AIRBUS INDUSTRIE

AIPS 01-02-006
Issue 1
Page 1 of 9
June 2006

AIPS

Airbus Industrie Process Specification

Installation of Lockbolts Pull type

© Copyright AIRBUS INDUSTRIE 2006. All rights reserved

Ref. no. AIPS 01-02-006

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Contents

1 Scope

2 Normative references

3 Definition, appplicability and limitation

4 Requirements

5 Process qualification

6 Appendix
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1 Scope
This Airbus Process Specification defines the requirement for the manual and automatic installation of pull-type
Lockbolts in metallic, FRP, FML and hybrid structure.
The purpose of this specification is to give design and quality 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.

This specification shall not be used as an inspection document unless parts or assemblies have been
manufactured according to this specification.

It shall be applied when mentioned in the relevant standard, material specification or drawing.

2 Normative references
This Airbus specification incorporates by dated or undated reference provisions from other publications. All
normative references cited at the appropriate places in the text are listed hereafter. For dated references,
subsequent amendments to or revisions of any of these publications apply to this Airbus specification only when
incorporated in it by amendment of revision. For undated references, the latest issue of the publication referred to
shall be applied.
National standards should be applied if Airbus standards are not available.
ABS1707: Holes geometries for use with protruding & countersunk head fasteners
AIPS 01-02-003: Preparation of Holes in Metallic Materials
AIPS 01-02-005: Preparation of Holes in FRP and Hybrids
AIPS 01-02-017: General Assembly and Installation of Fasteners
AIPS 05-05-001: Sealing of Aircraft Structures Inside and Outside Fuel Tank Area's

3 Definition, applicability and limitations

3.1 Definition
Grip length Maximum/minimum assembly thickness that a fastener is capable of joining.
FRP Fibre Feinforced Plastics

3.2 Applicability
This Airbus specification is applicable when invoked by the drawing directly or through another document for the
purpose given in the scope. When processing to AIPS 01-02-006 is required, it shall be invoked on the drawing by
the words “Installation of Lockbolts Pull Type" of AIPS 01-02-006. Process instructions shall not be called on
drawing.
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3.3 Limitations of the process

3.3.1 If an Al lockbolt is installed in an interference fit, the length-code limited to –060. Al lockbolt with a length-
code superior to 060 must be installed in clearance fit. Otherwise, the mechanical properties can’t be
guarentee.

4 Requirements

4.1 Technical requirements

4.1.1 Holes/countersinks

4.1.1.1 Hole preparation

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

4.1.1.2 Hole/countersink geometry

Holes and countersinks shall meet the requirements defined in ABS1707 for FRP materials, the Natco's hole
standards for metallic structure or the drawing.

4.1.1.3 Surface finish

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

4.1.2 Assembly/Clamping

4.1.2.1 Parts shall be assembled and clamped to the general installation requirements of AIPS 01-02-017. In
case of conflict this AIPS 01-02-006 prevails.

4.1.2.2 Unless otherwise specified interfay sealant shall be applied to the requirements of AIPS 05-05-001.

Sealant
For fasteners including a breakable pin-tail, no specific
protection is required for the break surface. Except for Top
Lockbolts aluminium collars in the bottom of the aircraft
structure and in configurations where the break surface is
within the collar. The cavity can be filled with sealant
according to relevant galvanic corrosion requirements. Bottom
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4.1.3 Installation

4.1.3.1 Lockbolt and collar standards shall be as defined on the drawing.

4.1.3.2 For grip length selection check AIPS 01-02-017.

4.1.3.3 Unless otherwise specified Lockbolts shall be wet assemblied to the requirements of AIPS 05-05-001.

4.1.3.4 Lockbolt grooves shall be free of sealant contamination prior installation of the collar.

4.1.3.5 Lockbolts shall be installed using approved pull-in tooling.

4.1.3.6 Collars shall be installed using approved swaging tooling.

4.1.3.7 The lockbolt is installed as follows depending on the installation conditions defined in ABS1707 for RFP
material or Natco’s holes standards for metallic structure:
- manually in the case of clearance fits,
- in the case of interference fits the pull-in tools should be used. If a pull-in tool isn’t available the
Lockbolt can be drived in by using a hammer and an aluminum mandrel.
Caution: It is generally not allowed to drive in Al-Lockbolts.

After installation, any damage to or deformation of the manufactured head or to the structure are not
allowed.

