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FREDSERT - Next Generation Threaded Insert Technology - Catalog

Here is a complete product catalog for Fredsert, the next generation threaded insert technology. Fredsert provides all types of threaded inserts and have the thread technology for steel & aluminum with titanium. Fredsert has state-of-the-art ISO 9001:2000 accredited manufacturing facility and certified to Military Specification. Full details here - http://fredsert.com/

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FREDSERT - Next Generation Threaded Insert Technology - Catalog

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  1. FREDSERT THREADED INSERTS Next Generation Threaded Insert Technology www.fredsert.com Product Catalog Revision M

  2. Introduction Fredsert threaded inserts, patented by the General Dynam- ics Corporation, have fostered new attachment concepts, improved flexibility in assembly operations, and reduced overall integration costs. Logistical support costs have also been reduced, since removal and replacement of inserts in the field is drastically simplified. For low to medium-volume applications, Fredserts are installed manually with a torque wrench, or semi-automated with an electric nutrunner. For production volumes, however, Fredsert installation can be fully-automated using either a CNC machine or a robot to apply torque. This unique capability provides signif- icant advantage over traditional inserts, which are difficult or impossible to fully automate due to the mechanical-clamping aspect of their installation. The Fredsert geometry delivers a combination of fric- tion fit and material compression to reliably lock in place, resisting vibration, tensile loading, and shear loading in the most demanding heavy-duty applications. One of the most unique features of a Fredsert is that it doesn’t permanently lock into place. Instead, its patented geometry enables it to break away at 80% of the rec- ommended installation torque, allowing quick and easy removal and replacement with the same equipment. By Another characteristic that sets the Fredsert product line apart is the fact that Titanium Fredserts are available as a standard product, in addition to those made from Stainless Steel and Zinc-plated Steel. Titanium Fredserts deliver weight savings of 40% over steel inserts of the same size. Titanium inserts from other lead- ing insert manufacturers are typically not an option, or they feature an extremely high price and long lead time. comparison, competitors’ inserts can only be removed by drilling them out and, in some cases, re-tapping to a larger thread size. This becomes difficult if the insert is installed in a large structure or a tight enclosure, because access and rigidity are limited. Another key benefit that differentiates Fred- serts from the competition is that they create a watertight seal without the use of a thread- locking agent, such as Loctite. The combina- tion of a tapered thread profile, 100% thread engagement, and a flanged head deliver a per- fect seal on the external thread of the insert. ‘Blind’ Fredserts also provide a watertight seal on the internal thread, because the thread bore doesn’t break through the bottom of the insert. Fredserts are designed and built in the USA. This product line is certified to MIL-I-45914A and is manufactured in a state-of-the-art, ISO 9001:2000 accredited facility. For more information, please visit www.fred- sert.com 2 3 www.fredsert.com www.fredsert.com

  3. Table of Contents Testimonials Introduction 2 “The multiple Fredsert styles and self-sealing feature provide a broad range of options for our designers, com- pared to other inserts on the market…” Table of Contents 4 Testimonials 5 “Fredserts are designed for the most demanding heavy- duty applications, making them perfect for use in the defense, heavy-equipment, automotive, and marine industries…” Part Number Definition 6 Product Offering and Material Options Female Style Inserts (Metric) Female Style Inserts (Inch) Appurtenance Style - Classic Appurtenance Style - Pro Male Style Hex Style Corrosion-Resistant Fredserts Fitting Style Non-Standards Self-locating Weld Boss Installation Bolt Lengths Fredsert Hole-Prep Combo Tools Fredsert Installation (CNC & Robotic, Manual, Semi-Auto) 7 8 10 12 14 16 18 20 22 24 26 30 33 34 “One of the things that really sets Fredserts apart is they’re easy to remove and replace if we shear off a bolt inside them. Other inserts I’ve used need to be drilled-out if this happens…” “Weight reduction is important to our company, so the fact that tita- nium Fredserts are 40% lighter and available off the shelf are real positives in my book…” “I’ve used pretty much every type of threaded fastener out there, and the Fredsert is definitely the easiest to install; plus you can remove it if you need to…” “Fredserts can be quickly and easily be removed and replaced using the same equipment, which pro- vides our company with substantial cost savings.” Frequently Asked Questions 36 Notes 39 4 5 www.fredsert.com www.fredsert.com

