How to Install Threaded Inserts . But, they’re not the only methods. They can also be pressed in, molded in, and even screwed in via self- tapping threads.

However, installation of inserts after molding reduces costs by shortening molding time. Post- mold installation also reduces the chance of scrap and mold damage resulting from dislodged inserts. Thermoplastics are solid at normal temperatures and can be remelted numerous times. Thermosets have a one- time reaction in their conversion from liquid to solid and cannot be remelted. Retention within the hole is provided by the melted plastic conforming to the external features of the insert.

A sufficient volume of plastic must be displaced to entirely fill these external features so the insert achieves maximum performance when the plastic solidifies. It’s important to ensure plastic flow into the features of the insert, since this dictates the fastener’s torque and pull- out performance. Both installation methods have advantages and disadvantages, which should be considered before investing in installation equipment. Ultrasonic Installation. An ultrasonic insertion machine converts electrical power into mechanical vibrations.

The downward force is typically provided by a pneumatic cylinder, while an ultrasonic horn delivers mechanical energy to the metal- plastic interface. Made from various metals, including titanium alloys, stainless steel and aluminum alloys, ultrasonic horns directly contact the metal insert. As the horn vibrates, the mechanical energy is transferred to the plastic surrounding the insert, creating frictional heat to melt the plastic. First, it’s fast.

Ultrasonic installation is generally fast for inserts less than 0. OD. And third, it’s flexible.

Horn sizes and shapes can be easily changed to accommodate different insert sizes. One is insufficient melting of the plastic, and it can happen for several reasons. This occurs because of damping, or the dissipation of mechanical energy from the horn. Damping results in poor installation because the horn’s mechanical energy is not localized around the insert.

JACK NUTS Jack Nuts are used for light duty, thin, or brittle material. They accomodate slightly oversized holes with a large back side footprint similar to a wall. Buy RS Pro Nickel Plated, M4 Brass Insert Diameter 5.6mm Depth 7.95mm, 14593. Browse our latest Inserts offers. Free Next Day Delivery. JACK NUT ® Threaded Inserts. The JACK NUT threaded insert is an economical blind fastener designed for assembly-line use in thin, soft, or brittle materials. Welcome to Threaded-Insert. Designed for secure and permanent set threads in cast and molded plastics, metals or ceramics. Molded and epoxy set inserts. McMaster-Carr is the complete source for everything in your plant. 98% of the products ordered ship from stock and deliver same or next day.

Groov-Pin is a leading U.S. Blind Rivet Supply has been specializing in Fasteners, Blind Rivets, Thread Repair Inserts, Thread Repair Kits, Blind Threaded Inserts and Installation Tools for the. The largest inventory or rivet nuts and rivet nut tools. Threaded inserts are also available for all applications.

This is a common problem with ultrasonic insertion. The result is high stress and poor retention within the plastic, which can lead to part failure, either during initial installation of the mating screw or worse, in the field. Damage to the insert or the plastic can be severe.

While sophisticated control systems can help solve this problem, they can nearly double the cost of the insertion machine. Minute metal flakes may appear when the ultrasonic horn vibrates against the insert and chips off the insert material. The metal- to- metal contact between the horn and the insert can create a loud noise. The bigger the insert, the louder the noise.

It’s very costly, if not impossible, to install multiple inserts at the same time. In some cases, the ultrasonic horn can damage the threads enough that the mating screw cannot be installed. Otherwise, damage to the internal threads is likely to occur. Horns are subject to wear and are expensive to replace. A horn can often cost more than $1,0. Thermal Installation. Thermal installation is accomplished by transferring heat from the tip through the insert to the plastic, or by preheating the inserts and then pressing them in.

In both cases, a controlled force is applied to the insert to ensure that the plastic is sufficiently melted before the insert is installed. Brass and aluminum are common choices.

This enables the insert to efficiently transfer heat to the plastic. It also enables the insert to cool down quickly after installation. However, thermal equipment that preheats the insert will have comparable installation time compared with ultrasonic equipment. In addition, when installing multiple inserts simultaneously, thermal insertion will offer faster throughput. Temperature, force and depth settings are adjustable. Lower installation forces enable fasteners to be inserted into thin- walled parts that would be destroyed by ultrasonic equipment.

Thermal equipment is approximately 5. Thermal installation equipment is comprised of a heated tip and a pneumatic cylinder. Insertion force is low—generally less than 5. Ultrasonic installation requires an electronic power supply, electronic timers, a transducer and an ultrasonic horn.

