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FASTENER TIPS: TESTING, TEST REPORTS, SUPPLIER OVERSIGHT

FASTENER TIPS: TESTING, TEST REPORTS, SUPPLIER OVERSIGHT. Approved for Public Release. Topics. Past Problems Quality Control Test Methods Test Variables Test Report Content. Approved for Public Release. Past Problems. Lack of hydrogen embrittlement relief Wrong wedge angles

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FASTENER TIPS: TESTING, TEST REPORTS, SUPPLIER OVERSIGHT

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  1. FASTENER TIPS: TESTING, TEST REPORTS, SUPPLIER OVERSIGHT Approved for Public Release

  2. Topics • Past Problems • Quality Control • Test Methods • Test Variables • Test Report Content Fastener Testing Approved for Public Release

  3. Past Problems • Lack of hydrogen embrittlement relief • Wrong wedge angles • Wrong gage lengths • Sampling • Process control of piercing diameter • Concentricity of head and/or socket to shank Fastener Testing Approved for Public Release

  4. Piercing Diameter Minor Diameter Out of Tolerance Minor Diameter Within Tolerance Fastener Testing Approved for Public Release

  5. Concentricity Socket is not centered in the head of the screw Socket is not centered in the head of the screw Head and shank are not concentric Fastener Testing Approved for Public Release

  6. Topics • Past Problems • Quality Control • Test Methods • Test Variables • Test Report Content Fastener Testing Approved for Public Release

  7. Quality Control Mil-I-45208 “Inspection System Requirement” Requires: • Clear and concise procedures. (Para. 3.2.1) • Use of calibrated equipment. (Para. 3.3) • Providing and maintaining adequate records (i.e. Objective Quality Evidence (OQE)). (Para. 3.2.2) Other quality standards may apply ,however the rules are basically the same (e.g. MIL-Q-9858, ISO 9001). Fastener Testing Approved for Public Release

  8. Topics • Past Problems • Quality Control • Test Methods • Test Variables • Test Report Content Fastener Testing Approved for Public Release

  9. Test Methods ASTM F606 Standard Testing Methods Are Typically Invoked Unless Otherwise Specified • Tensile / Yield / Elongation (Mach. specimens) • Axial Tension (Full Size fasteners) • Proof load (Full Size fasteners) • Wedge tension (Full Size fasteners) • Hardness Fastener Testing Approved for Public Release

  10. Test Methods Flat surface Cylindrical surface • Hardness testing performed on a convex cylindrical surface • Correction factors of ASTM E18 need to be applied Fastener Testing Approved for Public Release

  11. Test Methods Determination Of Proper Wedge Angle For Wedge Testing • ASTM F606 (Unless otherwise specified) • ASTM A574 (Socket Head Cap Screws) • MIL-S-1222H3 (Titanium, SC 10-122) Fastener Testing Approved for Public Release

  12. Test Methods Gage Lengths Are Different For Ferrous And Non-ferrous Fasteners Fastener Testing Approved for Public Release

  13. Test Methods Plated Steel Fasteners May Require Additional Processing And Testing • The plating process can cause Hydrogen Embrittlement of steel fasteners. • Post plate baking is normally required to drive off hydrogen introduced into the base material • Hydrogen Embrittlement can cause delayed cracking. • Stress Durability Testing may be required to determine the effectiveness of the post plate baking process. Fastener Testing Approved for Public Release

  14. Test Methods Determining Sample Size And Test Requirements • The manufactured lot size is needed to determine the correct number of samples. • Type of specimens. • Machined specimens • Full size fasteners Fastener Testing Approved for Public Release

  15. Test Methods Determining sample size and test requirements FF-S-86 Fastener Testing Approved for Public Release

  16. Test Methods Determining sample size and test requirements FF-S-86 Fastener Testing Approved for Public Release

  17. Test Methods Determining sample size and test requirements Mil-S-1222 Fastener Testing Approved for Public Release

  18. Test Methods Determining sample size and test requirements Mil-S-1222 Fastener Testing Approved for Public Release

  19. Topics • Past Problems • Quality Control • Test Methods • Test Variables • Test Report Content Fastener Testing Approved for Public Release

  20. Test Variables Variables that can affect test results • Fixturing, Alignment. • Speed of applied load. • Test Specimen preparation (Surface finish). • Tool marks act as stress risers. Fastener Testing Approved for Public Release

  21. Topics • Past Problems • Quality Control • Test Methods • Test Variables • Test Report Content Fastener Testing Approved for Public Release

  22. Test Reports • Name of Testing Organization • Date of the test • Purchase Order number and Item number • Manufactured lot size • Material Spec. Alloy, Type, Class, Grade, Condition • Type of specimen tested (machined vs. full size) • Traceability to hardware (Lot Code) • Acceptance criteria. • Statement of acceptance or rejection • Units should be the same as those contained in the acceptance spec. (lbs vs. psi) • Signature of test organization representative and date. Fastener Testing Approved for Public Release

  23. Test ReportsC of C Fastener Testing Approved for Public Release

  24. Test ReportsChemicals Fastener Testing Approved for Public Release

  25. Test ReportsMechanicals Fastener Testing Approved for Public Release

  26. Test ReportsMechanicals Fastener Testing Approved for Public Release

  27. Test ReportsMechanicals Fastener Testing Approved for Public Release

  28. Test ReportsNDT Fastener Testing Approved for Public Release

  29. Test ReportsNDT Fastener Testing Approved for Public Release

  30. Summary • Past Problems • Quality Control • Test Methods • Test Variables • Test Report Content Fastener Testing Approved for Public Release

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