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System for testing bolts with various platings, lubricants, nuts, and tightening procedures tests 200 fasteners, and processes and summarizes the results, within one month. System measures input torque, nut rotation, bolt clamping force, bolt shank twist, and bolt elongation, data is printed in report form. Test apparatus is described.
Testing procedures, data reduction, and data interpretation methods used to study the mechanical behavior of graphite-polyimide bolted joints at room temperature, -157 C (-250 F), and 315 C (600 F) are described. The load transfer characteristics, from one bolt to another, in double-bolt joints were determined by examining data generated in previous investigations. From the results, it appears the increase in load-carrying capacity by adding a second bolt in tandem can be predicted.
Pin attached to bottom of hole through long axis of machine bolt can be used to indicate correct bolt tension without torque meters or extensometers. Bolt elongates when tightened, but pin does not, and so appears to recede within bolt head. Steps cut in exposed end of pin would indicate acceptable range of tightness. Design would be particularly convenient in field locations without specialized instrumentation.
Testing procedures and data reduction and interpretation techniques were established for a program to study the mechanical behavior of bolted joints at room temperature, -157 C (-250 F), and 315 C (600 F). The load transfer characteristics, from one bolt to another, in double-bolt joints were investigated by examining data generated in previous investigations. From the results, it appears the increase in load-carrying capacity by adding a second bolt in tandem can be predicted.
Strain data from a series of bolted joint tests is presented. Double lap, double hole, double lap, single hole, and open hole tensile specimens were tested and the strain gage locations, load strain responses, and load axial displacement responses are presented. The open hole specimens were gaged to determine strain concentration factors. The double lap, double hole specimens were gaged to determine the uniformity of the strain in the joint and the amount of load transferred past the first bolt. The measurements indicated roughly half the load passed the first bolt to be reacted by the second bolt.
Stiffened composite panels proposed for fuselage and wing design utilize a variety of stiffener-to-skin attachment concepts including mechanical fasteners. The attachment concept is an important factor influencing the panel's strength and can govern its performance following local damage. Mechanical fasteners can be an effective method for preventing stiffener-skin separation. One potential failure mode for bolted panels occurs when the bolts pull through the stiffener attachment flange or skin. The resulting loss of support by the skin to the stiffener and by the stiffener to the skin can result in local buckling and subsequent panel collapse. The characteristic failure modes associated with bolt push-through failure are described and the results of a parametric study of the effects that different material systems, boundary conditions, and laminates have on the forces and displacements required to cause damage and bolt pushthrough failure are presented.
The problems associated with overtorque applied to the Booster Separation Motor (BSM) Igniter Adapter high strength 200 KSI (1379 Mpa) A286 CRES bolts and the threaded holes of the 7075-T73 aluminum alloy BSM cases are addressed. The evaluation included torque, tensile, and stress corrosion tests incorporating the A286 CRES bolts and the 7075-T73 aluminum alloy BSM cases. The tensile test data includes ultimate tensile load (UTL), Johnson's 2/3 yield load (J2/3YL), proportional limit load (PLL), and total bolt stretch. Torque tension data includes torque, torque induced load, and positive and negative break-away torque. Stress corrosion test data reflect the overtorque and the resulting torque induced loads sustained by the A286 CRES bolts torqued into a 7075-T73 aluminum alloy forged dome with threaded holes. After 60 days of salt fog exposure, the positive and the negative break-away torques, the subsequent mechanical property tensile test results, and the BSM dome threaded hole axial tensile pullout loads are reported.
Thermal changes in tensile stresses and strains in bolt and in corresponding compressive stresses and strains in bolted material estimated more accurately by use of equations incorporating two refinements over previous equations. Elasticity of bolted material and radial thermal expansion also taken into account. Refined equations improve design and analysis of bolted joints assembled at one temperature (e.g., room temperature) and in which specified minimum tension must be maintained (and/or specified maximum tension not exceeded) at higher or lower operational temperature.
Improved technique for ultrasonic nondestructive measurement of loads in bolts involves use of pulsed phase-locked loop interferometer. Provides for correction of errors and for automatic readout of loads in bolts. Actual bolt load measured, using transducers rebonded after bolts tightened. Calibration block and thermometer added. Technique applicable to critical fasteners in aerospace applications, nuclear reactors, petroleum and other chemical processing plants, steel bridges, and other structures.
