Contrary to rivets, bolts/screws have in the aeroengine technology not lost its importance. Especially
ducts of sheet metal, for example around struts of turbine exhaust casings for an aerodynamically efficient
shape are riveted (Ill. 23.3.2-1). In older aeroengine types some OEM use rivets for the axial fixing of the blades
in the axial fixierung of the blades in the disk slots
(volume 2, Ill. 6.2-5.2).
Do bolts have in the aeroengine technology contrary to the „normal“ machine engineering specifics?
Concerned are not special properties. The combination of the operation loads in the limit range of the material potential
is the specific feature. Thereby it is about highest static and dynamic strength, often at maximum service
temperature. To guarantee thereby the high safety for the aeronautical use, highest quality is needed. The material
properties are utilised with the use of the design
limits (design lines).
For bolts of high-strength steels is the goal to utilise the maximum strength with sufficient insensitivity
for hydrogen embrittlement and stress corrosion cracking
(SCC). For this also must be guaranteed the required residual stresses from coatings and/or the lubrication and the tensioning (Fig. "Operation loads of bolts" and Ill.
23.3.1.1-3). Media may not weaken the bolt material under high tension stresses with deteriorations like
corrosion (SCC), diffusion (SMIE) or meltings (LME).
Some problems of bolts will be also discussed in other volumes of this edition besides the following
chapters. There are illustrations, respectively texts which deal with several aspects and are therefore repeatedly offered.
A special problem exists with the deterioration of a
bolt by the lubricant (Fig. "How to loosen bolts and nuts").
This danger is associated with sliding
additions like metals or MoS. Unfortunately in many
handouts, respectively company
informations there are no sufficient hints. In contrary, it is only pointed
at „proprietory”. Because of this, it is necessary during
change of the product, to assure oneself
its harmlessness. This is necessary, even if the product seemingly meets the specifications. A
test/approvval should take place under inclusion of the OEM.
Finally, again a remark about alternative
materials. Instead steels and
nickel alloys, offer themself titanium alloys and fibre reinforced plastics. Titanium alloys as materials for bolts have found till
now nearly no application in the aeroengine technology. This primarily depends from the tendency of
titanium alloys for seizure/galling. Although coatings/layers by
electrical oxidation (similar „Eloxal“ at
Al alloys) and dry lubricants are offered at the market, a noteworthy use in the aeroengine technology
till now got not known by the author. Seemingly these coatings/layers or lubrications can not
convincing prohibit a deterioration or damage of such bolts during tensioning or loosening.
A further problem of titanium alloys may be the danger of a
deterioration from fretting. Do micromovements occur, which also in many cases can not sufficient certain ruled out, the
fatigue strength can drop 70% (volume 2, Ill. 6.1-8). In contrast to this, for Ni alloys and steels this
deterioration is only in the range of 10%.
Bolts from (long) fibre reinforced plastics
(FRPs) have the disadvantage of a relatively low
application temperature and overloading of the thread. Anyway, obviously such bolts are planed for the use in
new aeroengine types.
Fig. "Bolts and rivets" (Lit. 23.3.1.1-16):
Service influences at bolts can get failure effective as a
mechanical load in combination with the drop in
strength.
Mechanical load acts at a bolt in height and type (bending, tension, shear, torsion).
Different to rivets, bolts are not intended for shear
loads. Therefore they also should not be used for such a
retaining effect. Bending of bolts by a onesided load can be prevented by design. An example is the bolting
of axial flanges from pressurized
casings. In one case, from the inside a V-bar is counter
tensioned (sketch below left). Also high g-loads at
flange boltings from rotors can produce markedly bending
or shear from corbelling masses like the nut and the bolt shaft of bolt head (sketch above middle).
Similar effective act different thermal expansions and elastic, load depending strain of the flanges at the
bolting (sketch above right).
Corrosion deteriorates in different ways. Develop pits (pitting corrosion), its
notch effect is especially for a dynamic load a problem. Bolt materials of the type 13% Cr steel tend to this failure mode
during stand still and watery electrolyte (condensate, sea atmosphere), without sufficient corrosion protection.
For high alloyed austenitic bolt materials
(e.g., A286) and Ni alloys (e.g., Waspalloy, IN718,
Nimonic alloys) the danger of sulfidation exists. Thereby
silver can act promoting (volume 3, Ill. 12.4-14).
