Thread Forming Technology for Light Metals

Thread Forming Technology for Light Metals

Cost & Design Savings Advantages High joint strength Safety against dynamic loads Consistently high clamp loads Self-locking vibration resistance Easy lead-in, low drive torque High stripping torque Opportunity to reduce installation depth Compatible with machine screw threads 1 % Hole Prep Costs Drilling Thread Cutting Cleaning 8 % 6 % 4 % 2 % Metric Screw ALtracs Plus Costs for assembly Costs for handling / hole preparation Costs for fastener ALtracs Plus vs. Machine Screw Compared to machine screws, cost savings of up to 4% can be achieved with thread forming fasteners. Self-tapping fasteners can be directly assembled into cast holes as opposed to the pre-drilling, thread tapping and subsequent cleaning of metal chips to prepare the hole to receive a machine screw. All these costs for hole preparation can be saved. 2

Characteristics, Benefits and Features 6 33 6 Thread The 6 degree fl ank angle of a standard thread forming or machine screw has reduced shear area between threads. A Nut ~ 1.5 A Screw 1 22 11 Load Flank Back Flank ALtracs Plus Thread The unique ALtracs Plus thread geometry provides greater shear area between threads resulting in higher pull out and strip out performance. A Nut ~ 3 A Screw 1 33 Flank Root Support Flank Geometry The smaller 33 degree fl ank angle of the ALtracs Plus fastener creates a stronger internal thread in the mating material than screws with a 6 degree fl ank angle. The larger tooth area of the female thread results in a more robust joint. The asymmetric fl ank design optimizes material displacement during the thread forming process and ensures maximum thread engagement. The profi le of the lower thread fl ank delivers increased strength which is critical for high load joints. Thread Cross Section The round body shape provides greater thread engagement compared to trilobular fasteners. This provides improved clamp retention and better long term joint behavior. Thread Forming Region The tapered thread forming lead-in with sharp crested threads helps to minimize debris generation and lowers drive torque. ALtracs Plus Thread Machine Screw Thread Compatibility The ALtracs Plus is designed to be completely interchangeable with machine screws. Therefore, ALtracs Plus can be used in existing tappeachine screw threads of the same size or alternately, a machine screw of the same size can be used in the thread formed by an ALtracs Plus fastener, eliminating any fi eld service concerns. 3

D/ h14* K js14* R max. 4xP L t ±1xP P L js15* t D/ h14* max. 4xP L t ±1xP P L js15* c t D/ h15* K js14* 9 R max. 4xP L t ±1xP P L js15* s t Fastener Standards D/ h15* 2 ±5 s K h14* R R max. 4xP L t ±1xP P L js15* d 2 d 2 d 2 d 2 WN 5152 WN 5151 WN 5154 WN 5117 HEX FLANGE FLAT ROUND WASHER PAN Semblex ALtracs Plus Nominal-Ø 16 18 2 22 25 3 35 4 5 6 [7 8 [9 1 12 14 External thread-ø 1.6 1.8 2. 2.2 2.5 3. 3.5 4. 5. 6. 7. 8. 9. 1. 12. 14. Thread core-ø d 2 1.12 1.32 1.45 1.61 1.88 2.3 2.66 3.2 3.87 4.59 5.56 6.23 7.2 7.86 9.86 11.86 Thread pitch P.35.35.4.45.45.5.6.7.8 1. 1. 1.25 1.25 1.5 1.75 2. Thread run-out X max.7.7.8.9.9 1. 1.2 1.4 1.6 2. 2. 2.5 2.5 3. 3.5 4. WN 5152 Head-Ø D 4. 4.4 5. 6. 7. 8. 1. 12. 16. Head Height K 1.5 1.6 2. 2.4 2.7 3.1 3.8 4.6 6. Radius R max.3.3.3.4.4.5.5.6.8 / AUTOSERT 6IP 7IP 8IP 1IP 15IP 2IP 25IP 3IP 4IP A Ref 1.75 2.5 2.4 2.8 3.35 3.95 4.5 5.6 6.75 Insertion Depth t min..65.7.9 1.1 1.1 1.5 1.75 2.2 2.6 max..85.85 1.1 1.3 1.4 1.8 1.9 2.6 3.1 WN 5151 Head-Ø D 5. 5.5 6. 7.5 9. 1. 11.5 14.5 19. Head Height K 1.5 1.6 2. 2.25 2.5 2.9 3.4 4.4 5.7 Washer Thickness s.6.6.6.7.8 1. 1.2 1.6 2. Radius R max.3.3.3.4.4.5.5.6.8 / AUTOSERT 6IP 7IP 8IP 1IP 15IP 2IP 25IP 3IP 4IP A Ref 1.75 2.5 2.4 2.8 3.35 3.95 4.5 5.6 6.75 Insertion Depth t min..65.7.9 1. 1.1 1.3 1.5 1.9 2.6 max..85.85 1.1 1.3 1.4 1.65 1.85 2.3 3.1 WN 5154 Head-Ø D 3.8 4.4 4.7 5.5 7.3 8.4 9.3 11.3 15.8 Cyl. Head Height c max.35.45.55.55.65.7.75.85.95 Radius R max.5.6.7.8.95 1. 1.3 1.6 2. / AUTOSERT 6IP 7IP 8IP 1IP 15IP 2IP 25IP 3IP 4IP A Ref 1.75 2.5 2.4 2.8 3.35 3.95 4.5 5.6 6.75 Insertion Depth t min..5.7.7.8.95 1.1 1.25 1.55 1.9 max..65.85.9 1.5 1.2 1.45 1.6 2. 2.4 WN 5117 Head-Ø D 11.5 14. 18. Width Across Flats SW 8. 1. 13. Head Height K 4.8 5.5 7.5 Washer Thickness s 1. 1.1 1.2 Radius R max.4.5.7 4

