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Eddy-current apparatus for inspection of bolts, studs, and other threaded fasteners detects flaws in threads, shanks, and head fillets. With help of apparatus, technician quickly inspects fasteners of various dimensions. Accommodates fasteners with diameters from 0.190 in. to 1 in. and with lengths up to 5 in. Basic design modified to accommodate fasteners of other sizes.
A device for testing fasteners such as nuts and bolts is described which consists of a fixed base plate having a number of threaded and unthreaded holes of varying size for receiving the fasteners to be tested, a torque marking paper taped on top the fixed base plate for marking torque-angle indicia, a torque wrench for applying torque to the fasteners being tested, and an indicator for showing the torque applied to the fastener. These elements provide a low cost, nondestructive device for verifying the strength of bolts and nuts.
Experimental and analytical studies of the development of delaminations around fastener holes in composite structures are presented. This type of delamination is known to occur in composite skins that are mechanically fastened to a poorly mating substructure. Results of an experimental study to determine the resistance of laminates to the initiation of assembly induced delaminations and the residual strength of assembly damaged coupons are presented for AS4/3501-6, IM7/8551-7A, and AS4/PEEK material systems. A survey of existing analytical models for predicting the residual strength and stability of delaminations is presented, and the development of a new model for predicting the initiation of delaminations around a fastener hole is outlined. The fastener hole damage initiation model utilizes a finite element based Fourier series solution, and is validated through comparisons of analytical and experimental results.
The solid rocket booster uses hydraulic pumps fabricated from cast C355 aluminum alloy, with 17-4 PH stainless steel pump port caps. Corrosion-resistant steel, MS51830 CA204L self-locking screw thread inserts are installed into C355 pump housings, with A286 stainless steel fasteners installed into the insert to secure the pump port cap to the housing. In the past, pump port cap fasteners were installed to a torque of 33 Nm (300 in-lb). However, the structural analyses used a significantly higher nut factor than indicated during tests conducted by Boeing Space Systems. When the torque values were reassessed using Boeing's nut factor, the fastener preload had a factor of safety of less than 1, with potential for overloading the joint. This paper describes how behavior was determined for a preloaded joint with a steel bolt threaded into steel inserts in aluminum parts. Finite element models were compared with test results. For all initial bolt preloads, bolt loads increased as external applied loads increased. For higher initial bolt preloads, less load was transferred into the bolt, due to external applied loading. Lower torque limits were established for pump port cap fasteners and additional limits were placed on insert axial deformation under operating conditions after seating the insert with an initial preload.
The invention described here in is a computer-implemented method and apparatus for controlling a hand-held tool. In particular, the control of a hand held tool is for the purpose of controlling the speed of a fastener interface mechanism and the torque applied to fasteners by the fastener interface mechanism of the hand-held tool and monitoring the operating parameters of the tool. The control is embodied in intool software embedded on a processor within the tool which also communicates with remote software. An operator can run the tool, or through the interaction of both software, operate the tool from a remote location, analyze data from a performance history recorded by the tool, and select various torque and speed parameters for each fastener.
Phase I: The use of adhesive locking features or liquid locking compounds (LLCs) (e.g., Loctite) as a means of providing a secondary locking feature has been used on NASA programs since the Apollo program. In many cases Loctite was used as a last resort when (a) self-locking fasteners were no longer functioning per their respective drawing specification, (b) access was limited for removal & replacement, or (c) replacement could not be accomplished without severe impact to schedule. Long-term use of Loctite became inevitable in cases where removal and replacement of worn hardware was not cost effective and Loctite was assumed to be fully cured and working. The NASA Engineering & Safety Center (NESC) and United Space Alliance (USA) recognized the need for more extensive testing of Loctite grades to better understand their capabilities and limitations as a secondary locking feature. These tests, identified as Phase I, were designed to identify processing sensitivities, to determine proper cure time, the correct primer to use on aerospace nutplate, insert and bolt materials such as A286 and MP35N, and the minimum amount of Loctite that is required to achieve optimum breakaway torque values. The .1900-32 was the fastener size tested, due to wide usage in the aerospace industry. Three different grades of Loctite were tested. Results indicate that, with proper controls, adhesive locking features can be successfully used in the repair of locking features and should be considered for design. Phase II: Threaded fastening systems used in aerospace programs typically have a requirement for a redundant locking feature. The primary locking method is the fastener preload and the traditional redundant locking feature is a self-locking mechanical device that may include deformed threads, non-metallic inserts, split beam features, or other methods that impede movement between threaded members. The self-locking resistance of traditional locking features can be directly verified during assembly by measuring the dynamic prevailing torque. Adhesive locking features or LLCs are another method of providing redundant locking, but a direct verification method has not been used in aerospace applications to verify proper installation when using LLCs because of concern for damage to the adhesive bond. The reliability of LLCs has also been questioned due to failures observed during testing with coupons for process verification, although the coupon failures have often been attributed to a lack of proper procedures. It is highly desirable to have a direct method of verifying the LLC cure or bond integrity. The purpose of the Phase II test program was to determine if the torque applied during direct verification of an adhesive locking feature degrades that locking feature. This report documents the test program used to investigate the viability of such a direct verification method. Results of the Phase II testing were positive, and additional investigation of direct verification of adhesive locking features is merited.
