AHG QTR - QUALIFICATION TEST REPORT EN6114-10-31 / QTR · EN6116 P4 09/2010 Aerospace series...

AHG QTR - QUALIFICATION TEST REPORT Ref.

EN6114-10-31 / QTR Ateliers de la Haute-

Garonne PROPRIETARY DOCUMENT / 62

REVISION 0 A B

DATE 20/10/2016 15/11/2016 18/11/16

COMPANY ATELIERS DE LA HAUTE-GARONNE

MANUFACTURING SITE

Z.I de Flourens 31130 FLOURENS - FRANCE

REFERENCE STANDARD

EN6114 – Edition P8 – June 2014

DATE 18/11/2016

All the information and results shown herein have been reviewed by AHG's engineering department.

This qualification test report describes AHG’s organization and processes in place to manage

Engineering and Manufacturing of EN6114 parts (bolts) according to EN6116 Edition P4.

Customer will be notified of any modification in manufacturing process of a product that has an impact on the sequence of manufacturing operations (process flow chart) and/or could

affect the requested requirements and agreements.

WRITER AHG Engineering APPROVAL CUSTOMER APPROVAL

Date : 18/11/2016 Name : Quentin GRIVEL Function : R&D engineer

Date : 18/11/2016 Name : Bertrand JEHENNE Function : R&D Manager

Date : Name : Function :

QUALIFICATION TEST REPORT

EN6114-10-31




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Record of revision

Date Revision Updating purpose

20/10/2016 0 Creation of the document

15/11/2016 A Update on the shank end machining process in the flow

chart

18/11/2016 B New sampling size and adding of AHG internal drawing for

shank end machining




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Contents

Record of revision ................................................................................................................. 2 1. Scope ............................................................................................................................. 5 2. Applicable documents .................................................................................................... 6 3. Process flow chart .......................................................................................................... 7 4. Quality Control Plan ......................................................................................................10 5. Product Test Report ......................................................................................................14

5.1 Sampling Plan ........................................................................................................15 5.2 Material ..................................................................................................................16

5.2.1 Supplier verification .........................................................................................16 5.2.2 AHG verification ..............................................................................................17

5.3 Heat treatment .......................................................................................................17 5.4 Visual Inspection ....................................................................................................19 5.5 Dimensional inspection ..........................................................................................20

5.5.1 Dimensional Requirements .............................................................................21 5.5.2 Other dimensional requirements .....................................................................22

5.6 Mechanical Inspection ............................................................................................23 5.7 Surface defect and discontinuities inspection .........................................................28 5.8 Metallurgical Inspection ..........................................................................................29

Table of figures

Figure 1: EN6114 Bolts ........................................................................................................14 Figure 2: EN6114 drawing ....................................................................................................20 Figure 3: Surface treatment ..................................................................................................35 Figure 4: Marking .................................................................................................................35 Figure 5: Tensile strength test ..............................................................................................36 Figure 6: EN6114-10-31 after tensile strength test ...............................................................36 Figure 7: Shear strength test ................................................................................................37 Figure 8: EN6114-10-31 after the shear strength test ...........................................................37 Figure 9: shear strength as a function of the displacement ...................................................38 Figure 10: Fatigue test ..........................................................................................................39 Figure 11: EN6114-10-31 after the shear fatigue test ...........................................................39 Figure 12: Cadmium thickness measurement .......................................................................49 Figure 13: Incomplete runout threads (head side) ................................................................51 Figure 14: Incomplete lead threads (including chamfer) .......................................................51 Figure 15: Thread measurement ..........................................................................................52 Figure 16: Recess torque test ...............................................................................................53 Figure 17: Bolt after recess torque test .................................................................................53 Figure 18: Embrittlement test ................................................................................................54 Figure 19: parts after embrittlement test and removal of the cadmium plating ......................54 Figure 20: evolution of the load during embrittlement test .....................................................55 Figure 21:Complete view of the thread, no cracks detected at the bottom of the thread, in the self-locking area ...................................................................................................................56 Figure 22:Deformation of the thread, no cracks detected at the bottom of the thread, in the self-locking area ...................................................................................................................56




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Table of Tables

Table 1: Sampling plan .........................................................................................................15 Table 2: Material information ................................................................................................16 Table 3: Raw material chemical analysis ..............................................................................16 Table 4: Raw material mechanical & metallurgical properties verification .............................16 Table 5: Alloy verification ......................................................................................................17 Table 6: Heat treatment specifications ..................................................................................17 Table 7: Heat treatment process ..........................................................................................17 Table 8: Stress relief and embrittlement relief treatment process .........................................18 Table 9: Visual inspection .....................................................................................................19 Table 10 : EN6114-10-31 Dimensional requirements ...........................................................21 Table 11: EN6114-10-31 other dimensional requirements ....................................................22 Table 12: EN6114-10-31 Mechanical requirements ..............................................................24 Table 13: Permissible discontinuities depth ..........................................................................28 Table 14: Metallurgical inspection requirements ...................................................................29

Table of Appendices Appendix 1: Certificate of conformity of raw material ............................................................31 Appendix 2: Dimensional inspection .....................................................................................34 Appendix 3: Visual Inspection ...............................................................................................35 Appendix 4: Tensile strength ................................................................................................36 Appendix 5: Shear strength ..................................................................................................37 Appendix 6: Fatigue strength ................................................................................................39 Appendix 7: Microstructure ...................................................................................................40 Appendix 8: Carburization and decarburization ....................................................................43 Appendix 9: Head Forming + Thread Forming ......................................................................46 Appendix 10: Head to shank fillet radius cold working (X25).................................................47 Appendix 11: Hexagonal Recess ..........................................................................................48 Appendix 12: Thickness measurement .................................................................................49 Appendix 13: Raw material verification .................................................................................50 Appendix 14: Incomplete Threads ........................................................................................51 Appendix 15: Gage for dimensional inspection .....................................................................52 Appendix 16: Hexagonal recess torque test .........................................................................53 Appendix 17: Embrittlement Test ..........................................................................................54




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1. Scope

This Qualification Test Report (QTR) gives all the results associated to the manufacturing of the qualification of the parts EN6114-10-31 according to EN6116 Edition P4. The customer related to this qualification is Airbus. The bolts covered by this qualification test report are 4340 steel alloy bolt with countersunk head and hexagonal recess. The improved thread rolling process avoids findings not acceptable into the threads after 3 installation cycles (torque tension test).