Bolts that arrest (or, more precisely, retard) onset of fatigue cracking caused by inelastic strains developed. Specifically developed to be installed in flange holes of unrestrained rocket engine nozzle. Fanges sometimes used to bolt nozzle to test stand; however, when rocket engine operated without this restraint, region around bolt holes experience severe inelastic strains causing fatigue cracking. Interference fits introduce compressive preloads that retard fatigue by reducing ranges of strains. Principle of these fatigue-arrestor bolts also applicable to holes in plates made of other materials and/or used for different purposes.
This report describes computational methods to probabilistically simulate fracture in bolted composite structures. An innovative approach that is independent of stress intensity factors and fracture toughness was used to simulate progressive fracture. The effect of design variable uncertainties on structural damage was also quantified. A fast probability integrator assessed the scatter in the composite structure response before and after damage. Then the sensitivity of the response to design variables was computed. General-purpose methods, which are applicable to bolted joints in all types of structures and in all fracture processes-from damage initiation to unstable propagation and global structure collapse-were used. These methods were demonstrated for a bolted joint of a polymer matrix composite panel under edge loads. The effects of the fabrication process were included in the simulation of damage in the bolted panel. Results showed that the most effective way to reduce end displacement at fracture is to control both the load and the ply thickness. The cumulative probability for longitudinal stress in all plies was most sensitive to the load; in the 0 deg. plies it was very sensitive to ply thickness. The cumulative probability for transverse stress was most sensitive to the matrix coefficient of thermal expansion. In addition, fiber volume ratio and fiber transverse modulus both contributed significantly to the cumulative probability for the transverse stresses in all the plies.
An ultrasonic bolt gage is described which uses a crosscorrelation algorithm to determine a tension applied to a fastener, such as a bolt. The cross-correlation analysis is preferably performed using a processor operating on a series of captured ultrasonic echo waveforms. The ultrasonic bolt gage is further described as using the captured ultrasonic echo waveforms to perform additional modes of analysis, such as feature recognition. Multiple tension data outputs, therefore, can be obtained from a single data acquisition for increased measurement reliability. In addition, one embodiment of the gage has been described as multi-channel, having a multiplexer for performing a tension analysis on one of a plurality of bolts.
It has been widely accepted that the phenomenon of time-dependent loosening of flange connections is a strong consequence of the viscous nature of the compression seal material. Characterizing the coupled interaction between gasket creep and elastic bolt stiffness has been useful in predicting conditions that facilitate leakage. Prior advances on this sub-class of bolted joints has lead to the development of (1) constitutive models for elastomerics, (2) initial tightening strategies, (3) etc. The effect of re-torque, which is a major consideration for typical bolted flange seals used on the Space Shuttle fleet, has not been fully characterized, however. The current study presents a systematic approach to characterizing bolted joint behavior as the consequence of sequentially applied torques. Based on exprimenta1 and numerical results, the optimal re-torquing parameters have been identified that allow for the negligible load loss after pre-load application
The Air Force Office of Scientific Research (AFOSR) has sponsored the Boundary Layer Transition (BOLT) Experiments to investigate hypersonic boundary layer transition on a low-curvature, concave surface with swept leading edges. This paper presents aeroheating measurements on a subscale model of the BOLT Flight Geometry, aerodynamic fairings, and Transition Module (TSM) in the NASA Langley 20-Inch Mach 6 Air Tunnel. The purpose of the test was to investigate and identify any areas of localized heating on the TSM for inclusion in the BOLT Critical Design Review (CDR). Surface heating distributions were measured using global phosphor thermography, and data were obtained for a range of model attitudes and free stream Reynolds numbers. Measurements showed low heating on the fairings and TSM. Additional analysis was completed after the CDR to compare heating on the TSM for the nominal BOLT vehicle reentry angle-of-attack with heating on the TSM for possible reentry angle-of-attack excursions. The results of this analysis were used in conjunction with thermal analyses from Johns Hopkins Applied Physics Lab (JHU/APL) and the Air Force Research Laboratory (AFRL) to assess the need for thermal protection on the flight vehicle TSM.
