DS-MAY26-PG24+25_Layout 1 11/05/2026 11:22 Page 3
FASTENINGS & ADHESIVES
PRODUCTS lightweight aluminium thread inserts for plastics
New from Spirol are the Series INS19, INS20, INS29, and INS30 aluminium thread inserts for plastics, which complement the existing brass product line. These are suitable for the most commonly used
installation methods, including Moulded-In, post-mould (cold) Press-In, and Heat/Ultrasonic installation. Heat and ultrasonic installation methods locally re-melt the surrounding plastic, enabling improved material flow into the Insert’s undercuts and knurls, increasing torque resistance and pull-out performance in the plastic assembly compared to Press-In Inserts. Aluminium provides significant weight reduction,
HOw DEEP ROllING HElPS ExPANSION bOlTS wITHSTAND AVIATION DEmANDS
Securing vital components such as engine mounts in aviation, expansion bolts need to withstand extreme vibrations and thermal loads, and meet the highest safety requirements. Titanium is a popular material in this industry because it is lightweight, with a strength of 1,600 MPa and a hardness of 49 HRC. But these properties make machining challenging. Titanium components must also be absolutely fail-safe, so manufacturers look
for alternative solutions that improve both strength and cost-effectiveness. However, a customer project by ECOROLL shows that, with the right tool and process parameters, titanium expansion bolts can be processed in just 28 seconds to reliably achieve the required service life. ECOROLL relies on deep rolling (also called roller burnishing), a forming process
that does not require any material removal and specifically strengthens the subsurface area of the component. In this specific application, the HG6-9 tool was used. The rolling force generates optimum surface pressure and applies maximum compressive residual stresses to the subsurface area without damaging the material. The selected feed rate ensures sufficient coverage of the surface while maintaining high process efficiency. The result: A homogeneous compressive residual stress state in the subsurface area, which prevents microcracks and increases fatigue strength by up to 100%. As an application example, an aerospace supplier found that its titanium expansion
bolts met the mechanical requirements but did not consistently achieve the required fatigue strength. Deep rolling with ECOROLL resulted in: 100% fatigue strength; 25% cost reduction – less tool wear meant less rework; 30% time savings as the processing time was reduced from over 40 seconds to 28 seconds; and lightweight construction compatible: No additional material usage, no weight increase. According to the customer, deep rolling not only ensured fatigue strength, but
also significantly reduced manufacturing costs, making the process an integral part of production today. So, with expansion bolts in aviation needing to be absolutely reliable – with
minimum weight and maximum cost-effectiveness – deep rolling with ECOROLL tools offers a proven superior solution, the company states.
ecoroll
www.ecoroll.de/en/ecoroll.html high performance aerospace fastening solutions
Fasteners are essential components for aircraft, and these need to withstand high speeds, intense vibration, and rapid shifts in temperature. In fact each fastener plays a critical role in maintaining structural integrity. Ateliers de la Haute Garonne (AHG) is
a leader in aerospace fastening solutions and specialises in the production of high- performance rivets, threaded fasteners, bolts, screws and lockbolts which are designed to meet the uncompromising demands of modern aircraft manufacturing and maintenance. AHG’s vertically integrated manufacturing approach allows complete control of quality
www.designsolutionsmag.co.uk
across every stage of production, ensuring that each fastener delivers exceptional strength, precision and reliability. They are engineered for structural integrity and durability, supporting applications across airframes, composite assemblies, and critical load-bearing components. As an authorised partner,
Aerco stocks and supplies AHG’s comprehensive range of aerospace fasteners, including solid rivets, structural fasteners, aerospace screws, lockbolts, and collars.
approximately 1/3 the weight of brass, making it an ideal choice for lightweight applications and weight-sensitive assemblies. In addition, 2024 aluminium is a lead-free alloy, supporting evolving environmental, health and safety requirements across global markets. Its galvanic properties also provide increased application flexibility when mating with dissimilar materials compared to traditional brass Inserts. The high strength of 2024 aluminium enables improved
joint integrity with less thread engagement, while delivering enhanced load-bearing capability. These attributes can contribute to more efficient designs, reduced assembly complexity, and improved overall performance.
spirol
www.spirol.com
aerco
https://aerco.co.uk/
mAY 2026 design solutions 25
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