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2. Applicable documents

Normative Reference

Issue Title

AMS6415 T 07/2012 Steel, Bars, Forgings, and Tubing

AMS2759-1 E 02/2009 Heat treatment of Carbon and Low-Alloy Steel parts – Minimum Tensile Strength Below 220ksi (1517 MPa)

AMS-QQ-P-416 D 07/2015 Plating, Cadmium (Electrodeposited)

AS8879 D 08/2004 Screw threads – UNJ Profile, Inch, controlled radius root with increased minor diameter.

ASME B46.1 2009 Surface texture (surface roughness, waviness and lay)

ASTM E112-13 02/2014 Standard test methods for determining average grain size

ASTM E 1444-12 11/2012 Standard Practice for Magnetic Particle Testing

EN2424 A 09/2008 Marking of Aerospace products

EN6114 P8 06/2014 Aerospace series Bolt – Countersunk head, Short thread, Inch series.

EN6116 P4 09/2010 Aerospace series Threaded bolts, light weight, Inch series, Technical Specification.

EN6117 P1 12/2006 Aerospace series – Specification for lubrication of fasteners with cetyl alcohol

NASM1312-5 Rev1 10/2012 Fastener test methods, Method 5, Stress durability

NASM1312-6 Rev 1 08/1997 Fastener test methods, Method 6, Hardness

NASM1312-8 Rev2 08/2011 Fastener test methods, Method 8, Tensile strength

NASM1312-11 08/1997 Fastener test methods, Method 11, Tension fatigue

NASM1312-12 Rev2 09/2012 Fastener test methods, Method 12, Thickness of metallic coatings

NASM1312-13 Rev2 03/2013 Fastener test methods, Method 13, Double Shear Test

TS1128 A 10/2013 AHG Specification – Technical Specification Essais et Echantillonnages




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3. Process flow chart

Manufacturing Industrial Process Flow Chart

A.H.G. Confidential

Part number or family EN6114 Manufacturing route number EN6114-10-31 D011S

Manufacturing process (1) Procedures are monitored by internal 01-000/PR procedure. Any change in internal procedure is checked to verify if the change

requires a Customer agreement/approval

Inspection Process

Special Process

Subcontracted process

Packaging & shipping process

Responsible

site (3) Equipment Operation Inspection

Procedure (1)

Issue

AHG Flourens Test Equipment Receiving inspection

Visual / Dimensional / Mechanical Metallurgical Tests according to ERP

04-000PR rev0

09/2012

AHG Flourens Hot heading machine Hot-Forging In-process (operator) 05-377/MO C 05/2010

AHG Flourens Degreasing Bath Degreasing In-process (operator) 05-354/MO F 11/2013

AHG Flourens Magnetic sorting In-process (visual) 44-406/MO 0 07/2002

AHG Flourens Argon furnace Solution heat treat

Continuous Process Control temperature and soaking time

06-485/MO B 05/2013

AHG Flourens Air furnace Aging


06-485/MO B 05/2013

AHG Flourens Sandblaster Sand-blasting In-process (visual) 47-464/MO B 12/2013

AHG Flourens Test Equipment

Inspection after heat treat

According to relevant control plan




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Responsible site (3)

Equipment Operation Inspection Procedure

(1) Issue

AHG Flourens or Tanger

Grinding machine Shank grinding In-process (operator) 05-603/MO E 02/2014

AHG Flourens or Casablanca

Machining machine Head machining In-process (operator) 05-545/MO C 04/2011


Marking machine Marking (2) In-process (operator) 05-704/MO D

07/2013


Grinding machine Head and shank

grinding In-process (operator) 05-603/MO E 02/2014


Cold working machine

Head to shank

radius cold working

In-process (operator) 05-412/MO H

03/2013


Machining machine Shank end

machining (4) In-process (operator) 05-537/MO

G 08/2011


Cold working machine

Shank to Thread

radius cold working In-process (operator) 05-412/MO

H 03/2013


Thread rolling machine

Thread Rolling In-process (operator) 05-379/MO K 12/2014


Degreasing fountain Degreasing In-process (operator) 47-393/MO B 03/2014


Broaching machine Hexagonal Recess

broaching In-process (operator) 05-591/MO A 07/2010


Degreasing fountain Degreasing In-process (operator) 47-393/MO B 03/2014


Inspection before coating


AHG Flourens

or Tanger Degreasing fountain Degreasing In-process (operator) 47-393/MO B 03/2014

AHG Flourens Sandblaster Sand-blasting In-process (visual) 47-464/MO B 12/2013

AHG Flourens Air furnace Stress relief


06-888/MO A 02/2015




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Responsible site (3)

Equipment Operation Inspection Procedure

(1) Issue

AHG Flourens Cadmium Bath Cadmium plating

Continuous Process Control time/surface and temperature

07-883/MO E 02/2015

AHG Flourens Delay Time 06-531/MO A 09/2013

AHG Flourens Air furnace

Embrittlement relief


06-888/MO A 02/2015

AHG Flourens Coating chain

Chromate passivation

Continuous Process Control time/surface and temperature

07-883/MO E 02/2015


Inspection after coating


AHG Flourens Paintbrush

Green paint identification on

bolt end In-Process (visual) 07-568/MO 0 04/2015

AHG Flourens Lubricant bath

Cethyl Alcohol Lubrication

In-Process (visual) 07-317/MO C 05/2010

AHG Flourens Test Equipment Final inspection

Visual, Mechanical and Metallurgical tests

AHG Flourens Scales Packaging In-Process (visual) 17-000/PR E 04/2013

AHG Flourens AS400

Shipment preparation

16-000/PR B 07/2011

AHG Flourens AS400 Invoicing 18-000/PR F 09/2003

AHG Flourens AS400 Delivery 18-000/PR F 09/2003

(2) Optional as marking can be performed during forging operation.

