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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Fastener joint and associated method for avoiding corrosion of dissimilar material fastener joints

A fastener for use in joining dissimilar materials manufactured by the process of producing the fastener with an external surface that forms an electrically insulating oxide layer when subjected to oxidation and, after manufacture and prior to use, subjecting the fastener to a pre-oxidation process to grow the desired oxide layer in situ on the external surface of the fastener. The present invention also provides a dissimilar material joint in which the pre-oxidized fastener is used to mechanically join dissimilar materials with the oxide layer electrically insulating the fastener from at least one of the dissimilar materials. The fastener may be a rivet used in friction self-piercing riveting (F-SPR). The fastener may be fabricated from an alloy capable of forming Al 2 O 3 or Cr 2 O 3 by thermal oxidation. The fastener may be pre-coated with Al or Cr that functions as a seed layer to form Al 2 O 3 or Cr 2 O 3 .

Lim, Yong Chae↗
NASA NTRS1972

Fasteners and fastening techniques: A compilation

Technology on fasteners and fastening devices is presented, as part of NASA's TU program to provide technical information on devices, methods, and techniques resulting from aerospace research. The material is divided into two sections which include: (1) data concerning a selected group of fasteners and concept for fasteners such as locking devices, couplings, and connect and release mechanisms; and (2) discussions on a number of fastening techniques such as those for mounting panel lamps, clamping flange bolts, stretching fasteners, and transferring fuel from a tanker to another vehicle.

Source record↗
DOE OSTI2012

Machining Elimination through Application of Thread Forming Fasteners in Net-Shaped Cast Holes

The ultimate objective of this work was to eliminate approximately 30% of the machining performed in typical automotive engine and transmission plants by using thread forming fasteners in as-cast holes of aluminum and magnesium cast components. The primary issues at the source of engineers reluctance to implementing thread forming fasteners in lightweight castings are: • Little proof of consistency of clamp load vs. input torque in either aluminum or magnesium castings. • No known data to understand the effect on consistency of clamp load as casting dies wear. The clamp load consistency concern is founded in the fact that a portion of the input torque used to create clamp load is also used to create threads. The torque used for thread forming may not be consistent due to variations in casting material, hole size and shape due to tooling wear and process variation (thermal and mechanical). There is little data available to understand the magnitude of this concern or to form the basis of potential solutions if the range of clamp load variation is very high (> +/- 30%). The range of variation that can be expected in as-cast hole size and shape over the full life cycle of a high pressure die casting die was established in previous work completed by Pacific Northwest National Laboratory, (PNNL). This established range of variation was captured in a set of 12 cast bosses by designing core pins at the size and draft angles identified in the sited previous work. The cast bosses were cut into nuts that could be used in the Ford Fastener Laboratory test-cell to measure clamp load when a thread forming fastener was driven into a cast nut. There were two sets of experiments run. First, a series of cast aluminum nuts were made reflecting the range of shape and size variations to be expected over the life cycle of a die casting die. Taptite thread forming fasteners, (a widely used thread forming fastener suitable for aluminum applications), were driven into the various cored, as-cast nuts at a constant input torque and resulting clamp loads were recorded continuously. The clamp load data was used to determine the range of clamp loads to be expected. The bolts were driven to failure. The clamp load corresponding to the target input of 18.5 Nm was recorded for each fastener. In a like fashion, a second set of experiments were run with cast magnesium nuts and ALtracs thread forming fasteners, (a widely used thread forming fastener suitable for magnesium applications). Again all clamp loads were recorded and analyzed similarly to the Taptites in aluminum cast nuts. Results from previous work performed on the same test cell for a Battelle project using standard M8 bolts into standard M8 nuts were included as a comparator for a standard bolt and nut application. The results for the thread forming fasteners in aluminum cast holes were well within industry expectations of +/- 30% for out of the box and robustness range testing. The results for the dry and lubed extreme conditions were only slightly higher than industry expectations at +/- 35.6%. However, when compared to the actual Battelle results (+/- 40%) for a standard bolt and nut the tread forming fasteners performed slightly better. The results for the thread forming fasteners in magnesium cast holes were all well within industry expectations of +/- 30% for all three conditions. The robustness range (.05mm larger and smaller holes than the expected wear pattern of a die casting die at full life cycle) results also fell within the industry expectations for standard threaded fasteners. These results were very encouraging. It was concluded that this work showed that clamp load variation with thread forming fasteners is consistent with industry expectations for standard steel bolts and nuts at +/- 30%. There does not appear to be any significant increase in clamp load variation due to the application of thread forming fasteners in as-cast holes of aluminum or magnesium over the effective life of a die casting mold. The fully implemented potential benefit of thread forming fasteners in as-cast holes of aluminum and magnesium is estimated to be 6 trillion Btu per year for North America. Economic benefit is estimated to be nearly $800 million per year. Environmental benefits and quality improvements will also result from full implementation of this technology.