  4. Part Number Definition Fredsert Product Offering Hex Style Appurtenance Style Female Style Corrosion - Resistant Male Style Fitting Style 1. Manufacturer G - General Dynamics 2. Product Revision 3. Insert Style(s) I - Female S - Male A - Appurtenance H - Hex F - Fitting 4. Thread Configuration M - Metric S - Standard MS - Combination 5. Pitch Direction R - Right L - Left 6. Insert Material T - Titanium S - Stainless A - Zinc-Plated Steel 7. Insert Coating FA = Electro-ceramic Coating Blank = Uncoated 8. Internal Thread Example: 9. External Thread Example: 10. External Thread Length Example: Metric: 54 = 54mm Inch: 038 = 0.38” 11. Insert Type T - Thru S - Blind 12. Head Thickness (Appurtenance Only) Example: Metric: 30 = 30mm Inch: 038 = 0.38” 13. Internal Thread Locking L1 = Pre-Load Locking L2 = Bottom Crimp L3 = Nylon Ring Fredsert Material Options Metric: 2025 = M20 x 2.5 Inch: 02528 = 1/4 - 28 Titanium (Ti 6Al-4V) - Excellent strength-to-weight ratio - High corrosion resistance - Great stability at low temperature - Non-Magnetic Metric: 3335 = M33 x 3.5 Inch: 05013 = 1/2 - 13 Passivated 303 Stainless Steel - Standard, general purpose material - Perfect for original equipment, repair applications Additional Materials Available Upon Request Zinc Plated Steel - 1045 Cold Drawn Steel - Excellent Corrosion Resistance - Standard, General Purpose Inconel - Perfect for areas exposed to high temperature - Engines, well-drilling, and nuclear - Non-Magnetic - High Corrosion Resistance FREDSERT Patent 6,530,731 (March 2003) 6 7 www.fredsert.com www.fredsert.com

  5. Female Style Metric Female Style - General purpose insert - Designed for strength & durability - Precision ID/OD thread concentricity - Can be mounted ‘Proud’ or ‘Flush’ relative to plate surface - Titanium option provides 40% weight savings over steel Didn’t find a standard to fit your application? Go to www.fredsert.com and click on “Request Quote”. We’ll be happy to design the insert you’re looking for. Installation torque values shown are for Titanium Fredserts installed in Aluminum. Different combinations of insert and workpiece material may require different torque value. Contact us with application details. 9 8 www.fredsert.com www.fredsert.com

