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ARMASERT BRASS INSERTS

ARMASERT BRASS INSERTS

Other product brochures available:

CONTENTS
Introduction 3 3 4 5 6 7 8 9 10 11 Product Range ArmaSert ArmaSert Sonic I ArmaSert Sonic II ArmaSert Expansion Performance Data Performance Data Specials Notes

TECHNICAL DATA & TOOLING

TECHNICAL DATA & TOOLING

POWER TOOLING

TWINCOIL

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2
POWER TOOLING
High volume, high speed power installation is achievable with the ArmaCoil range of Pneumatic or Electrically Operated Power Tools. Pneumatic Tooling can be hand held or bench mounted for increased production output, especially if tape feed inserts are used. Suitable for Free Running or Screw Locking ArmaCoil inserts. The Electric Inserting Tool is a fully automatic tool which installs the ArmaCoil insert to depth and automatically reverses out in a single lever action.

The comprehensive catalogue for ArmaCoil inserts. All the data on material and finishes available, tool selection and ordering codes. New additions are the ArmaCoil dimensions in their free state plus Prevailing Torque figures for Screw Lock Inserts. Professional, workshop and thread repair kits are now included.

3 TWINCOIL

TwinCoil inserts are two inserts, one inside the other, for the repair and/or recovery of stripped or off-centre tapped holes. The outer TwinCoil is always Free Running and the inner can be either Free Running or Screw Locking. Lengths are from 1.5D upwards, 1D inserts due to the shorter inner insert are not recommended. TwinCoil Kits come complete with tap, Outer Inserting Tool and both Inner and Outer inserts. The Inner Inserting Tool is not included as it is a standard tool.

Introduction
Armstrong Precision Components have produced Inserts for Plastic Mouldings for over 40 years. The stringent quality standards applied to the ArmaCoil wire thread insert, used extensively in the Aerospace industry, are reflected in the quality of our ArmaSerts.

Product Range
The original Armstrong female threaded Brass Insert. A threaded insert with a knurled outside diameter suitable for cold push or hot installation into thermoplastic materials. The insert is symmetrical which lends itself to automatic bowl feeding and placement for increased production rates. Available in sizes from M2.5 to M6 and #4 to 1/4.

Sonic I

ArmaSert Sonic I is made from a high strength grade of brass suitable for installation by Ultrasonic vibration or heat insertion. Counterbores at each end of the thread eliminate the risk of riveting the thread over during ultrasonic assembly. The symmetrical body design incorporates undercuts to enhance the pull-out strength. Designed to fit into a near parallel hole with a maximum taper of 0.05mm. Available in sizes from M2.5 to M6 and #4 to 1/4.

Sonic II

A true Ultrasonic installation insert with knurls, undercuts and vanes to give maximum installation strength in moulded tapered holes. Each size is available in two body lengths, long and short, to give the designer greater flexibility in the choice of insert. Although designed for ultrasonic installation the insert can be installed using heat. Available in sizes from M2.5 to M6 and #4 to 1/4.

ArmaSert Expansion is a two-piece insert for use in thermoset plastics. The body of the insert is fitted with a small spreader plate which, when Depressed, forces the knurled portion into the parent material creating a high strength re-useable thread. Designed to fit in blind, flat bottomed holes, the installation is simple and requires no specialist tooling.

Armstrong Precision Components manufacture a vast rang of specially designed inserts to meet the requirements of individual customers. Our technical department is available to discuss your particular needs. See page 10 for guidelines on designing special inserts.

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Specials

Expansion

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ARMASERT Heat or Cold Installation

Properties
Knurled brass body internally threaded. Symmetrical design for automatic assembly. Pilot ends for accurate location. High pull-out and torque resistance. Fast installation.