The sulfur not seldom comes from unsuitable, sulfur containing lubrication greases/pastes
(MoS2 , Fig. "Approved lubrication media").
Oxidation is a main problem at bolts and hot parts. It causes after longer operation periods to
stuck the bolts respectively nuts. During
loosening of the connection, in spite the use of
high temperature lubricants, the deterioration danger of the thread
and/or of a torsion overload of the shaft with
crack formation up to the fracture exists (Fig. "Jamming causes of bolts and nuts"). This excludes in many cases a reuse. Therefore
as a precaution the affected bolt sets are generally exchanged during the assembly. This is caused from
the insufficient surem non destructive testability. Typical example are bolts of flanges at turbine rotors.
Oxidation can also have a positive
aspect. It offers threads of bolts/nuts from austenitic materials
(Ni alloys, high alloyed steels) a certain protection against seizing
/galling. In hot parts the former usual silver plating as „lubricant” will more and more be abandoned, because of the deterioration
danger. With this, the danger during tensioning of metallic bare threads from new bolts
arises. Here a targeted preoxidation in air in an oven at operation temperature can find a remedy.
Fretting wear occurs everywhere, where it comes to micromovements between the components of
the bolting. The so developing fresh metallic surfaces and the
adrasion are influenced from oxidation (volume 2, Ill. 6.1-4). This can
accelerate the wear. In contrast, oxides with the
effect of a dry lubricant (volume 2, Ill. 6.1-18) can minimize the wear. Basically the fatigue strength of the usual bolt
materials is not so affected by fretting as titanium alloys (volume 2, Ill. 6.1-8).
Liquid metal embrittlement (LME) is a crack formation/embrittlement during sufficient high
tension stresses and influence of wetting metal
melts (volume 4, Ill. 16.2.2.3-10.1, -10.2, -10.3 and Ill.
16.2.2.3-11). Silver (Fig. "Bolt fracture at hot parts by silver") and
cadmium are especially dangerous. This applies also for a
deterioration in the solid condition by diffusion
(SMIE). This danger decreases markedly at
preoxidized/oxidized surfaces, because a wetting contact to the melt is prevented.
Influence of foreign objects/force especially occurs as
secondary failure at flange boltings from
rotors (Fig. "Identifying fractured bolts at rotors"). For example, if during assembly a
tool was forgotten (Fig. "Foreign object remained by assembly") or the fracture
of a bolt happened (Fig. "Identifying fractured bolts at rotors"). A further possibility is the damage during axial
rubbing of the bolt heads or of the nuts.
Material changes during the service can be caused from
aging, overheating or diffusion of foreign material. These may be only expected during
unusual operation conditions. The selection of the
bolt material should certainly prevent such deteriorations.
Fig. "Operation loads of bolts" (Lit. 23.3.1.1-1 up to Lit. 23.3.1.1-4): A bolt connection without forces from the
outside is a internal stress stytem. In it the
stresses are in a balance (volume 4, Ill. 16.2.2.4-1 and Ill.
16.2.2.4-2). From the outside acting operation forces change this condition, respectively the internal
stresses, until balance exists. The bolt gets the tensile loading through the support/flange. It takes the
internal stresses from the pretension. As long as this is the case, only a part of the service load acts at the
bolt (diagrams above). Is the pretension fully
compensated, e.g., the flanges begin to lift off, further
increases of the load act fully at the bolt (diagramm above left). So a
lower pretension of the bolt causes a higher operation stress
of the bolt (Fig. "Avoiding fatigue cracks at bolts"). This especially becomes noticable at
dynamically high loaded bolts of the aeroengine design.
Is the bolt, according to its strength, sufficient high prestressed
(diagram above right), dynamic stesses can kept sufficient
low. Regarding the prestress of the bolt as mean stress, leads its lowering
to a markedly higher usable fatigue strength of the bolt
material (diagram below). So it is very
important, that the in the instructions specified
tightening torque, determined from the designer, is kept.
To guarantee the necessary pretension, it must be payed attention at the required
lubrication conditions (Fig. "Influence of pretension at fatigue"). Besides the
lubricant also the coating plays an important role. It must correlate
absolutely the specifications.
To guarantee, during unusual high loads, sufficient pretension,
reduced bolts/tension screws are used. The relatively low spring stiffness is reached with a waisted shank/reduced shaft (sketch middle
right). Typical example of use are `containment
loaded' (by impact of fragments) flange
boltings (volume 2, Ill. 8.2-15) of casings. Similar bolt connections are also needed at extreme
rub processes, e.g. during unbalances
from a rotor blade failure (volume 2, Ill. 8.1-15).