  6. Female Style Inches Female Style Fredsert Data Installation Data A B C D P Q R S T U V Minimum Effective ID Thread Depth (inch) Install Torque (ft-lbs) Head Thick- ness (inch) Min C'bore Dia (inch) Min C'bore Depth (inch) Class 3B Thread in Parent Material Min Thread Depth (inch) Drive Tool Combo Tool Overall Length (inch) Min Drill Depth (inch) Tap Drill (inch) Part # Part Code Head Dia (inch) ID Thread GAISRT01632-03816-033S 805 #8-32 0.33 0.45 0.50 0.13 0.52 0.15 3/8 - 16 0.55 0.45 0.313 D-1.5 C60 60 GAISRT01632-03816-033T 806 #8-32 Thru 0.45 0.50 0.13 0.52 0.15 3/8 - 16 0.55 0.45 0.313 D-1.5 C60 60 GAISRT01932-04414-037S 810 #10-32 0.31 0.50 0.55 0.13 0.57 0.15 7/16 - 14 0.60 0.50 0.368 D-1.5 C61 60 GAISRT01932-04414-037T 811 #10-32 Thru 0.50 0.55 0.13 0.57 0.15 7/16 - 14 0.60 0.50 0.368 D-1.5 C61 60 GAISRT01924-04414-037S 808 #10-24 0.31 0.50 0.55 0.13 0.57 0.15 7/16 - 14 0.60 0.50 0.368 D-1.5 C61 60 GAISRT01924-04414-037T 809 #10-24 Thru 0.50 0.55 0.13 0.57 0.15 7/16 - 14 0.60 0.50 0.368 D-1.5 C61 60 GAISRT02528-05013-038S 818 1/4 - 28 0.37 0.50 0.60 0.13 0.62 0.15 1/2 - 13 0.60 0.50 0.422 D-2 C62 110 GAISRT02528-05013-038T 819 1/4 - 28 Thru 0.50 0.60 0.13 0.62 0.15 1/2 - 13 0.60 0.50 0.422 D-2 C62 110 GAISRT02520-05013-038S 816 1/4 - 20 0.37 0.50 0.60 0.13 0.62 0.15 1/2 - 13 0.60 0.50 0.422 D-2 C62 110 GAISRT02520-05013-038T 817 1/4 - 20 Thru 0.50 0.60 0.13 0.62 0.15 1/2 - 13 0.60 0.50 0.422 D-2 C62 110 GAISRT03124-05612-048S 823 5/16 - 24 0.47 0.60 0.70 0.13 0.72 0.15 9/16 - 12 0.70 0.60 0.484 D-3 C63 130 GAISRT03124-05612-048T 824 5/16 - 24 Thru 0.60 0.70 0.13 0.72 0.15 9/16 - 12 0.70 0.60 0.484 D-3 C63 130 GAISRT03118-05612-048S 820 5/16 - 18 0.47 0.60 0.70 0.13 0.72 0.15 9/16 - 12 0.70 0.60 0.484 D-3 C63 130 GAISRT03118-05612-048T 821 5/16 - 18 Thru 0.60 0.70 0.13 0.72 0.15 9/16 - 12 0.70 0.60 0.484 D-3 C63 130 GAISRT03824-06311-063S 827 3/8 - 24 0.50 0.75 0.81 0.13 0.83 0.15 5/8 - 11 0.85 0.75 0.531 D-4 C66 130 GAISRT03824-06311-063T 828 3/8 - 24 Thru 0.75 0.81 0.13 0.83 0.15 5/8 - 11 0.85 0.75 0.531 D-4 C66 130 GAISRT03816-06311-063S 825 3/8 - 16 0.50 0.75 0.81 0.13 0.83 0.15 5/8 - 11 0.85 0.75 0.531 D-4 C66 130 GAISRT03816-06311-063T 826 3/8 - 16 Thru 0.75 0.81 0.13 0.83 0.15 5/8 - 11 0.85 0.75 0.531 D-4 C66 130 GAISRT03816-06311-088T 860 3/8 - 16 Thru 1.00 0.81 0.13 0.83 0.15 5/8 - 11 1.10 1.00 0.531 D-4 C66A 130 GAISRT04420-07510-072S 831 - General purpose insert 7/16 - 20 0.66 0.84 0.90 0.13 0.92 0.15 3/4 - 10 0.94 0.84 0.656 D-4.5 C67 275 GAISRT04420-07510-072T 832 7/16 - 20 Thru 0.84 0.90 0.13 0.92 0.15 3/4 - 10 0.94 0.84 0.656 D-4.5 C67 275 - Designed for strength & durability GAISRT04414-07510-072S 829 7/16 - 14 0.66 0.84 0.90 0.13 0.92 0.15 3/4 - 10 0.94 0.84 0.656 D-4.5 C67 275 GAISRT04414 07510 072T GAISRT04414-07510-072T 830 830 7/16 7/16 - 14 14 Thr Thru 0 84 0.84 0 90 0.90 0 13 0.13 0 92 0.92 0 15 0.15 3/4 3/4 - 10 10 0 94 0.94 0 84 0.84 0 656 0.656 D 4 5 D-4.5 C67 C67 275 275 - Precision ID/OD thread