Comparing Huck Bolts to Welding. 

Vibration-resistant Huck® Bolt provides a safe secure fastening solution that is gaining recognition as a great alternative to welding. Heavy-duty equipment manufacturers and structural fabricators engage welders in the mistaken belief this was the only way to ensure the intergrity of a joint. Now there is a choice with direct-tension swaged Huck® Bolts. In many instances Huck® Bolts are the superior hassle-free option to welding without any of its draw backs. Huck® bolts are an engineered fastener that has proven itself in demanding applications such as truck body fabrication, truck trailers, railroad tracks, railroad crossings, defence vehicles, planes and so much more.

Today's article we shall review how Huck fasteners are a better option than welding with numerous advantages. Huck® Bolts are a pin & collar combo that are available in a wide range of sizes in both steel and aluminium. An advanced engineered fastener that is installed via a direct tension technique with a Huck gun, this means the pin is pulled up whilst the collar is simultaneously swaged into the locking grooves of the pin, deforming the collar into the grooves. Then the tool breaks off the excess pintail and installation is complete. See How Huck® Works Here. This simple unique direct tension installation means the HuckBolt delivers consistent clamp for a strong, stable, and vibration-resistant joint.

6 Key benefits of vibration-resistant Huck Bolts over welding. 

SAFETY.

Welding is a potetially hazardous activity. Whether it's fires from a random sparks, dangerous fumes, or spent rods littering the assembly floor; welding can interfere with worksite safety and so much more. 

SIMPLICITY.

Huck® Bolts are easy to install with minimal amount of training. The Huck system only requires a trigger press to deliver high, consistent preload. No operator discretion or adjustment required.

SPEED.

A HuckBolt® can be installed in as little as 2 seconds due to the short time required to apply the tool to the pin and initiate the installation cycle. The quick & easy installation saves valuable assembly time.

COST SAVINGS.

Huck Bolts don't require certified trained labour to install. A quick visual inspection is all it takes to ensure a solid joint. Once installed, there are no ongoing maintenance costs.

STRUCTURAL INTEGRITY.

Huck® is famous for a high-level of vibration-resistance, creating semi-permanent joint that will perform in extreme conditions for years to come without the issues of weld fatigue.

RANGE.

Wide range of pin & collar Huck® bolts and structural rivets so there's bound to be a fastener to suit. At Aerobolt®, we have a comprehensive range that's readily available on our shelves. 

Huck Bolt vs. Welding: Comparison.

Looking at critical issues we list main considerations in point form. 

1. Strength and Durability:

• Huck Bolts: Huck bolts provide high-strength fastening and are known for vibration resistance, making them suitable for high-stress environments. They are mechanically applied, ensuring a consistent and secure joint. Huck bolts are often used in applications such as truck chassis, trailers, utes, emergency vehicles, planes, bridges, and railways.
• Welding: Welding fuses two metal surfaces together to form a single piece, often creating a joint stronger than the base materials themselves. It can withstand very high loads and is widely used in structural applications such as pipelines, shipbuilding, and heavy machinery.

2. Installation and Skill Requirement:

• Huck Bolts: Requires specific installation tools that don't require the skill associated with welding. The process is quicker and more controlled, as it involves simply placing and tightening the bolt with a specialised tool.
• Welding: Requires a skilled operator to ensure proper joint quality. It can be more time-consuming due to the need for proper alignment, weld penetration, and inspection. Welding also requires more extensive safety measures (e.g. protection from sparks and fumes).

3. Maintenance:

• Huck Bolts: Can be inspected and replaced relatively easily without altering the structure, making them low-maintenance and easy to replace.
• Welding: If a welded joint fails, repairing it requires cutting or grinding the weld and re-welding. It can be labour-intensive, and poor weld quality can lead to structural failure over time.

4. Flexibility and Disassembly:

• Huck Bolts: Ideal for applications where disassembly might be required. Bolted joints can be removed with minimal damage to the parts.
• Welding: Permanent and cannot be easily undone without damaging the components. Disassembling welded joints requires cutting or grinding, which can weaken the material.

