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The Boeing 787 Dreamliner will be the most fuel-efficient airliner in the world when it enters service in 2008. To help achieve this, Boeing will utilize state-of-the-art carbon fiber for primary structures. Advanced manufacturing techniques and processes will be used in the assembly of large composite structures. Electroimpact has proposed a system utilizing the low recoil Low Voltage Electromagnetic Riveter (LVER) to drill and install bolts. A test program was initiated between Boeing Materials Process and Engineering (MP&E) and Electroimpact to validate the LVER process for swaging titanium collars on titanium pins in composite material. This paper details the results of these tests.

The Automated Rivet Interference Inspection System (ARIIS) has been developed by Boeing to replace the traditional time consuming, operator dependent methods of measuring rivet interference by hand. The new ARIIS method utilizes a Laser micrometer and a precision stepper motor/bench center that are integrated with a PC. Studies show a reduction in measurement variation by a factor of four to five when comparing the ARIIS system to traditional blade micrometer hand methods. The ARIIS system provides built in Statistical Process Control (SPC) for machines that install fluid tight fatigue rated rivets. This is accomplished by automatically keeping records on each inspected fastener. The system on command will generate X bar and R charts, as well as other SPC data on button height, button width, and all interference characteristics over time. Also all pertinent tooling, structure, materials, and aircraft information is automatically recorded for tracking.