concentricity GAISRT05020-08809-082S 836 1/2 - 20 0.75 0.95 1.13 0.13 1.15 0.15 7/8-9 1.05 0.95 0.766 D-6 C68 500 GAISRT05020-08809-082T 837 1/2 - 20 Thru 0.95 1.13 0.13 1.15 0.15 7/8-9 1.05 0.95 0.766 D-6 C68 500 - Can be mounted ‘Proud’ or ‘Flush’ relative to plate surface GAISRT05013-08809-082S 833 1/2 -13 0.75 0.95 1.13 0.13 1.15 0.15 7/8-9 1.05 0.95 0.766 D-6 C68 500 GAISRT05013-08809-082T 834 1/2 - 13 Thru 0.95 1.13 0.13 1.15 0.15 7/8-9 1.05 0.95 0.766 D-6 C68 500 - Titanium option provides 40% weight savings over steel GAISRT05618-08809-091S 840 9/16 - 18 0.81 1.03 1.19 0.13 1.21 0.15 7/8 - 9 1.13 1.03 0.766 D-6 C69 500 GAISRT05618-08809-091T 841 9/16 - 18 Thru 1.03 1.19 0.13 1.21 0.15 7/8 - 9 1.13 1.03 0.766 D-6 C69 500 GAISRT05612-08809-091S 838 9/16 - 12 0.81 1.03 1.19 0.13 1.21 0.15 7/8 - 9 1.13 1.03 0.766 D-6 C69 500 GAISRT05612-08809-091T 839 9/16 - 12 Thru 1.03 1.19 0.13 1.21 0.15 7/8 - 9 1.13 1.03 0.766 D-6 C69 500 GAISRT06318-10008-100S 844 5/8 - 18 0.87 1.13 1.25 0.13 1.27 0.15 1 - 8 1.23 1.13 0.875 D-6 C71 500 GAISRT06318-10008-100T 845 5/8 - 18 Thru 1.13 1.25 0.13 1.27 0.15 1 - 8 1.23 1.13 0.875 D-6 C71 500 GAISRT06311-10008-100S 842 5/8 - 11 0.87 1.13 1.25 0.13 1.27 0.15 1 - 8 1.23 1.13 0.875 D-6 C71 500 GAISRT06311-10008-100T 843 5/8 - 11 Thru 1.13 1.25 0.13 1.27 0.15 1 - 8 1.23 1.13 0.875 D-6 C71 500 GAISRT07516-12507-119S 848 3/4 - 16 1.13 1.38 1.42 0.19 1.44 0.21 1-1/4 - 7 1.48 1.38 1.109 D-7 C73 700 GAISRT07516-12507-119T 849 3/4 - 16 Thru 1.38 1.42 0.19 1.44 0.21 1-1/4 - 7 1.48 1.38 1.109 D-7 C73 700 GAISRT07510-12507-119S 846 3/4 - 10 1.13 1.38 1.42 0.19 1.44 0.21 1-1/4 - 7 1.48 1.38 1.109 D-7 C73 700 GAISRT07510-12507-119T 847 3/4 - 10 Thru 1.38 1.42 0.19 1.44 0.21 1-1/4 - 7 1.48 1.38 1.109 D-7 C73 700 GAISRT08814-13806-131S 852 7/8 - 14 1.31 1.53 1.69 0.22 1.71 0.24 1-3/8 - 6 1.63 1.53 1.219 D-9 C74 800 GAISRT08814-13806-131T 853 7/8 - 14 Thru 1.53 1.69 0.22 1.71 0.24 1-3/8 - 6 1.63 1.53 1.219 D-9 C74 800 GAISRT08809-13806-131S 851 7/8 - 9 1.31 1.53 1.69 0.22 1.71 0.24 1-3/8 - 6 1.63 1.53 1.219 D-9 C74 800 GAISRT08809-13806-131T 850 7/8 - 9 Thru 1.53 1.69 0.22 1.71 0.24 1-3/8 - 6 1.63 1.53 1.219 D-9 C74 800 GAISRT10012-15006-150S 856 1 - 12 1.50 1.75 1.84 0.25 1.86 0.27 1-1/2 - 6 1.85 1.75 1.344 D-10 C76 1000 GAISRT10012-15006-150T 857 1 - 12 Thru 1.75 1.84 0.25 1.86 0.27 1-1/2 - 6 1.85 1.75 1.344 D-10 C76 1000 GAISRT10008-15006-150S 854 1 - 8 1.50 1.75 1.84 0.25 1.86 0.27 1-1/2 - 6 1.85 1.75 1.344 D-10 C76 1000 GAISRT10008-15006-150T 855 1 - 8 Thru 1.75 1.84 0.25 1.86 0.27 1-1/2 - 6 1.85 1.75 1.344 D-10 C76 1000 Didn’t find a standard to fit your application? Go to www.fredsert.com and click on “Request Quote”. We’ll be happy to design the insert you’re looking for. Installation torque values shown are for Titanium Fredserts installed in Aluminum. Different combinations of insert and workpiece material may require different torque value. Contact us with application details. 11 10 www.fredsert.com www.fredsert.com