(3) The responsible site in this qualification is written in bold In this batch, marking was performed at the marking step

(4) AHG internal drawing of the shank end machining has been updated. The value of the shank end diameter before thread rolling has been reduced from [14.876 ; 14.892] to [14.840 ; 14.850], in order to pass the torque tension test (see appendix 19)




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4. Quality Control Plan

The quality control plan (inspection route) for the qualification of Steel EN6114 bolts is given below:

Quality control plan

A.H.G. Confidential

Standard EN6114 Quality control plan number EN6114-10-31 JDBFPB200

(1) Procedures are monitored by internal 01-000/PR procedure. Any change in internal procedure is checked to verify if the

change requires a Customer agreement/approval

In-process inspection

Specific inspection

Process name /

Operation Inspected

Characteristic

Methods

Measurement method

Sample Procedure Revision

Size Frequency

Raw material

receiving inspection

Alloy check Optical emission

Spectrometry or other alloy verification method

1 One bar per receiving /

100% of receiving

04-000/MO L 03/2014

Surface quality

Visual inspection with magnification

1 One bar per receiving /

100% of receiving

CoC

Conformance to Material standards

requirements N/A 100% of receiving

IN-PROCESS INSPECTION

Hot-Forging

Surface quality & marking

Visual inspection with magnification

5 Beginning of production

05-516/MO H 06/2014

3 every hour

5 End of production

Dimensions Caliper / micrometer / dial indicator / Gage /

3D optical machine


3 every hour

5 End of production

Discontinuities Micro examination 2 Beginning of production 05-377/MO C 05/2010

Degreasing Cleaned parts Visual examination N/A Once per lot 05-354/MO F 11/2013

Magnetic sorting

Foreign parts (aluminium)

Magnetic sorting 100% 44-406/MO 0 07/2002




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Process name /

Operation Inspected

Characteristic

Methods

Measurement method


Size Frequency

Solution Heat Treat

Temperature and soaking time

Temperature and time controlled by computer

100% 06-485/MO B 05/2013

Aging

Temperature and soaking time

Temperature and time controlled by computer

100% 06-485/MO B 05/2013

Sand blasting Surface quality Visual examination N/A Once per lot 47-464/MO B 12/2013

Inspection after Heat-treatment

Overheating Micro examination 3 Once per lot 08-505/MO D 09/2012

Shear strength Double shear test 3 Once per lot 08-058/MO AD 5/2014

Hardness Hardness test

refer to EN6116

Once per lot 08-146/MO T 10/2013

markings (AHG, reference)

Visual examination 10 Once per lot

08-402/MO D 02/2014

Surface quality

Visual inspection (X 10 magnification)

25 Once per lot

Dimensions

Caliper / micrometer / dial indicator / Gage /

3D optical machine 3 or 10 Once per lot

Metallurgical defects Head to shank radius

filet Micro examination 5 Once per lot 08-921/MO A 03/2014

Shank grinding All impacted

dimension and surface quality

micrometer / 3D optical machine / visual

examination


05-897/MO A 01/2014

2 every hour

2 End of production

Head

machining

All impacted dimension and surface quality


examination


05-897/MO A 01/2014

2 every hour

2 End of production

Marking* Marking Visual examination


05-897/MO A 01/2014

2 every hour

2 End of production

Head and shank

grinding



examination


05-897/MO A 01/2014

2 every hour

2 End of production

Head to shank

radius cold working


3D optical machine / visual examination


05-897/MO A 01/2014

2 every hour

2 End of production

Discontinuities Micro examination 1 Before production 05-412/MO H 03/2013

Shank end machining



examination


05-897/MO A 01/2014

2 every hour

2 End of production

Shank to thread radius cold

working


3D optical machine / visual examination


05-897/MO A 01/2014

2 every hour

2 End of production




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Process name /

Operation Inspected

Characteristic

Methods

Measurement method


Size Frequency

Thread rolling



examination


05-897/MO A 01/2014

2 every hour

2 End of production

Discontinuities Micro examination 2 Before production 05-379/MO K 12/2014

Degreasing Cleaned parts Visual examination N/A Once per lot 47-393/MO B 03/2014

Hexagonal

recess broach


Dial indicator / visual examination / Gage

Go/NoGo


05-897/MO A 01/2014

2 every hour

2 End of production


Inspection before coating


Visual examination TS1128 Once per lot 08-057/MO M

02/2014

Rugosity Fingernail comparison EN6116 Once per lot 08-444/MO B 09/2012

Discontinuities Magnetic inspection EN6116 Once per lot 08-759/MO A 06/2014

Dimensions


3D optical machine TS1128 Once per lot 08-458/MO E 03/2015


Sand blasting Surface quality Visual examination N/A Once per lot 47-464/MO B 12/2013