A payload launch lock mechanism includes a base, a preload clamp, a fastener, and a shape memory alloy (SMA) actuator. The preload clamp is configured to releasibly restrain a payload. The fastener extends, along an axis, through the preload clamp and into the base, and supplies a force to the preload clamp sufficient to restrain the payload. The SMA actuator is disposed between the base and the clamp. The SMA actuator is adapted to receive electrical current and is configured, upon receipt of the electrical current, to supply a force that causes the fastener to elongate without fracturing. The preload clamp, in response to the fastener elongation, either rotates or pivots to thereby release the payload.
In support of the Deep Space Habitat project a number of composite rack prototypes were developed, designed, fabricated and tested to various extents ( with the International Standard Payload Rack configuration, or crew quarters, as a baseline). This paper focuses specifically on a composite rack prototype with a direct tie in to Space Station hardware. The outlined prototype is an all composite construction, excluding metallic fasteners, washers, and their associated inserts. The rack utilizes braided carbon composite tubing for the frame with the sidewalls, backwall and flooring sections utilizing aircraft grade composite honeycomb sandwich panels. Novel additively manufactured thermoplastic joints and tube inserts were also developed in support of this effort. Joint and tube insert screening tests were conducted at a preliminary level. The screening tests allowed for modification, and enhancement, of the fabrication and design approaches, which will be outlined. The initial joint tests did not include mechanical fasteners. Adhesives were utilized at the joint to composite tube interfaces, along with mechanical fasteners during final fabrication (thus creating a stronger joint than the adhesive only variant). In general the prototype was focused on a potential in-space assembly approach, or kit-of-parts construction concept, which would not necessarily require the inclusion of an adhesive in the joint regions. However, given the tie in to legacy Station hardware (and potential flight loads with imbedded hardware mass loadings), the rack was built as stiff and strong as possible. Preliminary torque down tests were also conducted to determine the feasibility of mounting the composite honeycomb panels to the composite tubing sections via the additively manufactured tube inserts. Additional fastener torque down tests were also conducted with inserts (helicoils) imbedded within the joints. Lessons learned are also included and discussed.
The main penetrations (supports and piping) through multilayer insulation systems for cryogenic tanks have been previously addressed by heat flow measurements. Smaller penetrations due to fasteners and attachments are now experimentally investigated. The use of small pins or plastic garment tag fasteners to each the handling and construction of multilayer insulation (MLI) blankets goes back many years. While it has long been understood that penetrations and other discontinuities degrade the performance of the MLI blanket, quantification of this degradation has generally been lumped into gross performance multipliers (often called degradation factors or scale factors). Small penetrations contribute both solid conduction and radiation heat transfer paths through the blanket. The conduction is down the stem of the structural element itself while the radiation is through the hole formed during installation of the pin or fastener. Analytical models were developed in conjunction with MLI perforation theory and Fouriers Law. Results of the analytical models are compared to experimental testing performed on a 10 layer MLI blanket with approximately 50 small plastic pins penetrating the test specimen. The pins were installed at 76-mm spacing inches in both directions to minimize the compounding of thermal effects due to localized compression or lateral heat transfer. The testing was performed using a liquid nitrogen boil-off calorimeter (Cryostat-100) with the standard boundary temperatures of 293 K and 78 K. Results show that the added radiation through the holes is much more significant than the conduction down the fastener. The results are shown to be in agreement with radiation theory for perforated films.
The Space Suit Portable Life Support System (PLSS) has a tight mass requirement to meet while also meeting other requirements for supporting a crewmember in space, on the Moon, or on Mars. To meet these requirements, atypical materials must be considered to close the mass budget allocations. However, many of these materials and processes are relatively new and untested. Therefore, initial analysis and testing of some new and advanced processes have been conducted following a roadmap presented last year. This material testing has focused primarily on thermoplastics, both additively manufactured and machined, to assess plating and fastening operations that will be required. These processes will provide additional strength and shielding capability typically only achieved with metallics. This testing has also helped to define a forward plan to certify these materials and processes for critical spaceflight applications. This report will review testing plated thermoplastics both for strength and thermal properties. It will also review fastener and fastening options and look at insert and fastener testing. It will also review state-of-the-art methods being considered elsewhere and some additional testing being conducted. Using the testing results researched here, there will be recommendations on applications for each of these types of methods going forward.
