In engineering applications where mechanical joints are exposed to constant motion or operational forces, vibration resistance becomes a mission-critical factor in ensuring long-term performance. Vibrations gradually degrade joint integrity regardless of the specific industry, and can lead to loosening and fatigue of mechanical joints.
Luckily, wire thread inserts are a proven solution in this respect, offering exceptional vibration resistance alongside a host of other performance benefits. Let’s take a closer look at how these components can help extend the life of mechanical joints and enable the integration of lightweight metals at the same time.
The constant battle of vibration in mechanical joints
Vibrations subject fasteners and joints to cyclical loading, creating a “fatigue effect” that can loosen bolts, damage threads and even wear down softer parent materials over time. In high-intensity environments like aircraft or high-speed vehicles, this can directly compromise safety and functionality. These applications often use lighter and softer materials to reduce weight and maximise fuel efficiency. The softer and lighter the parent material (such as aluminium or magnesium) the greater the risk of fretting wear/thread stripping and eventual joint failure.
How wire thread inserts protect against vibration
Wire thread inserts are helically coiled elements installed into tapped holes to create a durable and precise internal thread. Their vibration resistance stems from both their material properties and their mechanical fit.
- Secure fit and load distribution: When a bolt or screw is tightened into an insert, the coil expands radially and axially to match the fastener’s threads. This results in a tight, uniform contact that resists the micro-movements caused by vibrations.
- Minimised loosening risk: By providing a consistent thread profile and tension distribution across the joint, wire thread inserts significantly reduce the chances of bolts backing out under cyclical or oscillating loads.
- Protection against fretting and wear: Vibrations can cause tiny relative movements between the fastener and the parent material, leading to fretting corrosion and wear. Wire thread inserts act as a barrier, absorbing these stresses before they can damage the parent material.
- Material and finish options for harsh environments: Inserts can be made from high-strength stainless steel, nickel alloys, or other specialist materials to maintain their grip under extreme conditions. Surface treatments, such as dry-film lubricants or cadmium plating, can further improve performance where vibrations coincide with high temperatures or corrosive exposure.
Wire thread inserts benefits beyond vibration resistance
Even though vibration resistance is a major advantage, wire thread inserts also deliver benefits that extend the overall durability and reliability of mechanical joints.
- Enhanced shear strength: Even in lightweight alloys inserts allow for higher torque loads without stripping threads.
- Corrosion resistance: Coatings and material selection help combat galvanic corrosion which can accelerate under vibration-induced wear.
- Extended service life: By protecting both fasteners and parent material inserts reduce the frequency of maintenance and replacement.
- Maintenance efficiency: Tangless designs allow for quick removal and installation without foreign object debris which is essential in critical industries like aerospace.
Applications where vibration resistance is crucial
Wire thread inserts are already widely used in a number of applications to protect mechanical joints from the impact of vibration. In aerospace they protect lightweight structures from joint loosening during turbulence or engine vibration. In automotive they maintain fastener integrity in engines, suspension systems and high-performance chassis components. In rail and heavy machinery they help Withstand constant vibration and shock loads in moving assemblies. And in electronics and defence, they help ensure stability in equipment subjected to operational or environmental vibrations.
Get the leading joint solution for vibration-heavy environments
Vibration can be the silent destroyer of mechanical joints, gradually eroding their integrity until failure occurs. Wire thread inserts offer a comprehensive solution by resisting loosening and wear caused by vibration as well as extending the operational life of components (especially those made from soft and lightweight materials).
At KATO® Advanex, our range of tanged and Tangless® wire thread inserts are engineered to deliver superior vibration resistance across industries. Available in multiple sizes, materials and finishes, they are fully compliant with aerospace, military and commercial standards, ensuring your designs remain strong and ready for anything.
To find out more about our range of inserts and products, download our guide below.