5. Environmental Factors:

• Huck Bolts: More resistant to fatigue and vibration over time, especially in heavy-duty and high-vibration environments (e.g., railways, trucks).
• Welding: Can be prone to cracking under constant vibration or fatigue stress if not performed correctly. It is sensitive to environmental conditions (e.g., temperature, moisture) during the welding process.

6. Cost:

• Huck Bolts: Generally, the tools and fasteners are specialised, which can increase upfront costs. However, lower labour costs and ease of installation can often offset this cost. 
• Welding: Equipment can be costly, and labour costs are higher due to the need for skilled welders. However, in high-load applications, welding may be the most economical long-term solution.

Applications:

• Huck Bolts: Railways, bridges, trucks, trailers, buses, aeroplanes, vehicles, and other high-vibration applications.
• Welding: Shipbuilding, construction, automotive frames, pressure vessels, and pipelines.

Problems with welding.   

Welding is time consuming, particularly in applications where in-depth inspection procedures are required. Welding requires skills, often highly paid technicians who can be both difficult to find and to retain. The heat generated by welding can often reduce the strength of the metals being joined, and damage critical surface coatings. In addition, welding dissimilar metals or pieces of varying sizes can be a challenge. Welding also often requires an on-going process of inspection, with many of these procedures being both costly and time consuming. And as most companies who make extensive use of welding as part of their manufacturing or fabrication process have discovered, the removal and/or rework of a weld can be problematic. Also, welding is a dirty, dangerous process with toxic fumes. Safety is a critical issue, since many fires have been started by a random spark created while welding. At the same time, spent rods and other remnants of the welding process are an ongoing housekeeping issue in workshops where welding is performed on a regular basis.

HuckBolt® – Eliminating the Effects of Vibration

In addition to providing faster, safer, and more accurate joining of pieces, there are several unique design elements of HuckBolts that also ensure their ultimate resistance to the effects of vibration. Compared to conventional nut and bolt installations, which can loosen in high-vibration environments, HuckBolts have proven to be impervious to the effect of vibration in a number of very demanding applications. The secret to this performance difference can be found in the unique HuckBolt design, in which the collar is fully swaged into the locking grooves of the pin.

In contrast, conventional nut and bolt fasteners leave a slight gap between the crest and root of the threads when installed. This gap becomes problematic when exposed to transverse vibration, and can allow for rapid loss of clamp.

Another key difference between HuckBolt® and conventional fastener installations is found in the structure of the threads of each of the fastening systems. Instead of the deep threads required to achieve a tolerance fit between conventional nuts and bolts, the HuckBolt pin requires only shallow locking grooves into which the collar is swaged. The shallow design of the locking grooves allows for a much larger pin root radius, which contributes significantly to the fatigue strength – up to 5 times that of a conventional nut and bolt. Overall, a HuckBolt lockbolt provides superior vibration resistance, as indicated by the study charted below

Huck® Structural Blind Rivets.

For applications where only one side of the joint material is accessible, performance-engineered Huck® rivets can often meet design requirements. These blind fasteners can deliver the shear and tensile strength to meet the demands of a number of heavy-duty applications. Available in diameters ranging from 4.8 mm (3/16) to 15.9 mm (3/4), these blind fasteners offer a combination of strength and vibration resistance, easy installation, and a high level of safe operation.

Huck Bolt V's Welding Summary.

Faster. Safer. Simpler & more cost-effective! That's Huck® and proven with several decades of flawless performance in trucking, rail, automotive, agriculture and many other industries. Find out why so many forward-thinking design engineers have made the switch from welding to HuckBolt® with the assistance of Aerobolt®. 

• Use Huck Bolts when you need high vibration resistance, easier installation, and future disassembly.
• Use Welding for permanent, strong joints where disassembly is not required and higher shear and tensile strength is needed.

It should be noted that HuckBolts and Huck structural blind riverts leave a protrusion, which may not be acceptable for some applications. However, there are many applications, where welding has been traditionally employed, in which these fasteners are a viable alternative. Engineered for easy installation, and long, reliable life, these direct-tension HuckBolts and structural blind fasteners can be a faster, more cost efficient, and safer alternative to traditional welding processes.

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