THREAD SIZE
M2.5 X 0.45 M3 X 0.5 M3 X 0.5 M3 X 0.5 M3.5 X 0.6 M3.5 X 0.6 M4 X 0.7 M4 X 0.7 M5 X 0.8 M6 X 1.0

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LENGTH (MM)
5.59 4.75 5.59 5.59

Product Data METRIC

PRODUCT CODE
742318256 742318322 742320914 742318314

HOLE DIAMETER (MM)

4.01 / 3.96 4.01 / 3.96 3.81 / 3.76 4.01 / 3.96

MIN. HOLE DEPTH (MM)

6.35 5.50 6.35 6.35 7.11 7.87 5.26 7.87 8.14 10.29

6.35 7.11

742318421 742318439

4.80 / 4.75 4.80 / 4.75

4.50 7.11 7.87

742318553 742318538 742318645

5.61 / 5.56 5.61 / 5.56 6.40 / 6.35 8.03 / 7.98

9.50

742318678

UNC
THREAD SIZE
4-40 6-32 6-32 6-32 8-32 8-32 8-32 10-24 10-24
1 4

LENGTH (INCH)
0.220 0.205 0.250 0.280 0.205 0.280 0.323

PRODUCT CODE
742311111 742311202 742311210 742311236 742311319 742311327 742311343 742311434 742311442 742318686

HOLE DIAMETER (INCH)

0.158 /0.156 0.189 /0.187 0.189 /0.187 0.189 /0.187 0.221 /0.219 0.221 /0.219 0.221 /0.219 0.252 /0.250 0.252 /0.250 0.316 / 0.314

MIN. HOLE DEPTH (INCH)

0.250 0.235 0.280 0.310 0.235 0.310 0.353 0.340 0.405 0.405

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UNF
THREAD SIZE
10-32 10-32

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0.310 0.375 0.375

LENGTH (INCH)
0.310 0.375

PRODUCT CODE
742312432 742312440

HOLE DIAMETER (INCH)

0.252 / 0.250 0.252 / 0.250

MIN. HOLE DEPTH (INCH)

0.340 0.405

HOLE SIZE
The hole sizes specified are for general guidance and may require slight adjustment to suit different materials or methods of installation. The design of the hole is parallel with a maximum of 0.05mm (0.002) moulding taper. We will be pleased to quote for non-standard lengths and thread forms.
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ARMASERT SONIC I Heat or Ultrasonic Installation

Properties
Completely symmetrical body requiring minimal orientation. Spigot at each end providing initial location in the hole reducing the risk of misalignment. Reduced moulding assembly scrap through missing inserts. Ideal for automatic feeding and installation. Increased pull-out forces. High jack-out torque.

THREAD SIZE
M2.5 X 0.45 M3 X 0.5 M3.5 X 0.6 M4 X 0.7 M5 X 0.8 M6 X 1.0

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LENGTH (MM)
5.8 5.8

Product Data METRIC

PRODUCT CODE
74241781301 74241781302

HOLE DIAMETER (MM)

4.0 4.0

MIN. HOLE DEPTH (MM)

6.8 6.8 8.2 9.2 10.5 14.0

7.2

74241781303

4.8

8.2 9.5

74241781304 74241781305

5.6 6.4 8.0

12.7

74241781306

UNC
THREAD SIZE
4-40 6-32 8-32
1 4

LENGTH (INCH)
0.226 0.281 0.321

PRODUCT CODE
74241781501 74241781502 74241781503

HOLE DIAMETER (INCH)

0.157 0.189 0.220

MIN. HOLE DEPTH (INCH)

0.268 0.321 0.362 0.551

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0.500

74241781505

0.315

UNF
THREAD SIZE
10-32

LENGTH (INCH)
0.375

PRODUCT CODE
74241781405

HOLE DIAMETER (INCH)

0.252

MIN. HOLE DEPTH (INCH)

0.413

Hole sizes specified are for general guidance. They may require slight variation to suit the plastic material and different methods of moulding. The design of the hole is parallel with a maximum of 0.05mm (0.002) moulding taper.

WALL THICKNESS
Minimum wall thickness required for maximum assembled strength is 50% of the hole diameter for most materials. Pre-production trials are recommended. We will be pleased to quote for non-standard lengths and thread forms.