36 MATERIALS SCIENCE↗
NASA NTRS2005

Fastener Starter

The Fastener Starter is a creative solution to prevent the loss of small fasteners during their installation. This is the only currently available tool that can firmly grip and hold a single screw, bolt, nut, washer, spacer, or any combination of these parts. Other commercially available fastener starters are unable to accommodate a variety of parts simultaneously. The Fastener Starter is a more capable and easier tool to use than prior tools. Its compact size allows it to be used effectively in cramped, difficult-to-see locations. Its design also allows it to be used with or without handles and extenders in other difficult-to-reach locations. It provides better protection against cross threading and loss of fasteners and associated parts. The Fastener Starter is non-magnetic and does not off-gas, thus meeting flight hardware requirements. The Fastener Starter incorporates a combination of features of several commercially available tools, providing an improved means of installing small fasteners. The Fastener Starter includes a custom molded insert that can be removed easily and replaced with a conventional tool bit (e.g., a screwdriver or hex-driver bit). When used with the insert, the Fastener Starter prevents cross threading and damage to internal threaded holes. This is achieved by allowing the fastener to slip within the tool insert when used without a conventional tool bit. Alternatively, without the insert and with a tool bit, the Fastener Starter can torque a fastener. The Fastener Starter has a square recess hole that accepts a conventional square drive handle or extension to accommodate a variety of applications by providing flexibility in handle style and length.

Chandler, Faith↗
DOE OSTI2026

Solar Photovoltaics Resilient Fasteners Levelized Cost of Energy (LCOE) Tool

Solar photovoltaics (PV) module fasteners are one of the most common structural failure points on PV systems, particularly in high winds and coastal areas with ocean spray. Some fastener types have been shown to survive these conditions at higher rates than others. The fastener type, material, quantity, and placement all impact performance. Fasteners that fail less often typically have a higher upfront cost, but this investment can pay off in savings from less frequent torque audits (which reduces O&M costs), reduced system damage, and decreased system downtime. We developed an Excel-based tool to evaluate different module fasteners for a PV system - either a new or retrofit project - and compare differences in upfront and outyear costs to determine the expected life cycle costs and simple payback periods of different fastener options. The tool is site-specific, with inputs including system attributes (such as system size, location, price of power) and fastener attributes (such as design, washer type, nut type, use of locking hardware, materials, installation time, and torque audit requirements). A baseline fastener scenario can be compared to up to four proposed fastener scenarios. In addition to presenting expected life cycle cost implications of the different fastener options, the tool produces results showing the reductions in outyear costs needed to offset any initial cost premiums for more reliable fasteners across four categories: preventative O&M, avoided damage, reduced downtime, and reduced insurance premiums. These numbers can serve as decision aids for users when considering fastener options on new or existing projects. This poster will present the tool, methodology, and scenarios using example sites to highlight the tool capabilities and how it can inform different fastener decisions on different projects. Future work includes incorporating lifetime expected damage costs by embedding damage function curves that the authors are developing from field data.

