Date: 28.07.

2013 Rev 0

Fasteners Test Procedure

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FASTENERS TESTING PROCEDURE

Prepared By Justin. A

Reviewed BY Jessen P Abraham

Approved By Ramasamy.S

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Description of content
Scope Reference Documents Testing Machine Tension testing of machined test specimens Tension testing procedure Full size bolt test method Full size bolt procedure Hardness test for externally fastener Hardness test for internally fastener Proof load test Proof load procedure Acceptance criteria report Annexure 1

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1. SCOPE

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The test procedures cover for conducting tests to determine the mechanical properties of externally and internally threaded fasteners, washers, and rivets. Property requirements and the applicable tests for their determination are speci ed in individual product standards. In those instances where the testing requirements are unique or at variance with these standard procedures, the product standard shall specify the controlling testing requirements. These test procedures describe mechanical tests for determining the following properties. a. b. c. d. Tension testing of machined test specimen Axial tension testing of full size Hardness test Proof load test

2. REFERENCE DOCUMENTS

a. Client / Engineer requirements b. Standard specification for carbon and alloy steel externally threaded metric fasteners as per ASTM F 568M c. Mechanical properties of fasteners made of carbon steel and alloy steelPart 1: Bolts, screws and studs with specified property classes Coarse thread and fine pitch thread as per ISO 898-1. d. Standard test methods for determining the mechanical properties of externally and internally threaded fasteners, Washers, and Rivets as per ASTM F 606 e. Standard test methods and definitions for mechanical testing of steel products as per ASTM A370. Mechanical properties of fasteners made of carbon steel and alloy steel part 2: Nuts with specified property classes Coarse thread and fine pitch thread as per ISO 898-2. f. Test methods for Rockwell hardness and Rockwell superficial hardness of metallic materials as per ASTM E18. g. Metallic materials Rockwell hardness test Part 1: Test method (scales A,B,C,D,E,F,G,H,K,N,T) as per ISO 6508-1 h. Metallic materials Tensile testing part 1: Method of test at room temperature.

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3. TESTING MACHINE

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a. Fine manufacturing industries, India, Model No. TFUC-1000, Capacity 1000 kN is the Computerized universal testing machine used for the tensile test. Tensile test yield strength and Offset percentage of proof stress used for Electronic Extensometer. b. The Machine an accuracy of 1% guaranteed from 2% to 100% of capacity of the machine. c. Universal testing machine calibrated annually according to ASTM E4-09a and BS EN ISO 7500-1. d. Universal Calibration services can be undertaken in presence of National / International inspection agencies like UKAS.
4. Tension testing of machined test specimen a. When bolts and studs cannot be tested full size, conduct tests using test specimens machined from the bolt or stud (Test Methods ASTM E 8). b. Bolts and studs 9 16 in. in diameter and smaller may be machined concentric with the axis of the bolt or stud. The specimen shall have a turned section as large as feasible and shall have a gage length four times the diameter of the specimen. See Fig. 1 and Fig. 2.

Fig 1 : Tension test specimen for bolt with Turned Down shank

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Fig 2 : Examples of small-size specimens proportional to standard 2 in gauge length specimen c. Bolts and studs 5 8 in. in diameter through 1 1 4 in. in diameter may have their shanks machined concentric with the axis of the bolt or stud, leaving the bolt head and threadedsection intact as shown in Fig. 1. d. Alternatively, bolts and studs5 8 in. in diameter through 1 1 4 in. in diameter may have theirshanks machined to a test specimen with the axis of thespecimen located midway between the axis and outside surfaceof the bolt or stud as shown in Fig. 3. Bolts of a small crosssection that will not permit taking the 0.500-in. round, 2-in.gage length test specimen shall have a turned section as largeas feasible and concentric with the axis of the bolt or stud.

Fig 3. Location of standard round 2 in gage length tension test specimen when turned from large size bolt. Page 5 of 19

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e. The gage length for measuring the elongation shall be four timesthe diameter of the specimen. Fig. 2 illustrates an example ofthese small-size specimens. For arbitration purposes, machinedtest specimens for bolts and studs 5 8 in. in diameter through1 1 4 in. in diameter shall be machined with the axis of thespecimen located midway between the center and outsidesurface. f. Bolts and studs 1 3 8 in. in diameter and larger mayhave their shanks machined to the dimensions of a 0.500-in.round, 2-in. gage length test specimen with the axis of thespecimen located midway between the center and outsidesurface of the bolt or stud as shown in Fig. 3. g. Machined test specimens shall exhibit tensilestrength, yield strength (or yield point), elongation, and reduction of area equal to or greater than the values of theseproperties speci ed for the product size in the applicableproduct speci cation when tested in accordance with thissection. h. Yield Strength Yield strength is the stress at which amaterial exhibits a speci ed limiting deviation from the proportionality of stress to strain. The deviation is expressed interms of strain, percent offset, total extension under load, etc Yield PointYield point is the rst stress in a material, less than the maximum obtainable stress, at which an increase in strain occurs without an increase in stress. Yield point is intended for application only for materials that may exhibit the unique characteristic of showing an increase in strain without an increase in stress. The stress-strain diagram is characterized by a sharp knee or discontinuity. Autographic Diagram MethodWhen a sharp kneed stress-strain diagram is obtained by an autographic recording device, take the stress corresponding to the stress at which the curve drops as the yield point (Fig. 4).

