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AIPS01-02-016
Issue 4
Page 1 of 13
April 2010
AIPS
Airbus Process Specification
Copyright reserved
Contents
1 Scope
2 Normative references
4 Engineering requirements
5 Technical qualification
8 Rework
1 Scope
This Airbus Process Specification defines the Engineering requirements for installation of rivetless nutplates.
This specification does not give detailed instructions; these are given in the Process Instructions (PI) / Airbus
Process Instruction (AIPI) and the Work Instructions.
This specification shall not be used as an inspection document.
It shall be applied when mentioned in the relevant standard, material specification or Definition Dossier.
2 Normative references
Only normative references cited in the text are listed hereafter.
The latest issue of the publication referenced shall be used.
ABS1295 Nutplate, rivetless, floating, variable counterbore
AIMS 03-02-004 Aluminium alloy (2024), Solution treated, controlled stretched and naturally aged (T351),
plate
AIMS 03-04-009 Aluminium alloy (2024), Solution treated, controlled stretched and naturally aged
(T351),Clad sheet and strip 0,8 ≤a≤ 6mm, Standard surface quality
AIMS 03-04-010 Aluminium alloy (2024), Solution treated and naturally aged (T42),Clad sheet and strip 0,2
≤a≤ 6mm, Standard surface quality
AIMS 03-04-011 Aluminium alloy (2024), solution treated and naturally aged (T3), clad sheet and
strip0,2mm ≤ a ≤ 6,0mm, Special surface quality
AIMS 03-04-012 Aluminium alloy (2024), solution treated and naturally aged (T42), clad sheet, plate
andstrip 0,2mm ≤ a ≤ 12,0mm, Special surface quality; Chemical milling quality
AIMS 03-04-013 Aluminium alloy (2024), solution treated controlled stretched and naturally aged clad
sheet, plate and strip 0,8mm< a ≤ 12,0mm, Special surface quality; Chemical milling
quality
AIMS 03-04-014 Aluminium alloy (2024), Solution treated and naturally aged (T3),Clad sheet and strip 0,2
≤a≤ 6mm, Standard surface quality
AIMS03-04-053 Aluminium alloy (2198) solution treated, controlled stretched and artificially aged (T851)
AIMS 03-05-009 Aluminium alloy (7175) solution treated, controlled stretched and artificially aged (T73511)
extruded bar and section 1,2 < a or D ≤ 100 mm with peripheral coarse grain control.
AIMS 03-05-029 Aluminium alloy (7050) solution treated, controlled stretched and artificially aged
(T73511),extruded section 1,2 mm ≤ a ≤ 38,0 mm with peripheral coarse grain control.
AIMS 03-18-002 Titanium Ti-P99002, annealed, sheet and strip 0,1 mm < a ≤ 6,0 mm.
AIPS 01-01-004 Installation of solid rivets
AIPS 01-02-003 Preparation of holes in metallic materials for fastening
3.1 Definition
Table 1:
Description Definition
The minimum thickness of the material the rivetless nutplate shall
‘Grip Length’
be installed into.
Hole in the base structure in which the rivetless nutplate shall be
‘Installation hole’
installed into.
‘Concave surface installation' An installation situation whereby the nutplate is installed on a
concave structure. Depending on the radius of the concavity, a
certain gap may occurr due to edge clashing of the retainer (see
figure 1).
Gap
Concave structure
sheet
Clip
Nut element
Retainer
Mandrel
Base structure
This Airbus Process Specification covers the requirements for the installation of rivetless nutplates per ABS1295
into the following materials:
• Al 2024 per
o AIMS 03-02-004
o AIMS 03-04-009
o AIMS 03-04-010
o AIMS 03-04-011
o AIMS 03-04-012
o AIMS 03-04-013
o AIMS 03-04-014
• Al 7050 per
o AIMS 03-05-029
• Al 7075 per
o DAN26, code H
• Al 7175 per
o AIMS 03-05-009
• Al-Li per
o AIMS 03-04-053
The dimensions of installation equipment shall be considered by the design and may limit the applicability of
rivetless nutplates per ABS1295.
Installation of rivetless nutplates is allowed on plane or convex surfaces without any restrictions.
On concave surfaces there may be a gap resulting from a clash between retainer bottom and the sheet surface
(refer to figure 1). That gap shall not exceed 0,2 mm, otherwise this process is not applicable.
4 Engineering requirements
Engineering requirements are minimum requirements specified by Responsible Engineering to ensure optimal
performance of the manufacturing process.
All Engineering requirements have to be met and controlled in production.
Rivetless nutplates shall only be installed into one single parent material.
Holes shall be prepared depending on the retainer diameter code and the variant as specified in the drawing to the
dimensions of Annex A, Table A.1, in accordance with the requirements on drilling per AIPS01-02-003.
Sealant shall be applied directly on the bottom of the retainer. The installation shall be conducted within the open
time of the product.
Sealing is sufficient, if there is a visible and steady sealant seam without gaps around the retainer.
The orientation of the retainer on the base structure can be freely chosen by the shop unless there are any
specifications given in the drawing.
The nose piece of the installation tooling shall be in full contact with the sheet surface (no gaps allowed) before
engaging the mandrel.
The mandrel shall be discarded after installation and shall not be re-used.
There is no need of paint stripping from the surface of the base sheet.