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HOLE SIZE

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ARMASERT SONIC II Ultrasonic Installation

Properties
Designed to fit moulded tapered holes. Knurled and vaned brass body internally threaded. Specially designed for ultrasonic installation. Providing high pull-out and torque resistance. Rapid installation. Special design permits automatic feeding. Lends itself to heat installation in many materials.

THREAD SIZE
M2.5X0.45 M2.5X0.45 M3X0.5 M3X0.5 M3.5X0.6 M3.5X0.6 M4X0.7 M4X0.7 M5X0.8 M5X0.8 M6X1.0 M6X1.0

LENGTH (MM) LONG (MM)

5.56 6.35 6.35 7.92 11.13 12.70

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SHORT (MM)
3.43

Product Data METRIC

PRODUCT CODE
742501310 742501307

DIAMETER A (MM)
4.37 4.37

DIAMETER B (MM)
3.71 3.99

HOLE SIZE MIN DEPTH (MM)

6.32 4.19 7.11 4.57 7.11 4.57 8.69 5.46 11.89 7.49 13.46 8.38 4.06/4.01 4.06/4.01 5.26/5.21 5.26/5.21

DIA. E (MM)
3.61/3.56 3.91/3.86

DIA. F (MM)

742501331

5.56

4.83

4.72/4.67

3.81

742501349

5.56

5.16

5.08/5.03

742501372

5.56

4.83

4.72/4.67

5.26/5.21 5.26/5.21 5.97/5.92 5.97/5.92 8.03/7.98 8.03/7.98 9.25/9.19 9.25/9.19

3.81

742501380

5.56

5.16

5.08/5.03

742501414

6.35

5.41

5.31/5.26

4.70 6.73

742501422 742501455 742501463 742501497

6.35 8.33 8.33 9.53

5.84 7.19 7.82 8.43

5.77/5.72 7.09/7.04 7.72/7.67 8.18/8.13

7.62

742501500

9.53

8.99

8.89/8.84

UNC
THREAD SIZE
4-40 4-40 6-32 6-32 8-32 8-32 10-24 10-24
1 -20 4 1 -20 4

LENGTH (MM) LONG (INCH)

0.219 0.250 0.312 0.375

SHORT (INCH)
0.135 0.150 0.185

PRODUCT CODE
742500374 742500382 742500473 742500465 742500531 742500549

DIAMETER A (INCH)
0.172 0.172 0.219 0.219 0.250 0.250

DIAMETER B (INCH)
0.146 0.157 0.190 0.203 0.213 0.230

HOLE SIZE MIN DEPTH (INCH)

0.249 0.165 0.280 0.180 0.342 0.215 0.405 0.225 0.530 0.330 0.160/0158

DIA. E (INCH)
0.142/0.140 0.154/0.152 0.186/0.184 0.200/0.198 0.209/0.207 0.227/0.225

DIA. F (INCH)
0.160/0.158 0.207/0.205 0.207/0.205 0.235/0.233 0.235/0.233

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742500610

0.297 0.297

0.251 0.272

0.247/0.245 0.268/0.266

0.278/0.276 0.278/0.276 0.364/0.362 0.364/0.362

0.225

742500615 742500739 742500741

0.500

0.375 0.375

0.332 0.354

0.322/0.320 0.350/0.348

0.300

UNF
THREAD SIZE
10-32 10-32
1 -28 4 1 -28 4

LENGTH (MM) LONG (INCH)

0.375 0.225 0.500 0.300

SHORT (INCH)

PRODUCT CODE
742500614 742500621 742500710 742500715

DIAMETER A (INCH)
0.297 0.297 0.375 0.375

DIAMETER B (INCH)
0.251 0.272 0.332 0.354

HOLE SIZE DIA. E (INCH)

0.247/0.245 0.268/0.266 0.322/0.320 0.350/0.348

DIA. F (INCH)
0.278/0.276 0.278/0.276 0.364/0.362 0.364/0.362

MIN DEPTH (INCH)

0.405 0.255 0.530 0.330

8 F

HOLE SIZE
A tapered hole is specified for easier mould release and more accurate positioning of the insert. The E and F diameters tabulated are suggested for general types of thermoplastics. Specific applications may require variations to these figures which should be established by production trials.