Fig. "Influence of pretension at fatigue" (Lit. 23.3.1.1-2, Lit. 23.3.1.1-8 and Lit. 23.3.1.1-16): The efficiency of a bolt/screw is determined by the residual share of the torque for the pretension. These influences can let with the same torque the pretension scatter up to 80 % (Fig. "Influence at the bolting durability"). For this reason it is especially important, to meet exactly the specified procedures during the bolting. So during the design planned minimum pretension can be guaranteed.
Fig. "friction forces on bolt connections" (Lit. 23.3.1.1-2 and Lit. 23.3.1.1-8): The
load transmission inside a thread can be simplified, compared with a
sloping level. Then the pretension force produced in the thread,
correlates a weight in axial/vertical direcction. A circumferential force by the tightening torque, loads the
sloping level, e.g. the thread flank (sketch left). In the opposite direction acts the
friction. The remaining force, respectively the related tensioning moment, produces the
axial pretension in the bolt.
The friction in the thread prevents a
loosening/untwisting of the bolt connection. Thereby the
clamming friction force is higher than the untwisting component from the pretension. Such a
self-locking is given at typical thread pitch of bolts. at least for static loads.
A vibration of the bolting can markedly lower the frictional coefficient of the flanks. This effect
is similar a vibrating inclined plane. Is thereby the self-locking
canceled, loosens the bolting (sketch right, Fig. "Locking effect at bolting connections").
Because of this reason, actuated by adherend self-locking
nuts (e.g., by locally ovalisation or springy tongues) are used. A further possibility are
form fitting lockings. For example for shaft nuts
bendable locking ears (Fig. "Anti twist devices for shaft nuts") are used. A further example are
locking wires (Fig. "Loosening of bolting from hot parts").
Fig. "Locking effect at bolting connections" (Lit. 23.3.1.1-8 and Lit. 23.3.1.1-11): Boltings of aeroengine components
underlie conditions which lead to a loosening during
operation. Already a decreasing pretension can
heavily increase a dynamic load if the flanges lift
off (Fig. "Operation loads of bolts"). With this the danger of a
fatigue fracture rises (Fig. "Appearance of bolt operation failures").
In an extreme case, an unsufficient secured nut can
separate. Then the danger of heavy foreign/
own object damages (OOD, DOD) exists.
Following influences can cause a dangerous drop of the bolt pretension:
Untwisting can occur due to unsufficient securing under
heavy vibrations (Fig. "friction forces on bolt connections" and Fig. "Loosening of bolting from hot parts").
Setting of the bolting by yielding of the
supports. Concerned is a locally plastic
deformation caused b
Yielding of threads and/or thread inserts
in light metal alloys (Fig. "Bolt connections in light metal castings").
Wear can promote a loosening at all contact surfaces, which influence the pretension. As main
mechanism during vibration wear (fretting), micromovements play a role. However a dangerous loosening by
wear of the bolting seems to be extremely seldom, at least for flange connections. Rather problems at
pipe clamps and its bolt fixtures are to expect (Fig. "Resonance vibration caused by P-clamps" and example 23.5.1-2).
Crack formation at the shaft or the thread from the bolt. Cracks can have different causes, which
also appear in combination:
Creep (volume 3, Ill. 12.5-3) is a plastic (lasting) deformation (elongation, compression) during
material specific elevated temperature (Ill. 12.5-1). This yielding can occur as well at the
bolt (shaft, thread) as also in the thread of a blind
hole or in the nut (Fig. "Bolt connections in light metal castings"). Also a
yielding of the flanges or of shims can have the same effect.
Differences in thermal expansion are possible during different
temperature distribution in the bolting, e.g., during nonsteady operation. Such influences are to expect especially at boltings in the hot gas stream (Fig. "Loosening of bolting from hot parts").
A further possibility is an unfavourable material
combination/thermal expansion coefficient
between flange material and bolt shaft. Depending of the combination during heating or cooling, prestress
can be lowered. Typical problem zones are axial pretensions of rotors, especially for
centric tension bolts (Fig. "Tightening torque surface and lubrication", volume 3, Ill. 12.6.3.3-6).