For the protection of the retainer by means of sealant and varnish, the specifications of AIPS07-01-006 shall be
followed.
Key Characteristics acc. to EN9103 are defined by responsible engineering based on a risk analysis for parts
manufactured by this process. Key characteristics shall be defined on product level and if necessary also on
process level.
They shall be subject to variation control by production organization according to EN9103.
Key Characteristics do not relieve the production organization from meeting all engineering requirements defined in
this document.
5 Technical qualification
The Technical Qualification shall be performed, according to the relevant Airbus procedure.
Representative test panels shall be produced in accordance with the dimensions shown in Appendix B – Process
qualification, Figure B1. Two test panels shall be produced for each relevant part number with sheet thicknesses
equal to the minimum thickness as specified by the applicable part standard for an individual part number.
Each test panel shall have twelve installation holes drilled using a suitable procedure meeting the requirements as
given in chapter 4.1.2. All hole diameters shall be measured and recorded in 0° and 90° direction.
Twelve rivetless nutplates in accordance with the specified part number shall be installed into the panel using
suitable installation tooling in accordance with the specifications of this AIPS. After installation, six rivetless
nutplates shall be torqued out in accordance with the specifications of NASM1312-31. The individual torque values
and failure modes shall be recorded.
The remaining six installed Rivetless nutplates shall be pushed out in accordance with the specifications of
NASM25027, chapter 4.5.3.5. The individual push loads and failure modes shall be recorded.
The results of the installation trial shall be compiled into a report to include the following information as a minimum.
• Check if sealant was applied under nutcage and that sealant forms a visible and closed seam.
• Check if surface protection in holes was re-treated as specified.
9 Rework
9.1 Repairs
Rivetless nutplates shall never be out-levered e.g. with a screwdriver. Only appropriate tooling shall be used to de-
install rivetless nutplates.
There are two basically different methods of repair for rivetless nutplates:
It shall be ensured that the nosepiece is in full contact with the retainer. Gapping is not allowed. The retainer shall
be pushed out completely with the tool.
Retainers can be replaced by either oversize rivetless nutplates (option A) or by riveted anchor nuts per
NAS1791/92 (option B), whereby option A shall be preferred. Option B shall only be used if agreed by the
responsible design office.
After reaming, the oversize rivetless nutplate shall be installed in accordance to the requirements of this AIPS.
This variant shall only be used for regular sized rivetless nutplates.
Any remaining metallic blank areas shall be re-protected in accordance with AIPS05-02-011.
Interfay sealant as specified per TN A 007 10003 shall be applied on the bottom of the nutcage in accordance with
AIPS05-05-001. The nutcage bottom shall be completely covered with sealant.
The riveted anchor nut shall be installed with aluminium solid rivets per EN6101 following the installation
parameters as specified by AIPS01-01-004.
Annex A
Hole dimensions
Table A.1: Installation hole diameters for regular sized rivetless nutplates per ABS1295 [in mm]
Table A.2: Installation hole diameters for oversized rivetless nutplates per ABS1295 [in mm]
Annex B
Process qualification – Test plate
Hole 1 Hole 12
2D Hole
2D Hole 2D Hole
RECORD OF REVISIONS
Clause
Issue Description of modification
modified
1 New standard
07/06
2 Clause 1 Removed: [...] according to the part standard ABS1295.
01/09 Clause 2 Normative references:
Removed: AIPS03-03-007, AIPS09-01-002
Added: TN10003, AIPS01-01-004, AIPS05-02-011, NASM1312, NASM25027
Clause 3.1 Definition of installation hole added
Figure 1 added
Figure 2 and 3 shifted to this chapter
Clause 3.3 Application remark for plane and convex surfaces added
Gap allowable (0,2mm) for concave surfaces specified
Clause 4.1.1 Added: “[…] before installation.”
Sentence added: “It is not permitted to disassemble the rivetless nutplate system
Clause 4.1.2 before installation.”
Complete wording deleted and replaced by “It is imperative, that the rivetless
nutplates are installed into metallic blank holes, i.e. existing paint inside the
installation hole shall be removed prior to installation, together with any existing
anodized layer. Holes shall be prepared depending on the retainer diameter code
and the variant as specified in the drawing to the dimensions of Appendix A – Hole
dimensions, Table 2 in accordance with the requirements of AIPS01-02-003.”
Headline renamed from ”Use of sealant” to “Sealing of rivetless nutplate”
Clause 4.1.3 Specification added: “Sealant can either be applied directly on the bottom of the
retainer or on the base structure or both. A contamination of the knurled flange
with wet sealant is permitted.”
Clause 4.1.4 Specification added: “The orientation of the retainer on the base structure can be
freely chosen by the shop unless there are any specifications given in the
drawing.”
Clause 4.1.5 Chapter added
Clause 4.1.6 Former chapter “Quality requirements” completely deleted
Clause 4.2 Repair methods (nut element/retainer replacement) and variants (A and B) added
Amount of test panels for qualification reduced to two
Clause 5 Test method for torque-out test specified (NASM1312)
Push-out test per NASM25027 added
Clause 6 Hole diameter tables for oversizes added
Annex A Al tolerances widened up for 10µm in accordance with long-term test results
Hole dimensions added for titanium and for -08 size
4 4.7 Implementation of key characteristics
04/10