11

Page Hole Preparation . . . . . . . . . . . . . . . . . . . . . . 2 Basic Part Numbers . . . . . . . . . . . . . . . . . . . . 4 Anatomy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Part Number Keys . . . . . . . . . . . . . . . . . . . . . 6 Configuration Options . . . . . . . . . . . . . . . . . 10 Installation Sequence . . . . . . . . . . . . . . . . . . 15 Installation Tooling . . . . . . . . . . . . . . . . . . . 16 Inspection Information . . . . . . . . . . . . . . . . 19 Shaving for Flushness . . . . . . . . . . . . . . . . . 20 Fastener Removal . . . . . . . . . . . . . . . . . . . . . 21

3rd Edition

ASP® Fastening System

PROCESS MANUAL

12

• Holes for ASP® fasteners are “straight”. No potting, bushings, inserts or stepped holes are required.

• There are 3 basic diameters. (Oversize diameters may be available)

Notes to Table: • Countersinks are 100°. • The product is available in tension head (AN509; pin and

sleeve), shear head (NAS1097; pin only) and protruding head (pin and sleeve) configuration.

• Countersink diameter limits shown in the table are theoreti-cal and intended for reference. When countersinking thin face sheets on sandwich panels, care must be taken to c’sink no deeper than necessary.

• Fillet radius figures apply to protruding head and flush head fasteners.

Suggestions for hole preparation and installation practice: • Clamping of the structure with temporary devices is very help-

ful in avoiding sheet separation, burrs/chips between the sheets and hole misalignment.

• Drill speeds are critical to achieve hole quality and productivity, while minimizing operator fatigue.

• Aluminum structure 4,000 to 6,000 RPM are recom-mended.

• For stainless or titanium 300 to 1,000 RPM are recom-mended.

• For Composite structure, carbide drills and c’sink cutters are recommended.

Recommendations for Hole Preparation

Nom Dia

Hole Dia

+.005” -.000”

Recom-mended Drill Size

Fillet Radius (Ref)

C’sink Dia

Tension Head

C’sink Dia

Shear Head

-06 .203” 13/64” .020” .386/.380 .302/.296

-08 .266” Letter “H” .025” .507/.500 .399/.393

-10 .328” 21/64” .030” .634/.626 .479/.472

13

• Lubrication of drills is very helpful in reducing drill wear, burrs and effort. Each shop has its own favorite drill lubes.

• Excessive “push” on the drill motor (dull drill) should be avoided as it can create sheet separation, and burrs and chips between the sheets.

• Hole normality is important. Angularity beyond 2° should be avoided.

• Countersink concentricity is critical, particularly with thin honeycomb face sheets. Generally, countersinks are normal to the structural surface. Flushness or head seating problems are caused by hole angularity beyond the 2° limit. Undersize countersink pilots are the most common cause of eccentricity problems and resulting cosmetics issues.

• These parts are commonly used in honeycomb panels with thin face sheets. Accuracy in countersink depth is critical in avoiding head pull through.

Recommendations for Hole Preparation Cont’d

14

Basic Part Numbers D

esc

riptio

n

Pin

C

on

figu

ratio

n

(spe

cifie

d)

