Bolt tightening with new materials

BOLTED JOINTS
by Erik Galdames Translation and adaptation of the presentation Condiciones reales de montaje at the Technical Meeting held on 20th July, 2012 organized by Galol, LOlleria (Spain)

Bolted joints Bolt tightening in real conditions

Basic considerations
Tightening of bolts with new materials show a

challenge when trying to obtain new results in the design of bolted joints Not only considerations of individual components are to be taken into account in a separate way, it is necessary to know their interaction and behaviour in their different combinations Theoretical data or data from charts are not only the sources to be considered, it is of vital importance to know the behaviour of the different materials in contact These facts have contributed to seek for practical solutions in the different specifications of some industrial sectors, mainly automotive industry, to study and determine solutions forr different problems that may occur
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Bolted joints Bolt tightening in real conditions

Basic considerations

Types of fasteners Types of coatings Mating materials Thread length Environmental conditions

Bolted joints Bolt tightening in real conditions

Types of fasteners

Metric threaded bolts, nuts Self-tapping metric screws Self-tapping screws Studs

Bolted joints Bolt tightening in real conditions

Design considerations

Geometry of parts Dimensions and tolerances Internally driven fasteners, externally

driven Clearance hole Thread length Surface pressure. Use of washers, type of material to fasten
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Bolted joints Bolt tightening in real conditions

Coatings of fasteners
The selection of the adequate coating for a certain

application plays an important role. The following families of coatings for fasteners exist in the automotive industry nowadays, not exclusively:
Zinc flake coatings with/without top-coats Electroplated zinc, zinc-nickel with/without top-coats Phosphating + oil

Bolted joints Bolt tightening in real conditions

Coatings of the mating surfaces

Coatings applied to the mating surfaces to

be fastened with bolts/nuts

Zinc flake coatings with/without top-coats
Electroplated zinc, zinc-nickel with/without top-

coats KTL No coating (e.g. Al-alloys)

Bolted joints Bolt tightening in real conditions

Coatings

Factors to be taken into account in their

selection:
Colour Property class of fasteners. Hydrogen embrittlement

avoidance Tightening with hexalobular tool, internal hexagonal tool, etc. Presence of pilot (form of the tip of the bolt) Service temperature Use in combination with locking features or microencapsulated coatigns DIN 267-27 or DIN 267-28 Contact with magnesium alloys Ground connections
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Bolted joints Bolt tightening in real conditions

Coatings
Coating
Zinc flake coatings

Typical applications
Chassis Motor compartment (areas exposed to high corrosivity) Aluminium joints Chassis Motor compartment (areas exposed to high corrosivity) Aluminium joints Chassis Motor compartment (areas exposed to high corrosivity) Aluminium joints

Adequate for
Bolts 10.9 Microencapsulated coating allowed (without lubricated topcoat) External thread < M6 Internal thread < M10

Less adequate for

Ground connections External thread <M6 Internal thread <M10 Internal drive features T30 Bolts 10.9, 1000 N/mm 2 Though less hydrogen embrittlement risk than pure eplated Zn. Service temperature > 150C Bolts 10.9, 1000 N/mm 2 Though less hydrogen embrittlement risk than pure eplated Zn. Service temperature > 150C

ZnNi

ZnNi black

External thread < M6 with internal drive feature Internal thread <M10 Self-tapping screws

Phosphating + oil

Multicomponent, oil circuits or transportation

Parts in motion without corrosion exposure Transport and limited storage in warehouses
Parts in contact with magnesium alloys Weld parts

Parts not multi-component Service temperature > 180C

Zn+passivation+top-coat (silicate) Zn+passivation

Mg alloys Weld parts

Bolts 10.9 Bolts 10.9

Bolted joints Bolt tightening in real conditions

Materials

Typical materials found in bolted joints

Chassis metal sheet Non-structural steel Sintered materials Cast steel Wrought Al alloys Cast Al alloys Mg alloys Ti alloys Zinc cast alloys
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Bolted joints Bolt tightening in real conditions

Materials
Material
Cold formed steel Non-allied structural steel Steel for quenching and tempering Sintered materials Austenitic stainless steel

Abbreviation
DC01 S700MC S355JR C45EC 34CrNiMo6 16MnCr5 Sint D30 X5CrNi18-12 X5CrNiMo17-12-2 X6NiCrTiMoVB25-15-2 EN-GJL-150 EN-GJS-40015U EN-GJS-500-7U EN-GJS-600-3U

Material No.
1.033 1.8974 1.0045 1.1192 1.6582 1.7131 1.4303 1.4401 1.4980 EN-JL1020 EN-JS1072 EN-JS1082 EN-JS1092

Standard
EN 10130 EN 10149-2 EN 10025-2 EN 10263-4 EN 10083-3 EN 10084 DIN 30910-4 EN 1008-3 EN 10269 EN 1561 EN 1563

Cast iron

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Bolted joints Bolt tightening in real conditions

Materials
Material
Cold formed Al alloys

Abbreviation
EN-AW-AlSi1MgMn-T6 EN AW-AlSi1MgMn-T4 EN AW-AlMg4, 5Mn0,7-H111 EN AC-AlSi6Cu4-SF EN AC-AlSi9Cu3(Fe) EN AC-AlSi7Mg0,3-T6 EN MC-MgAl9Zn1(A)-F-D EN MC-MgAl6Mn-D TiAl6V4 ZP3 ZP5

