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84 THE DISTRIBUTOR’S LINK LAURENCE CLAUS HOW FASTENERS ARE MADE - PART 2: HOT HEADING AND SCREW MACHINING from page 8 But how much heat is needed and what is the difference between warm and hot forming? Naturally, some contemplate that question and reply that the answer is obvious, “it’s the temperature.” Of course, they are correct, the discriminator between warm forming and hot forming is simply the magnitude of the temperature. However, in technical terms it is not that simple. A more precise answer to that question would be that the process temperature is either above or below some “critical temperature.” In fact, warm forming is conducted below a critical temperature and hot forming above it. What, though, is a critical temperature? The answer to this will vary from material to material but generally means a temperature where either an internal transformation occurs, or an external reaction is triggered. Steel provides an excellent example of a critical temperature where internal transformation occurs. When fastener steels, which almost always possess less than 0.5% carbon, are heated up, they undergo their first transformation between about 1300°F and 1650°F. When this critical temperature is reached, if held there long enough, the steel will transform from whatever structure it possesses (most likely some mix of Ferrite and Pearlite) to the elevated temperature structure known as Austenite. Austinite is soft and very formable, and thus is an advantageous structure to be working with if extreme forming is necessary. Titanium provides an excellent example of a metal with a critical temperature that triggers an external reaction. When Titanium reaches temperatures of about 1600°F to 1800°F and is in contact with surrounding air, it will react with the oxygen in the air and form a brittle and undesirable oxide layer known as Alpha Case. Thus, Titanium must be processed at lower temperatures that will not trigger this undesirable condition. So, the manufacturer’s choice of operating temperature becomes a function of what the lowest critical temperature is for the material and the consequences of exceeding it. Whether warm or hot forming, however, the addition of heat is sometimes necessary to facilitate a successful forming process. In general, this process is employed for one of two reasons. There are some materials that simply will not form without the addition of heat. A couple of common examples include Titanium, many of the Nickel alloys (like Inconel and Hastelloy) , and some Stainless Steel alloys. The other reason is that the parts are too big to run on a cold header. In fact, the largest cold headers usually reach maximum capacity between about 1 ¼ and 1 ½ inches in diameter. There are a couple of reasons for this, but the most significant is a practical one, going beyond this size increases the scale of the equipment beyond what is efficient and feasible to work with. Most warm and hot heading processes only address a small section of the workpiece, usually the head. Surely there are high speed hot formers that heat the entire workpiece and present it to multiple dies like a multistation cold heading parts former to create complex and intricate part geometries. However, it is more common, especially for larger diameter or very long parts to be formed in single or double blow vertical presses and horizontal upsetters. In these processes a blank is either sheared or cut from long bar stock. The area of the part to be formed (usually the head) is heated in an off-line, stand-alone induction heater. It is allowed to reach the appropriate temperature and then loaded into the press or upsetter and struck by a punch (see Figure 1). The result is a part with the desired head form (see Figure 2). FIGURE 1: HEAD FIRMED IN VERTICAL PRESS CONTINUED ON PAGE 126
THE DISTRIBUTOR’S LINK 85 Sherex Fastening Solutions’ Optisert, the best performing round body rivet nut on the market, was recently awarded as a winner of the 2023 Fastener Innovation Awards by WorldwideFastenerSources. com. The innovative Optisert was chosen as a winner because of its incredible performance against spin-out. Its proprietary combination of an engineered knurled body and underhead wedge design helps it grip into the base material to prevent it from spinning. In softer materials, like aluminum, plastics, and composites, the spin-out performance matches that of a full hex body rivet nut. This award “aims to recognize the people and companies to encourage Research & Development in the fastener industry,” as stated in the release by Mike McGuire, president of WorldwideFastenerSources. com. “We are proud that the Fastener Innovation Awards are based on technical advancements compared to what exists in the marketplace today,” McGuire was quoted in the release. This is now the second recognition for Optisert, as it was also a finalist for the Route to Fastener Innovation 2023. Optisert took over 7 years of research and development to become part of Sherex’s standard part offering. That meant lots of testing and tinkering to make sure Optisert would be ready to perform as a premier round body rivet nut in softer materials. “A driving force in the evaluation process is that the fasteners be innovative in assemblies today and that they will become tomorrow’s standard,” the award release said. “Our philosophy is continuous improvement with innovative solutions for customers’ fastening applications.” Sherex Fastening Solutions is a leading manufacturer of fasteners for thin sheet material applications in steel, aluminum, and composite materials. Sherex manufactures rivet nuts, clinch nuts, inserts for composite, stud and nut plates, and through the acquisition of Disc- Lock, wedge-locking washers and nuts. Sherex services a wide-range of industries, including automotive, general manufacturing, renewable energy, agricultural, and aerospace. For additional information on any of the Sherex brand fasteners, tools, and automation please contact Sherex at 1-866-474-3739 or visit our website at www.sherex.com.
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In the Spring 2024 issue of 6 DISTR
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6 THE DISTRIBUTOR’S LINK E&T Fast
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fastenerlinks THE DEFINITIVE WEB DI
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fastenerlinks BRINGING YOU THE FAST
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fastenerlinks BRINGING YOU THE FAST
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THE DISTRIBUTOR’S LINK 141 YOUNG
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