14 SOLAR ENERGY↗
NASA NTRS1994

An instrumented fastener for shear force measurements in joints

A preliminary investigation has been conducted on instrumented fasteners for use as sensors to measure the shear loads transmitted by individual fasteners installed in double-splice joints. Calibration and load verification tests were conducted for instrumented fasteners installed at three fastener torque levels. Results from calibration tests show that the shear strains obtained from the instrumented fasteners vary linearly with the applied load and that the instrumented fasteners can be effectively used to measure shear loads transmitted by individual fasteners installed in double-splice joints. Tests were also conducted with three instumented fasteners installed in a typical double-splice joint. The test results showed that the load distribution between individual fasteners is dependent on the location of the fastener in the joint and the fastener torque level.

Sawyer, J. W.↗
NASA NTRS1994

Quick connect fastener

A quick connect fastener and method of use is presented wherein the quick connect fastener is suitable for replacing available bolts and screws, the quick connect fastener being capable of installation by simply pushing a threaded portion of the connector into a member receptacle hole, the inventive apparatus being comprised of an externally threaded fastener having a threaded portion slidably mounted upon a stud or bolt shaft, wherein the externally threaded fastener portion is expandable by a preloaded spring member. The fastener, upon contact with the member receptacle hole, has the capacity of presenting cylindrical threads of a reduced diameter for insertion purposes and once inserted into the receiving threads of the receptacle member hole, are expandable for engagement of the receptacle hole threads forming a quick connect of the fastener and the member to be fastened, the quick connect fastener can be further secured by rotation after insertion, even to the point of locking engagement, the quick connect fastener being disengagable only by reverse rotation of the mated thread engagement.

Weddendorf, Bruce↗
NASA NTRS1992

An instrumented fastener for shear force measurements in joints

Results are presented of a preliminary investigation of instrumented fasteners for use as sensors to measure the shear loads transmitted by individual fasteners installed in double splice joints. Calibration and load verification tests were conducted for instrumented fasteners installed at three fastener torque levels. Calibration test results show that the shear strains obtained from the instrumented fasteners vary linearly with the applied load and that the instrumented fasteners can be effectively used to measure shear loads transmitted by individual fasteners installed in double splice joints. The load distribution between individual fasteners is found to be dependent on the location of the fastener in the joint and the fastener torque level.

Sawyer, James W.↗
NASA NTRS2002

Characterization of Ceramic Matrix Composite Fasteners Exposed in a Combustion Liner Rig Test

Combustion tests on SiC/SiC CMC (Ceramic Matrix Composite) components were performed in an aircraft combustion environment using the Rich-burn, Quick-quench, Lean-burn (RQL) sector rig. SiC/SiC fasteners were used to attach several of these components to the metallic rig structure. The effect of combustion exposure on the fastener material was characterized via microstructural examination. Fasteners were also destructively tested, after combustion exposure, and the failure loads of fasteners exposed in the sector rig were compared to those of as-manufactured fasteners. Combustion exposure reduced the fastener failure load by 50% relative to the as-manufactured fasteners for exposure times ranging from 50 to 260 hours. The fasteners exposed in the combustion environment demonstrated failure loads that varied with failure mode. Fasteners that had the highest average failure load, failed in the same manner as the unexposed fasteners.

Verrilli, Michael J.↗
NASA NTRS2002

Captive Fastener Device

A captive fastener device is utilized to hold two members together. The device is comprised of a housing which may be securely attached to the first member. Within the housing is a spring which biases a bottom of a first lip of a cup washer. The top of the first lip contacts the top of the housing when the fastener is not engaged. The fastener has a ledge at the bottom of the fastener head which rests on a top surface of a second lip of the cup washer. The bottom surface of the second lip contacts the first member when the fastener has fully engaged the second member to secure the first and second members together. The first lip of the cup washer has a greater diameter than the second lip. The first lip also has a greater diameter than the fastener. When the fastener is not engaged, a top surface of the first lip engages a bottom surface of the top of the housing. The housing top has an access hole of smaller diameter than the outer diameter of the fastener head which retains the fastener within the housing when the fastener is not engaging the second member.

Dowling, Timothy Edward↗