Stress relief

Surface quality Visual examination N/A Once per lot 06-888/MO A 02/2015

Temperature and Soaking time

Temperature & Time controlled by computer

100% 06-888/MO A 02/2015

Cadmium plating

Coating

Visual examination N/A Once per lot 07-883/MO E 02/2015


100% 07-883/MO E 02/2015

Dimensions (Pitch diameter and

shank diameter) Micrometer 5 Once per lot

Once per lot

07-883/MO

Coating thickness X-ray Spectrometry 5 Once per lot 08-898/MO B 12/2014

Delay Time

Time controlled by computer

N/A Once per lot 07-883/MO E 02/2015

Embrittlement relief

Surface quality Visual examination N/A Once per lot 06-888/MO A 02/2015

Temperature and Soaking time


100% 06-888/MO A 02/2015




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Process name /

Operation Inspected

Characteristic

Methods

Measurement method


Size Frequency

Chromate passivation

Aspect Visual examination 5 Once per lot 07-883/MO E 02/2015

Coating thickness X-ray Spectrometry 5 Once per lot 08-898/MO B 12/2014

Dimensions (Pitch diameter and

shank diameter) Micrometer 5 Once per lot 07-883/MO E 02/2015

Inspection after coating


Visual examination refer to EN6116

Once per lot 08-057/MO M

02/2014

Dimensions


3D optical machine

refer to EN6116

Once per lot 08-458/MO E 03/2015

Coating thickness X spectrometry

refer to EN6116

Once per lot 08-898/MO B 12/2014

Green paint

identification Green paint at bolt

end Visual examination 100% Once per lot 07-568/MO 0 04/2015

Cethyl Alcohol Lubrication

Cleaned parts Visual examination N/A Before Lubrication

07-317/MO C 05/2010

Lubricated parts Visual examination N/A After Lubrication

FINAL INSPECTION

Final Inspection

Aspect and Marking Visual inspection refer to EN6116

Once per lot 08-057/MO M 02/2014

Coating and finish Visual inspection

refer to EN6116

Once per lot 08-601/MO C 02/2014

Hexagonal Recess functionality

Go/NoGo Gage & Torsional capability

refer to EN6116

Once per lot 08-997/MO 08-841/MO

0 06/2015 E 09/2013

Microstructure Micro inspection

refer to EN6116

Once per lot 08-418/MO J 11/2014

Grain flow Head and threads

Micro inspection refer to EN6116

Once per lot 08-400/MO C 09/2011

Grinding burns Micro examination

refer to EN6116


Cold Working head to shank radius

Micro examination refer to EN6116


Overheating Micro examination

refer to EN6116

Once per lot 08-505/MO D 09/2012

Decarburization Decarburization depth

refer to EN6116


Hydrogen embrittlement

Stress durability refer to EN6116

Once per lot Subcontracted operation

Tensile strength Tensile test

refer to EN6116

Once per lot 08-403/MO E 04/2015

Shear strength Double shear test

refer to EN6116

Once per lot 08-058/MO AE 04/2015

Fatigue Life Fatigue machine

refer to EN6116





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5. Product Test Report

In order to qualify the parts of the engineering standard EN6114 mentioned in section 1, the following batch has been manufactured in accordance with the Process Flow Chart given in section 3 and inspected in accordance with the Quality Control Plan given in section 4:

Part Number Batch Number

EN6114-10-31 316838 P028 F001

Figure 1: EN6114 Bolts

These parts have been performed in accordance with the requirements of the standard EN6114 P8 and the technical specification EN6116 Edition P4.




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5.1 Sampling Plan

This section defines the sampling used for the tests as specified in the requirements, for each manufactured qualification batch. AHG has performed dimensional measurements with Major sample size (level A). Airbus and AHG agreed on a reinforced sampling based on 151 parts batches.

Table 1: Sampling plan

Tests Sampling requirement origin Number of specimens

Testing site

Material – Alloy and CoC verification

EN6116 Table 1 & ANNEX 2 Reinforced control

1 External laboratory

Grain flow in Head EN6116 Table 1 & ANNEX 2

Reinforced control 20

AHG Flourens Control Laboratory

Grain flow in threads EN6116 Table 1 & ANNEX 2



Cold work in head to shank fillet


10 AHG Flourens

Control Laboratory

Coating EN6116 Table 1 & ANNEX 2



Finish / Lubrication EN6116 Table 1 & ANNEX 2



Marking EN6116 Table 1 & ANNEX 2



Dimensional inspection EN6116 Table 1 & ANNEX 2



Surface roughness EN6116 Table 1 & ANNEX 2



Appearance EN6116 Table 1 & ANNEX 2



Embrittlement EN6116 Table 1 & ANNEX 2



Hardness EN6116 Table 1 & ANNEX 2



Ultimate Tensile Strength EN6116 Table 1 & ANNEX 2



Double Shear strength EN6116 Table 1 & ANNEX 2



Tension – tension Fatigue EN6116 Table 1 & ANNEX 2



Hexagonal recess torsional capability


13 AHG Flourens

Control Laboratory

Discontinuities EN6116 Table 1 & ANNEX 2



Microstructure EN6116 Table 1 & ANNEX 2



Decarburization EN6116 Table 1 & ANNEX 2



Grinding Burns EN6116 Table 1 & ANNEX 2






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Tests Sampling requirement origin Number of specimens

Testing site

Torque tension test ME1612185 3 AHG Flourens

Control Laboratory

5.2 Material

5.2.1 Supplier verification

Table 2: Material information

Specification AMS6415 Supplier ASCOMETAL

Coil # 224396 Heat # 069294 Material 4340 Steel

Diameter 16.10 mm +/-0.02 Condition (at receipt)

Annealed

Table 3: Raw material chemical analysis

Table 4: Raw material mechanical & metallurgical properties verification

Mechanical and metallurgical properties (capability test)

Characteristic Specification Requirements Actual Values

Condition at receipt

Hardness AMS6415 Max 255 Hbw 211 HB

The certificate of conformity of the raw material is attached in appendix 1.

Chemical Analysis

(%) C Mn Si P S Cr Ni Mo Cu

Min 0,38 0,65 0,15 - - 0,70 1,65 0,20 -

Max 0,43 0,85 0,35 0,025 0,025 0,90 2,00 0,30 0,35

Actual 0.418 0.757 0.264 0.008 0.0062 0.892 1.786 0.2373 0.252




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5.2.2 AHG verification

Table 5: Alloy verification

Inspection Requirements Method Specification Conformity

Raw Material verification

4340 Steel per AMS6415 or equivalence

Alloy verification methods

Subcontracted: chemical analysis

EN6116 Table 1 p8

Compliant (In appendix 13)

5.3 Heat treatment

Heat treatment of the parts has been performed as specified in the AMS2759-1. No specific requirements for heat treatments are specified in the applicable standard. The heat treatment has been performed so that mechanical and metallurgical properties meet the requirements.

