The Augustus Group Products Projects and Engineering Consulting

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1 The Augustus Group Products Projects and Engineering Consulting PRELOAD CONTROL STRETCH AND ULTRASONICS Jesse Meisterling

2 Bolt Preload Definition: Initial Preload: the tensile stress created in an individual fastener when first tightened. Residual Preload: the tensile stress in an individual fastener when the joint tightening process is completed. Operational Bolt Load or In Service Tension: resultant bolt load under operating conditions; temperature, pressure, external loads, etc.

3 Bolt Basics A bolt is a spring. F The elastic behavior of our bolting materials keeps everything together. Stretch has been used for many years to control preload. As long as the initial loading of the fastener is below the yield point, the from zero load to the target will be proportional to the tension force in the fastener. Stretch Angle Torque Load Load If the fastener is taken beyond the yield point it is still the elastic stretch that produces the residual bolt load. An unload stretch measurement will produce an accurate load measurement in the fastener.

4 A Bolt is a Spring Real-time plot of: Angle i.e. strain Load i.e. stretch Torque M10x Head bolt

5 Bolt Basics Bolt Tension Variation using Torque and Torque+Angle A large automotive manufacturer has a Torque+Angle tightening strategy QA requirement on each manufacturing lot of a M11 x 100 bolt, Class 10.9 head bolt. Two manufacturers produce the fastener, the fastener test lab is within 10 miles of each plant. Three bolts from each lot are sent to the lab for testing, the bolts are fresh: no time dependent oil volatilization or settling Each bolt is tightened into a load cell with a torque-angle-controlled spindle. Over 1000 lots have been tested to date.

6 Bolt Basics Bolt Tension Variation using Torque and Torque+Angle M11 x head bolt. Load After Torque Only Average Load: 65,672 N 3 sigma: +-17,215N coeff var: 26.2% manufacturer 1 manufacturer 2 Load N Load after Torque+Angle Average Load: 65,330N 3 sigma: +- 9,239N coeff. var: 14.1% manufacturer 1 manufacturer Bolt #

7 Stretch Control of Preload HOOKE'S LAW: Force is proportional to stretch F p =(A s EΔL)/L Where: F p = Preload A s =Tensile area of fastener E=Modulus of elasticity ΔL=Stretch L= Initial unstressed length

8 Stretch Control of Preload My old friend: E=σ/ε Modulus = stress/ strain stress = F/A strain = ΔL/L E=30e 6 for steel Expand to stretch calculation formula

9 Stretch Control of Preload Stretch control is the most accurate method of measuring preload in the field. Used in critical applications in many industries Nuclear: Valves, RPV, RCP, Steam Generators Petro-Chemical: Hydrogen service, Rotating equipment Automotive: quality control on assembly Stationary Engines: Connecting rod studs Aerospace

10 Stretch Calculations All Thread Stud Grip Length Total Stressed Length σ Effective Length Effective length is the equivalent constant stress length of a fastener. If Steel-Steel and >8 threads engagement then 1/2 diameter is the rule of thumb for L eff

11 Stretch Calculations All Thread Stud 1-8x6 Grip length=3 L eff = =4 1 diameter, As=0.60in 2 F=70% of yield=70ksi=42,000lbs. ΔL =L* F p /(A s *E)=(4*42,000)/(0.60*30e6)= F

12 Stretch Calculations To compute stretch you must consider the fastener as a system of springs in a series T H L B L T T N ΔL =(F p / E) [(L B /A B )+(L T /A s )+(T H /2A B )+(T N /2 A s )]

13 Stretch Measurement Mechanical Accuracy 5 trained mechanics 4 load steps average of all five looks good Average

14 Stretch Measurement Accuracy Stretch in fully threaded 1/2" steel bolt loaded to 70% of yield calc'd with As, Ar and 0.001" measurement error As ΔL Root ΔL % Error - Root and As 0.001" measurement error 35.0% 30.0% Stretch (in) % 20.0% 15.0% % error w/ As as base % Threaded length (in) 5.0%

15 Ultrasonic Stretch Measurement Stretch or Load Measurement Time Pulse Echo Ultrasonic Wave During Tightening: Fastener elongates with load Speed of ultrasonic wave reduces with load CHANGE IN TIME IS DIRECTLY PROPORTIONAL TO STRETCH OR LOAD

16 Ultrasonic Stretch Measurement Ultrasonic wave pulse-echo Δ time of flight measurement is analogous to stretch measurement for fastener load determination: single-ended micrometer Δ Slope: Δ F / Δ t is ultrasonic stiffness of the bolt spring During tightening the fastener elongates with load Pulse t 1 t 2 Echo Δt Loading the bolt creates stretch and lowers the velocity, increasing the time-of-flight Δ t Zero load (time) measurement Δ F - Δ L

17 Ultrasonic Stretch Measurement Delta time verses stretch or load Total dt Total change in time delta time ns dvdt dldt Change in time from change in Total change in time Load Lbs.

18 Ultrasound and Bolts Pulse-echo ultrasonic measurement for bolt load determination: delta load/delta time. In the bolt: ultrasound is ultrasound, force is force and delta time is delta time Today, it is not a significant task to make hardware that has the required time measurement resolution: ~0.2ns. Getting the ultrasound in and out of the fastener is the major issue. Important: how the hardware locks on the proper (same) echo cycle every time (remove and replace). Pulse Echo Ultrasonic transducer Typically a wave packet of 3-8 cycles at MHz (depending on manufacturer), every time a reading is taken is the significant issue. Any questions: ask me.

