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A Survey of Fastening Techniquesforshipbuilding SSC-260 A SURVEY OF FASTENING TECHNIQUESFORSHIPBUILDING This document has been approved for public release and salq its distribution is unlimited. SHIP STRUCTURE COMMITTEE 1976 SHIP STRUCTURE COMMITTEE AN INTERAGENCY ADVISORY COMMITTEE DEOICATEO TO IMPROVING THE STRUCTURE OF SHIPS MEMBER AGENCIES: ADDRESS CORRESPONDENCE TO: Un,t<d S,. $,, Coat Guocd Se. r,t.,y NoW Seo Sp, m, Commond Ship S!ructur, Commis+ee M,l,, ory See),h Command U.S. Coat Gw’d Heodqwrlers Mar,,, m, Admini,!mt ion Wmhing$ on, D.C. 20590 Amcr, an B.c... of Sh,pping SR-207 The Ship Structure Conrnittee recognized, as a result of studies sponsored on the use of aluminum and fiberglass in ship construction, that a variety of joining techniques must be considered. Many mechanical and adhesive techniques have been employed in other industries . Some of these methods might have a marine application and provide an alternative to welding. ‘This report describes the study that was made of these alternative fasten- ing techniques. It is not an endorsement by the Ship Structure Committee of any concept or process. Many of these concepts would require a more penetrating examination before they could be adopted. However, much of the material has not been readily available to the marine community. In some cases this information might prove useful especially in weight critical applications. This report is published to assist in developing cost effective and safe fastening techniques. Comments on this report and suggestions for areas of critical need in ship structural research would be most welcome. ‘&&k?” Rear Admiral , U. S. Coast Guard Chairman, Ship Structure Committee SSC-260 Final Report on Project SR-207, “Fastening Techniques Evaluation’ A SURVEY OF FASTENING TECHNIQUES FOR SHIPBUILDING by N. Yutani , and T. L. Reynolds Boeing Commercial Airplane Company under Department of the Navy Naval Sea Systems Command Contract No. NOO024-73-C-5077 . This document has been approved for pub lie m lease and sa k; its distribution is unlimited. U. S. Coast Guard Headquarters Washington, D.C. 1976 ABSTRACT This report is aimed at defining fastening processes and techniques that are not widely used in ship construction today in terms of their applicability snd potentisl for improving cost, construction, reliability, and maintenance of hull structures and attachments. The study includes similar and dissimilar met al-to-metal and met .al-to-nonmetsl joints, a generic fsstener matrix of typi csl fasteners, fastener installation equipment and processes, proposed applications of explosion- bonded materisls , and cost comparisons of vs,rious fabrication techniques. Fusion welding, diffusion bonding, friction welding, snd adhesive bondirig are discussed. Several fastener stsndsrds and vendor proprietary fasteners are included as figures. Extractions from Seeing Design Manual sections on mechanical fastening and adhesive bonding are included as reference attachments. Fastening systems and techniques that merit further study or verification are identified. -ii- — -—- ..— — CONTENTS ~ I. INTRODUCTION . 1 Background . 1 Scope. 2 II. INVESTIGATION AND ANALYSIS . 4 Identification of Problem Areas for Study. k General Fastener Matrix... II Mechanical Fastening and Hole Preparation. 9 Explosion Banding . 31 Adhesive Bonding . 46 Welding . 48 Mechanical Rending . 51 III . CONCLUSIONS AND RECOMMENDATIONS . 51 IV. RECOMMENDED AREAS FOR FURTHER STUDY. 53 APPENDICES . 54 A Piping Systems . 55 B Water Systems . 57 c Oiland Air Systems . 59 D Bonding Facilities Equipment . 61 E In-Place Tube Welding . 63 F Electrical Systems and Their Attachments . 67 G Optical Laser Applications . 69 11 Boeing Design Manual, Section 17, Fasteners. 72 I Boeing Design Manual, Section 26, Adhesive Bonding . 114 LIST OF REFERENCES . 133 ADDITIONAL SOURCES OF INFORMATION. 134 ACKNOWLEDGEMENTS . 135 . 111 LIST OF FIGURES FIGURE NO. PAGE 1. Exsmple Machine Bolt Standard . , . 10 2. Exsmple Blind Rivet Standard, . 12 3. Exsmple Taper Shank Bolt Standard . 13 4. Omark-Winslow 1{S-2Spacematic Drill . , . .!. $ 14 Squeeze Yoke Rivebolt Installation on ’747 Spar. ,.. 14 z: Hi-Shear Bus Hi-Lok Fastener Standard . 16 7. Ri-Shear Six-Wing Fastener Standard . 18 8. Wing Splice Joint,.. 22 9. Hand Riveting T2T Spar... 22 10. Riveting Stringera to ’747 Upper Wing Panel on Gemcor Drivematic Riveting Machines. 22 11. Gmark-Winslow Track Drill. 24 12. Boeing-Developed Electromagnetic Riveter. 24 13. Boeing Electromagnetic Riveter and Gmark-Winslow Track Drill. 28 14. Boeing Cold Expansion Sleeve System . , . 2fj 15. Air/Hydraulic Puller for Cold Working Holes . 28 I-6 . Schematic of Explosion Bonding Process Illustrating Jetting Phenomenon Which Removes Oxides and Foreign Matter From Surfaces Being Joined... ,.. 