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ARMASERT EXPANSION Thermoset Insert

Properties
Suitable for thermoset plastics. Knurled brass body internally threaded. Integral spreader plate for positive fixing. High strength re-usable thread. Fast economical assembly. For use in blind holes.

THREAD SIZE
M3X0.5 M3.5X0.6 M4X0.7 M4X0.7 M5X0.8 M6X1.0

INSERT LENGTH (MM) THREAD LENGTH (MM)

6.35 7.95 7.95 9.50 9.50 4.78 6.38 7.95 7.95 6.38

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PRODUCT CODE
741154215 741160212 741160618 741164610 741168215 741157218

Product Data METRIC

BODY DIAMETER (MM)

3.96 5.56 5.56 6.35 7.95 4.78

MANUAL TOOL
748100062 748100310 748100336 748100443 748100500 748100252

SEMI-AUTO TOOL
748300134 748300035 748300068 748300068 748300076 748300100

12.70

11.13

UNC
THREAD SIZE
4-40 5-40 6-32 6-32 8-32 8-32 10-24 10-24
1 -20 4

INSERT LENGTH (INCH) THREAD LENGTH (INCH)

0.250 0.313 0.313 0.375 0.313 0.375 0.375 0.438 0.188 0.250 0.250 0.313 0.250 0.313

PRODUCT CODE
741110217 741111512 741112510 741112718 741113518 741113716

BODY DIAMETER (INCH)

0.156 0.188 0.188 0.188 0.219 0.219

MANUAL TOOL
748100039 748100104 748100161 748100187 748100310 748100336

SEMI-AUTO TOOL
748300019 748300027 748300043 748300043 748300068 748300068 748300076 748300076 748300100

0.313 0.375

741114714 741114813

0.250 0.250

748100419 748100427

0.500

0.438

741115919

0.313

748100500

UNF
THREAD SIZE
10-32 10-32 10-32

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INSERT LENGTH (INCH) THREAD LENGTH (INCH)

0.313 0.375 0.250 0.313 0.375

PRODUCT CODE
741120513 741120711 741120810

BODY DIAMETER (INCH)

0.250 0.250 0.250

MANUAL TOOL
748100435 748100443 748100468

SEMI-AUTO TOOL
748300076 748300076 748300076

0.438

HOLE SIZE
Hole preparation can be drilled or moulded. The diameter should not exceed 0.05mm (0.002) above the body diameter of the insert. Any moulding taper should also be within these limits. The base of the hole should be flat bottomed with at least 12 the insert diameter of material below. Hole depth should equal the length of insert. A minimum wall thickness of 2/3 body diameter is recommended. Certain applications may tolerate thinner wall sections.

SEATING PRINCIPLE
Place the insert into the hole and ensure it is pushed down to depth. Depress the spreader plate using the correct tool until the spreader is fully seated. The knurled portion of the body is forced outwards creating high frictional retention.

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PERFORMANCE DATA
Many tests can be performed on assembled inserts to establish their performance capabilities. The two tests that ArmaSert inserts have been subjected to are: Tensile the ability of the insert to withstand a straight pull load before failure. Jack-out the rotational force which will cause the insert to turn or pull out of the hole. These tests were performed in our own laboratory and give general guidelines for insert selection.

