of attaching many of these sub-assemblies requires use of blind fastening systems. The most common of these methods is the riveted nut plate. The attaching satellite rivet holes, besides adding to the complexity, cost of assembly, and manufacturing have proven to be a major source of fatigue-induced structural cracks. Nut plates have never been approved for primary structural attachment, which necessitates use of sacrificial doublers to provide a blind attachment. Furthermore, attempts to produce an effective “rivetless” nut plate have been marginally successful because these systems do not consistently deliver either the necessary resistance to push-out force and torque or are based on mechanical locking features that have a negative effect on fatigue. The purpose of this paper is to outline the development, testing and qualification of an advanced design rivetless nut plate system. The ForceTec® (FtCx™) rivetless nut plate system presented utilizes hole cold expansion technology to radially expand a nut retainer into the fastener hole. Torque and push-out resistance are achieved by the resultant high interference fit of the retainer. Residual compressive stresses induced in the metal surrounding the hole during cold expansion and the reduction in applied cyclic stress range, caused by the high interference fitted retainer, significantly improve resistance to fatigue cracking. This system significantly reduces the high stress concentration associated with other methods and has demonstrated superior nut plate qualities with fast, consistent and reliable installation. ForceTec provides an alternative to conventional riveted nut plates with, there inherent problems, and provides significant fatigue life improvement of the installation over riveted and rivetless nut plate styles currently used by the aerospace industry. This paper will also discuss the manufacturing savings that can be realized by using this advance fastening system and how it is being used for primary structural attachment.