  7. Appurtenance Style Classic Appurtenance Style - Classic - General purpose insert - Designed for strength & durability - Precision ID/OD thread concentricity - Can be mounted ‘Proud’ or ‘Flush’ relative to plate surface - Titanium option provides 40% weight savings over steel A shock-absorbing feature can be applied to any Appurtenance style Fredsert. This feature is designed to allow the insert to deform, thereby absorbing a substantial amount of force instead of transmitting it like a solid insert would. A shock absorbing Fredsert can be applied to protect occupants and sensitive equipment by reducing the amount of force trans- ferred into the vehicle. Please contact us with specific applica- tion details and we’ll design a shock-absorbing Fredsert to fit your needs. Didn’t find a standard to fit your application? Go to www.fredsert.com and click on “Request Quote”. We’ll be happy to design the insert you’re looking for. Installation torque values shown are for Titanium Fredserts installed in Aluminum. Different combinations of insert and workpiece material may require different torque value. Contact us with application details. 12 www.fredsert.com 13 www.fredsert.com

  8. Appurtenance Style Pro Appurtenance Style - Pro - Used where a stand-off or clearance is required - No driver needed - socket head built into Fredsert - Eliminates need for weld bosses - Designed for strength & durability - Precision ID/OD thread concentricity - Titanium option provides 40% weight savings over steel Didn’t find a standard to fit your application? Go to www.fredsert.com and click on “Request Quote”. We’ll be happy to design the insert you’re looking for. Installation torque values shown are for Titanium Fredserts installed in Aluminum. Different combinations of insert and workpiece material may require different torque value. Contact us with application details. www.fredsert.com 8 14 www.fredsert.com 15

  9. Male Style Male Style - Used where an externally-threaded boss is needed - Designed for strength & durability - Precision thread concentricity - Titanium option provides 40% weight savings over steel Installation torque values shown are for Titanium Fredserts installed in Aluminum. Different combinations of insert and workpiece material may require different torque value. Contact us with application details. Didn’t find a standard to fit your application? Go to www.fredsert.com and click on “Request Quote”. We’ll be happy to design the insert you’re looking for. 16 17 www.fredsert.com www.fredsert.com

  10. Hex Style Hex Style - Bolt installed from opposite side of plate - Provides design flexibility for difficult areas - Designed for strength & durability - No driver needed - socket hex built into Fredsert - Precision ID/OD thread concentricity - Titanium option provides 40% weight savings over steel Installation torque values shown are for Titanium Fredserts installed in Aluminum. Different combinations of insert and workpiece material may require different torque value. Contact us with application details. Didn’t find a standard to fit your application? Go to www.fredsert.com and click on “Request Quote”. We’ll be happy to design the insert you’re looking for. 19 18 www.fredsert.com www.fredsert.com

  11. Extreme Corrosion Resistant Extreme Corrosion Resistant - Electro-ceramic coating eliminates potential for galvanic corrosion - Used in areas where standing water can become trapped - Alodine® EC2 coating is patented by the Henkel Corporation - Please visit www.henkelec2.com/features.htm for coating details Extreme Corrosion-resistant coating can be applied to any standard or custom Fredsert, upon request. Installation torque values shown are for Titanium Fredserts installed in Aluminum. Different combinations of insert and workpiece material may require different torque value. Contact us with application details. Didn’t find a standard to fit your application? Go to www.fredsert.com and click on “Request Quote”. We’ll be happy to design the insert you’re looking for. 20 21 www.fredsert.com www.fredsert.com

  12. Fitting Style Fitting Style - Used where a hydraulic fitting passes through a wall - Fredsert creates seal on external threads without Loctite - Designed for strength & durability - Precision ID/OD concentricity - Titanium option provides 40% weight savings over steel Didn’t find a standard to fit your application? Go to www.fredsert.com and click on “Request Quote”. We’ll be happy to design the insert you’re looking for. Installation torque values shown are for Titanium Fredserts installed in Aluminum. Different combinations of insert and workpiece material may require different torque value. Contact us with application details. 23 22 www.fredsert.com www.fredsert.com

  13. Non-Standard Fredserts Non-Standard Fredserts - Thin wall designs - Non-standard ID/OD thread combinations - Medium/Light-duty designs Installation torque values shown are for Titanium Fredserts installed in Aluminum. Different combinations of insert and workpiece material may require different torque value. Contact us with application details. Didn’t find a standard to fit your application? Go to www.fredsert.com and click on “Request Quote”. We’ll be happy to design the insert you’re looking for. 25 24 www.fredsert.com www.fredsert.com