ArmaSert TENSILE
SIZE
M3 X 5.59

(N)
MATERIAL
PERSPEX ABS

INSTALLATION METHOD
ULTRASONIC HEAT ULTRASONIC HEAT HEAT HEAT HEAT ULTRASONIC ULTRASONIC ULTRASONIC ULTRASONIC HEAT

SAMPLE 1
1846 3248 756 845

SAMPLE 2
1912 3108 756 889

SAMPLE 3
1801 2969 734 911

SAMPLE 4
1934 3148 711 934

SAMPLE 5
1868 3019 734 845 3905 5520 1125 1982 6028 10412 2132 3616

PERSPEX M4 X 7.11 ABS

PERSPEX M6 X 9.5 ABS

JACK-OUT
SIZE
M3 X 5.59

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3856 1255 6038 1813 3666 1275 6556 1933 3487 1275 6556 1893 3786 1265 6277 2002 5679 1833 6107 2012 5958 1893 5699 1933 10810 3357 10711 3218 10362 3337 10561 3437

(Nm)

MATERIAL
PERSPEX ABS

INSTALLATION METHOD
ULTRASONIC HEAT HEAT HEAT HEAT HEAT ULTRASONIC ULTRASONIC ULTRASONIC ULTRASONIC ULTRASONIC HEAT

SAMPLE 1
1.412 0.678 2.486 1.356 6.779 3.390 1.695 0.678 2.712 2.260

SAMPLE 2
1.243 0.960 3.107 1.356 6.214 3.107 5.649 1.469 0.565 3.954 2.488

SAMPLE 3
1.186 1.130 2.825 1.638 6.214 2.542 7.344 1.582 0.678 4.519 3.390

SAMPLE 4
1.356 1.243 3.390 1.469 7.344 2.825 6.779 1.469 0.734 3.954 3.672

SAMPLE 5
1.130 1.695 1.130 0.791 3.390 3.954 1.808 3.672 6.779 16.948 2.825 6.779

PERSPEX M4 X 7.11 ABS

PERSPEX M6 X 9.5 ABS

16.948 7.344

16.948

16.948

16.948

TENSILE
The force in Newtons (N) required to pull the insert out of the material. The insert is pulled through a hole considerably larger than the diameter of the insert.

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JACK-OUT
The torque required in Newton Metres (Nm) to cause the insert to turn in the moulding. As with the Tensile test the clamped member does not enhance the performance figures.

These tests give an indication of the retention properties between the moulding and the insert.
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PERFORMANCE DATA ArmaSert Sonic I TENSILE (N)

SIZE
M4 X 8.2

MATERIAL
NYLON 66 ABS NYLON 66

INSTALLATION METHOD
HEAT ULTRASONIC HEAT HEAT ULTRASONIC HEAT HEAT ULTRASONIC HEAT

SAMPLE 1
3334 2307 3326 4242 3160 3960 7249 5538 6603

SAMPLE 2
3610 2659 3204 4575 3179 3741 6590 5175 6953

SAMPLE 3
3375 2614 3027 4306 2830 3460 7439 5524 7443

SAMPLE 4
3437 2472 2967 4256 3316 3811 7772 6029 7458

SAMPLE 5
3246 2617 3265 5177 3018 3981 7144 6394 7137

M5 X 9.5

ABS NYLON 66

M6 X 12.7

ABS

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INSTALLATION METHOD
HEAT HEAT HEAT HEAT ULTRASONIC HEAT HEAT

JACK-OUT
SIZE
M4 X 8.2 M5 X 9.5

(Nm)

MATERIAL
NYLON 66 ABS NYLON 66 ABS NYLON 66 ABS

SAMPLE 1
2.95 1.70 3.00 2.70 7012 6.80 5.90

SAMPLE 2
2.90 1.40 3.20 2.60 6567 7.00 5.10

SAMPLE 3
3.30 1.50 4.00 2.25 6438 5.60 4.30

SAMPLE 4
2.90 1.55 4.10 2.55 5931 7.80 4.00

SAMPLE 5
3.25 1.85 3.95 2.45 7053 5.80 3.50

M6 X 12.7

ArmaSert Sonic II TENSILE (N)