Material No.
EN AW-6082 EN AW-6082 EN AW-5083 EN AC-45000 EN AC-46000 EN AC-42100 EN-MC21120 EN-MC21230 3.7165.1 ZP0400 ZP0410

Standard
EN 754-2

Al alloy castings

EN 1706

Mg alloys Ti alloys Zinc alloy castings

EN 1753 DIN 17862 EN 12844

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Bolted joints Bolt tightening in real conditions

Mating materials
Some softer materials present problems in the

assembly due to the increase of friction. E.g. Al and Mg alloys show higher friction compared to steel. The same bolt with the same coating may present different behaviour when the mating material is an Al-alloy Surface roughness plays an important role, as well as geometry of the bearing surface of the fastener (concave, convex). This could influence the friction behaviour enormously. E.g. Worst case concave surface. Thread length also has a strong influence. When the mating surface between both elements to tighten is larger, unexpected effects may occur, since friction in the thread is higher
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Bolted joints Bolt tightening in real conditions

Thread length
MATERIAL Min. Rm Min. Brinell Hardness No. (BHN) Longitud de roscado mn. (tornillos 10.9)

Hardened steel, tempered Tempered steel, hardened Low-and unalloyed steel

1000 MPa 800 Mpa 400 Mpa

0,8d 1,0d 1,3d

Al and Mg alloy castings

CuZn alloys Sintered parts

80 BHN
60 BHN 350 MPa 510 MPa

2,0d (8.8) 2,5d (10.9) 2,7d ( 8.8)

1,3d 1,0d
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Bolted joints Bolt tightening in real conditions

Other materials
Unions with self-tapping screws on plastics may show

unexpected effects Creep of polymers produces drop of preload, thus loosening the union For unions with high preload, use of metal sleeves is recommended Microencapsulated coatings increase coefficient of friction during assembly. With the introduction of new developed products (tot 0,12 to 0,16) this effect can be avoided It is not allowed in some automotive specs to use microencapsulated coatings over top-coats with integrated lubricants due to the risk of lack of adhesion of the locking feature over the top-coat
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Bolted joints Bolt tightening in real conditions

Other factors

Use of washers. They change pressure applied on the bolted union Geometry of washers (Aussentrger or concave washer). The most complicated case in bolted unions due to the reduced contact surface Galvanic compatibility (galvanic series). Special attention to materials like Al, Mg or stainless steel.

Cu. Not compatible with most of the coatings that provide cathodic protection Al alloy. Compatible with zinc flake coatings, zinc-nickel Anodized Al. Not recommended for fasteners with zinc flake coatings or electroplated zinc alloys Mg alloys. Not compatible with zinc flake coatings. Compatible with some electroplated zinc coatings with special top-coats

Specific surface. Avoid relatively small areas of the less noble metal with a larger surface of the most noble metal

E.g. A zinc plated bolt fastened to an anodized aluminium sheet or a stainless steel panel. The surface of the bolt is smaller than the Al sheet (or stainless steel sheet). Finally, the bolt is corroded

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Bolted joints Bolt tightening in real conditions

Other factors
Galvanic series
Platinum Gold Graphite Titanium Silver Stainless steel (passive) Nickel (passive) Bronze Nickel (active) Lead Stainless steel (active)

Cathodic

Anodic

Iron
Steel Aluminium Zinc Magnesium

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Bolted joints Bolt tightening in real conditions

Temperature and relative humidity
Service temperature. There is a risk of self-loosening at

high temperatures in some coatings with integrated lubricant due to loss of self-retention. For this reason, coating systems must comply with VDA 235-203 requirements before approval Relative humidity also has a strong influence. Before comparing results it is necessary that parts can be conditioned before testing. Relative humidity has influenced in the assembly conditions in some cases, so this has led to misinterpretation over the quality of the parts received by the customer Too high humidity may produce a higher lubrication and a too dry environment may increase coefficient of friction
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Bolted joints Bolt tightening in real conditions

Other factors
Type of tightening procedure

Tightening below yield point. If torque controlled tightening is performed, friction has a strong influence and a short variation in torque may influence in a greater variation of preload. E.g. In torque controlled tightening, a torque variation of 15% T can produce a preload variation of F 35%. With angle controlled tightening F 13% Tightening beyond yield point. The maximum design of the bolt is used when bolt is assembled beyond the yield point. When bolt is tightened within the plastic range, friction under the head of the bolt plays a less important role with a torque/angle controlled tightening procedure

High speed tightening. Tightening in two steps (e.g. 200 rpm,

stop, final tightening at 20 rpm). Speed of rotation can be higher in some cases, thus friction effects may vary Use of spindle

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Bolted joints Bolt tightening in real conditions

Summary
In the design of bolted joints not only the mechanical

characteristics of the bolt have to be considered individually. The other materials used in the union play a vital role Furthermore, not only the coating systems applied influence exclusively in the tightening process, other factors must be considered. A different coating system may influence tightening process dramatically It is of vital importance to know the conditions of the bolted union of the different materials, their interaction and how they behave in the different situations encountered Temperature and humidity conditions are also important, mainly when comparing different unions
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Bolted joints Bolt tightening in real conditions

Further reading

VDI 2230-1 VDA 235-203 KAMAX Schraubenbrevier Pierre R. Roberge. Handbook of corrosion engineering K. Kayser. High-tensile bolted joints. Design Parameters, Assembly, Locking features K. H. Kbler, W. J. Mages. Handbuch der hochfesten Schrauben

Erik Galdames, 2006 Gua de las uniones atornilladas

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