TESTING TEST REPORTS SUPPLIER OVERSIGHT FASTENER TIPS Approved

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

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

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 3 Approved for Public Release

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

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

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

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 7 Approved for Public Release

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

Test Methods ASTM F 606 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 9 Approved for Public Release

Test Methods Flat surface Cylindrical surface • Hardness testing performed on a convex cylindrical surface • Correction factors of ASTM E 18 need to be applied Fastener Testing 10 Approved for Public Release

Test Methods Determination Of Proper Wedge Angle For Wedge Testing • ASTM F 606 (Unless otherwise specified) • ASTM A 574 (Socket Head Cap Screws) • MIL-S-1222 H 3 (Titanium, SC 10 -122) Fastener Testing 11 Approved for Public Release

Test Methods Gage Lengths Are Different For Ferrous And Nonferrous Fastener Testing 12 Approved for Public Release

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 13 Approved for Public Release

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 14 Approved for Public Release

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

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

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

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

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

Test 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 20 Approved for Public Release

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

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 22 Approved for Public Release

Test Reports C of C Fastener Testing 23 Approved for Public Release

Test Reports Chemicals Fastener Testing 24 Approved for Public Release

Test Reports Mechanicals Fastener Testing 25 Approved for Public Release

Test Reports Mechanicals Fastener Testing 26 Approved for Public Release

Test Reports Mechanicals Fastener Testing 27 Approved for Public Release

Test Reports NDT Fastener Testing 28 Approved for Public Release

Test Reports NDT Fastener Testing 29 Approved for Public Release

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