Executive Summary The aerospace industry operates under a relentless mandate to optimize aircraft performance, reduce fuel consumption, and lower carbon emissions. Among the myriad strategies deployed to achieve these objectives, weight reduction remains paramount. While massive structural components and propulsion systems frequently dominate discussions surrounding lightweighting, the critical role of fasteners is often understated. Modern commercial and military aircraft utilize millions of individual fasteners, representing a substantial cumulative weight penalty. Consequently, the materials and manufacturing methodologies used to produce these vital components are undergoing intense scrutiny. This comprehensive white paper [...]

Cold heading, also known as cold forming or cold forging, is the dominant manufacturing process for producing the vast majority of fasteners, such as screws, bolts, and rivets, used across industries today. This detailed analysis explores the principles of cold heading, its numerous advantages over alternative methods, the materials and equipment involved, and the key factors contributing to its continued dominance in the highly competitive fastener market. Principles of Cold Heading Cold heading is a high-speed, near-net-shape metal forming process performed at or near room temperature. It involves placing a [...]