@ AIPI 01-02-015

Issue 2
AIRBUS Page 1 of 16
April 2010

AIPI

Airbus Process Instruction

INSTALLATION OF BLIND BOLTS THREADED TYPE

© AIRBUS – 2008 AIPI 01-02-015

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Contents

1. GENERAL 3
1.1. Purpose 3
1.2. Normative references 3
1.3. General description 4
1.4. Limitations 4
2. MEANS TO BE EMPLOYED AND SHOPFLOOR CONDITIONS
5
2.1. PRODUCTS AND MATERIALS 5
2.2. TOOLS & MACHINES 5
2.3. SHOPFLOOR CONDITIONS 6
3. PROCESS 6
3.1. PREPARATION OF THE WORK 6
3.2. DESCRIPTION OF THE OPERATIONS 8
3.3. FINISHING OF FASTENERS 8
4. PROCESS QUALITY CHECK AND FOLLOW-UP 9
4.1. PRE-OPERATION CHECK 9
4.2. SERIAL PRODUCTION CONTROL 10
4.3. REMOVAL OF FAULTY BLIND BOLTS 13
4.4. OVERSIZE FASTENERS 13
5. MONITORING PROVISIONS 14
6. HEALTH, SAFETY AND ENVIRONMENT 14
7. ANNEX 15

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1. GENERAL

1.1. Purpose

The purpose of this specification is to give the assembly and manufacture requirements to
manufacturers. Although the essential requirements of a process are defined, the specification does not
give complete in house process instructions, these shall be given in the manufacturers detailed process
instruction and supporting work instructions.

The purpose of this instruction is to provide all of the recommendations and general rules necessary to
the correct installation of Blind bolts “Threaded Type”

1.2. Normative references

ASNA0081 Blind Bolts with Self-Locking 100° Countersunk Head

ASNA0082 Blind Bolts with Self-Locking Hexagonal Head
ABS0254 Bolt, Blind, Protruding Head, Self-Locking
ABS0255 Bolt, Blind, Hex Head, Self-Locking
ABS0256 Bolt, Blind, 100° Flush Tension Head, Self-Locking
ABS0257 Bolt, Blind, 130° Flush Shear Head, Self-Locking
NAS1671 Fastener – Blind, Internally Threaded, External Sleeve, High
Temperature, Protruding Head, Self-Locking (3)

NAS1672 Fastener – Blind, Internally Threaded, External Sleeve, High

Temperature, Flush Head, Self-Locking
AIPI 01-02-003 Preparation of Holes in Metallic Materials
AIPI 01-02-005 Preparation of Holes in Fibre Reinforced Plastic (FRP) and Mixed
(FRP/Metal) assemblies for Fastening.
AIPI 01-02-017 General Assembly and Installation of Fasteners
AIPI 05-05-001 Sealing of Aircraft Structures
AIPI 05-05-004 Wet installation of fasteners
AIPI 09-01-002 Cleaning with solvents
AP2039 Technical Qualification of Standard Parts
AP2253 Technical Qualification of Manufacturing Processes

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1.3. General description

The blind fasteners components are:

- a corebolt
- a body,
- a sleeve.
Some other elements can be added:
- (an installation nut,)
- (an insert,)

Treaded Corebolt
Pull stem

Thread

Installation nut

Body
Breakoff groove
Locking groove

Insert
Locking
Sleeve collar

The threading of the corebolt forms the sleeve on the back side of the assembly and breaking-off
the corebolt.

1.4. Limitations

The limitations described in AIPS 01-02-015 shall be taken into account, except if other
indications are specified in drawing or in the applicable engineering documentation.

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2. MEANS TO BE EMPLOYED AND SHOPFLOOR CONDITIONS

2.1. PRODUCTS AND MATERIALS

The fasteners which can be used in shop floor are listed in §1.2.

Remark : specific precisions Visu-Lok ASNA0081 and ASNA0082:

There are 3 types of self-locking for ASNA0081/0082 :

ASNA0081 / ASNA0082 : Type1 = Type W

ASNA0081A / ASNA0082A : Type2 = Type Y and Z
ASNA0081B / ASNA0082B : Type3 = Z

Type 1 : W : Type 2 : Y and Z : Type 3 : Z :

self-locking self-locking on 3 points in 120° self-locking on 3 points in 120° on the body
realized on the on the body and with a Nut
thread by
deformation

Braking
Nut Braking

2.2. TOOLS & MACHINES

Typically, the installation is realized with :

- pneumatic screw driver eg

247,6

139,7

∅B
Immobilisateur Entraîneur Accouplement de torquage

Note : the maximum rotation speed is 540rpm.

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- hand wrenches eg :

56 à 60

30 à 35
Entraîneur
Douille

∅ 21

146 (série 718) 185 (série 729)

The implementation of the manufacturing tools and equipment is under the responsibility of each
Department in charge.
This equipment shall be approved and calibrated according to Quality Insurance Procedure.
This validated equipment must meet the requirements of AIPI01-02-015
For workshop/process qualification, the workshop to be qualified must prove that it meets the
requested requirements in AIPS01-02-015.