Certification of adhesively bonded structures is currently a challenge for aircraft manufacturers. The ability to certify bonds in primary structure can reduce dependence on fasteners and this will enable more efficient manufacturing. For example, drilling holes and installing fasteners in bonded joints can be a potentially significant bottleneck in airframe manufacturing. In addition, fasteners increase the airframe weight and can add stress concentration areas. Reducing fastener count can accelerate manufacturing and improve aircraft performance. NASA is currently investigating nondestructive evaluation (NDE) techniques to assess bond integrity. For example, bond thickness influences bond strength and therefore NDE techniques are being investigated to determine bond thickness. For bonded metal structures, there is a large difference in the thermal diffusivity between the 7075 aluminum alloy metal adherends and aircraft grade adhesive. Multi-layered thermal models show a large variation in the thermal response for bondline adhesive thicknesses that vary from 100 to 300 microns for adherend thicknesses of 0.163 cm. Experimental through-transmission thermal measurements reveal promise to quantitatively characterize the bondline thickness. Results were validated with X-ray computed tomography and optical microscopy measurements, and influence of porosity on the thermal model and measurements are investigated.
Certification of adhesively bonded structures is currently a challenge for aircraft manufacturers. The ability to certify bonds in primary structure can reduce dependence on fasteners and this will enable more efficient manufacturing. For example, drilling holes and installing fasteners in bonded joints can be a potentially significant bottleneck in airframe manufacturing. In addition, fasteners increase the airframe weight and can add stress concentration areas. Reducing fastener count can accelerate manufacturing and improve aircraft performance. NASA is currently investigating nondestructive evaluation (NDE) techniques to assess bond integrity. For example, bond thickness influences bond strength and therefore NDE techniques are being investigated to determine bond thickness. For bonded metal structures, there is a large difference in the thermal diffusivity between the 7075 aluminum alloy metal adherends and aircraft grade adhesive. Multi-layered thermal models show a large variation in the thermal response for bondline adhesive thicknesses that vary from 100 to 300 microns for adherend thicknesses of 0.163 cm. Experimental through-transmission thermal measurements reveal promise to quantitatively characterize the bondline thickness. Results were validated with X-ray computed tomography and optical microscopy measurements, and influence of porosity on the thermal model and measurements are investigated.
The Space Suit Portable Life Support System (PLSS) has a tight mass requirement to meet while also meeting other requirements for supporting a crewmember in space, on the Moon, or on Mars. To meet these requirements, atypical materials must be considered to close the mass budget allocations. However, many of these materials and processes are relatively new and untested. Therefore, initial analysis and testing of some new and advanced processes have been conducted following a roadmap presented last year. This material testing has focused primarily on thermoplastics, both additively manufactured and machined, to assess plating and fastening operations that will be required. These processes will provide additional strength and shielding capability typically only achieved with metallics. This testing has also helped to define a forward plan to certify these materials and processes for critical spaceflight applications. This report will review testing plated thermoplastics both for strength and thermal properties. It will also review fastener and fastening options and look at insert and fastener testing. It will also review state-of-the-art methods being considered elsewhere and some additional testing being conducted. Using the testing results researched here, there will be recommendations on applications for each of these types of methods going forward.
A compilation is presented which supplies technical information on the assembly of diverse components into functional assemblies and subassemblies, as well as information on several fasteners and fastening techniques that join components, subassemblies, and complete assemblies to achieve a functional unit. Quick-disconnect fasteners are described, along with several devices and methods for attaching thermal insulators, and for joining and separating objects in the absence of gravity.
An improved sealing method has been developed for the exposed metal fastener surfaces of the Solid Rocket Booster vehicle for the Space Shuttle launch system. The method employs properly sized flexible plastic caps filled with catalyzed polysulfide sealant, frozen and stored. At the time of use, the caps and sealant are thawed and positioned on the fasteners. The sealant covers the exposed portion of the fastener and prevents salt water damage. The method is one of high reliability with low installation and inspection costs.
A design solution is developed for the fabrication of an all-composite helicopter airframe cabin roof structure. Although this is inherently a complex structure, the parts count has been minimized by the avoidance of many mechanical fasteners, and a weight reduction of 26% has been obtained. The reduction of parts and elimination of mechanical fasteners will also result in a lowering of labor costs. The bonded graphite/epoxy elements of the structure employed aluminum tooling with control on all mating surfaces to yield accurate bond lines. A summary of static test results is presented for the basic structure and for the structure with mechanically fastened skin stiffeners. It is shown that the shear buckles caused the skin to peel from the stiffeners at about 960 lb/in. shear flow, calling for the addition of stiffeners with more bond area.
Measurement does not affect joint parameters. Verification of analytical and strength-prediction methods for bolted composite joints based generally on data obtained experimentally from double-lap-joint specimens. In mechanically fastened joints, stresses maximal at fastener holes. Ability to measure accurately hole elongations without affecting joint parameters provides better understanding of elastic and plastic behavior of joint material leading to failure mechanisms in mechanically fastened joints required for design of more-efficient, lightweight composite joints.
Proposed fastener for attaching electroplating anode improves quality of plating and increases productivity. Notches in twist-lock fastener mates with projections on end of anode bar. Fastener made of titanium for compatibility with copper-plating solution. Also constructed in snap-on, snap-off configuration.