Fig 4 stress strain diagram showing yield point corresponding with top of knee Page 6 of 19

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i.Tensile Strength

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Calculate the tensile strength bydividing the maximum load the specimen sustains during atension test by the original cross-sectional area of the specimen. j. Elongation: Fit the ends of the fractured specimen togethercarefully and measure the distance between the gage marks tothe nearest 0.01 in. for gage lengths of 2 in. and under, and tothe nearest 0.5 % of the gage length for gage lengths over 2 in. A percentage scale reading to 0.5 % of the gage length may beused. The elongation is the increase in length of the gagelength, expressed as a percentage of the original gage length. Inreporting elongation values, give both the percentage increaseand the original gage length. If any part of the fracture takes place outside of themiddle half of the gage length or in a punched or scribed markwithin the reduced section, the elongation value obtained maynot be representative of the material. If the elongation someasured meets the minimum requirements speci ed, nofurther testing is indicated, but if the elongation is less than theminimum requirements, discard the test and retest. k. Reduction of Area Fit the ends of the fracturedspecimen together and measure the mean diameter or the widthand thickness at the smallest cross section to the same accuracyas the original dimensions. The difference between the areathus found and the area of the original cross section expressedas a percentage of the original area, is the reduction of area. 5. Tension testing procedure a. Completion of tensile test specimen preparation shall be ensured. Tensile Plate type test specimen width and corresponding thickness of the reduced section shall be measured. b. Tensile test reduced section minimum dimension of this test piece, maximum dimension of test piece shall not exceed. c. Cross sectional area shall be obtained by multiplying the width by the thickness. d. The original cross-sectional area shall be calculated from the measurements of the appropriate dimensions. The accuracy of the calculation depends on the nature and type of the test piece. e. The gage marks for measuring elongation after fracture shall be made on the flat or on the edge of Page 7 of 19

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the flat tension test specimen and within the parallel section; for the gage length specimen, one or more sets gage marks may be used, intermediate marks within the gage length being optional. Rectangular 2-in. gage length specimens, and round specimens, gauge marked with a double-pointed center punch or scribe marks. One or more sets of gage marks may be used; however, one set must be approximately centered in the reduced section. These same precautions shall be observed when the test specimen is full section. f. The test machine shall be set up and zeroed in such a manner that zero force indication signifies a state of force on the specimen, as indicated in the zeroing of the test machine. 6. Full size bolt test method It is preferred that bolts be tested full size, and it iscustomary, when so testing bolts to specify a minimumultimate load in pounds, rather than a minimum ultimatestrength in pounds per square inch. Three times the bolt nominal diameter has been established as the minimum bolt length subject to the tests described in the remainder of this section. Sections A proof load, section C proof load time of loading apply when testing boltsfull size. Section D Axial tension testing of full size bolts shall apply where the individualproduct speci cations permit the use of machined specimens. Section A. Proof Load Due to particular uses of certainclasses of bolts it is desirable to be able to stress them, whilein use, to a speci ed value without obtaining any permanentset. To be certain of obtaining this quality the proof load isspeci ed. The proof load test consists of stressing the bolt witha speci ed load which the bolt must withstand without permanent set. An alternate test which determines yield strength of afull size bolt is also allowed. Either of the following Methods,1 or 2, may be used but Method 1 shall be the arbitrationmethod in case of any dispute as to acceptance of thebolts. Section -B. Proof Load Testing Long BoltsWhen full sizetests are required, proof load Method 1 is to be limited inapplication to bolts whose length does not exceed 8 in. (203mm) or 8 times the nominal diameter, whichever is greater. Forbolts longer than 8 in. or 8 times the nominal diameter,whichever is greater, proof load Method 2 shall be used. (a) Method 1, Length MeasurementThe overall length ofa straight bolt shall be measured at its true center line with aninstrument capable of measuring changes in length of 0.0001in. (0.0025 mm) with an accuracy of 0.0001 in. in any 0.001-in.(0.025-mm) range. The preferred method of measuring thelength shall be between conical centers machined on the center line of the bolt, with mating centers on the measuring anvilsThe head or body of the bolt shall be marked so that it can beplaced in the same position for all measurements. The bolt shallbe assembled in the testing equipment as outlined in Page 8 of 19