A bolt installation and removal (BIR) system is used for assembling and disassembling a nuclear vessel. The BIR system includes a platform with a stand for supporting the nuclear vessel. A track extends around an outside perimeter of the platform and multiple tool carts include wheels that roll on the track. Tool towers are located on the carts and include tool assemblies configured to install and remove bolts on the nuclear reactor vessel. Magazine towers also extend up from the tool carts next to the tool towers and include magazines that hold bolts for exchanging with the tool assemblies. Drive mechanisms move tool heads in the tool assemblies around a first vertical axis, vertically up and down, and laterally to more simply and reliably install and remove the bolts in a radioactive underwater environment.
This report presents the derivation of the factored interaction equations for preloaded bolts in two- or three-dimensional space. This is an extension of the previous work of the first author which covered factored interaction equations consisting of load or stress-ratios which were either solely constant or solely varying quantities. The factored interaction equations for preloaded bolts consist of an axial load-ratio that is a combination of a constant quantity, preload and thermal load at preload, and a varying quantity, tensile and bending loads, and was not covered under the previous work. Two forms of the factored interaction equations for preloaded bolts, arising from two perspectives, are presented and compared. Closed form solutions for the tensile, shear, and bending loads as functions of the other concurrent loads that produces zero margin of safety are presented.
An infrared thermography measurement technique has been installed in the Langley Aerothermodynamic Laboratory. The system is calibrated for use with commercially available thermoplastics and ceramic materials, and to the surface temperature ranges when exposed to the facility hypersonic flow. Herein an uncertainty quantification is performed, revealing 5% surface temperature and 20% heat transfer uncertainty bands to two-sigma confidence. As a first application of the test measurement technique, an investigation was conducted to explore the correlation between the height of forward facing (FF) and rearward facing (RF) two-dimensional steps, free stream Reynolds number, and the onset of boundary layer transition from laminar to turbulent in Mach 6 flow on a 50% scale Boundary Layer Transition (BOLT) flight test vehicle geometry. Computational predictions were generated to identify potential x/L locations of transition onset for various flow conditions with a smooth outer mold line geometry and are compared to experimental results. The BOLT Step Test was conducted in the NASA Langley Aerothermodynamic Laboratory 20-inch Mach 6 wind tunnel at Reynolds numbers between 1.4 and 11.3 million conditions for various step heights. Data were collected using a developmental infrared thermography test technique and reduced to heat transfer for comparison with CFD solutions. This is a preliminary assessment of the developmental infrared thermography test technique used to acquire and reduce the experimental data. insight into the ongoing comparative analysis of the effects of FF and RF steps on boundary layer transition for the BOLT geometry in Mach 6 flow.
An infrared thermography measurement technique has been installed in the Langley Aerothermodynamic Laboratory. The system is calibrated for use with commercially available thermoplastics and ceramic materials, and to the surface temperature ranges when exposed to the facility hypersonic flow. Herein an uncertainty quantification is performed, revealing 5% surface temperature and 20% heat transfer uncertainty bands to two-sigma confidence. As a first application of the test measurement technique, an investigation was conducted to explore the correlation between the height of forward facing (FF) and rearward facing (RF) two-dimensional steps, free stream Reynolds number, and the onset of boundary layer transition from laminar to turbulent in Mach 6 flow on a 50% scale Boundary Layer Transition (BOLT) flight test vehicle geometry. Computational predictions were generated to identify potential x/L locations of transition onset for various flow conditions with a smooth outer mold line geometry and are compared to experimental results. The BOLT Step Test was conducted in the NASA Langley Aerothermodynamic Laboratory 20-inch Mach 6 wind tunnel at Reynolds numbers between 1.4 and 11.3 million conditions for various step heights. Data were collected using a developmental infrared thermography test technique and reduced to heat transfer for comparison with CFD solutions. This is a preliminary assessment of the developmental infrared thermography test technique used to acquire and reduce the experimental data. insight into the ongoing comparative analysis of the effects of FF and RF steps on boundary layer transition for the BOLT geometry in Mach 6 flow.