Make sure that the manufactured head has made contact before positioning the collar.

4.1.4 Post-installation

4.1.4.1 Heads and collars shall be seated to the requirements of AIPS 01-02-017.

4.1.4.2 Heads and collars shall be free of damage and/or defects. Refer to Appendix 1 for acceptable and
unacceptable defects.

4.1.4.3 Lockbolt and collar positions shall be checked using the pin position and swage gauges as given in
Appendix 2

4.1.4.4 After installation, preload level in the assembly shall be reached as defined in corresponding
specifications. This requirement shall be covered by preload mesurement testing during process
qualification only. (see section 5)

4.1.4.5 Countersunk heads shall be flush to the requirements of the drawing.

4.1.4.6 Trimming of countersink heads is prohibited

4.2 Quality requirements

The manufacturing shop shall be approved to the requirements of the Airbus Quality Assurance Function for the
production and supply of parts assembled to this process

4.2.1 Process
All processes shall be qualified in accordance with section 5.
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4.2.2 Tooling/Equipment
All tooling/equipment shall be obtained from controlled sources and shall be certified as suitable for intended use
and conforming to the requirements of this specification.

4.2.3 Lockbolts/Collars
All Lockbolts and collars shall be qualified and shall be obtained from Airbus approved sources.

4.2.4 Personnel
All operators shall be fully trained to perform the installation of Lockbolts according to this specification.

5 Process qualification
For technical qualification: Refer to AIRBUS qualification procedure for Manufacturing Process

Following points shall be particularly assessed on min, intermediate and max considered diameters :

- 10 parts shall be installed in min underlap and 10 parts in max overlap grip condition with the
maximum angled surface under collar as defined in relevant drawings.
- Preload measurements shall be performed for all parts by means of the paddle method.
- For each grip (max. and min.) :
Æ 5 fasteners shall be tested with 0° backside slope
Æ 5 fasteners shall be tested with maximum allowed backside slope (see standards and technical
specs)
- Micrograph sections of installed parts shall be completed
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6 Appendix
APPENDIX 1

The following defect is acceptable:

a) A continuous burr and/or flanged burr is
permissible without definite installation
direction

The following defects are unacceptable:

a) Forming of a circular mark at intersection

between the conical and cylindrical sections of
the collar.

b) Tearing of protection at the upper end.

c) Presence of a crack on outside surface, on the Inside

diameter
top of the collar.

d) Presence of a crack or cracks along the edge

e) Presence of a crack on outside surface, on

sides.

f) Damage (E.g. material removal, …)

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APPENDIX 2

FASTENER
NOMINAL DIAMETER GAUGE REFERENCE
PIN COLLAR (mm) (HUCK)
4,17 HG 110-05
ASNA2043 4,83 110-06
ASNA2048 5,56 110-07
ASNA2391 6,35 110-08
ASNA2025
ASNA2392 7,92 110-10
ABS0548 9,51 110-12
ABS0549 11,11 110-14
12,70 110-16
EN6050
EN6100 EN6051 4,17 HG 150-05
EN6120
4.17 HG 150-05
EN6050
4,81 150-06
EN6100 EN6054
5,56 150-07
EN6120
6,35 150-08
4,17 HG 118-05
4,81 118-06
ABS0094
6,35 118-08
ABS0095
ASNA2045 7,92 118-10
ASNA2041
9,51 118-12
ASNA2042
11,11 118-14
12,70 118-16
4,17 HG 162-05
4,81 162-06
5,56 162-07
6,35 162-08
7,92 162-10
ABS0998 ABS 0999
9,51 162-12
11,11 162-14
12,70 162-16
14,29 162-18
15,88 162-20
4,81 HG 134-06
ASNA2054 6,35 134-08
ASNA2044
ASNA2040 7,92 134-10
9,51 134-12
4,81 HG 164-06
5,56 164-07
6,35 164-08
7,92 164-10
ABS1504
ABS1505 9,51 164-12
ABS1506
11,11 164-14
12,70 164-16
14,29 164-18
15,88 164-20
4,17 HG 100-05
4,81 100-06
ABS0270 6,35 100-08
ABS0268 7,92 100-10
ABS0269 9,51 100-12

ABS0644 4,81 HG 140-06

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RECORD OF REVISIONS

Clause
Issue Description of modification
modified

1 All New specification

06/06