A hollow screw and related process of making is provided, wherein the hollow screw is formed from a generally circular corrosion resistant stainless steel disk cut from flat roll stock. The hollow screw includes a head and an elongated and hollow shaft having a wall thickness between about 0.2 to about 0.7 millimeters extending therefrom and defining a shank portion and a threaded portion having a plurality of threads thereon with a rotational drive mechanism configured to facilitate tightening via the threads. The process involves annealing to soften the stamped hollow screw, followed by thread rolling, and then age hardening the hollow screw. As such, the resultant hollow screw is relatively lightweight, about 50% the mass of a solid core screw made from the same material, with a sufficient thread strength to meet most aerospace applications and contributes to important aircraft fuel economy.

A security fastener for installation on a wheel having a recess hole extending from a recess entrance of a first diameter comprising an end portion concentric with a longitudinal axis of the fastener, the end portion configured to mate with a corresponding element of the recess hole, an intermediate skirt portion having a side wall region with a diameter within about 6 millimeters of the diameter of the recess entrance, a drive portion having a tapered outer surface and a plurality of circumferentially spaced longitudinally extending key-receiving grooves in the tapered outer surface arranged in a lock pattern to which a driving torque may be applied, the tapered outer surface sloping downward and outward away from the longitudinal axis of the fastener from a top surface to the skirt portion at a taper angle of at least 11 degrees.

A fastener system includes a fastener and a driver, each of which have three alternating lobes and troughs that define the drive surfaces. The three alternating lobes and troughs are each defined by an outer radius portion, a drive side transition, an inner transition radius, and a reverse drive portion. The fastener recess and the driver each also have a side wall defined by the outer transition radius that tapers at a taper angle relative to the rotational axis. The fastener side wall may taper at about 60. The driver side wall may taper at about 60. Alternatively, the driver side wall may taper at an angle at least 10 less than the taper angle of the recess side wall, such as 42. The drive side transition defines a drive angle which may be between 0 and 5.