Such areas would be inaccessible to an ultrasonic horn. Applications that need multiple inserts on multiple planes can be accommodated with platen- style thermal installation machines. Fantastic Four The Trial Of Galactus Vs Phoenix'>Fantastic Four The Trial Of Galactus Vs Phoenix. Prototyping or low- volume applications can be accommodated with manual equipment. A wide range of insert sizes can be handled on the same machine by switching out the interchangeable heat tips. Any insert can be installed—headed or nonheaded. How To Install G3 Sling For Sale. The inserts are simply loaded into the feeder and advance through a tube to a guarded heating chamber.

The operator would then load the plastic component into the fixture, and activate the machine to install the insert. This is important for very small inserts, which are difficult to singulate and orient. The maintenance and spare part costs are low. Replacement tips cost approximately $5. This enables the melted plastic to fully flow into all retention features.

Performance of inserts that are ultrasonically installed is often lower because the plastic is not able to fully flow into retention features. This happens because of the minimal heating generated only at the point of interference between the insert and the host. As much as 7. 5 percent of an insert’s performance is a direct result of how well it was installed. As a result, all the factors that affect installation must be carefully controlled to maximize performance. With so many different combinations of insert types, plastic types and performance requirements, engineers are well- advised to consult with experts on insert installation. The right choice of insert and installation method can be the difference between part failure in the field and part integrity for the intended life of the assembly.

Installing Threaded Inserts - Boat. US Magazine. To Magazine Home Page. By Don Casey. How to simply create solid, near- permanent threads inside a damaged screw hole.

Heli. Coils — the classic screw thread insert for use in metal. You know the moment, when you decide to tighten that screw or nut just a little more and, whoosh, the driver suddenly spins. The smart answer is to install a bigger screw. Sometimes that works.

Another ploy is to fill the hole with something — anything from matchsticks to space- age polymer — then reinstall the same screw. This also works. But a better course, and one too rarely considered by boat owners, can be to use a threaded insert.

Have a persistent leak under some piece of hardware? A blind insert — meaning the bottom is closed — bonded into place can provide a permanent seal. Let's get up to speed. For 7. 5 years, gearheads and bikers have been repairing stripped threads with a tightly wound stainless- steel spring called a Heli. Coil. The wire of the spring is diamond shaped, effectively creating threads on both the inside and outside of the coil. Drill the stripped hole slightly oversize, tap it to match the outside threads, thread the Heli. Coil into the hole (made easier by a slight reduction in diameter caused by .

But the correct generic term is screw thread insert (STI). STIs create solid, near- permanent threads inside a damaged screw hole. The installation of an STI is exactly like that of any threaded fastener.

You need a pilot hole the root size of the insert; the package the insert comes in will normally specify the drill size. It is essential to drill the hole to the correct size. It is also important for the hole to be straight (see sidebar). The material you're working with will determine the best insert and how to install it. Metal. If the insert is being installed in metal, most will require tapping the hole, although there are some self- tapping types for soft metals. The tap is likely to be a special size and thread intended just for this particular insert and typically comes with the insert as a kit.

Coil inserts may also require an insertion tool to tighten the coil. Plastic. Illustration: . The amateur way is to thread the insert onto a bolt. Use pliers to hold the bolt with the insert in place on the hole, applying downward pressure. Heat the bolt with a soldering iron.

The heat transfers to the insert, which after a minute or so should begin to sink into the softening plastic. Continue with downward pressure until the insert is at the desired depth, then remove the heat and hold the bolt steady long enough for the plastic to stiffen.

Wood. Illustration: . But as a rule, STIs will prove more durable. These are typically spun in, much like a wood screw. Some have a hex socket and are installed with an Allen wrench.

Slotted inserts can be installed with a screwdriver, but because the slot is fragile, the better method is to thread a nut, then the insert, onto a long bolt. Lock the nut against the insert, then turn the insert into the hole with a wrench or socket. Or cut the head from the bolt and chuck the whole rig into a power screwdriver. When installing inserts this way, putting the slot in the hole first makes for a neater installation, and the slot helps to cut the threads. Composite Or Fiberglass.

The usual procedure for thick or cored composite is to epoxy a knurled insert into a snug- fit hole. An alternative is to tap the hole in the composite and install an STI, coating both hole and insert with epoxy.

With either type, the insert should be mounted on a well- greased screw to protect the internal threads from the epoxy. A bonded insert will be both stronger and more durable than a sheet- metal screw driven directly into the fiberglass, but it is not a suitable substitute for a thru- bolt with a backing plate.

The well nut is yet another type of threaded insert — a rubber bushing with a flange at one end and a nut imbedded in the other. Tightening the screw compresses the bushing, causing it to swell. Only as strong as the rubber, well nuts are light- duty fasteners, but ideal for some marine applications because they seal, insulate, cushion, and can be installed without rear access. To get a full sense of the vast array of available inserts, search the Internet for . Don Casey has written eight books on boat repair and maintenance including This Old Boat, a comprehensive guide to refitting an older, fiberglass boat.— Published: April/May 2.