Pin

P

/N

Sle

eve

C

on

figu

ratio

n

(ma

ting

slee

ve) S

lee

ve

P/N

L

oc

k Co

llar

P/N

Do

ub

le F

lush

Fu

ll Sh

an

k 1

00

° Te

nsio

n

Asp

FF

1

00

° Te

nsio

n

Asp

F-S

A

sp-L

C

Do

ub

le F

lush

Fu

ll Sh

an

k 1

00

° Sh

ea

r A

sp1

00

F

10

0° T

en

sion

A

spF

-S

Asp

-LC

Do

ub

le F

lush

Re

du

ce

d S

ha

nk

10

0° T

en

sion

2

Asp

50

9F

1

00

° Te

nsio

n

Asp

F-S

A

sp-L

C

Do

ub

le F

lush

Re

du

ce

d S

ha

nk

10

0° S

he

ar

2A

spF

F

10

0° T

en

sion

A

spF

-S

Asp

-LC

Flu

sh-P

rotr F

ull S

ha

nk

10

0° T

en

sion

A

spF

P

Pro

tr He

ad

2

Asp

P-S

A

sp-L

C

Flu

sh-P

rotr F

ull S

ha

nk

10

0° S

he

ar

Asp

10

0P

P

rotr H

ea

d

2A

spP

-S

Asp

-LC

Flu

sh-P

rotr R

ed

uc

ed

Sh

an

k 1

00

° Te

nsio

n

2A

sp5

09

P

Pro

tr He

ad

2

Asp

P-S

A

sp-L

C

Flu

sh-P

rotr R

ed

uc

ed

Sh

an

k 1

00

° Sh

ea

r 2

Asp

FP

P

rotr H

ea

d

2A

spP

-S

Asp

-LC

Pro

tr-Flu

sh R

ed

uc

ed

Sh

an

k P

rotr H

ea

d

2A

spP

F

10

0° T

en

sion

A

spF

-S

Asp

-LC

Pro

tr-Pro

tr Re

du

ce

d S

ha

nk

Pro

tr He

ad

2

Asp

PP

P

rotr H

ea

d

2A

spP

-S

Asp

-LC

Pro

tr-Pro

tr Fu

ll Sh

an

k P

rotr H

ea

d

Asp

PP

P

rotr H

ea

d

2A

spP

-S

Asp

-LC

P/N

Exa

mp

le fo

r Pin

: 2A

spF

F - D

T0

8 - 0

6

P/N

Exa

mp

le fo

r Sle

eve

: Asp

F - S

- DT

08

P

/N E

xam

ple

for C

olla

r: Asp

- LC

- 2A

C0

8

15

Asp® pins carry the following identification head markings: The Huck symbol as manu-

facturer’s identification.

A letter “F” or “P” to identify the

head style of the mating sleeve

and a grip dash number (Full

shank tension and protruding

head only). Pins and sleeves are identified

with the letters “V” to indicate

Titanium 6AL-4V or “EU” for A-

286 Cres material. No material

letter indicates alloy steel.

The Huck symbol is used for

manufacturer’s identification on

the sleeves also.

Anatomy of Asp® Components

Identification Head Markings

Straight or spiral Lock Grooves

Lock Collar

Break Neck

Pintail with Pull Grooves

AN509 Tension Heads

Threaded Sleeve

F16

EU

Hex Recess (pin)

EU

Driving Recesses (sleeve)

Double Flush AspFF-EU06-16

16

Part Number Logic (Full Shank Pins) (O

) Asp

F F

- V 0

8 - 1

2 A

C

Co

atin

gs: “A

C” in

dic

ate

s NA

S4

00

6 typ

e A

lum

inu

m c

oa

ting

No

lette

r on

Tita

niu

m p

ins in

dic

ate

s no

co

atin

g

N

o le

tter o

n a

lloy ste

el p

ins in

dic

ate

s Ca

d p

latin

g

N

o le

tter o

n A

-28

6 p

ins in

dic

ate

s pa

ssivate

d

Grip

len

gth

in 1

/16

inc

h in

cre

me

nts

Dia

me

ter d

ash

nu

mb

er (e

.g. -0

8 =

.26

3” sh

an

k dia

)

Ma

teria

l: V =

6A

l-4V

Tita

niu

m

DT

= 8

74

0 a

lloy ste

el

EU

= A

-28

6 sta

inle

ss stee

l

Sle

eve

he

ad

style: “F

” = 1

00

° Flu

sh te

nsio

n h

ea

d; “P

” = P

rotru

din

g h

ea

d

Pin

he

ad

style: “F

” = 1

00

° flush

ten

sion

he

ad

; “10

0” =

10

0° flu

sh sh

ea

r he

ad

Ba

sic p

art n

um

be

r for F

ull S

ha

nk fa

sten

er

(O) in

dic

ate

s Ove

rsize re

pa

ir dia

me

ter

17

Part Number Logic (Reduced Shank Pins) (O

) 2A

sp F

F - V

08

- 12

AC

C

oa

ting

s: “AC

” ind

ica

tes N

AS

40

06

type

Alu

min

um

co

atin

g

N

o le

tter o

n T

itan

ium

pin

s ind

ica

tes n

o c

oa

ting

No

lette

r on

allo

y stee

l pin

s ind

ica

tes C

ad

pla

ting

No

lette

r on

A-2

86

pin

s ind

ica

tes p

assiva

ted

Grip

len

gth

in 1

/16

inc

h in

cre

me

nts

Dia

me

ter d

ash

nu

mb

er (e

.g. -0

8 =

.26

3” sh

an

k dia

)

Ma

teria

l: V =

6A

l-4V

Tita

niu

m

DT

= 8

74

0 a

lloy ste

el

EU

= A

-28

6 sta

inle

ss stee

l

Sle

eve

he

ad

style: “F

” = 1

00

° Flu

sh te

nsio

n h

ea

d; “P

” = P

rotru

din

g h

ea

d

Pin

he

ad

style: “5

09

” = 1

00

° flush

ten

sion

he

ad

; “F” =

10

0° flu

sh sh

ea

r he

ad

;