Drop of the E-modulus at temperature (volume 3, ill. 12.4-1). This applies for flanges and boltings.
A lowering in stiffness acts at pretension, vibration and micro movements.
Fig. "Bolt prestress decrease during service": From experience, irritations can arise with bolts, which are taken from the storage. This may be the case, if the specified tightening torque is not reached, because the bolt deformed unusual during tightening, respectively deformed plastically unacceptable. If this behaviour can not be assigned the bolt quality, its assembling condition must be checked. Thereby the instructions in the manual must be exactly respected. There are cases, in which an additional lubrication of the thread is not sheduled. For example, shows the thread remains of conservation oil, which before the screwing should have been removed, this can trigger the undesirable effect.
Fig. "Influence at the bolting durability" (Lit. 23.2.1.1-8 bis Lit. 23.3.1.1-10 ): The achievable prestress of a bolt depends crucial from the „efficiency” of the thread and with this from the friction forces. These are essential determined from the tribological conditions between the thread of nut and bolt:
The chart contains relative friction
coefficients. 1,00 applies for untreated suefaces. The
markedly drop of the friction during the use of a
lubricant can be seen. Also an additional
coating or the change of a coating can influence the bolt efficiency markedly.So an increase of the friction coefficient
about 30 % (gray area in the chart) must be considered in the tightening torque. For this reason a
deviation from the coatings, specified by the OEM, is not accptable.
Also a not scheduled additional
lubrication can act deteriorating (Fig. "Bolt prestress decrease during service"). In this case, for
the bolt exists the danger of overload during tensioning.
Fig. "Tightening torque surface and lubrication": Tension bolts
for the axial tensioning of rotors must keep up a minimum pretension
also during instationary operatio. This guarantees an exact
specified pretensioning process. With this
the rotor gets the necessary stiffness and so a vibration behavior, according to the design.
The more elastic the pretensioning, i.e. the longer and thinner the elongated length, the better
thermal caused expansion differences can be compensated (Fig. "Locking effect at bolting connections", volume 3, Ill. 12.6.3.3-6).
Thereby the long bolt shaft gets not unacceptable twisted during tightening of the nut, if at the side
of the nut, spanner flats are applied (mostly square-end). These enable a
backing.
Outward located tension bolts (sketch left) can better follow temperature changes as
a centric tension bolt (sketch right). At centric tension bolts in the turbine area, the temoerature difference between
rim and interior zone (hub) is especially large (volume 3, Ill. 11.2.3.1-8 ). Drops the pretension too
much, failures can occur (volume 3, Ill. 12.6.3.3-6). This is the case, when for example during
shut down of the aeroengine, the blading and the rim cool down very fast and the relative massive inner zone of
the trurbine wheels is much more tardy (volume 3, Ill. 11.2.3.1-8).
Fig. "Rotor tension bolts" (Lit. 23.3.1.1-5, Lit. 23.3.1.1-6, Lit. 23.3.1.1-7 and Lit. 23.3.1.1-16): During
tensioning, according the feeling, the scatter band grows about the uncertainty of the tightening torque.
From experience the pretension of thinner
bolts (e.g., M12) rather above the yield
point. In contrast thicker bolts are
too low tensioned (e.g., M14). This can be avoided with
torque control tightening („A“
). Usually for this, a torque wrench is used. This can be, depending from the specification,
displaying and/or triggering. Of course, such wrenchs must be
calibrated as specified. Anyway, caused by
the friction forces, for the pretensioning only remains a
usuable fraction of about 10% („A”, chart
left). Even if the scatter of the torque display lays below ±10%, it is understandable that this can lead
due to relative little variations of the friction forces to a
large scatter range of the prestress of up to
80%. This correlates a tightening
factor (maximum prestress /minimum prestress) of 1,6 bis
1.8. This can be not acceptable for the high loaded boltings of the aeroengine technology.
The meaning of the minimum pretension requires in critical cases a
controlled tensioning process. For this several processes are available, which however demand requirements.
Impulse controlled tensioning is carried out with an
impact wrench. Here also the tightening
torque is adjustable respectively possible to trigger.
This procedure has the advantage,to trigger no
response moment. However it underlies many
influences at the achieved pretension:
This leads to a very bad tightening
factor in the region of 2,5-4,0. With an optimizing 1,5-2,5 can
be reached. This may not be enough for many cases. Therefore such tools are rather used at the
disassembly for the loosening of boltings.
