Boeing Fasteners

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777 TRAINING MANUAL FASTENERS -- INTRODUCTION TO FASTENERS Introduction to Fasteners This section provides a review of the most common fasteners and auxiLiary parts used in Boeing airpLanes today. It shouLd be noted that the Latest revision of the StructuraL Repair ManuaL or manufacturers' documentation, shouLd be consuLted to ensure that this information has not been superseded by design changes or reguLatory authority action

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777 TRAINING MANUAL

1/64 OS 1/32 OS

STD

1/64 OS 1/32 OS

STD

1/64 OS 1/32 OS

BACC30M

BACC30M

BACC30R

BACC30M

BACC30M

BACC30R

BACC30M

BACC30M

BACC30R

XDA

XDE

XKA

XNL

XNP

XSG

YJA

YLE

YLF

BACB30FN

BACB30FQ

BACB30KF

BACB30FN*A

BACB30FQ*A

BACB30KF*A

BACB30NW*K

BACB30NW*K*

BACB30NW*K*

BACC30X

BACC30X

BACC30AC

BACC30X

BACC30X

BACC30AC

BACC30X

BACC30X

BACC30AC

XNB

XMS

XSL

XXZ

XUD

XTX

YLR

YXN

YXP

BACB30JC

BACB30LX

BACB30LY

BACB30JC*A

BACB30LX*A

BACB30LY*A

BACB30NY*K

BACB30NY*K*

BACB30NY*K*

BACC30M

BACC30M

BACC30R

BACC30M

BACC30M

BACC30R

BACC30M

BACC30M

BACC30R

XCZ

XDD

XKJ

XNJ

XNN

XSJ

YHY

YLC

YLD

BACB30FM

BACB30FP

BACB30KK

BACB30FM*A

BACB30FP*A

BACB30KK*A

BACB30MY*K

BACB30MY*K*

BACB30MY*K*

BACC30X

BACC30X

BACC30AC

BACC30X

BACC30X

BACC30AC

BACC30X

BACC30X

BACC30AC

XMX

XMY

XSM

XPB

XTZ

XUB

YLK

YLG

YLH

BACB30MB

BACB30MC

BACB30MD

BACB30MB*A

BACB30MC*A

BACB30MD*A

BACB30NX*K

BACB30NX*K*

BACB30NX*K*

SAMPLE HI-LOK DRAWING CODES

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FASTENERS - INTRODUCTION TO FASTENERS

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777 TRAINING MANUAL FASTENERS -- PERMANENT AND REMOVABLE THIS PAGE INTENTIONALLY LEFT BLANK

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777 TRAINING MANUAL FASTENERS -- PERMANENT AND REMOVABLE Fasteners There are two major classifications of fasteners; permanent and removal. Permanent fasteners are those that require destroying part or all of the fastener when removing it from the airplane. Examples of these are rivets, lockbolts or Hi-loks. Removable fasteners would include fatigue or structural bolts.

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777 TRAINING MANUAL

BACR15BA RIVET BACB30FM HEX-DRIVE OR HI-LOK

BACR15BB RIVET

BACB30DX LOCKBOLT

I

MS 90353 PULL RIVET

PERMANENT FASTENERS

BACN10HR 12 PT. NUT BACN10JC SELF LOCKING NUT

BACB30PC SHOULDER BOLT \

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BACS21AE QUICK-RELEASE SCREW

BACB30US 12 PT. TENSION BOLT REMOVABLE FASTENERS

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FASTENERS-PERMANENT AND REMOVABLE

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Telescoping bolt where length is uncertain

777 TRAINING MANUAL

For all tapered holes (special nut required)

For out-ofround holes

For holes with countersink on wrong side

For mismatched bolt holes

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For holes too near the edge

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For double countersunk holes

For redrilled holes that still don't match

For holes countersunk too deep

For holes not square

For holes drilled crooked and then straightened up (nut is hard starting) Binocular bolt, for double-drilled holes

For use where pilot hole does not clean up

Serrated head for all vice-grip torquing

Assembler's special, for oversize and stepped holes

SPECIAL FASTENERS FOR THAT UNIQUE REPAIR

FASTENERS-PERMANENT AND REMOVABLE

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777 TRAINING MANUAL FASTENERS -- RIVETS - IDENTIFICATION MARKS SoLid Shank Rivet MateriaLs

Solid Shank Rivet Head Styles

SoLid shank rivets are avaiLabLe in a variety of materiaLs. The soLid shank rivets instaLLed on Boeing aircraft are usuaLLy made from 2017, 2117, 2024 or 7050 aLuminum aLLoy. The part number suffix and rivet identification marks give the rivet material.