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Section - D. and the proof load speci ed in the product speci cation shallbe applied. Upon release of this load the length of the bolt shallbe again measured and shall show no permanent elongation. Atolerance of 60.0005 in. (0.0127 mm) shall be allowedbetween the measurement made before loading and that madeafter loading. Variables, such as straightness and thread alignment (plus measurement error), may result in apparent elongation of the fasteners when the proof load is initially applied. In such cases, the fastener may be retested using a 3 percent greater load, and may be considered satisfactory if the lengthafter this loading is the same as before this loading (within the0.0005-in. tolerance for measurement error). Section C. Proof Load-Time of LoadingThe proof load is tobe maintained for a period of 10 s before release of load, whenusing Method 1. (a) Method 2, Yield StrengthThe bolt shall be assembledin the testing equipment as outlined in section- D. As the load isapplied, the total elongation of the bolt or any part of the boltwhich includes the exposed six threads shall be measured andrecorded to produce a load-strain or a stress-strain diagram. The load or stress at an offset equal to 0.2 percent of the length of bolt occupied by 6 full threads shall be determined by themethod described in yield point off set methods. This loador stress shall not be less than that prescribed in the product speci cation. Section -D. Axial Tension Testing of Full Size BoltsBolts areto be tested in a holder with the load axially applied betweenthe head and a nut or suitable xture (Fig. 5), either ofwhich shall have sufficient thread engagement to develop thefull strength of the bolt. The nut or xture shall be assembledon the bolt leaving six complete bolt threads unengagedbetween the grips, except for heavy hexagon structural boltswhich shall have four complete threads unengaged between thegrips. To meet the requirements of this test there shall be a tensile failure in the body or threaded section with no failure at the junction of the body, and head. If it is necessary to record or report the tensile strength of bolts as psi values the stress area shall be calculated.

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Fig 5 . Tension testing full- size bolt. 7. Full bolt test procedure a. b. c. d. e. Ensure the specifications of the received bolt. Measuring the bolt diameter and length. Calculate the original cross section area of the bolt. Attaching the jigs of bolt to the jaw of machine. The test machine shall be set up to zero in such a manner that zero force indication signifies a state of force on the specimen, as indicated in the zeroing of the test machine. f. Fit the bolt to the jigs. g. Ensure the jigs & bolt assemblies h. Directly apply the tensile load to the bolt. i. Determination of yield strength: When yield strength is measured using software, the yield strength will be automatically given by the system. j. Determination of tensile strength: Calculate the tensile strength by dividing the maximum load carried by the test specimen by the original cross-sectional area of the test specimen. When software is being used in testing, the value is automatically given by the system Page 10 of 19

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k. Determination of elongation: Fit the fractured ends together carefully and measure the distance between the gage marks to get the increased (final) gage length. Calculate the elongation by dividing the difference in gage lengths (original and final) by the original gage length. When the software is used enter the final gage length to the system to give the percentage automatically. Note: Bolt dia should be maximum 20mm and length should be minimum 75mm according to our facilities. 8. Hardness Tests for Externally Fasteners Tests shall be conducted after the removal of any surface oxide, decarburization, plating or other coating. All readings shall be within the hardness values listed in the product speci cation. The average of all readings on the same part shall be considered as the product hardness. Test results shall conform to the product speci cation for the lot represented by the test specimens to be considered conforming. Test specimen preparation and hardness test shall be conducted in accordance for Rockwell hardness test. The method used is at the option of the manufacturer, with regards to the size and grade of the products. Routine Test Locationsfor testing the hardness of the nished product, the following test locations can be used: a. For hex and square head bolts; test shall be conducted on the wrench ats, top of head, unthreaded shank, end of bolt or at the arbitration location. b. For studs, products without parallel wrench ats and for head styles other than hex and square; tests shall be conducted on the unthreaded shank, end of the bolt or stud or at the arbitration location. c. Stress relieved products are measured anywhere on the surface or through the cross section. Refer to the product speci cation for particular test location or use the arbitration location. d. The Rockwell Hardness Scale may be used for all product diameters. Laboratory InspectionAfter observing product hardness and routine Test Locations, a minimum of three readings shall be taken on each sample of nished product. Arbitration Test LocationHardness tests shall be conducted at the mid-radius (r/2) of a transverse section through the threads taken at a distance of approximately one diameter from the point end of the bolt or one end of the stud. Four readings shall be taken from the point end of the bolt or one end of the stud. Four readings shall betaken approximately 90 to one another on the same plane, if product

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size permits. Smaller diameter products may also usethe opposite parallel surface area of the bolt head end assectioned above. (See Fig. 6).