Extension controlled tightening. The elongation is under consideration of the
bolt strength direct proportional to the bolt
pretension. Thereby the material (modulus of elasticity) and the
cross section course assume as a constant. The larger the
length of elongation (clamping length), the more
exactly is the process. Accuracies better than +-5 % can be expected. This correlates a
very good tightening factor of 1,2. Therefore it is predestined for the
pretension adjustment of the tension bolts/rods
of rotors (Fig. "Tightening torque surface and lubrication"). Precondition for this
demanding process is a good accessibility (frame below).
The elongation can also be identified with ultrasonic
sound from one side („B2“). Thereby
advantage can be taken, influencing the runtime of the
sound in the bolt shaft by the tightening process
(acusto-elastic effect, Lit. 23.3.1.1-7). This is
markedly larger than it correlates the pure
elongation (diagram at the left side above right). Requirement for the measurement, i.e. sound reflextion and
coupling/contacting are suitable end faces (grinding surfaces)
at the head and the bolt end. An advantage
of the process is the continuous measuring of the pretension during the tightening
process.
During the angle controlled tightening
(„C”), the bolt is first torque controlled tightened
(torque wrench). This is followed by a tightening with a calculated angle of twist until to the
beginning plastification. This so called
strain controlled tightening (yield controlled tightening) let expect
an excellent tightening factotr of
1.0, because the yield point (0,2% plastic elongation) is certeinly reached.
Is the tightening torque above the angle of twist continiually monitored, the
reaching of the yield point (also elastic limit, elastic limit) shows with the
flattening of the curve. This effect can be used for
an electronic control.
Twist angle controlled processes demand an application specific
testing and require a sufficient elongation
length. Additionally the plastic deformation can
exclude a reuse.
Fig. "Type of screw locking" (Lit. 23.3.1.1-3 and Lit. 23.3.1.1-12):
Locking devices for bolts and nuts must
correlate the specifications in the manual. Unauthorized changed, respectively
additional locking measures like adhesives at the
thread (Fig. "Problems with additional bolt locking") or a safety wire to a self
locking (threaded insert, counter nut) can rather lower the safety.
The pinched off too long ends of a locking
wire, can be a special problem. Are these not held
as prescribed and so secured against jumping off (Fig. "Assembly as FOD risk"), the danger exists, that these fall in
not covered openings of the oil system. As foreign objects, they trigger extensive failures, e.g., in
the compressor (volume 1, Ill. 5.2.1.1-6 and Ill. 5.2.1.3-5) or in the oil system.
During application of mechanical lockings like locking wires or shims, the specified procedure
must be used. The laying of locking wires must correlate the locking effect. The wires must not be
dangerously weakened or get a critical deterioration during service (fretting). They also must not damage
other components like pipe lines by fretting (Ill.
23.5.2-5). Damages or unfavourable use of a
locking/securing element during deformation can cause cracks and/or fractures (Fig. "Anti twist devices for shaft nuts"). For example a
broken locking lug (sketch below right, Fig. "Locks and securings of bolts") can trigger in the gear itself heavy secondary
failures, if it gets into the toothing.
Self locking/securing nuts (sketch above left) are, corresponding the introductions in the
manual, reusable. From many a time use, the function of the self securing can be deteriorated by wear
and/or deformation.
Fig. "Anti twist devices for shaft nuts" (Lit. 23.3.1.1-13): For the
fixing of components on shafts frequently
can locks are used (sketch below, Fig. "Locks and securings of bolts"). With these, components like gear wheels or rotor disks are
tensioned and fixed on the shaft. These nuts have a can lock from sheet metal.This has since long proven in
the aeroengine technology. However, during operation exist potential problems,
which must be considered. At their symptoms must be payed attention during overhaul.
The securing/locking naturally demands a suitable
`activation'. This usually takes place with a
plastic deformation. Thereby a locking
lug is bended into a notch (sketch middle) or produces with the
specified tool an indentation (sketch above). In this case it must be payed attention, that on one hand a
sufficient large deformation guarantees the necessary securing effect. On the other hand no
cracks or unacceptable weakening damages like
notches may occur. These can be the start of
fractures by vibration fatigue. Thereby the locking effect is lost and foreign object
damages/own object damages from the fragments must be feared.