  14. Self-Locating Weld Boss Metric Self-Locating Weld Boss - Available in variety of materials - Eliminate need for fixture to locate Weld Bosses - Can be used in manual or friction welding applications - Shear strength increase over plain Weld Boss - Requires shallow spot-face in plate Weld Boss Material Options - STL = High Strength Alloy Steel (100 ksi) - AL = 6000-Series Aluminum Alloy - CRES = 303 Stainless CRES - Other materials available upon request 26 www.fredsert.com www.fredsert.com 27

  15. Self-Locating Weld Boss Inches Self-Locating Weld Boss - Available in variety of materials - Eliminate need for fixture to locate Weld Bosses - Can be used in manual or friction welding applications - Shear strength increase over plain Weld Boss - Requires shallow spot-face in plate Weld Boss Material Options - STL = High Strength Alloy Steel (100 ksi) - AL = 6000-Series Aluminum Alloy - CRES = 303 Stainless CRES - Other materials available upon request 28 www.fredsert.com www.fredsert.com 29

  16. Bolt Lengths Installation Bolt Lengths 31 30 www.fredsert.com www.fredsert.com

  17. Bolt Lengths Combo Tools Hole Prep Conventional Tooling Hole Prep Fredsert Combo Tool - Eliminate (3) Tool-changes per hole versus conventional hole-prep - Reduce setup time, cycle time, inventory, toolholders, etc - No center drilling needed, even on irregular surfaces - Coated and uncoated options available - Short lead time & reasonable price - Perfect concentricity of counterbore to thread Refer to “Combo Tool” column on standard Fredsert pages to find appropriate tool. Fredsert Combo Tools feature a 135-degree drill point; other options available upon request. 33 32 www.fredsert.com www.fredsert.com

  18. Fredsert Instalation CNC Installation (Fully Automated) The CNC installation method uses an adaptor similar to a tension / compression tap holder to pull Fredserts from a tray and install them into tapped holes at a speci- fied torque value. This capability enables users to combine machin- ing and insert installation in one setup, a significant step toward Lean Production. This level of pro- cess control also ensures consistent and accurate installation every time, since the location and installation are precisely controlled by the CNC program. Incorporating this pro- cess requires relatively little invest- ment, because the most expensive component, the CNC machine, is already there to machine the part. - Low-production and high-production options - Each driver covers several different Fredserts - Built for durability from heat-treated tool steel Refer to “Drive Tool” column on standard Fredsert pages to find appropriate driver. Manual Robotic Installation (Fully Automated) The robotic installation method con- sists of a robotic arm with an elec- tric nut-runner that picks Fredserts from a tray and installs them into tapped holes. Such a set-up allows manufacturers to install inserts into several surfaces of a compo- nent in a single setup. Guided by an on-board vision system, robotic structures are assembled in aero- space, defense, automotive, and other industries. installation ensures proper place- ment regardless of variation in the workpiece. This approach allows installation into multiple surfaces in a single setup; perfect for applica- tions involving large, complex parts. Fully automated threaded insert installation dramatically changes the way aluminum components and Assemble driver to Fredsert with bolt for both manual and semi-automated installations. The ability to fully automate instal- lation also reduces overall process time and cost. Tighten Fredsert in threaded hole until snug. Install Fredsert to speci- fied torque value (see chart). Remove driver from Fredsert after install is complete. Semi-Automated Tighten Fredsert in hole until snug. Install Fredsert to speci- fied torque value (see chart). Remove driver from Fredsert after install is complete. Place torque wrench on Fredsert. 35 34 www.fredsert.com www.fredsert.com