2.3. SHOPFLOOR CONDITIONS

The assembly operations do not claim specific conditions.

However, the use of sealant not polymerized during the assembly operations must verify the
conditions described in AIPI05-05-001 and AIPI 05-05-004.

3. PROCESS
3.1. PREPARATION OF THE WORK

3.1.1. Hole preparation

Holes shall be drilled, countersunk and deburred to the requirements in AIPS 01-02-003 for metallic
structure or AIPS 01-02-005 for CFRP and hybrid structure.

3.1.2. Hole/countersink geometry

Holes and countersinks geometries shall meet the requirements defined in ABS1707.

Holes diameter shall meet those indicated in ABS1707 or in AIPS 01-02-015 (whether not included in the
first one).
Drawings or applicable documentation shall indicate the type of tolerance to use as per ABS1707 and/or
AIPS 01-02-015.

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3.1.3. Surface finish

Unless specified otherwise on drawings, the surface finish of both the hole and the countersink shall meet
the requirements in AIPS 01-02-003 for metallic structure or AIPS 01-02-005 for CFRP and hybrid
structure.

3.1.4. General aspects of the fasteners

For the contact between two parts to be assembled, the holes cleanliness and the choice of length
fasteners, see AIPI 01-02-017.

For the free distance behind the structure to other component close to it, see hereafter (AIPS 01-02-015).

3.1.5. Use of washers

The use of washers under the formed head (blind side) is not allowed.
Exceptionally and only for grip length adjustment of protruding-head blind bolts, it could be accepted to
install under concession one washer with a maximum thickness of 1,6 mm. This washer must to be placed
under the manufactured head (For more details and material choice, see AIPS 01-02-015).

3.1.6. Wet installation

If wet installation is required, see AIPS 05-05-004.

Before cure time of the sealant , check the bolt head seating with feeler gauge

3.1.7. Assembly process on sealant

To ensure a correct flow of the sealant (“Contact Metal-Metal”) the procedure of temporary fastening will be
as follows:

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- installation of the sealant
- installation of temporary fasteners in every holes (100%)
- removal of one temporary fastener out of two
- installation of fasteners
- removal of remaining temporary fasteners
- installation of fasteners

Note: Fasteners installation shall be carried out within the sealant service life-time. Excessive sealant
squeeze-out of the material, which might soil the tools when performing this operation has to be avoided.

3.2. DESCRIPTION OF THE OPERATIONS

This process installation is only valid for fasteners equiped with installation nut :
1. Insert the fastener into the bore and place the installation means over the fastener. The
hexagon of the nut inside the hexagon of the installation tool.
Note: It is also possible to insert the fasteners into the equipment first and then into the hole.
2. Start of turning of fastener stem. The hexagon prevents the fastener from rotating. The bulb
starts to form. During this operation, take special care on the correct support of the tooling.
3. Fastener bulb has been formed.
4. Fastener installation completed and stem broken off.

The tool for installation must be maintained in the axis of the fastener in order to avoid any bending stress in
the fastener.

3.3. FINISHING OF FASTENERS

If the possible protrusion of the fastener corebolt is not allowed due to aerodynamic requirements
(see AIPS 01-02-015, paragraph 4.2.4.1, figure 6 - countersunk head type, as detail), even when meeting
the requirements in this document, its shaving can be performed until meeting drawing requirements or
applicable documentation (minimum value has not to be exceeded).
This machining operation has to be performed after checking the corebolt break off limits as indicated
in AIPS 01-02-015 paragraph 4.2.4.1.
Care shall be taken to avoid damage to the surface of the manufactured fastener head, as well as the
structure surface.
Cracks on the head surface as consequence of the shaving operation are unacceptable.

The milling system shall not produce rotation of the spindle in order to avoid loss of pretension (eg :
no use of left turning tool).
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Precision:
Trimming of fastener heads is strictly forbidden. Only trimming of internal break off is authorized.
Method:
The trimming operation can be performed with a carbide cutter:
a) End cutter.
b) Side cutter (e.g.: portable "RECOULES" machine, type: 702.05.005).

Important remark :

If it is required by the applicable drawings and in general whenever possible, the surface of the
countersinking of the hole as well as the fastener head and corebolt break -off area once installed, will
be duly protected against corrosion, especially when metallic materials and/or alloy steel fasteners are
used. When there are electrical conductivity requirements, applicable engineering documents or
process specifications have to be followed.

The system for corrosion prevention to be selected shall be in compliance with the requirements of the
specific program and/or applicable documentation (drawings, Airbus directives, etc.).

4. PROCESS QUALITY CHECK AND FOLLOW-UP

4.1. PRE-OPERATION CHECK

4.1.1. Visual check of fasteners before installation

The fasteners delivered to the assembly lines must remain in their original packaging, the packaging will be
marked with the supplier's manufacturing batch No..
Visually inspect the fasteners before installing them in the bores:
- signs of corrosion unacceptable,
- major defects on fastener unacceptable (crack, etc.),
- presence of a lubricating product.

