THE CONSEQUENCES OF BOLT FAILURES

by

Charles C. Roberts, Jr.

A bolt is a threaded fastener utilized throughout industry to secure two or more mechanical
parts together. There are a wide variety of threaded fasteners available including hex head
bolts, carriage bolts, machine screws, studs, tapping screws, socket head bolts and plow bolts.
A representative hex head bolt, shown in Figure 1, is characterized by a threaded portion, an
unthreaded shank and a hexagonly shaped cap or head. Figure 2 shows the cap stamped with
the name of the manufacturer and a symbol indicating it to be a grade 5 bolt with a minimum
tensile strength of 120000 psi. Bolts may be subjected to thousands of pounds of tensile force
as well as alternating forces at a range of frequencies. When a threaded fastener cannot sustain
the expected loading and becomes detached, a significant loss may occur. Although rare, bolt
failure has caused wheel detachment on vehicles, structural failure in buildings, and crashes of
aircraft. This article presents several examples of bolt failures that have been involved in
serious losses. The claims professional is usually involved early in the analysis of the accident
and is influential in the early decisions as to the failure analysis of the threaded fastener
involved. Through a review of these case studies, the claims professional can gain insight into
how to handle future assignments involving bolt induced losses.

FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4

FAILURE AS A RESULT OF AN OVERLOAD

Many accidents can be characterized as an impact with a non-compliant object such as a truck
impacting a concrete bridge support. In these cases, bolt failure due to overload can occur.
Figure 3 is a view of a bolt that fractured in the threaded area. The 45 degree full-slant fracture
surface indicates high tensile loads. The fine, gray appearance of the fracture surface is
consistent with a sudden overload failure. In this case, other bolts on the mechanical part had
failed, transferring the load to the remaining bolt shown in Figure 3, resulting in an overload.
Figure 4 is a view of the fracture surface of a steering gear output shaft of a large truck. The
truck was involved in an accident and a question arose as to the role of the steering unit as a
possible cause. Microscopic examination of the fracture shows a full-slant fracture surface
(about 45 degrees) and evidence of a shear-face tensile fracture, characteristic of an overload.
It was concluded that the fracture of the output shaft was most likely a result of the accident
and not a cause. Figure 5 is a view of a similar fracture surface at the threaded end of a wheel
spindle with its characteristic 45 degree fracture surface and fine gray appearance. This is a
typical overload during a vehicle rollover accident. Figure 6 shows a typical threaded tie rod end
on a vehicle steering system. The severe distortion of the bolt prior to failure suggests that an
external force from the impact deformed the tie rod end, causing a failure.

FAILURE FROM LACK OF LOCKING MECHANISM

In order to prevent bolts from loosening over time, various locking mechanisms are employed.
They include lock washers, locking nuts, jam nuts, mechanical deformations, wire wrap, cotter
pins, metal locks, expansion anchors, helical coils and polymer locking compounds. Machinery
that is subject to vibratory environments usually is equipped with some sort of locking
mechanism. If the locking mechanism is not applied to the machinery during manufacture, a
catastrophic event may result. Figure 7 is a view of a hoist transmission used in a large crane.
The bolt shown in Figure 8 was found out of position after the crane transmission jumped out
of gear dropping a heavy load. In Figure 7, the arrow points to the location of the bolts.
Specifications called for a polymer locking compound to be applied to the bolt threads to
prevent backing out. No compound was found on the bolt threads or in the threaded hole. Con