  19. Frequently Asked Questions Q. Is it necessary to begin threading the Fredsert in by hand to get it started? break through the bottom of the insert. Q. When preparing a tapped hole to install a Fredsert, is it necessary to counterbore the hole? A. For manual installation, starting the insert by hand is important to avoid cross-threading the insert and damaging the tapped hole in the parent material. For high-volume Fredsert installations, drive tools are available that eliminate the need to assemble the driver to the insert with a bolt. These spring-loaded drivers enable Fredsert installation in a fraction of the time. A. The only reason to counterbore the hole is if the application requires that the insert mount flush with the material surface. Otherwise, the insert can be mounted “proud”, where the Fredsert flange sits on top of the material surface. Appurtenance- style Fredserts are always mounted proud because they are used as a stand-off. There is no Fred- sert performance difference between flush mount and proud mount. Background Information and a flanged head deliver a perfect seal on the OD thread of the insert. “Blind” Fredserts also deliver a watertight seal on the ID thread, because the ID thread bore doesn’t break through the bottom of the insert. Q. Why is a Fredsert, called a “Fredsert”? A. Fredserts were initially designed for the Expedi- tionary Fighting Vehicle (EFV) by an Engineer named Fred Wheeler. Fred designed the product to meet the unique demands of the EFV program, which included a water-tight seal, solid locking to prevent back-out, corrosion resistance in extended saltwa- ter exposure, and the ability to be easily removed and replaced in the field. The use of Fredserts has since expanded to a number of other applications both inside and outside General Dynamics. Q. What happens if I break a bolt off inside the Fredsert? Q. What is the typical delivery lead time for Fredserts? A. If possible, remove the Fredsert with the bolt still in and replace with a new Fredsert in the same hole. If you can’t remove the Fredsert with the bolt still in, you’ll need to drill out the bolt, then check the inter- nal threads of the Fredsert. A. Standard Fredserts are generally available in 1-2 week, or less. For large orders and custom geom- etries, a lead time of 2-4 weeks is typical. Fredsert Geometry Q. How does a Fredsert lock into place? Q. Is there a cost advantage to using Fredserts? Q. What should I do if I’ve reached the rec- ommended installation torque value and the Fredsert is not yet “seated” on the surface of the plate? A. The Fredsert geometry is effective in that it com- bines a tapered thread profile, 100% thread engage- ment, cutting flutes and a flanged head. These unique features deliver a combination of friction fit and material compression that reliably lock a Fred- sert in place. Fredserts were designed to resist vibration, tensile loading and shear loading in the most demanding heavy-duty applications. Q. What materials are Fredserts made from? A. The fact that Fredserts can be quickly and easily removed and replaced using the same equipment provides substantial logistical cost benefits. If a customer wants to use a titanium threaded insert to take advantage of 40% weight savings, the best option is a Fredsert. Threaded insert manufactur- ers primarily offer Stainless and Alloy Steel inserts. The pricing for Stainless Steel Fredserts is very comparable to that of the competitors. Most competitors do not offer threaded inserts in Titanium, and those that do typically offer ‘non- standards’, resulting in a high price and several months lead time. Titanium Fredserts, on the other hand, are reasonably priced with short lead time. Request a quote and let us prove it to you. A. Fredserts are available in Titanium, Passivated Stainless Steel, Inconel, and Zinc-plated steel. For more details on these materials, please refer to page 7. For extremely corrosive applications, an electro- ceramic coating is available that eliminates poten- tial for galvanic corrosion. For more details, please refer to page 20. A. If you’ve reached the proper torque value and the Fredsert has yet to seat on the plate, you can go 10% above the recommended installation torque to see if it will seat. If it still will not seat, remove the Fredsert and run a tap down through the hole to clean out any burrs or debris that may be causing the problem. Q. What effect does Fredsert quality have on the installation process? Q. How do Fredserts compare with competitive inserts, such as Keensert, Rosan or Helicoil? A. Fredserts are manufactured to tight specifi- cations to ensure consistent and reliable perfor- mance. Fredserts are inspected on the latest visual inspection equipment to ensure that the critical design elements are produced within specifica- tion. The Fredsert inspection process requires that manufacturers closely monitor quality, eliminating potential for variation. Q. When a Fredsert is being removed, at what torque value will it break-away and start to back out? A. One of the most unique features of a Fredsert is that it doesn’t permanently lock into place. Instead, its patented geometry causes it to break away at approximately 80% of the recommended installa- tion torque value, allowing it to be quickly and easily removed and replaced using the same equipment. By comparison, other inserts on the market can only be removed by drilling them out and, in some cases, re-tapping to the next largest tap size. This drilling and/or tapping process is especially difficult if the insert is installed in a large structure or a tight enclosure because access and rigidity are limited. Another feature that sets Fredserts apart is the fact that Titanium Fredserts are available as a standard product, in addition to those made from Stainless, Inconel, and Zinc-plated steel. Titanium Fredserts deliver weight savings of 40% over steel inserts of the same size. Titanium inserts from other leading insert manufacturers are either not an option or they are quoted at a high price with sev- eral months lead time. A third key benefit that differentiates Fredserts from the competition is the fact that they create a watertight seal without the use of a thread lock- ing agent, such as Loctite. The combination of a tapered thread profile, 100% thread engagement, A. “Break-away value” is the torque that it takes to back the Fredsert out. After initial installation, break-away will be approximately 80% of installa- tion torque value. If the same insert is re-installed into the same hole, the break-away value will be slightly reduced. The reason is that a Fredsert actu- ally cuts material as it’s installed, so if you install a Fredsert into a hole for a second time, there’s no material to cut. Even so, the tapered thread profile, 100% thread engagement, and flanged head will still deliver a break-away torque of 65-75% of the recom- mended installation torque. Installation, Removal & Replacement Q. What equipment is required to install and remove Fredserts? Fredsert Application Q. How does a user decide which Fredsert size to use? A. - Installation tool (see ‘Drive Tool’ column on standard Fredsert pages) - Allen head cap screw (See ‘Bolt Length’ chart on page 30 for lengths) - Allen wrench to assemble driver to Fredsert - Torque wrench with the proper torque range for insert being installed A. The Fredsert size chosen depends on the bolt size being used in the application, as well as the thickness of the material it’s being installed into. The Fredsert product line has been developed with a generous safety factor between the bolt break- away torque and the Fredsert break-away torque to ensure that the Fredsert will not back out when the bolt is removed. Q. Is it necessary to use a thread-locking agent, such as Loctite, when installing Fredserts? Q. Can a Fredsert be removed and reused? A. No. There is no need for using Loctite for install- ing a Fredsert, unless you are doing a repair proce- dure. The combination of a tapered thread profile, 100% thread engagement, and a flanged head deliver a perfect seal on the OD thread of the insert. “Blind” Fredserts also deliver a watertight seal on the ID thread, because the ID thread bore doesn’t A. Fredserts can be removed and re-installed, as long as there’s no damage to the insert or the tapped hole. This is not recommended on a repeated basis, though, because when you install a Fredsert, the cutting edges can eventually become dull, leading to galling of the threads in your parent material. Q. Are there applications where a Fredsert is not the best option? A. The only case where competitive inserts have an advantage over Fredserts is in an application where 37 36 www.fredsert.com www.fredsert.com

