Are you worried about repairing stripped screw holes while working with aluminum (in British English)? Don’t fret any longer! I have an excellent solution to tackle this issue. In this article, I will reveal the right decision that effectively resolves your problem.
Read on to discover the right decision to effectively solve your problem, and say goodbye to stripped screw holes in aluminum once and for all.
What Causes Aluminum Screw Holes to Be Stripped?
Aluminum, classified as one of the soft metals, requires careful handling to prevent shape deformation. One critical issue with aluminum is the potential damage caused by applying excessive torque or force while driving screws into it.
Even under a load or encountering sudden jolts, the threads of an Aluminum Screw Hole can be adversely impacted. Furthermore, incorrect screw threads’ shapes or sizes during insertion can lead to stripping.
Lastly, overuse of the Aluminum Screw Hole can also result in stripping.
3 Methods To Fix A Stripped Screw Hole In Aluminum
Given the stripped nature of your screw hole, you’re likely experiencing issues with screw stability, causing wobbling or rotation troubles. There’s no need for concern, as I’ve encountered this challenge in my work and have successfully employed various effective solutions. Without any unnecessary delay, let’s delve into the central aspects of this discussion.
1. Using Heli-coil
Opting for a Heli-coil is an excellent remedy for your predicament. You’ll find its installation procedure manageable. I’ve outlined the steps for installing a Heli-coil in aluminum below to assist you further.
- Start by ensuring that you have the correct Heli-coil kit for the screw size and pitch that you intend to use. Gather all the necessary tools and materials.
- Use the provided drill bit from the Heli-coil kit to carefully drill out the damaged screw hole. Be cautious about enlarging the hole within the specified size for the Heli-coil insert.
- After drilling, use the tap provided in the kit to create new threads inside the enlarged hole. Apply lubricating oil to facilitate smooth tapping and prevent the tap from binding.
- Throw the Heli-coil insert onto the installation tool included in the kit. Insert the coil into the newly tapped hole, ensuring it sits flush with the surface of the aluminum.
- Gently turn the installation tool to thread the Heli-coil into the hole. Once properly in place, use a screwdriver to leave the coil securely inside the hole.
- With the Heli-coil in place and the screws fitting correctly, you can reassemble the components attached to the aluminum piece.
The Heli-coil provides a strong and durable thread, allowing you to use the screw hole as if it were never stripped.
Note: The Heli-coil set includes all the necessary tools for the task. While it may come at a slightly higher cost, the product is remarkably efficient and proves its effectiveness.
Alternative: you can opt for Keensert or Threaded Metal Insert instead of Heli-coil. The induction process for Keensert or Threaded Metal Insert closely resembles that of Heli-coil, which is why I am not providing a separate explanation for it.
2. Creating Threads and Placing a Large Screw
In situations of this nature, resorting to a larger screw is a viable option. This entails generating a thread using a Hand Tap Set that’s marginally larger than the stripped screw hole in aluminum (using a Hand Tap Set as previously outlined in the method). Next, you can proceed with the installation of a larger screw.
Note: You should consider a larger screw that aligns with the threading of the Tap Set.
3. Try Liquid Stripped Thread Repair (for a Temporary Solution)
In the present era, several brands designed liquid for repairing stripped threads are readily accessible in the market.
It’s important to be aware that these solutions offer a temporary fix. Once this liquid is injected into the stripped screw hole in aluminum, its function ceases only upon the screw becoming secured.
Nonetheless, this product might not deliver optimal results for robust or high-vibration equipment.
Installing Screws Without Repairing Stripped Aluminum Holes
If obtaining or gathering Heli-coil, Large Screw, liquid stripped thread repair, and accessory tools aren’t immediately feasible, there are alternative methods available for temporarily installing a Screw (Screws must be new or in good condition). I will outline these approaches in the following discussion.
Twisted by Thread Tape
Before insertion, carefully apply thread tape (commonly known as Teflon tape) to the threads of the screw. This thread tape not only offers a temporary grip but also assists in securing the screw, all without directly repairing the stripped hole.
For optimal results, ensure that you’re working with new or undamaged screws.
Use copper wire
I employed this method as a short-term fix, and it proved effective. The procedure is quite straightforward: you’ll need thin copper wires, which should be carefully separated.
Next, take these thin copper pieces and insert them one by one into the screw hole that was stripped in the aluminum. Shape them into a U shape before driving the screw into the hole and tightening it securely. Done!
If screw holes in aluminum are not required, what to do?
If you find that the screw holes are no longer needed, you have the option to close them up. The process involves welding to fill the hole, but it’s important to know that ordinary welding techniques won’t work for aluminum in this scenario. Instead, a specialized welding method known as TIG (Tungsten Inert Gas) welding must be utilized.
TIG welding is suitable for aluminum and ensures a proper and secure fill for the hole. Once the hole is filled, any uneven surfaces can be smoothed out by carefully sanding it with Dremel Tools, resulting in a flush and uniform finish.
Conclusion
If you found these solutions helpful in resolving your stripped screw hole issues in aluminum, don’t keep it to yourself. Share this knowledge with your friends and colleagues who might also benefit from these techniques. And if you have any insights or experiences to share, leave a comment below to contribute to the community’s understanding.
Thank you for reading!
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