Table 6: Heat treatment specifications

Heat treatment Furnace number Specification Responsible

Solution Heat Treatment F25 AMS2759-1 AHG

Aging F26 AMS2759-1 AHG

Table 7: Heat treatment process

Solution heat treatment

Specification Requirement Actual recorded

Temperature (°C) AMS2759-1 table 2B p8

& table 5 p 13

806°C – 826°C Oil Quench

813.7°C – 817.7°C

Soaking Time 1H – 2 H 1H30

Aging Specification Requirement Actual recorded

Temperature (°C)

AMS2759-1 table 3A p9

439°C – 449°C* 440.5°C – 444.8°C

Soaking Time 2 H – 2 H 10 2H00

* Tempering temperature suggested by AMS2759-1 is 496°C. AHG experience evidenced that requested mechanical properties were reached with a 444°C Temper.




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Table 8: Stress relief and embrittlement relief treatment process

Furnace number: 17 Responsible: AHG

Stress relief (before plating)


Temperature (°C)

AMS-QQ-P-416 Table 1 p14

187°C – 193°C 189.50°C -189.80°C

Baking Time

4 H minimum 4 Hours and 12 minutes

Furnace number: F31 Responsible: AHG

Embrittlement relief (after plating)


Temperature (°C)

AMS-QQ-P-416 Table 1 p14

187°C – 193°C 189.50°C – 190.10°C

Baking Time

23 H minimum 23 Hours and 12 minutes

Time between

cadmium plating and embrittlement relief

4H maximum 1 Hour and 2 minutes




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5.4 Visual Inspection

Table 9: Visual inspection

Inspection Specification Requirement Method Values C NC

Marking EN2424 style B

According EN2424 Style B.

Basic number + diameter

dash number + AHG monogram

Markings on head

depressed max 0,25 mm

Visual inspection

“EN6114 10 Monogram”

The picture is in

appendix 3.

X

Coating AMS-QQ-P-416 Type II

class 2

Cadmium Plating shall be smooth, adherent, uniform in appearance, free of from

defects.

Visual inspection

Cadmium Plating is in line with the requirements

The picture is in appendix 3.

X

Finish EN6117

According to

EN6114 table 1 Fastener shall be

completely covered by Cetyl Alcohol.

Visual inspection

No defect

Parts uniformly covered

X

Appearance EN6116

Burrs and tool marks not

acceptable

Visual inspection

No defect not acceptable

X

Bolt identification

EN6114 p5

Table 1

A green paint identification at thread end

Visual inspection

See appendix 3 X




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5.5 Dimensional inspection

The dimensional inspection of the parts is in accordance with the requirements of the standard EN6114, Figure 1 page 8 and Table 3 page 9 to 11. Threads dimensions are in accordance with AS8879 table 3 except for major diameter defined in EN6114 Table 3 (TD). Thread and recess dimensions are also checked through Go/NoGo gages. For each specimen, individual dimension measurements are reported in attachment 2 of the QTR.

Figure 2: EN6114 drawing




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5.5.1 Dimensional Requirements

Table 10 : EN6114-10-31 Dimensional requirements

Identification Characteristic Inspection method Requirement (mm) Batch results (mm)

Min Max Min Max

A1 Head diameter Micrometer 25,27 26,52 25.459 25.552

A Theoretical diameter 3D optical machine - 26,52 26.388 26.520

- Recess chamfer angle 3D optical machine 90° 100° 92.8° 100.0°

- Countersunk angle 3D optical machine 99° 101° 99.3° 100.0°

- Countersunk angle / shank concentricity

Dial indicator - 0,127 0.030 0.120

- Head / shank excentration

Dial indicator - 0,254 0.000 0.050

D Shank diameter Micrometer 15,824 15,849 15.835 15.846

Y Recess entry diameter 3D optical machine 7,77 8,28 7.957 8.082

W Width across flats in recess

3D optical machine and Go/NoGo gage

6,40 6,49 6.46 6.47

T Recess depth Dial indicator 5,47 5,97 5.58 5.79

- Incomplete run out threads

3D optical machine - 2,11 1.976 2.105

- Incomplete lead threads (including chamfer)

3D optical machine 1,41 2,82 2.254 2.391

M Head height at protrusion diameter

Trulok system 1,496 1,602 1.556 1.602

Z Conical surface of head height


K Shank to thread transition


- Diameter in I 3D optical machine - 15,545 15.409 15.475

G Grip length Calliper 49.083 49.337 49.241 49.335

G+B Total length 3D optical machine 65.206 65.714 65.540 65.610

J Shank to thread radius 3D optical machine 9,40 10,03 9.500 10.020

r Head to shank filet radius

3D optical machine 1,016 1,270 1.058 1.256




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Identification Characteristic Inspection method Requirement (mm) Batch results (mm)

Min Max Min Max

P Hole depth Dial indicator - 8,08 7.251 7.660

TD Major diameter Micrometer 15,545 15,697 15.609 15.625

- Pitch diameter Micrometer 14,869 14,958 14.872 14.896

- Minor diameter 3D optical machine 14,072 14,244 14.094 14.122

- Shank straightness Dial indicator - 0,100 0.040 0.050

- Functional threads 3D optical machine and thread gage

- 1,411 0.637 0.782

COMPLYING NOT COMPLYING

5.5.2 Other dimensional requirements

Table 11: EN6114-10-31 other dimensional requirements

Inspection Method Requirement Specification Results C N/C

Surface texture on shank, under head,

radius R, thread flanks and thread root

Visual or fingernail

comparison Max 0.8 µm

ASME B46.1

0.8 µm X

Surface texture on

other surfaces

Visual or fingernail

comparison Max 3.2 µm 3.2 µm X

Distortion in head to shank fillet area

Comparator Or

Micro examination

Distortions shall not exceed 0.05 mm.