  20. Frequently Asked Questions Notes the absolute minimum space claim is required. Because Fredserts feature a flanged head, they take up a slightly larger area than competitive inserts such as Helicoil and Keensert. Q. Are Fredserts effective in applications where a water-tight seal is needed? A. A key benefit that differentiates Fredserts from the competition is the fact that they create a 100% watertight seal without the use of a thread lock- ing agent, such as Loctite. The combination of a tapered thread profile, 100% thread engagement, and a flanged head deliver a perfect seal on the OD thread of the insert. “Blind” Fredserts also deliver a watertight seal on the ID thread, because the ID thread bore doesn’t break through the bottom of the insert. Marketing & Distribution Q. How can I request a quote for a custom Fredsert? A. On the Fredsert website, select the “Build Custom” tab, enter necessary information, and click the “Build” button. The design tool will build a custom Fredsert geometry specifically for your application. If you’d like to have a cost and lead time quote for this custom Fredsert, click on the “Request a Quote” button. Q. Are Fredserts available for commercial use? A. Fredserts are manufactured for commercial sale exclusively through Miller Precision Industries. Contact Miller Precision at 419-453-3251. Q. Who can I contact for Fredsert technical support? A. Contact Jason Deters, General Dynamics Land Systems, at 586-825-5664, or Miller Precision at 419-453-3251. 39 38 www.fredsert.com www.fredsert.com

  21. FREDSERT Threaded Inserts - Aircraft/Aerospace Industry - Military Vehicles - Pneumatic and Hydraulic Fittings - Agricultural Equipment OEMs - Ship and Submarine Applications - Automotive - Aluminum Engine Blocks & Castings - Transportation Industries - Truck, Train, Bus OEMs Fredsert Features & Benefits - Certified to MIL-I-45914A - Lower Total Cost - Simple Installation - Simple Replacement - Short Lead Time - Fully Automated Installation Option - Locking Internal Thread Available - Available in Variety of Materials - Built with Pride in the USA For more information contact: General Dynamics Land Systems email: fredsert@gdls.com or Miller Precision Industries tel: 419.453.3251 www.fredsert.com Product Catalog Revision M

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