PRODUCT NEWS
VISUAL VERIFICATION
STAR FASTENERS
NEW INNOVATION FOR LOCKBOLTS
Star Fasteners has developed a clever
colour changing indicator that visually
verifies that Lockbolts have been installed
correctly.
The new red coating helps to improve final
product quality checks, crucially making
pre-assembled, uninstalled fasteners much
easier to identify. Dan Starbuck, Director
at Star Fasteners explains “we were asked
by a customer to remove welding from
their production process in a safety
critical application. We worked with them
to specify in a Lockbolt pin and collar
fastener. They were so pleased with the
outcome as manufacture time was halved
and health and safety issues associated
with welding were completely removed.
There was just one concern and that was
at the final quality inspection stage (PDI).
Their question of how can we tell that a
Lockbolt has been installed completely
needed to be addressed. To a trained eye
this is simple, but the customer wanted
further assurance. We developed the
Lockbolt colour changing collar coating
to give a clear visual warning; if the collar
is red it is an instant indication that the
fastener hasn’t been correctly installed or
fully swaged”
The Lockbolt fastener is a is a two-part
fastening system that consists of a pin
and collar, “Lockbolts are installed using a
direct tension technique in which the pin
is pulled and the collar is simultaneously
swaged into the locking grooves of the
pin. The material is clamped together,
which creates structure and strength.”
In most cases, Lockbolts can replace
welding. They are faster, safer, more
productive and an environmentally friendly
alternative method of joining. Advanced,
two-piece fasteners are installed using a
torque-free, direct-tension, swaged-on
method, providing for a reliable installation.
This method of joining ensures a consistent
clamp which is the key to a strong, reliable
hold – so users know that the joint is
permanent and vibration-resistant.
The patent pending colour changing
Lockbolt collar coating is applied by Star
Fasteners. A visible change occurs when
the collar is swaged, in this case from red
(uninstalled) to silver (installed). The firm
explains: “It’s a definite visual that the
fastener has been installed correctly. The
bright red colouring, which you can see
when the collar has not been swaged is
very easy to see. If for example a fastener
has been accidentally missed in the
production process, the nose assembly is
damaged or is becoming worn, or a collar
has only been part swaged, then the red
coating can be used as a precursory visual
indicator, great for quality control purposes.
Some Lockbolt collars have swage bumps
or bar indicators on the flange, these are
partially flattened on installation, but
cannot necessarily be easily seen from
a distance or in low light. Operators and
quality managers have to be fully aware of
their correct installation and if necessary,
carry out additional checks using a swage
gauge to identify fasteners that have not
been correctly installed. The advantage of
Star Fasteners’ method means operators do
not require that level of familiarity. All they
need to know is that a red collar has not yet
been installed”.
While a new development, the colour
changing Lockbolt collar has proved to be
popular and is already in use with a number
of chassis builders. With the implications of
product recalls in terms of time, monetary
cost and brand reputation, this innovation
appears likely to be a requirement in
automotive production and safety critical
applications.
In fact, potential applications for the colour
changing Lockbolt collar are as varied as
they are for a standard Lockbolt, including
solar and wind power, agricultural and
commercial vehicles and machinery, rail,
bridge building, screening equipment,
portable / steel framed buildings and other
industrial applications.
Find out more email
[email protected]
or call +44(0)1159324 939
Issue 39 PECM
143