Distortions shall not

extend beyond 0.89 mm

EN6116 ANNEX4 p17

See appendix 10 X

Cadmium plating

thickness

NASM1312-12 X-ray method

From 8 µm to 15 µm AMS-QQ-P-416 type 2

class 2

From 8.10 µm To 9.86 µm

(See appendix 12)

X




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5.6 Mechanical Inspection

Average of Ultimate tensile value and ultimate double shear values are calculated based on EN6116 ANNEX10 and ANNEX13 notes. Threaded adapters in line with NASM1312-11 are used for tension fatigue and tensile strength tests.

10 tests for batch acceptance (see certificate of conformity) – 20 tests have been performed for

qualification.




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Table 12: EN6114-10-31 Mechanical requirements

Test Method Requirements Individual, average Values Specification C NC

Tensile Strength

NASM 1312-8

EN6116 Annex 9 bis p28

≥ 137 900 N

And

𝑋 ̅ − 𝐾 ∗ 𝑆 ≥ M

With

𝑋 ̅𝑡ℎ𝑒 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑜𝑓 𝑡ℎ𝑒

𝑣𝑎𝑙𝑢𝑒𝑠 𝐾 = 3

𝑀 = 137 900 𝑁 𝑆 𝑡ℎ𝑒 𝑠𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛

Sample Value (N)

1 163764,7

2 162013,5

3 163822,1

4 162800,5

5 164631,8

6 164090,2

7 164852,4

8 164120,7

9 164503,3

10 164065,2

11 164342,6

12 165549,6

13 163658,0

14 164380,0

15 163765,7

16 165307,4

17 164771,5

18 165388,0

19 165695,3

20 165932,8

𝑋 ̅̅ ̅ = 164 372.8 𝑁

𝑆 = 967.2 𝑁

𝑋 ̅̅ ̅ − 𝐾 ∗ 𝑆 = 161 471.1𝑁

Thus individual values exceed the minimum

required and 𝑋 ̅ − 𝐾 ∗ 𝑆 ≥ M

The test is compliant.

For each sample the failure is located in the head.

The pictures of the test are in appendix 4.

EN6114 Table 2 p6

EN6116

Annex 10 p30

X




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Tension Fatigue

NASM-1312-11

EN6116

appendix 9bis p28

Upper load: 48 250 N

Lower load: 4 825 N

Minimum individual life time : 45 000 cycles

Minimum average life time : 65 000 cycles

Maximum life time :

130 000 cycles


𝑣𝑎𝑙𝑢𝑒𝑠

Sample Values (cycles) 1 130 000 2 130 000 3 130 000 4 130 000 5 130 000 6 130 000 7 130 000 8 130 000 9 130 000

10 130 000 11 130 000 12 130 000 13 130 000 14 130 000 15 130 000 16 130 000 17 130 000 18 130 000 19 130 000 20 130 000

𝑋 ̅ = 130 000 𝐶𝑦𝑐𝑙𝑒𝑠 smallest individual life time:

130 000 cycles =>the test is compliant

See appendix 6

EN6114 Table 2 p6

EN6116 ANNEX11 p31

X




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Double Shear Strength

NASM-1312-13*

EN6116

Annex 12 bis p32

≥ 294 900 N

And

𝑋 ̅ − 𝐾 ∗ 𝑆 ≥ M

With


𝑣𝑎𝑙𝑢𝑒𝑠 𝐾 = 3

𝑀 = 294 900 𝑁 𝑆 𝑡ℎ𝑒 𝑠𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛

Sample Values (N)

1 305898,1

2 305425,2

3 306473,6

4 305705,8

5 306730,4

6 305754,3

7 306358,3

8 305100,7

9 304797,0

10 305166,8

11 305071,4

12 305347,4

13 305562,5

14 307645,2

15 308894,8

16 308758,9

17 309727,9

18 309453,5

19 309777,0

20 308700,0

𝑋 ̅ = 306 817.5 𝑁

𝑆 = 1754.9𝑁

𝑋 ̅̅ ̅ − 𝐾 ∗ 𝑆 = 301 552.6

Thus individual values exceed the minimum

required and 𝑋 ̅ − 𝐾 ∗ 𝑆 ≥ M

the test is compliant

The pictures of the test are in appendix 5

EN6114 Table 2 p6

EN6116

annex 13 p33

X




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Hexagonal

recess torsional capability

EN6116 ANNEX7

p23

The hexagonal socket

shall withstand the torsional moment

of 31.08 N.m without failure

31.5 N.m without failure

See appendix 16

EN6116 ANNEX7 p23 X

Hardness

NASM1312-

6

Rockwell hardness

Hardness

test performed after heat treatment

and before thread rolling

40 – 44HRC

Sample Values (HRC)

1 41.39

2 41.14

3 41.44

4 41.99

5 40.09

6 41.09

7 41.19

8 41.11

9 41.13

10 40.88

The values are in line with

the requirement.

EN6114 Table 1 p5 X

Embrittlement

NASM 1312-5

Load: 117 215 N (85% UTS)

Duration: 23H

Compliant

Fasteners have been sustained at minimum 85% UTS during 23 hours. No

cracks have been observed after the test.

See appendix 17

EN6116 Table 1 p10 X

Torque tension test

ME1612185 3 installations cycles at 115 N.m, no crack after

examination

Compliant, no crack (see appendix 18)

Note: the results of this test are also in AHG report RT-

346, in which three following batches have been tested

compliant

ME1612185 X

*: In accordance with the section 5.1.4 of the NASM1312-13, the double shear tests were continued to a point in which the stress-strain curve is flat, and the tests were stopped when the curve started to decrease (just before breaking the parts), in order to reach the maximum allowable stress as shown in Figure 9: shear strength as a function of the displacement, and avoid to deteriorate the integrity of the shear dies.




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5.7 Surface defect and discontinuities inspection

A magnetic inspection has been performed first. Requirements are in line with EN6116 ANNEX14 p35.