Rivet head styles incLude universal and flush varieties. FLush heads styles include standard, briLes, shear, and index.

Rivets made from 2017, 2117, and 7050 aluminum alloy and nickeL-copper alloy can be used and stored at room temperature. Rivets made from 2024 aluminum aLloy must be soLution heat treated and then stored at a temperature of -10°F (- 23°C), or lower. After removal from cold storage the rivets must be completely driven within 15 minutes. Rivets that are removed from coLd storage and not instaLled should be discarded. In some locations Monel rivets are used. Monel rivets are made of 66% Nickel, 30% Copper and 4% Iron. Monel is corrosion resistant and can be used in high temperature appLications without significant property reductions.

The modified fLush head is the briles rivet and gives improved bearing in thin sheets, seals in the countersink, improves fatigue Life, has greater head strength in tension and can save weight due to improved fatigue life in thin sheet. 7050-T73 rivets or briLes were introduced with the 767 program. These rivets have the same aLlowables as the 2024-T31 rivets but are sufficiently ductiLe that they can be driven in the "as received" condition up to 1/4 inch diameter without cracking. The modified universaL head and shear head offer a weight savings over the standard universaL head or flush, respectively. The sLug rivet has no manufactured head, the head is formed during driving, nearly always on automatic drivers (Gemcor Drivematic).

o Other rivet aLloys include A286 CRES, 300 series CRES ~ and a Limited number of titanium-columbium are used in N

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777 TRAINING MANUAL

MODIFIED 0 100 0 RIVET DESCRIPTION UNIVERSAL UNIVERSAL 100 CSK )HEAR HEAD MATERIAL

2117(AD)

MARKS

2017(D)

RAISED DOT EXCEPT [*]

2024(DD)

RAISED DOUBLE DASH EXCEPT [*]

5056

--10-32 1/4-28 90-125 180-250 5/16-24 3/8-24 300-500 7/16-20 510-840 1/2-20 870-1300 9/16-18 1300-1800 5/8-18 1900-2300 3/4-16 3300-4300 7/8-14 5100-6700 1-12 OR 1-14 7000-10,900 1-1/8-12 9500-13,000 15,800-19,200 1-1/4-12 1-3/8-12 20,000-24,000 --1-1/2-12 ~MAXIMUM

DRY BOLT

LUBRICATED BOLT

LUBRICATED BOLT

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--70-80 145-180 275-330 370-440 500-575 800-1000 1350-1650 2800-3300 3900-4500 6200-7000 8300-9400 11,000-12,000 16,000-17,000

---

30-35 65-100 130-200 220-410 370-690 630-1070 1000-1470 1400-1900 2400-3500 3700-5500 5100-8900 6900-10,700 11,500-15,700

-----

20-25 50-75 90-125 150-250 260-425 440-650 700-920 1000-1200 1700-2150 2600-3400 3600-5500 4900-6700 7500-9700

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NUT TIGHTENING TORQUE VALUES TORQUE + OR - 10 PERCENT WHEN BOLT IS INSTALLED BY WRENCHING HEAD.

SEE STRUCTURAL REPAIR MANUAL FOR LATEST DATA.

FASTENERS - BOLT TORQUE REQUIREMENTS

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777 TRAINING MANUAL FASTENERS -- WASHERS Washers For general use, plain washers (AN 960, BACW10BP()P) are used under nuts. They provide a uniform bearing area and act as a spacer to adjust for fastener grip length and material thickness. The bolt and nut installation specification (BAC 5009), allows one washer under the fastener head, and two washers under the nut. Plain washers may also used under the collars of lockbolts or hiloks or under the head of solid rivets to distribute the fastener bearing load over a larger area. This is particularly important in plastic or carbon fiber assemblies. In installations where spring lockwashers (AN 935) are used, plain washers must be fitted between the part and the lockwasher to prevent damage to the material.

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In fatigue critical joints, preloaded-indicating washers are used to optimize fatigue life and handle greater in-service stresses. They act by compressing the inner ring to the point where the outer ring cannot be moved, thus achieving the required preload.

Countersunk washers (BACW10BP()C) are used under the head of protruding head bolts to provide head-to-shank fillet relief on high strength fasteners such as BACB30US and BACB30LE bolts. Self-aligning washers (BACW10CA) are used with fasteners in non-parallel joint design where counterboring of the slope surface is unacceptable. These washers will accommodate a maximum slope of 8 degrees. A concave and a convex washer make up the self-aligning washer assembly.