Fastener Standards Nominal Value [mm Tolerance Range over 3 over 6 over 1 over 18 over 3 over 5 over 8 to 3 to 6 to 1 to 18 to 3 to 5 to 8 to 12 h 14 -.25 -.3 -.36 -.43 -.52 h 15 -.4 -.48 -.58 -.7 -.84 js 14 ±.12 ±.15 ±.18 js 15 ±.2 ±.24 ±.29 ±.35 ±.42 ±.5 ±.6 ±.7 Semblex ALtracs Plus 16 18 2 22 25 3 35 4 5 6 [7 8 [9 1 12 14 External thread - Ø 1.6 1.8 2. 2.2 2.5 3. 3.5 4. 5. 6. 7. 8. 9. 1. 12. 14. External thread - Ø tolerance ±.4 ±.4 ±.4 ±.4 ±.5 ±.5 ±.5 ±.6 ±.6 ±.7 ±.7 ±.7 ±.9 ±.9 ±.9 ±.9 Core Thread - Ø tolerance +.12 +.12 +.12 +.12 +.14 +.14 +.14 +.16 +.16 +.18 +.18 +.18 +.22 +.22 +.22 +.22 Partial Thread L - tolerance ±.35 ±.35 ±.4 ±.45 ±.45 ±.5 ±.6 ±.7 ±.8 ±1. ±1. ±1.25 ±1.25 ±1.5 ±1.75 ±2. For full thread, please note thread run-out x max. Manufacturing range and thread length: (Figures in dark gray field = thread length). Partial thread length for countersunk heads on request. Semblex ALtracs Plus 16 18 2 22 25 3 35 4 5 6 7 8 9 1 12 14 [mm 1.6 1.8 2. 2.2 2.5 3. 3.5 4.5 5. 6. 7. 8. 9. 1. 12. 14. Length L [mm 3.5 ±.24 3.5 4 ±.24 4 4 4 4.5 ±.24 4.5 4.5 4.5 4.5 5 ±.24 5 5 5 5 5 6 ±.24 5 6 6 6 6 6 7 ±.29 5 6 6 7 7 7 7 8 ±.29 5 6 6 7 8 7 8 8 9 ±.29 5 6 6 7 8 7 9 9 1 ±.29 5 6 6 7 8 9 9 1 1 12 ±.35 5 6 6 7 8 9 11 1 12 12 14 ±.35 5 6 6 7 8 9 11 12 12 14 14 16 ±.35 5 6 6 7 8 9 11 12 15 14 16 16 18 ±.35 6 6 7 8 9 11 12 15 14 16 18 18 2 ±.42 6 7 8 9 11 12 15 18 16 19 2 2 22 ±.42 7 8 9 11 12 15 18 21 19 21 22 25 ±.42 8 9 11 12 15 18 21 24 21 23 25 3 ±.42 9 11 12 15 18 21 24 27 23 28 3 35 ±.5 11 12 15 18 21 24 27 3 28 32 4 ±.5 12 15 18 21 24 27 3 36 32 5 ±.5 15 18 21 24 27 3 36 42 6 ±.6 18 21 24 27 3 36 42 7 ±.6 21 24 27 3 36 42 8 ±.6 24 27 3 36 42 9 ±.7 27 3 36 42 1 ±.7 3 36 42 = min. length (countersunk head) Length L +.6 ) = max. length with alternative thread forming zone available Manufacturing range does not necessarily indicate stock items 5