Table 13: Permissible discontinuities depth

Location Defect Test Method

Maximum depth normal to surface (mm)

Requirement Measurement

Head to shank fillet, root of bolt

threads No rateable discontinuities

Magnetic inspection per ASTM E 1444

0.013

No discontinuity

observed

Pin thread Laps and surface defects 0.2

Shank to thread transition area

Laps and foldbacks 0.13

Grip or shank diameter

Seams - Not extending into head-to-shank fillet or threads

0.2

Non-bearing surface of head

Laps, seams, nicks or gouges. Not more than three

discontinuities 0.41

Hex socket No cracks 0

COMPLYING NOT COMPLYING




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5.8 Metallurgical Inspection

Requirements and sampling are in line with EN6116 Table 1 requirements.

Table 14: Metallurgical inspection requirements

Inspection Requirement Method Result C N/C

Grinding burns Grinding burns are not permitted on shank, head to shank fillet or bearing surface.

Visual + micro-examination on all questionable parts.

50X to 100X magnification.

No grinding burns

The results are in

accordance with the requirements.

X

Carburization and

decarburization

Decarburization shall not exceed the depths specified in the

standard EN6116 annex 14

Complete + partial decarburization 0,08 mm max

Micro examination at 100X magnification

The results are in

accordance with the requirements.

No decarburization

See attachment 8

X

Microstructure

No crack or internal burst shall be permitted. Microstructure shall be free from bursts, voids, gross alloy

segregation or inter granular carbide precipitation.

Microstructure shall also be free from overheating.


The results are in line with the

requirements.

See attachment 7

X

Grain Flow in Head

Head must be forged.

Micro examination

at 10X magnification

Grain flow is

continuous and follows the head to shank fillet radius

See attachment 9

X




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Inspection Requirement Method Result C N/C

Grain Flow in Threads

Formed by single rolling process after thermal treatment. Permissible discontinuities as per EN6116 ANNEX3 p15.


Grain flow is

continuous and follows the general

thread contour. The grain flow

density is maximum at the root of the

thread.

See attachment 9

X

Cold work in head to shank

fillet

Head to shank fillet area shall be cold worked after heat treatment to meet fatigue requirements.


Head to shank fillet is cold worked after

heat treatment

Fatigue test compliant and see

attachment 10.

X

Micro -examination

No cracks in Hex-socket EN6116 ANNEX 14.2 p35

Micro examination x100

No cracks observed See attachment 11

X

Permissible discontinuities per EN6116 ANNEX 14.2 p35

All observed surface defects are

acceptable regarding the requirement

X




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Appendix 1: Certificate of conformity of raw material




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Appendix 2: Dimensional inspection

min max

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20A1 Head diameter 25,488 25,459 25,55 25,488 25,484 25,477 25,487 25,471 25,493 25,481 25,484 25,473 25,495 25,552 25,53 25,512 25,492 25,49 25,486 25,485 25,459 25,552A Theoretical diameter 26,498 26,41 26,493 26,482 26,48 26,42 26,397 26,45 26,52 26,452 26,482 26,502 26,508 26,507 26,506 26,489 26,493 26,517 26,478 26,388 26,388 26,520

Recess chamfer angle 92,806 98,369 97,082 94,265 93,714 99,656 99,588 99,574 99,79 99,971 99,028 98,322 94,787 93,115 98,745 94,887 93,873 97,803 99,799 94,936 92,8 100,0

Countersunk angle 99,6 100,0 99,8 99,3 99,6 99,7 99,6 99,6 99,8 100,0 99,9 99,8 99,6 99,7 99,8 99,5 99,6 99,7 99,3 99,7 99,3 100,0

Countersunk angle / shank concentricity 0,04 0,075 0,08 0,1 0,12 0,07 0,05 0,06 0,03 0,05 0,07 0,09 0,07 0,12 0,11 0,08 0,07 0,1 0,08 0,07 0,030 0,120

Head / shank excentration 0,02 0,03 0,01 0,03 0,02 0,05 0,03 0,005 0 0,01 0,02 0,03 0,04 0,03 0,03 0,05 0,02 0,01 0,015 0,02 0,000 0,050D Shank diameter 15,835 15,84 15,846 15,841 15,84 15,846 15,839 15,841 15,84 15,841 15,838 15,84 15,842 15,84 15,841 15,84 15,845 15,835 15,837 15,841 15,835 15,846Y Recess entry diameter 8,002 8,061 8,069 8,079 8,001 8,009 8,058 8,082 7,987 8,029 8,015 7,957 7,993 8,058 8,036 8,006 7,958 7,98 8,067 8,079 7,957 8,082W Width across th flats in recess 6,46 6,46 6,46 6,46 6,47 6,47 6,46 6,46 6,46 6,47 6,47 6,46 6,46 6,47 6,47 6,47 6,47 6,47 6,46 6,46 6,46 6,47T Recess depth 5,62 5,62 5,61 5,58 5,67 5,65 5,73 5,65 5,69 5,79 5,62 5,72 5,72 5,77 5,65 5,58 5,77 5,59 5,64 5,66 5,580 5,790

Incomplete run out threads 2,03 1,976 2,097 2,026 2,053 2,057 2,061 2,105 2,099 2,096 2,03 2,088 2,104 2,105 2,103 2,103 2,101 2,058 2,046 2,1 1,976 2,105

Incomplete lead threads (including chamfer)2,391 2,354 2,333 2,338 2,358 2,337 2,349 2,254 2,364 2,316 2,346 2,371 2,384 2,27 2,298 2,38 2,382 2,354 2,261 2,343 2,254 2,391M Head heigth at protrusion diameter 1,598 1,556 1,602 1,602 1,602 1,591 1,592 1,581 1,601 1,595 1,602 1,599 1,601 1,602 1,6 1,602 1,593 1,6 1,584 1,585 1,556 1,602Z Conical surface of head height 0,391 0,371 0,375 0,379 0,401 0,393 0,366 0,393 0,383 0,381 0,381 0,424 0,394 0,39 0,382 0,402 0,395 0,434 0,394 0,401 0,366 0,434K Shank to thread transition 0,447 0,524 0,491 0,524 0,712 0,513 0,563 0,475 0,48 0,543 0,545 0,544 0,448 0,496 0,707 0,466 0,493 0,49 0,489 0,518 0,447 0,712