Fig. "Jamming causes of bolts and nuts" (Lit. 23.3.1.1-8 and Lit. 23.3.1-14):
Stuck/jammed bolts and nuts are especially at
hot parts in aeroengines a frequent phenomenon. This can have different causes, which also can occur
in combination.
Austenitic materials like Ni alloys and high-alloyed CrNi steels and especially titanium alloys
tend during tightening or loosening of bolts and nuts to
seizing/galling (Ill. 23.3.2.1-1). Cause is the
very thin natural oxide film, which is destroyed from the sliding process under high surface pressure. So
it comes to an intense contact of fresh reactive metal
surfaces. Such a fusion/welding also occurs at
the supporting contact surface of nut and bolt head especially with titanium alloys and Ni alloys.
Can first signs of seizure be noticed, every further tightening will increase the
deterioration. A typical feature is, that also the untwisting is no more possible. In such a case, the connecrion must be careful
loosened and is with unaccptable damages no more usable.
Oxidation („freezing“) appears in the threads of hot parts boltings. The oxides have a larger
volume than the base material. This leads to a
clamping/jamming effect. Do the oxides have
bad sliding properties, this effect can still increase. Unsuitable lubricants can promote the blocking.
Corrosion („seizing up by rust”) occurs especially at boltings of steel in the colder region. Here
condensate can form and sea atmosphere can act. Also the corrosion may play a role during the growth of the
oxide volume. Unsuitable auxilary material, which for example disintegrate at operation temperature
(e.g., MoS2 containing), can even aggravate the corrosion (Fig. "Approved lubrication media").
Fretting (vibration wear) can form on contact surfaces during micro movements. For example
such appearances can be found after longer operation periods also at the contact surfaces of boltings
from of rotors and flanges. Develops inside the threads oxidizing abrasive (fretting wear, `friction rust',
Fig. "Lubrication caused fretting wear", volume 2, Ill. 6.1-3), this can act like corrosion products.
Often a `breakaway' of nuts is possible, however
without a total twisting off. This may have
several causes, which also intensify in combination:
Remedies against jamming/sticking of nuts and bolts:
Appropriate (specification conform) application of the
specified lubricant. If already a coating
with dry lubricant is present use only specified procedures. If seemingly necessary, use no additional lubrication.
To be considered:
Fig. "How to loosen bolts and nuts" (Lit. 23.3.1.1-8 and Lit. 23.3.1.1-14): The
loosening of sticking boltings can be
facilitated with different measures. However these must always be permitted, according to the instructions in
the manual.
Rust remove, mostly as spray, facilitate, at least after a
residence time as well the loosening as the unscrewing of the nut. However here
attention is needed. Only for the application
approved removers/solvents may be used. For example with
Cl containing media the danger of a deterioration of
titanium components exists (volume 1, Ill. 5.4.2.1-6 and Ill. 5.4.2.1-8). At high strength steels,
stress corrosion cracking can develop.
MoS2 containing media can develop at sufficient operation temperatures
sulfidation at Ni alloys (volume 1, Ill. 5.4.5.1-4) or trigger
under tension stresses cracking (Fig. "Unsuitable lubricant leading to fracture").
Mechanical shock loading, for example by an
impact wrench (Fig. "Rotor tension bolts"). These devices are
used during disassembly. Thereby the thread must not be damaged to avoid a hindering of the
untwisting process.
Before the untwisting of the nut, protruding
thread must be carefully cleaned from corrosion
products and firm sticking lubricant remains.
Heating the bolt to 50-100 °C.
This decreases in many cases the friction coefficient.
Fig. "Dangers to bolts at temperatures" (Lit. 23.3.1.1-17):
`High' operation temperature is a relative term. It can,
depending from the tribological system and materials, already lay in the range of 200 °C or not before
above 400°C. In this temperature range, potential danger of deterioration
exists. Thereby failure mechanismy are concerned like:
Embrittlement by diffusion: At temperatures of 600°C, silver can diffuse into the surface of Ni
alloys (volume 3, Ill. 12.4-14). For titanium alloys this process begins at about 200°C.
Cadmium can get dangerous for steels and titanium alloys, already at temperatures above 200 °C (volume 4, Ill.
16.2.2.3-11). Thereby the melting point of the plating is not reached (SMIE). This is supported from
tensile stresses like they appear in the bolt shaft or the thread. Has the
diffusion penetrated a critical part of the bearing cross section, a brittle fracture will occur. Is a nut broken off together with the bolt shaft
under these operation conditions, also the suspicion of such an embrittlement exists (Fig. "Brittle failure modes of bolts and nuts"
and Fig. "Bolt fracture at hot parts by silver").