32 17. Corrosion Test Results . 36 18. Deckhouse Mockup--Aluminum/Steel Transition Joints. , . 41 19. Proposed Bimetallic Applications. 44 20. Typical Chemical Processing Line. , . 60 21. Typical Spray Booth for Applying Adhesive Primer. 60 22. Typical Oven For Precuring Adhesive Primer. 60 23. Clean Room For Assembly of Parts to be Bonded . 60 24. Aluminum Honeycomb Core Machining Equipment , . 62 25. Ultrasonic Nondestructive Testing Equipment . 62 26. Typical Commercial Inplace GTA Tube Welding Power Supply/ Programmer and Weld Head.. 64 27. Typical Commercial Inplace GTA Tube Welding Head With Auxiliary Bridge Tool... 64 28. Clearance Envelope for Typical GTA Pipe Welding Crawler Head, . 64 29. Auxiliary BridgeTool. 64 30. Tubing Weld Joint Configurations for GTA Tube Welder. 65 31. Typical Commercial Miniature GTA Tube Welding Crawler Unit With AVC , Torch Oscillation, and Wire Feeder. 66 32. Typical GTA Tube Welding Head . , . 66 33. Typical MCT Cable & Tube Assemblies . 68 34. Installation of Multicable Transit Frsme . 68 35. Flat Cable Assembly Compared to Round Wire Bundle . ,.. 70 36. Flat Cable to Round Wire Tra~sition . 70 37. Flat Cable/Round Wire Junction Box . 70 TABLE NO. = 1. Alternate Applications Table . 5 2. Generic Fastener and Applications Matrix . 6 Blind Nut Selection Chart--Countersunk Head Type . 19 ;: Blind Nut Selection Chart--Protruding Head Type . 20 Voi-Shan Visu-Lok Blind Fastener . , . 21 2: Interference Profiles--Hand Driven--EMR . 25 7. EMR Technical Information--Boeing 747 Production System . 26 8. Delron Selector Chart--Honeycomb and Sandwich Panel Fasteners . 30 9. Met als That liaveBeen Explosively Bonded to Themselves . 32 10. Dissimilar Metal Combinations That Have Been Explosively Bonded . 33 11. Corrosion Testing of Explosion-E@nded Transition Joints . 36 12. Mechanical Testing of Explosion Bonded Transition Joints . 38 13. Fatigue Testing Explosion-Bonded Transition Joints and Mechanical Connections . 39 14. Comparative Maintenance and Repair Associated With Mechanical Fastening Versus Detastrip for Attachment of Aluminum Deck Houses to Steel Decks. 40 15. Aluminum Deck House Fabrication Cost Analysis . 42 16. NAA Dissimilar-Metal Bonding Processes . , . 50 17. Cost Comparison for Aluminum Alloy and Stainless Steel Valves . 56 18. Material Costs--Bilge System in Ballast Tanks (U.S. Dollars) . 56 19. Material Cost--Ballast System (U.S. Dollars) . 58 —v- SHIP STRUCTURE COMMITTEE The SHIP STRUCTURE COMMI~EE is constituted to prosecute a research prograr to imorove the hul 1 structures of ships by an extension of knowledge pertaining to design, materials and methods of fabrication. RADM W. M. Benkert, USCG Chief, Office of Merchant Marine Safety U.S. Coast Guard Headquarters Mr. P. M. Palermo Mr. M. Pitkin Asst. for Structures Asst. Administrator for Naval Ship Engineering Center Conmwrci al Development Naval Ship Systems Comnand Maritime Administration Mr. K. Norland Mr. C. J. Whitestone Vice President Maintenance & Repair Officer American Bureau of Shipping Military Sealift Cotmnand SHIP STRUCTURE SUBCOMMITTEE The SHIP STRUCTURE SUBCOMMITTEE acts for the Ship Structure Committee on technical matters by providing technical coordination for the determination of goals and objectives of the program, and by evaluating and interpreting the results in terms of ship structural design, construction and operation. NAVAL SEA SYSTEMS COMMAND AMERICAN BUREAU OF SHIPPING Mr. C. Pohler - Nember Mr. S. G. Stiansen - Chairman Mr. J. B. O’Brien - Contract Administrator Mr. I. L. Stern - Member Mr. G. Sorki n - Member Dr. H. Y. Jan - Member U.S. COAST GUARD SOCIETY OF NAVAL ARCHITECTS & MARINE ENGINEERS LCi2R E. A. Chazal - Secretary CAPT C. B. G1ass - t@mber Mr. A. B. Stavovy - Liaison LCDR S. H. Davis - Member LCDR J. N. Naegle - Member WELDING RESEARCH COUNCIL MARXTIME ADMINISTRATION Mr. K. H. Koopman - Liaison Mr. N. Hamner - Nember INTERNATIONAL SHIP STRUCTURES CONGRESS Mr. F. Dashnaw - Member Mr. F. Seibol d - Member Prof. J. H. Evans - Liaison Mr. R. K. Kiss - Member U.S. COAST GUARD ACAOEMY QI.ITARY SEALIFT COMMAND CAPT W. C. Nolan - Liaison Mr. D. Stein - Member Mr. T. W. Chapman - Nember STATE UNIV. OF N.Y. MARITIME COLLEGE Mr. A. B. Stavovy - Member CDR J. L. Sinmwns - Member Or. W. R. Porter - Liaison NATIONAL ACADEMY OF SCIENCES AMERICAN IRON & STEEL INSTITUTE SHIP RESEARCH COMMITTEE Mr. R. H. Sterne - Liaisofl Mr. R. W. Rumke - Liaison Prof. J. E. Coldberg - Liaison U.S. NAVAL ACADEMY Dr. R. Bhattacharyya - Liaison vi I. INTRODUCTION IA. BACKGROUND There are many differences and similarities between conventional ship and air- frame assembly methods. These differences range from the obvious to the very subtle and are related to the particular fabrication techniques and the design philosophy
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