Fig 6. Hardness Arbitration test location 9. Hardness Tests for internally Fasteners

a. Product HardnessFor routine inspection of both heat treated and non heat-treated nuts, hardness shall be determined on the bearing face or wrench ats after removal of any oxide, decarburization, plating, or other coating material. Rockwell or Brinell hardness shall be used at the option of the manufacturer, taking into account the size and grade of the product. b. The preparation of test specimens and the performance of hardness tests for Rockwell testing shall be in conformance with the requirements of test Methods. c. Readings when taken on the bearing face shall be halfway between the major diameter of the thread and one corner. The reported hardness shall be the average of two hardness readings located 180 apart. The readings when taken on the wrench ats shall be one third of the distance from a corner to the center of the wrench face. The reported harness shall be the average of two readings located from opposite corners. d. Sample nuts shall be sectioned laterally at approximately one half ( 1 2 ) of the nut height. Such samples need not be threaded, but shall be part of the manufacturing lot that was formed (in the case of heat-treated nuts, formed and heattreated) with the product to be shipped. All readings shall be conducted on a Rockwell Hardness testing machine. e. Non heat-Treated Nuts (See Fig. 7)Two readingsshall be taken 180 apart at the core (halfway between themajor diameter if threaded, or blank hole if not threaded) anda corner of the nut. The Page 12 of 19

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reported hardness shall be the averageof the two readings, and in addition both readings shall bewithin the hardness values listed in the product speci cation.

Fig 7. Non heat - Treated nut f. Heat-Treated Nuts (See Fig. 8)Two sets of threereadings 180 apart shall be taken. The three readings shall betaken across the section of the nut at the following positions: Position 1As close to the major diameter, as possible, if threaded, orhole side wall if the nut is blank, but no closer than 2 1 2 mes the indentdiameter. Position 2At the core (halfway between the major diameter, ifthreaded, or hole side wall, if blank) and a corner of the nut. Position 3As close to the corner of the nut as possible, but no closerthan 2 1 2 mes the indent diameter.

Fig 8 . Heat - Treated nut Page 13 of 19

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g. The reported hardness shall be the average of all sixreadings. In addition all readings shall be within hardnessvalues listed in the product speci cation. h. For nuts on which hardness and proof load tests areperformed, acceptance based on proof load requirements shalltake precedence in the event of controversy with hardness tests. 10. Proof load test A sample nut shall be assembled on a hardened threaded mandrel or on a bolt conforming to the particular speci cation. A load axial with the mandrel or bolt and equal to the speci ed proof load of the nut shall be applied. The nut shall resist this load without stripping or rupture. If the threads of the mandrel are damaged during the test the individual test shall be discarded. Assemble the nut to be tested on a hardened threaded mandrel or a test bolt as illustrated in Fig. 9 a) Tension Method or Fig. 9(b) Compression Method. The hardened test mandrel and the tension method shown in Fig. 9(a) shall be mandatory as a referee if arbitration is necessary. Apply the speci ed proof load for the nut against the nut. The nut shall resist this load without stripping or rupture, and shall be removable from the test bolt or mandrel by the ngers after the load is released. Occasionally it may be necessary to use a manual wrench or other means to start the nut in motion. Use of such means is permissible, provided the nut is removable by the ngers following the initial loosening of not more than one-half turn of the nut. If the threads of the mandrel or test bolt are damaged during the test, discard the test. The test bolt shall have threads appropriate to the standard speci ed for the nut being tested and shall have a yield strength in excess of the speci ed proof load of the nut being tested.Mandrels shall have a hardness of 45 HRC minimum and shall have threads conforming to Class 3A except that the maximum major diameter shall be the minimum major diameter plus 0.002 in. or 0.25 times the major diameter tolerance (whichever is greater) of Class 3A threads. The proof load shall be determined at a free running cross head speed not exceeding 1.0 in/minute and shall be held at load for 10s minimum.

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Fig 9. a. Tension method

Fig 9. B Compression Method 11. Proof load procedure a.We are using the compression method for proof load test to the nut. Page 15 of 19

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b. Choose the bolt specification either same as nut or higher specification. c. Keep the appropriate support block on the machine bed. d. Zeroing of the test machine: The testing machine shall be set up in such a manner that zero force indication signifies a state of zero force on the specimen. e. The magnitude of the application of compression load to the nut should be greater than the load mentioned as per standard to the nut. f. While loading ensure the non-displacement of the nut. Hold the proof load for 10s 12. Acceptance criteria Fasteners acceptance criteria as per ASTM F568M

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13. Report

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Test information to be reported shall include the following when applicable: a. Material Grade and sample identification b. Applicable test code c. Test specimen dimensions d. Original gage length e. Yield load and yield strength f. Tensile load and tensile strength g. Gauge length after testing h. Elongation I. Reduction of area j. Hardness Value k. Proof load l. Percentage of Chemical composition

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Annexure 1

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