Diameter in I 15,428 15,415 15,459 15,409 15,436 15,475 15,436 15,458 15,454 15,466 15,417 15,44 15,435 15,436 15,441 15,451 15,44 15,419 15,415 15,456 15,409 15,475G Grip length 49,32 49,334 49,312 49,325 49,335 49,29 49,287 49,33 49,295 49,281 49,297 49,295 49,251 49,295 49,335 49,325 49,241 49,264 49,31 49,33 49,241 49,335

G+B Total length 65,54 65,58 65,59 65,56 65,56 65,61 65,58 65,58 65,57 65,59 65,55 65,54 65,57 65,58 65,57 65,54 65,55 65,55 65,58 65,61 65,540 65,610J Shank to thread radius 9,5 9,558 9,852 9,996 9,756 9,503 10,02 10,005 9,506 9,508 9,663 9,641 9,96 9,654 9,504 9,766 9,888 9,691 9,646 9,588 9,500 10,020r Head to shank filet radius 1,119 1,155 1,178 1,141 1,073 1,212 1,12 1,121 1,219 1,058 1,113 1,256 1,16 1,192 1,115 1,179 1,122 1,177 1,182 1,168 1,058 1,256P Hole depth 7,282 7,394 7,417 7,253 7,49 7,626 7,596 7,66 7,496 7,251 7,41 7,352 7,595 7,552 7,337 7,567 7,539 7,278 7,305 7,607 7,251 7,660

TD Major diameter 15,618 15,616 15,625 15,624 15,618 15,615 15,616 15,617 15,623 15,609 15,62 15,624 15,618 15,609 15,618 15,619 15,623 15,622 15,614 15,622 15,609 15,625

Pitch diameter 14,877 14,872 14,887 14,877 14,88 14,891 14,89 14,889 14,896 14,89 14,882 14,892 14,887 14,878 14,887 14,894 14,896 14,883 14,887 14,893 14,872 14,896

Minor diameter 14,094 14,107 14,107 14,106 14,104 14,102 14,1 14,103 14,103 14,102 14,099 14,113 14,122 14,094 14,107 14,104 14,101 14,1 14,115 14,11 14,094 14,122

Shank straightness 0,047 0,048 0,043 0,046 0,042 0,05 0,04 0,05 0,049 0,049 0,04 0,047 0,04 0,041 0,044 0,04 0,046 0,048 0,05 0,05 0,040 0,050

Functional threads 0,669 0,657 0,71 0,637 0,676 0,682 0,669 0,72 0,672 0,675 0,664 0,666 0,782 0,782 0,681 0,637 0,696 0,699 0,706 0,713 0,637 0,782

measures




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Appendix 3: Visual Inspection

Figure 3: Surface treatment

Figure 4: Marking

Green paint




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Appendix 4: Tensile strength

Figure 5: Tensile strength test

Figure 6: EN6114-10-31 after tensile strength test




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Appendix 5: Shear strength

Figure 7: Shear strength test

Figure 8: EN6114-10-31 after the shear strength test




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Figure 9: shear strength as a function of the displacement

0

50

100

150

200

250

300

350

0 0,5 1 1,5 2 2,5

SHEA

R S

TREN

GTH

(K

N)

DISPLACEMENT (MM)

shear strength as a function of the displacement




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Appendix 6: Fatigue strength

Figure 10: Fatigue test

Figure 11: EN6114-10-31 after the shear fatigue test




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Appendix 7: Microstructure

Microstructure examination at X100: compliant

In the head:

200 µm




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In the shank:

200 µm




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In the thread:

200 µm




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Appendix 8: Carburization and decarburization

No decarburization under the head (X100) => Compliant

200 µm




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No decarburization on the top of the head (X100) => Compliant

200 µm




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No decarburization in thread (X100) => Compliant

200 µm




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Appendix 9: Head Forming + Thread Forming

Thread Forming => Compliant

Head Forming => Compliant

1 mm

1 mm




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Appendix 10: Head to shank fillet radius cold working (X25)

Cold worked area inspection

Maximum distortion Distorted area

(max 0.89 mm) Above (max 0.0508mm) Below (max 0.0508mm)

0.018 mm 0.036 mm 0.879 mm

500 µm




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Appendix 11: Hexagonal Recess

No crack in the hexagonal recess

200 µm




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Appendix 12: Thickness measurement

Figure 12: Cadmium thickness measurement

Requirement: from 8 μm to 15 μm Result: Compliant

10 tests for batch acceptance (see certificate of conformity) – 11 tests have been performed for

qualification.

Sample Values (µm) C NC 1 8.10 X

2 8.40 X

3 9.86 X

4 9.82 X

5 9.20 X

6 9.28 X

7 9.40 X

8 9.44 X

9 9.26 X

10 9.24 X

11 9.20 X

12 8.84 X

13 9.05 X




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Appendix 13: Raw material verification




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Appendix 14: Incomplete Threads

Figure 13: Incomplete runout threads (head side)

Figure 14: Incomplete lead threads (including chamfer)

Point I




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Appendix 15: Gage for dimensional inspection

Figure 15: Thread measurement




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Appendix 16: Hexagonal recess torque test

Figure 16: Recess torque test

Figure 17: Bolt after recess torque test




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Appendix 17: Embrittlement Test

Figure 18: Embrittlement test

Figure 19: parts after embrittlement test and removal of the cadmium plating




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Figure 20: evolution of the load during embrittlement test




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Appendix 18: Torque tension test

Figure 21:Complete view of the thread, no cracks detected at the bottom of the thread, in the self-locking area

Figure 22:Deformation of the thread, no cracks detected at the bottom of the thread, in the self-locking area




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Appendix 19: AHG internal drawing for shank end machining

Note: the dimension DR has been reduced from [14.876 ; 14.892] to [14.840 ; 14.850], in order to pass the torque tension test.




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Appendix 20: Certificate of conformity




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AHG QTR - QUALIFICATION TEST REPORT EN6114-10-31 / QTR · EN6116 P4 09/2010 Aerospace series...

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