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
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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