Crack formation and embrittlement through penetration of a
melt: This phenomenon is called `liquid metal embrittlement' (= LME, volume 4, Ill. 16.2.2.3-11). With
silver this possibility exists from about 900°C (volume 3, Ill. 12.4-4). For steels,
copper is an example. Corresponding with the low
melting temperature, lead can act deteriorating
already at markedly lower temperatures.
Sulfidation from MoS2 containing lubricants
can act in two different ways:
Under water/condensate and acting of salt
(sea atmosphere), MoS2 seems to promote corrosion
at steels. This can dangerous weaken the cross section, as well as making the bolt respectively the
nut jamming (Fig. "Approved lubrication media").\
Concluding should be mentioned, that during stand still and
acting aggressive condensate, silver can be dissolved from bolts and
nuts. Does ths percipitate at operation temperature at other
locations (e.g., turbine disks), there pittings can develop, triggered by sulfidation (volume 3, Ill. 12.4-14).
This may be a reason besides the risk of diffusion, why OEMs
use no silver plated bolts and nuts at hot
parts.
Example 23.3.1.1-1 (Lit 23.3.1.1-18): At the freight version of a big four engined airplane type,
an aeroengine separated. The following investigation showed a big
fragment, broken from the rim of the turbine
disk 2nd stage. Thereby such intense unbalances occurred, that the front mounting of the aeroengine was
overloaded and fractured. So this was a secondary failure. The
primary failure was a loosening of the bolting
from the turbine stator in front. This flapped back and rubbed against the turbine disk. This was therby
so weakened, that it came to the fracture.
Cause for the loosening must be seen in the attaching of the
bolting. Thinkable is:
Comment: About the danger of such a failure through loosening of the bolting, already warns the aeroengine manual. Obviously this was not a first case. Crucial seems to be a not sufficient torque. So the boltimg could get overloaded.
Example 23.3.1.1-2 (Lit 23.1.1-19, see volume 2, example 10-13 ): At the aeroengine mountings af a
large 4-engine airliner, loosened respectively
untwisted nuts from connection bolts
have been found.
At least in one case the bolts have slided out. As cause, the
lubrication and/or the tightening of the
nut is suspicious.
Comment: If such a connection bolt of the aeroengine mount drops out/fails the aeroengine can separate
and so a serious safety problem arises.
(sketch symbolic)
Example 23.3.1.1-3 (Lit 23.1.1-20): During the execution of an AD (airworthiness directive) the
connection bolts of the aeroengine frontmount of a twoengined airliner got
a too low torque. With this the increased
danger of a fatigue fracture exists, The bolts in question belonged to a secondary thrust load path. These
act during the fracture of the primary system.
Comment: Obviously these connection bolts have a
fail safe function. It is needed, when the
primary aeroengine mounting fails. Just therefore, it must always guaranteed to avoid certain a separating of the
aeroengine and with this a high risk.
(sketch symbolic)
References
23.3.1.1-1 „Dubbels Taschenbuch für den Maschinenbau“, Band I, 12. Auflage, 1964,
Springer-Verlag, page 658
23.3.1.1-2 G.Niemann, „Maschinenelemente”, Erster Band, 5. Auflage, 1961, Springer-Verlag,
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23.3.1.1-3 A.Erker, „Die vorgespannte Schraubenverbindung unter Dauerbeanspruchung und
Überlastungen“, M.A.N.-Forschungsheft 1953, page 1-17.
23.3.1.1-4 K.H.Illgner, „Ermüdungsverhalten von Schraubenverbindungen” (Fatigue Behaviour of
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23.3.1.1-5 E.Grabher, „Schraubenverbindungen - Gestaltung - Berechnung”, 2002,
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23.3.1.1-6 „Methods of Tightening Threaded Fasteners“, 2006, www.boltscience.com , page 1-4.
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23.3.1.1-12 NTSB Identification IAD961A098, „Incident Jun-17-96”, 1996, page 1-3.
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23.3.1.1-15 I.E.Traeger, „Aircraft Gas Turbine Engine Technology, Second Edition”, Verlag :
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23.3.1.1-18 Special Airworthiness Information Bulletin SAIB: NE-07-4, „Subj: Pratt &
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