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As an option to aluminum, plain cadmium plated steel washers are frequently used adjacent to structural ~ surfaces as they better resist the cutting action of co: ~ the nut, especially if a specified torque has to be ~ applied. Where the material next to the nut is steel, use steel washers. '"

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777 TRAINING MANUAL

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CONVEX

L.A

COUNTERSUNK WASHER

GENERAL PURPOSE FOR WASHERS: - DISTRIBUTION CLAMP UP BEARING LAOD - PREVENT GALLING - DISSIMILAR MATERIAL COMPATIBILITY - GRIP LENGTH ADJUSTMENT - FILLET RELIEF FOR FATIGUE RATED BOLTS - SELF-ALIGNMENT FOR ANGLES BETWEEN 2-8 DEGREES

CONCAVE

SELF-ALIGNING WASHER 2 - 8 DEGREES

2 WASHERS

~ (WP22, BACW10AK)

TYPICAL INSTALLATION

OUTER PLI RING OUTER PLI RING

INNER PLI RING

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TOOL HOLES (3) 120· APART (APPROXIMATE)

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(BEFORE LOADING CONDITION ILLUSTRATED)

BEFORE LOADING NOTE: OUTER PLI RING - - FREE TO TURN.

AFTER LOADING NOTE: INNER PLI RING COMPRESSED, OUTER PLI RING NO LONGER FREE TO TURN; INDICATING PROPER PRELOAD. INNER PLI RING NOT REUSABLE.

PRELOAD INDICATING WASHER (PLI) FOR 220 KSI NUTS BACW10AM

FASTENERS - WASHERS

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777 TRAINING MANUAL FASTENERS -- NUTS / NUTPLATES Nuts / Nutplates Nuts are generaLLy classified as tension or shear. Tension nuts are avaiLabLe in strengths of 180 or 220 KSI. Shear nuts are avaiLabLe in 125 KSI strength. Nuts are seLected to have a tensile strength equaL to or greater than the mating boLt or screw. Nut pLates are used in "cLose outs" or other pLaces with Limited or no access. They are attached with rivets. NutpLates are primariLy used in shear appLications and are predominantly of 125 KSI strength with a limited number rated at 160 KSI.

ALignment of the casteLLated nut and the boLt cotter pin hoLe whiLe staying within the specified torque range is accompLished by changing the boLt grip Length and/or adding washers. For fLight safety appLications, FAR 25.607 states that each removabLe boLt, screw, nut, pin or other removabLe fastener must incorporate two Locking devices.

ALL removabLe fasteners require Locking mechanisms. Some exampLes are: SeLf-Locking nut CastelLated nut secured with a cotter pin Safety wire. The threads on seLf-Locking nuts are typicaLLy deformed to provide the additionaL friction to hold the fastener. The minimum to maximum Locking torque range is used to find the condition of a used seLf-Locking nut and boLt set. See chapter 20 of the Maintenance ManuaL (Standard Practices) or procurement specification BPS-N-70 for these ranges. CasteLLated nuts fasteners having '" ~ shalL be secured 8, the instaLLation 9 9 5018, MS33540 or '".., ~

are used with externalLy threaded drilled holes in the threaded area and with cotter pins in accordance with requirements specified in BAC 500 9 , chapter 20 (Standard Practices).

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777 TRAINING MANUAL

SHEAR NUT BACN10JC

TENSION NUT BACN10HR

CLIP-ON

DEFORMABLE THREADS

BACN10KB

BACN10KF

BACN10KA

BACN10YD

NUTPLATES

FASTENERS - NUTS / NUTPLATES

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777 TRAINING MANUAL FASTENERS -- SCREWS Screws Screws made of lower strength materials than bolts, are used in non-structural applications such as in passenger and flight deck areas, baggage compartment sidewall liner attachments, fairings, removable panels and other secondary structural installations. Screws which have the same strength as bolts of the same diameter, may be used for structural joints, although it is important to ensure that screw threads are not placed in bearing. Screws are identified by several coding systems, of which the most common are the 'AN' and 'NAS' series. 'AN' identifies the fastener as an Air Force/Navy Standard and 'NAS' signifies that the fasteners are National Aircraft Standards. Boeing numbers are used for special purpose fasteners. An example of these would be the BACS12ER titanium screws used in the flux valve installation where a corrosion resistant, antimagnetic fastener is required. Another example is the BACS12FA screw used to attach the sidewall liners in the lower baggage compartments.

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777 TRAINING MANUAL

BACS12FA

BACS12ER

-6--+-1NAS 623

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777 TRAINING MANUAL FASTENERS -- HOLE FIT CLASSIFICATION AND APPLICATION General The National Aircraft Standard 618 lists the industry standards for bolt diameters and corresponding hole sizes. The fits for the various hole classifications have been shown for several representative bolt sizes. The hole tolerance limits for class II and class III holes are not as critical as those for the other classes. Interference fit holes are always smaller than the fastener shank diameter. Clearance fit holes are always larger than the fastener shank diameter. Fit Classification Transition fit holes can be smaller, same or larger than the fastener shank diameter. Close Ream holes are same or slightly larger than the fastener shank diameter.