4.1.2. Grip length

The grip length must be realized at the axis of the hole by using gauge.

When collars are installed against slopes, the measurement is realized in the plane A-A (according to figure).

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4.2. SERIAL PRODUCTION CONTROL

The following factors will be taken into account for the acceptability of the installed fasteners.
- Dimensional finish of the formed head.
- Cracks.
- Gaps.
- Protruding and sinking of the fastener core bolt break-off limits.
- Seating of the manufactured head and formed head.
- Concavity, and sinking or maximum protuberance of the countersunk head

For the typical installation defects, see Annex A1 of AIPS 01-02-015.

For all the values about inspection requirements, see AIPS 01-02-015.

4.2.1. Dimensional finish of the formed head

When formed head is visible, it is forbidden to have gap between formed head and the part to be
assembled.
Visual inspection and caliper gauge must be used to control the form and dimensional finish of the formed
head (Values in AIPS 01-02-015)

4.2.2. Cracks

All fasteners components shall be free of cracks in any direction or location.

This is checked by visual inspection.

4.2.3. Gaps

The gap between the parts (AIPS 01-02-015) is verified by cross section during the Qualification Process.

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For dimpled sheets, the separation is checked by using a feeler gauge.

4.2.4. Position of the Corebolt. Break off limits.

See the maximum allowable distance of the corebolt fracture surface in Tables 8 to 11 of the AIPS 01-02-
015 (the value “x” depends of the fastener used).

To check this measure, use gauges:

Gauges:
To conduct the break off check, place the gauge on the installed fastener as shown above.

High break off check:

The two lugs of the gauge must pass over each side of the screw. If the gauge can rock, break off has been
made too high.

Low break off check:

Repeat the procedure using the "low break off" end as shown. If the gauge does not rock, break off has
been made too low.

High break off Low break off High break off Low break off
check. check. check. check.
The gauge must The gauge must The gauge must The gauge must
not rock. rock. not rock. rock.

The mini and maxi value of the gauge must be in accordance with AIPS 01-02-015 for each fasteners (the
value depends of the fastener used)

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4.2.5. Seating of the manufactured head and formed head

The following has to be checked (values in AIPS 01-02-015)

- Maximum inclination angle of the hole.

- Maximum angle of the countersunk axis.
- Eccentricity of the countersunk and fastener axis.
- Misalignment between hole axis and countersunk axis.

-The formed head (blind side) must present a complete and symmetrical shape. See typical defects
and their acceptability criteria in Annex A and B.
-No gaps between the formed head (blind side) and the surface of the structure are allowed.
-The maximum sinking or protuberance values of the countersunk head shall accomplish the
requirement specified in drawings or applicable engineering documents, according to each program.
-Shaving of the fastener head to accomplish this requirement is not allowed.
-If the head of the fastener shows a concave shape after the installation, this may be an indication of
poorly made countersink or a metallurgical flaw in the fastener head. This kind of defect is unacceptable.
This can be checked by using a feeler gauge.

4.2.6. Installation on slope

Shop head side gradient must be ≤ 5°

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4.3. REMOVAL OF FAULTY BLIND BOLTS

For the process to removal faulty blind bolts, see AIPS 01-02-015.
Each method and means must be validated by the departments in charge.
The first step is to drill the centre part of the fastener but not the total diameter to avoid enlargement
of the hole (see table under) :

Ø of the fastener (mm) Max Ø of the cutter

3,97 3,6
4,8 3,97
6,3 5,16
7,9 6,35
9,49 7,14

Special tools (different for each type of fastener and diameter), will be used to perform this operation.
Usually these tools have a drill guide at each end, one for a pilot drill, the other guide for a final
dimension drill :

Special care must be taken to avoid rotation of the fastener during drilling.
Note: Do not drill through entire fastener nut body to avoid enlargement of hole.

The second step is to push the drilled fastener with a punch and remove the head from its housing.
Take the necessary precautions in order not to damage the receiving hole wall with the knockout punch.

4.4. OVERSIZE FASTENERS

After removal of the defective fastener, if the hole is not damaged (without scratches and cracks) and within
tolerances, replace by a new fastener as initially planned.
If the hole is damaged or outside tolerances, replace by an oversize fastener.
The oversize tolerances are given by ABS1707.

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5. MONITORING PROVISIONS

The Quality supervisor must check for correct application of the Quality Assurance provisions defined
by each Shop-floor/Site and in accordance with 6.3 AIPS01-02-15.

The surveillance plan will be drawn up taking into account the parameters to be monitored in the
process used.

Refer to the workshop/process QTPs (Qualification Test Program) to define the monitoring provisions;
local entity quality is responsible for monitoring frequency.

6. HEALTH, SAFETY AND ENVIRONMENT

Apply the local safety regulations.

It is in the responsibility of the user of this specification to apply appropriate safety and health
practices and to determine the applicability of regulatory limitations prior to use.

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7. ANNEX

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RECORD OF REVISIONS

Issue Date Modified pages Description and reason for change

Issue 1 Oct 2008 Creation
Issue 2 April 2010 15/16 Appendix 7, Annex added

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