19 History NASA developed ultrasonic bolt load measurement for the Space Shuttle Main Engines in the late 60s, using analog hardware with 0.1ns time resolution: Erdman hardware. Screw-in transducers for good Repeatability Each bolt type is acoustically ground to the same ultrasonic length Hand-held transducer boxes were first commercialized in the late 70s targeting stretched bolts: refineries, electric generating and other large bolts with lots of stretch. need couplant to get ultrasound into bolt Glue-on transducers appear in early 80s no couplant but large and not rugged Thin-film transducers move to aerospace, automotive test and development, 2001.

20 Technology Reliable ultrasonic load readings using hand-held transducers are always an issue: remove and replace technology is operator dependant `remember single ended micrometer analogy training is most important! Bolt size is limited, smaller-stiffer the spring, the smaller the stretch, the difficulty goes up. Replace operator with permanent transducers Original NASA SSME threaded head transducer Hand-held magnetic transducer Glue-on transducer

21 Technology

22 Technology Solution for couplant: Make the transducer part of the bolt. The Thin-Film Transducer Thin-film sputter deposition technology creates an ultrasonic transducer that is: ~24μm thick, very low profile low mass, dynamic layers are ceramic and metal rugged, high temperature no bonding agent Electrode Protective layer Piezoelectric Thin-film Bolt

23 Technology The Permanently Mounted Transducer Sputtered Fastener Coating Your fastener Coated with piezoelectric thin-film Proven low temperature vacuum process

24 Technology Reading the the Permanent Mounted Transducer (PMT) One touch: no coupling gel No operator Remove & Replace variance Hand tools non-magnetic probe: just change the std. socket magnetic probe: small and simple hand wrench: manual real-time load control Slip rings Right angle nut runners

25 PMT in the field: relaxation Problem: manufacturer of large off-road vehicles uses 180ksi bolt for axle flange: bolts break. Bolt supplier wants to solve problem with lower strength bolt. What happens on the production floor? 4000XXX Engineering Test Report Solution: 50 each axle flange bolts, 4 strength grades, tightened to 2000 ft-lbs. Data taken after assembly and after 24 hrs. Ultrasonic Clamp Load (lbs) 140, , , , ,000 90,000 80,000 70,000 60,000 50,000 40,000 30,000 20,000 Ultrasonic Clamp Load Measurement In Axle Assembly - 13 Bolts per Sample Group Installed to 2,000 ft-lb 180 ksi Proof Load - 139,500 lbs 1st Tightening On Left Side Of Axle 180 ksi Average + 3 Sigma Average - 3 Sigma Average 180 ksi - 10 min 180 ksi - 24 hrs 170 ksi - 10 min 1st Tightening On Right Side Of Axle 170 ksi 170 ksi - 24 hr 170 ksi - 10 min 2nd Tightening On Left Side Of Axle 170 ksi Bolt Strength - Measurement Period 170 ksi Proof Load - 131,700 lbs 2nd Tightening On Right Side Of Axle 150 ksi 170 ksi - 24 hr Gr 8-10 min Gr 8-24 hr

26 PMT in the field: relaxation Problem: customer of casting supplier wants to move to a magnesium oil pan cover. Can the magnesium cover be substituted for the aluminum with no long term load/temp relaxation problems? Magnesium Aluminum Aluminum Different bolt geometry's are PMT coated, assembled in aluminum and magnesium test articles and thermally cycled (20 hours 150C 4 hours - 40 C) for 21 days.

27 PMT in the field: relaxation Solution: Magnesium exhibits initial lower loads but relaxation is flat. Load Over Time M6X1 Mg 13.75mm Bolt Flange M6X1 Mg 15.25mm Bolt Flange M10X55 Mg 18.75mm Bolt Flange M6X1 AL mm Bolt M10X55 AL mm Bolt / 13 10/ 15 10/ 17 10/ 19 10/ 21 10/ 23 10/ 25 10/ 27 10/ 29 10/ 31 11/ 2 Ther mal Cycled (20 hour s 150C 4 hour s -40 C) 21 Cycles

28 PMT in the field Large diesel engine maker wants to study gasket loads of field rebuild procedures, in the field (makes sense). 3/4x10 head bolts. 10 heads - 8 bolts per head

29 PMT in the field: relaxation Field torqueangle assembly procedure Head bolt load after 250 hrs Head bolt load after 4000 hrs

30 PMT in the field: relaxation Solution: 4000 hours of field operation with PMTs no couplant, no magnets, no problems. Field torqueangle assembly procedure, average of each head group Average head bolt load after 250 hrs Average head bolt load after 4000 hrs

31 PMT in the field: relaxation Main Bearing cap bolt assembly load study Procedure: snug torque + fixed angle to elastic target Data collected: Assembly load Assembly torque Embedment load Load after dyno Break-away torque after dyno kn M10x100 Main Bearing Bolt Steel Bolt in Aluminium Block Nm Assembly Load After Dyno Unload Torque Embedment assembly Torque

32 PMT in the field: relaxation 2000 Hours: at 300 F for gasket relaxation tests Same bolts are in for another 2000 hours!

33 PMT in production A twin spindle inline tool was built to monitor the elastic torque-angle process of 17,000 M10x100 Torx head main bearing cap bolts. Bolts were PMT coated and uni-moly coated (barrel). Assembled once in line-boring operation, and then assembled in unit. Operation was semi-manual and low volume: 50 engines/week. PMT control box Main bearing Copyright caps The Augustus Group 2006 Production tool

34 PMT in production Results: Production Data 17, M10x110 steel bolts into Al, Unimoly paste coating snug + angle, recorded final ultrasonic load, angle and torque at wrench shut-off. Test did not affect operator or process at all!

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