.

Class I, II and III holes are larger than the fastener shank diameter.

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TRANSITION SIZE

BOLT DIAM

777 TRAINING MANUAL

II=>

CLOSE REAM

CLASS I

CLASS II

CLASS III

HOLE DIAM

FIT

HOLE DIAM

FIT

HOLE DIAM

FIT

HOLE DIAM

FIT

HOLE DIAM

FIT

3/16

.1885 .1895 !:L:>

.190 .187

+.0015 -.0025

.1905 .1895

+.0020 +.000

.194 .190

+.0055 +.0005

.199 .190

+.0105 +.0005

.229 .218

+.0405 +.0285

114

.2485 .2495

.250 .247

+.0015 -.0025

.2505 .2495

+.0020 .000

.254 .250

+.0055 +.0005

.261 .250

+.0125 +.0005

.291 .279

+.0425 +.0295

II=> IN

ALUMINUM STRUCTURE ONLY

!:L:>SHOWN AS .190 IN SOME HANDBOOKS

HOLE CLASS I FICA TION

.

FASTENER APPLICATION

TRANSITION FIT

LOCKBOLTS AND HILOKS IN ALUMINUM STRUCTURE

CLOSE REAM

LOCKBOLTS AND HILOKS OTHER THAN THE ABOVE. CLOSE TOLERANCE BOLTS WITH

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777 TRAINING MANUAL FASTENER -- SUBSTITUTION Genera l When adapting the typical repairs shown in the SRM to suit actual conditions, it may be necessary to use fasteners of a different type to those originally specified.

An ALERNATIVE fastener is a fastener with equal or greater strength properties than the initial fastener. However, an alternative fastener cannot be used when: They do not give the necessary pressure or fuel sea l Non-magnetic fasteners are necessary and the fastener is magnetic Fastener thread length, grip length or diameter is not available Access does not permit fastener installation Fastener installation tools are not available.

The fastener selection for SRM repairs is based on: Strength Corrosion protection Weight Temperature Fatigue properties Method of installation. It can be necessary to install alternative fasteners because: The specific fastener is not available It is not easy to get access to a necessary location The special repair is different from the general repair.

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An EQUIVALENT fastener is a fastener which is directly interchangeable with the initial fastener. Usually the equivalent fasteners are given under a vender part number and are not always the same as those supplied to the Boeing Company.

NOTE: Do not use the Fastener Substitution Tables to find alternatives for the fastener listed in the ALTERNATIVE column. Use of fasteners from different fastener groups is permitted, but the alternative fasteners must have equal or greater strength. Tension-type fasteners are permitted in tension and shear applications. However, shear-type fasteners are not permitted in tension applications. An example of a fastener substitution table is shown below.

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BACB30FM()A()

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747 SRM

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FASTENER

A2 86 CRES, CAD PLATED, 95 KSI SHEAR, CETYL AL COHOL LUBRICATED, 45 OoF MAXIMUM TE MPERATURE

SPS HI -SHEAR SPS VOl-SHAN DEUTSCH WEST COAST WEST COAST HI-SHEAR HI-SHEAR HI-SHEAR HI-SHEAR HI-SHEAR HI-SHEAR

62550_} HLl8PB HLl8PB HL18PB [!) HLl8PB HLl8PB WC22HLIOVAP HL10VAZ HL440 HSTIOAG HSTIOAP HST10AZ

DEUTSCH SPS HI-SHEAR VOl-SHAN HI-SHEAR HI-SHEAR HI-SHEAR HI-SHEAR HI-SHEAR

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HLl8KD HL18KD HL10V HL 10VAZ HSTIOAG HSTIOAP HSTI OAZ

HI-SHEAR HI-SHEAR HI-SHEAR SPS DEUTSCH

HLIOVAP HL 10VAZ HL440UC HL440UC HL440UC

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ALTERNATIVE

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BACB30FM()-() BACB30FM() A() BACB30FM()AK() !m"I] BACB30MB()-() [!]!] BACB30MB ( l A ( l BACB30GW()-() BACB30GW( lA( l BACB30DX()-() BACB30DX()A() BACB30HC()-() BACB30HC()A() BACB30NX()K()} I"IJTV1 BACB30MY()K() l.!!L!..J BACB30NE()-() BACB30LM() - ()

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BACB30NM()K () } BACB30NR ()K () BACB30LJ()-() BACB30NF()-() BACB30FD()-() BACB30F D() P () BACB30VT ()K 0 BACB30VNOKO

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