“P

” ind

ica

tes p

rotru

din

g h

ea

d

Ba

sic p

art n

um

be

r for R

ed

uc

ed

Sh

an

k faste

ne

r

(O) in

dic

ate

s Ove

rsize re

pa

ir dia

me

ter

18

Part Number Logic (Sleeves) (O

) Asp

F - S

- V 0

8 A

C

Co

atin

gs: “A

C” in

dic

ate

s NA

S4

00

6 typ

e A

lum

inu

m c

oa

ting

No

lette

r on

Tita

niu

m p

ins in

dic

ate

s no

co

atin

g

N

o le

tter o

n a

lloy ste

el p

ins in

dic

ate

s Ca

d p

latin

g

N

o le

tter o

n A

-28

6 p

ins in

dic

ate

s pa

ssivate

d

Dia

me

ter n

um

be

r (e.g

. -08

= .2

63

” sha

nk d

ia)

Ma

teria

l: V =

6A

l-4V

Tita

niu

m

DT

= 8

74

0 a

lloy ste

el

EU

= A

-28

6 sta

inle

ss stee

l

“S” in

dic

ate

s slee

ve c

om

po

ne

nt

Sle

eve

he

ad

style: “F

” = 1

00

° flush

ten

sion

he

ad

; “P” in

dic

ate

s pro

trud

ing

she

ar

Asp

slee

ve is a

10

0° flu

sh te

nsio

n h

ea

d p

er M

S2

46

94

2

Asp

slee

ve is a

low

pro

file p

rotru

din

g sh

ea

r he

ad

(O) in

dic

ate

s Ove

rsize re

pa

ir dia

me

ter

19

Part Number Logic (Lock Collar) A

sp - L

C - 2

AC

08

Dia

me

ter d

ash

nu

mb

er o

f pin

an

d sle

eve

Ma

teria

l: 2A

C =

22

19

Alu

min

um

M

V =

Tita

niu

m

“LC

” ind

ica

tes lo

ck c

olla

r

Asp

is ba

sic p

art n

um

be

r for b

oth

, ten

sion

an

d sh

ea

r ra

ted

pin

s an

d/o

r slee

ves

110

Configuration Options

AN509 Tension Heads

AN509 Tension Head

Double flush AN509 Tension Heads; Full Shank; P/N family AspFF

Full Shank Pin

Double flush NAS1097/AN509 Heads; Full Shank; P/N family Asp100F

Full Shank Pin

NAS1097 Shear Head

111

Configuration Options

AN509 Tension Head

Flush AN509 Tension Head and Protruding Head; Full Shank; P/N family AspFP

Full Shank Pin

Full Shank Pin

NAS1097 Shear Head

Protruding Shear Head

Flush NAS1097 Shear Head and Protruding Head; Full Shank; P/N family Asp100P

Protruding Shear Head

112

AN509 Tension Heads

Configuration Options

Flush AN509 Tension Heads; Reduced Shank; P/N family 2Asp509F

Flush NAS1097 Shear Head and 509 Tension Head; Reduced Shank; P/N family 2AspFF

Reduced Shank Pin

Reduced Shank Pin

AN509 Tension Head NAS1097 Shear Head

113

Configuration Options

Flush AN509 Tension Head and Protruding Head; Reduced Shank; P/N family 2Asp509P

Flush NAS1097 Shear Head and Protruding Head; Reduced Shank; P/N family 2AspFP

Reduced Shank Pin

Reduced Shank Pin

NAS1097 Shear Head Protruding Shear Head

AN509 Tension Head Protruding Shear Head

114

Configuration Options

Protruding Head and 509 Flush Tension Head; Reduced Shank; P/N family 2AspPF

Protruding Head and Protruding Head; Reduced Shank; P/N family 2AspPP

Reduced Shank Pin

Reduced Shank Pin

Protruding Shear Head

AN509 Tension Head Protruding Head

Protruding Head

115

Installation Sequence

1) Pin inserted into structure. Sleeve started on pin

2) Sleeve tightened with torque con-trolled tool

3) Lock collar is placed over pintail

4) Power tool is applied to the pintail. Lock collar is swaged into place. 100% of the swage load is reacted in the fas-tener, none is applied to the sandwich panel

5) Pintail separates. Installation complete

Caution: Over torquing can crush the honeycomb

116

Installation Tooling

Installing the sleeve component: • Sleeve will thread freely onto the pin. • Sleeve may be tightened using a driver bit by hand or

with a torque controlled power tool. Care must be taken not to over torque the sleeve to avoid crushing of soft cores or the honeycomb sandwich. AFS does not recommend specific tightening torque values. User determines torque based on desired compression of the specific joint geometry and materials.