Design Guidelines ca. 1.8 x - Al/Zn ca. 2 x - Mg 3 d t t e = Nominal Diameter d t = Hole Diameter Top = Hole Diameter Middle t e = Insertion Depth All indications in mm. For pre-hole design, please choose or d t ~.25 x max 1.5.5 x t e t e Recommendations for cast, drilled, punched or extruded pre-holes in aluminum, magnesium, zinc, copper, brass and bronze up to a hardness of 14HB Hardness Al, Zn, Cu up to 55 HB Mg up to 9 HB Al, Zn, Cu 55-115 HB Al, Zn, Cu 115-14 HB t e 1. x 1.5 x 2. x.5 x 1. x 1.5 x 2. x.5 x 1. x 1.5 x 1.6 1.46 1.48 [1.51 1.8 1.63 1.65 [1.69 2. 1.83 1.85 [1.89 2.2 1.98 2. [2.4 2.5 2.2 2.25 [2.3 3. 2.65 2.7 [2.76 3.5 3.1 3.15 [3.22 4. 3.55 3.6 [3.68 5. 4.4 4.5 [4.6 6. 5.3 5.4 [5.52 7. 6.2 6.3 [6.44 8. 7. 7.2 [7.36 9. 7.9 8.1 [8.28 1. 8.8 9. [9.2 12. 1.6 1.8 [11.4 14. 12.3 12.6 [12.87 1.46 1.48 1.49 [1.52 1.63 1.65 1.67 [1.71 1.83 1.85 1.87 2.3 [2.9 2.3 [2.37 2.75 [2.83 3.2 [3.29 3.65 [3.75 4.6 [4.73 5.5 [5.66 6.4 [6.58 7.4 [7.61 8.3 [8.54 9.2 [9.46 11. [11.31 12.9 [13.27 [1.91 1.98 2. 2.3 [2.7 2.2 2.25 2.3 [2.35 2.65 2.7 2.75 [2.81 3.1 3.15 3.2 [3.27 3.55 3.6 3.65 [3.73 4.4 4.5 4.6 [4.7 5.3 5.4 5.5 [5.62 6.2 6.3 6.4 [6.64 7. 7.2 7.4 [7.56 7.9 8.1 8.3 [8.48 8.8 9. 9.2 [9.4 1.6 1.8 11. [11.24 12.3 12.6 12.9 [13.17 1.48 1.49 1.51 [1.54 1.65 1.67 1.68 [1.72 1.85 1.87 1.89 [1.93 2. 2.3 2.5 2.35 [2.42 2.8 [2.88 3.25 [3.34 3.7 [3.8 4.7 [4.83 5.6 [5.76 6.6 [6.78 7.5 [7.71 8.4 [8.64 9.4 [9.66 11.2 [11.51 13.2 [13.57 [2.9 2.25 2.3 2.35 [2.4 2.7 2.75 2.8 [2.86 3.15 3.2 3.25 [3.32 3.6 3.65 3.7 [3.78 4.5 4.6 4.7 [4.8 5.4 5.5 5.6 [5.72 6.3 6.4 6.6 [6.74 7.2 7.4 7.5 [7.66 8.1 8.3 8.4 [8.59 9. 9.2 9.4 [9.6 1.8 11. 11.2 [11.44 12.6 12.9 13.2 [13.47 6

Material ALtracs Plus fasteners are manufactured from carbon steel and neutral hardened to HRC 33-39. Alternate materials available upon request. Coatings & Platings A wide variety of plating and coating options can be applied to meet specific customer requirements for corrosion resistance and joint performance. Design Guidelines Lubrication Lubrication is suggested for all thread forming applications in light metals. Contact our Sales or Engineering Services team for recommendations. Specials / Examples ALtracs Plus fasteners can be manufactured with many popular internal and external drive systems to meet assembly requirements. Theoretical Assembly Parameters ALtra CALC validates applications, reducing engineering and development time and cost. Application and test assembly examples populate database Parameters help the designer to understand predicted joint behavior of the ALtracs Plus fastener TORX PLUS and AUTOSERT are registered trademarks of Acument Intellectual Properties, LLC in the United States and other countries. ALtracs Plus is a registered trademark of EJOT Verbindungstechnik GmbH & Co. KG. 7

Engineering Services Design & Technical Assistance VA/VE Project Support Product Engineering Samples Training Programs On-Site Technical Support Application Testing Product Teardowns Value Added Services Technical Sales Team Focused Manufacturing & Logistics Facilities Integrated Supply Base Sourcing Solutions Customized Labeling and Packaging EDI Capable Global Partnerships - North America, Europe & Asia Certifications & Accreditations Registered to ISO/TS 16949 ISO 91 ISO 141 Final Inspection Laboratory Cert. #794.1 Applications Laboratory Cert. #794.2