Improved Flush Fastener

Modern, high performance aircraft depend on the attainment of very flush fastener installations on their outer mold line (OML) surfaces to reduce parasitic drag and (in the case of stealthy "low observable" type aircraft) radar energy scattering. At the same time "cost of ownership" issues are driving the aerospace industry to produce more economical manufacturing and field supportable processes and techniques. This SBIR will develop the fastener and manufacturing technologies to repeatedly produce countersunk fasteners having installed tolerances of less than +/-0.001" while reducing the cost and number of man-hours required to install them. In this program, LAMBDA OMEGA will evaluate current fastener and fastener installation rates and installation technology, collect data to determine commercially available fastener installation rates and installation tolerances. We shall also evaluate potential technology enhancements and propose practical solutions to current shortfalls. We shall also quantify the benefits of a very flush fastener installation in terms of fastener installation cost reductions, aerodynamic drag reduction and potential radar cross section reduction, and perform a preliminary product design.