• The pin head may be retained against rotation with a hex key.

• The screw driver bit is a special part as shown in the table below:

Dia AFS P/N

-06 106524

-08 106525

-10 107735

Caution: Screw driver bit may cam out if over torqued.

117

Swaging the lock ring with straight on access: • After the sleeve component is tightened to the desired torque, the lock collar is placed onto the pintail, the

pintail is engaged with a power tool and the lock collar is swaged in place. This locks the components together mechanically and assures that they function as a unit.

• In 95% of all cases, there is access for straight on tools. Recommended power tools for straight access are AFS ergonomic Models 202, 2012 and 244. (Caution: Model 2012 pulls –06 and some -08 dia only!)

• Nose tools attaching to all these tools are shown in the table below. All of these nose attachments fit directly onto Models 202, 2012 and 244 without adapters.

Installation Tooling Cont’d

Dia Straight-On Nose Attach

-06 99-2642

-08 99-2645

-10 99-2648

Note: The tools and nose attachments shown on this page are only the most basic styles. For other available configurations refer to www.alcoafasteners.com.

Model 244 Pneudraulic Tool

118

Swaging the lock ring with limited access: • After the sleeve component is tightened to the desired torque and the lock collar is placed in position, the

pintail is engaged with a power tool and the lock collar is swaged in place. This locks the components together mechanically and assures they function as a unit.

• In some cases off-set tools are required for limited access. Recommended power tools for off-set access are AFS ergonomic Model 244OS or all-hydraulic Model 206-375.

• Nose tools attaching to all these tools are shown in the table below. All of these nose attachments fit directly onto Models 244OS and 206-375 without adapters.

Installation Tooling Cont’d

Dia Offset Nose

Attach

-06 99-3728

-08 99-3729

-10 99-3730

Note: The tools and nose attachments shown on this page are only the most basic styles. For other available configurations refer to www.alcoafasteners.com.

Model 206-375

Hydraulic Tool

Model 244 OS Pneudraulic Tool

119

Prior to Shave

Pin Protrusion

Min Max

–06 (13/64) .020” .107”

-08 (17/64) .030” .119”

-10 (21/64) .035” .129”

Fastener Diameter

Collar Flash

Max Flash Height

Max Collar Height

–06 (13/64) .020” .010”

-08 (17/64) .030” .013”

-10 (21/64) .040” .016”

Fastener Diameter

The fastener must be checked for the limits in pin height, collar height and collar flash prior to shaving. After protrusion verification, pin and collar may be shaved flush to the top of the sleeve head.

Pin Protrusion Collar Flash Collar Height

Lock Groove

120

Clean up Shave

The pin is designed to break approxi-

mately .030” to .090” above flush, depend-

ing on the actual thickness of the struc-ture. On countersink

head parts, where aerodynamic flush-

ness is required, shaving of the pro-truding pin area is

required. Since the pin material is hard,

high speed rivet shav-ers (20,000RPM) with carbide tipped cutters

are most effective.

As installed Asp® fastener

Asp® fastener shaved flush

121

Fastener Removal

Since pin and sleeve are locked

together with a swaged lock collar,

drilling out of the lock collar is

required.

1) Using a guide bushing and a drill

slightly smaller than the hole

diameter, the lock collar is drilled out

2) Remnants of lock collar are

pried out, sleeve is unthreaded and pin

is tapped out of the hole.

122

AFS ASP® Fasteners and Installation Tools

are offered through AFS authorized Distributors

Alcoa Fastening Systems

Aerospace Products Carson Operations

Tucson, AZ 1 800 421 1459

Installation Tools

Commercial Products Kingston Operations

Kingston, NY 1 800 431 3091

For a list of authorized Distributors, please call

1 800 421 1459

Or visit www.alcoafasteners.com

Alcoa Fastening Systems © Printed in USA 2005

The purpose of this manual is to provide general guidelines regarding the use of Alcoa Fastening Systems ASP® fasteners. In the event of conflict between this manual and the user’s company policies, the user should refer to his/her own company’s policies.

For Fastener and Installation Tooling Info, Please visit www.alcoafasteners.com