SIZE MATERIAL
PERSPEX M3 X 6.35 ABS

INSTALLATION METHOD
ULTRASONIC HEAT ULTRASONIC HEAT ULTRASONIC HEAT ULTRASONIC HEAT ULTRASONIC HEAT ULTRASONIC HEAT

SAMPLE 1
3885 2889 1112 1023 4085 5460 1846 1673 10013 11010 3387 2869

SAMPLE 2
3945 2550 1112 1089 3786 6078 1833 1574 9964 10910 3387 2929

SAMPLE 3
3836 2550 1112 1112 4184 4424 1793 1654 9615 11159 3288 3019

SAMPLE 4
3866 3048 1089 1045 3945 5878 1793 1703 9914 11109 3417 3048

SAMPLE 5
3866 3288 1089 1045 4145 5709 1863 1574 9764 10810 3457 2550

PERSPEX M4 X 7.92 ABS

M6 X 12.70

JACK-OUT
SIZE
M3 X 6.35

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ABS

PERSPEX

(Nm)
INSTALLATION METHOD
ULTRASONIC HEAT ULTRASONIC HEAT ULTRASONIC HEAT ULTRASONIC HEAT ULTRASONIC HEAT ULTRASONIC HEAT

MATERIAL
PERSPEX ABS PERSPEX

SAMPLE 1
2.542 1.808 1.695 1.017 6.214 5.084 3.390 2.260 11.298 11.298 3.954 3.446

SAMPLE 2
2.825 1.921 1.469 0.847 5.932 4.519 2.825 3.107 11.298 12.428 4.237 3.672

SAMPLE 3
3.107 2.147 1.130 1.017 5.649 4.802 3.672 2.825 9.886 12.428 3.954 4.237

SAMPLE 4
2.825 2.304 1.130 0.791 5.649 4.519 3.107 2.825 11.298 14.123 4.519 3.954

SAMPLE 5
2.825 1.977 1.017 0.847 5.084 4.519 3.390 3.390 11.298 14.123 3.954 4.237

M4 X 7.92 ABS PERSPEX M6 X 12.70 ABS

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ARMASERT SPECIALS

Armstrong Precision Components can produce special inserts to customer designs.

Our Technical staff are available to assist in the selection and design of the insert.

Design Guidelines
INSTALLATION METHODS
Ultrasonic Heat Cold Moulded-in. For maximum strength.

Fast, high strength post moulded installation but equipment cost high. Good post moulded strength with less expensive equipment.

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Lower moulded strength relying on friction retention but minimal equipment cost.

INSERT DESIGN
Class of thread

6H for Metric 3B for Unified

Diamond Knurled Body to prevent rotation. Undercuts for good pull-out resistance. Knife-edge vanes for pull-out in harder materials. Pilot ends for location in the hole reducing alignment problems. Threads counter-bored at each end for ultrasonic installation (threads can be riveted over during installation). Cold or heat inserts have countersinks for improved screw engagement.
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IMPROVING PERFORMANCE

Cold installation will not benefit from undercuts (solid plastic cannot flow into grooves). Diamond knurls will resist rotation (torque) and pull-out. Increasing the coarseness of the knurl may not increase the performance. The softened plastic will not always flow completely to fill the valleys of the knurl. Additional heat or dwell time during installation can reduce the strength properties of the plastic. Straight knurls will give maximum resistance to torque but no resistance to pull-out. Undercuts give maximum resistance to pull-out but no resistance to rotation. The best compromise is a combination of diamond knurls and undercut(s). Deeper or wider undercuts may not improve the performance as the displaced plastic cannot completely fill the voids.

NOTES

Product Quality Assurance

Armstrong Precision Components Ltd is approved to: ISO9001: 2000 Plus AS9100 Rev B ISO14001: 2004 OHSAS 18001: 1999 Investor In People CERT No: FM00049 CERT No: EMS507767 CERT No: OHS507769

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Armstrong Precision Components Ltd
Stoneferry Business Park, Foster Street, Hull HU8 8BT United Kingdom Main Sales Accounts Technical t: t: t: t: +44 +44 +44 +44 (0)1482 (0)1482 (0)1482 (0)1482 325425 591569 591589 591579 f: +44 (0)1482 327229 f: +44 (0)1482 326986 f: +44 (0)1482 591576 e: info@apc-caparo.com w: www.apc-caparo.com
0207-2K

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