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http://www.croberts.com/bolt.htm
FIGURE 1
FIGURE 2
FIGURE 3
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FIGURE 4
METAL FATIGUE
Metal fatigue is the phenomenon characterized by progressive crack growth during cyclic loading. A crack
is often initiated at a flaw or stress riser (sharp notch) in a part. Cyclic forces such as vibrations or repeated
impact cause the crack to increase in size until the part can no longer sustain the load, and a final fracture
occurs. Figure 9 is a view of a classical reverse bending fatigue fracture of a bolt. The arrows point to the
initiation sites of the fatigue crack. The small lines or striations on the metal surface show the advance of
the crack from the exterior to the inside of the bolt. The rutted gray area in the middle of the bolt is the
area of final fracture where the bolt cross-section was reduced and the bolt could not carry the load. See
Insurance Adjuster Magazine, March 1983, regarding fatigue related failures. Metal fatigue can be a result
of a design deficiency as well as improper assembly of the part.
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FIGURE 5
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FIGURE 7
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FIGURE 9
FIGURE
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FIGURE 15
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FIGURE 17
FIGURE 18
FIGURE 19
FIGURE 20
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CORROSION FAILURE
Corrosion of metals can be disastrous to threaded fasteners (see Claims Magazine, September, 1993).
Surface and pitting corrosion attacks threaded fasteners as a result of contact with moisture or other
corroding media. Since bolts often carry high loads, stress corrosion cracking (also called environmentally
assisted cracking) is another corrosion related failure mode. Corrosion, coupled with forces in a bolt, tends
to accelerate cracking. Figure 18 shows a damaged dump trailer after a rollover accident. Figure 19 is a
view of a suspension related clamp on the dump trailer. The clamp failed, causing the axle to part from the
vehicle and an accident. Views of the fracture surfaces show progressive environmentally assisted cracking
as a cause of the bolt failure. Such failures are normally discovered during periodic inspections, a typical
maintenance procedure on large vehicles.
FIGURE 21
EVIDENCE HANDLING
As can be seen by the previous examples, the fracture surface plays a significant role in the analysis of
threaded fastener failures. Consequently, the appropriate handling of the failed bolt as evidence
encompasses the protection and preservation of the fracture surface. A light oil coating on the fracture
surface helps reduce corrosion, provided the surface films on the fracture surface are not significant. If
surface films must be preserved, the sealing in a dry, air tight container is helpful. Removal of the bolt from
the vehicle or piece of machinery requires care. Figure 20 shows the result of improper removal. The
person removing this bolt used a hammer and screw driver which damaged the fracture surface. In Figure
21, a torch cut has badly damaged the fracture surface. In some cases, the bolt cannot be dislodged. Then
the whole part should be removed and possibly be cut away at a later date.
CLOSING
When threaded fastener failure appears to be a cause of a loss, a few fundamental investigative measures
are in order. First, thoroughly photograph the parts involved, preferably in their undisturbed state. Save the
mechanical system, ie. the automobile, piece of machinery or device for possible future analysis. If parts
must be removed, avoid damage to the fracture surfaces of failed parts. Avoid hammering or torching the
parts as depicted in Figures 20 and 21. Save the parts in an environment that intends to inhibit the onset of
corrosion and reduces the chances of additional deformation from handling. Obtain as much history as
possible on the usage and maintenance of the mechanical system. Finally, place interested parties on notice
as to testing and disassembly to avoid the pitfalls of spoliating the evidence (see Claims Magazine, June
1992).
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CLAIMS MAGAZINE
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