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In an effort to simplify and speed up manufacturing time for aircraft structure, a pure mechanical system has been developed by Fatigue Technology Inc. (FTI) to perform the Split Sleeve Cold Expansion (SsCx™) process to fastener holes. Historically, fastener holes requiring cold working for fatigue life enhancement are cold worked with a system which requires a manual hydraulic puller. This system works well and has been in place for more than 30 years. This paper will discuss a new type of system that uses a simplified mechanical-only process that does not require hydraulic pneumatic or electrical systems. This new type of Automated Cold Expansion™ (AtCx™) puller unit has recently been fitted to an automated work cell that machines aircraft sub-components. This new cold expansion puller utilizes only simple rotary motion and converts it to a linear motion. The puller can be fitted to any kind of automated work cell, NC machine, or drilling and riveting equipment.

Reduced manufacturing costs and flow time, along with increased structural fatigue life and reduced in-service maintenance problems can be realized with the Fatigue Technology Inc. (FTI) ForceMate® (FmCx™) system of installing high-interference bushings into aircraft structures. Bell Helicopter reported [1] a projected $24 million cost savings with the use of ForceMate. This paper will describe the ForceMate system in detail as well as an alternative bushing installation method, BushLoc, and the manufacturing benefits realized with their use. The ForceMate bushing installation system installs bushings with a consistently high level of interference in a fraction of the time of traditional methods, such as shrink and press fit. It is a safer method, reduces hardware variability and provides a higher integrity bushing installation with significant structural fatigue life improvement.