Boeing Fasteners

AlTEON A BOEING COMPANY

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Repair ManuaL or manufacturers' documentation, shouLd be consuLted to ensure that this information has not been superseded by design changes or reguLatory authority action
code in the hoLe Location cross in accordance with an NAS 523 PLus SymboL System. The fastener is identified by a two or three-Letter code pLaced in the upper Left corner of the pLus symboL. The code aLso defines the mating component, where appLicabLe. Fastener diameter and manufactured head Location are identified by the numeric-Letter code pLaced in the upper right corner of the pLus symboL. The diameter is given 1/32 NDS of an inch for aLL permanant fasteners. ALL removabLe boLts are given in 1/16 TH of an inch. Countersinking and dimpLing instructions are shown in the Lower Left corner of the pLus symboL. The Lower right corner gives the grip Length in 1/16TH of an inch.

To faciLitate standardization and usage, aLL vendor fasteners and attachment devices are assigned a Boeing part number. CLassifying part number prefixes used at Boeing are: BACB30 BoLts, LockboLts or Hi Loks BACC30 CoLLar BACF FiLLer BACN10 Nuts and NutpLates BACR15 Rivets BACS Shims or Screw BACW Washers Fastener SymboLs Permanent fasteners are identified on an engineering drawing by pLacing the appropriate fastener symboL and

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AlTEDN A BOEING COMPANY

777 TRAINING MANUAL

FASTENER SYMBOL CODE INSTALLATION: STD PER BAC 5004, FLUID TIGHT PER BAC 5047, TAPER SHANK PER BAC 5054 TAPER SHANK BOLT INFO

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BASIC CODE ENCLOSED = FLU~ "XX OPEN = STANDARD ~ XX

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/ X X X W

~DXC

MFDN =HDNEARLOC SIDE F = FAR SIDE

" "~ SPOT WELD OPT

DIMPLE CSK INFO o = DIMPLE X = NUMBER OF SHEETS DIMPLED C = CSK IN STRUCTURE

XZK-6

/

DIA DASH NO.

~ LENGTH

DASH NO.

= BACR15BB-6D

PROTRUDING HEAD TYPICAL DRAWING DETAIL SHOWING FASTENER CALLOUT

= BACB30MY8C

PROTRUDING SHEAR HEAD HILOK (HEAD ON FAR SIDE) 8 UP 100'x.llR GHl IHL

INTRODUCTION TO FASTENERS (SHEET 1)

FASTENERS - INTRODUCTION TO FASTENERS

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ALTEON PROPRIETARY - Copyright
I.s


HEAD TYPE

STEEL

A286

TITANIUM

CAD PLATED (Low Alloy Steel 4340)

CAD PLATED (Stainless Steel)

ALUMINIZED PAINT (6AL- 4V)

STD SHEAR HD

¢ Ltd

TENSION HD I

SHEAR HD

Ltr

TENSION HD

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9o

Ltd

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



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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'.S


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

r

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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specific applications.

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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
RAISED CROSS

1100(A)

82 CSK INDEX 0

120 0 CSKiCB BRILES

SLUG

STANDARD RIVET NO. BACR15BB BACR15FT BACR15BA BACR15CE BACR15DG BACR15FH BACR15FV BACR15BO

8 a'i a'i ~ 8 a'i a'i rY E) Q'i ~ ® ~'i ~ 0 a'i C)V @ ©'i ~ 0 DIMPLED

82 CSK INDEX 0

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* NO HARKING

* NO MARKING

* INDENTED

~ (!j? ~ ~

DOUBLE

D~

~

PLAIN

7050(KE)

RAISED CIRCLE EXCEPT [*]

MONEL
PLAIN

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* INDENTED

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* INDENTED

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FASTENERS - RIVETS - IDENTIFICATION MARKS



777 TRAINING MANUAL FASTENERS -- RIVET ALLOYS Rivet Alloys Rivet alloys in common use with their respective shear strengths and material codes, are shown in the table. Here are the applications for the different rivet alloys: 1100-F Non-structural 5056-H32 For magnesium structure 2117-T3 General structure, nutplate attachment, fuel-tight, and fatigue-critical joints. 2017-T3 General structure, fatigue-critical joints, and not for use in fuel-tight joints. 2024-T31 Ice-Box, must be refrigerated after heattreat until installed. Used on the wings. Do not use for nutplate attachment. 7050-T73 Use only where high strength is required. Monel Use in titanium, CRES, and nickel alloy structure. Requires high squeeze force.


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777 TRAINING MANUAL RATED SHEAR STRENGTH (Fsu)

ALLOY

RIVET MATERIAL CODE

9500 PSI

A

5056-H32 MAG USE ONLY

28,000 PSI

B

2117-T3 PRIMARILY WING

30,000 PSI

AD

2017-T3

38,000 PSI

D

2024-T31 ICE BOX RIVET

41,000 PSI

DD

7050-T73 (BRILES)

41,000 PSI

KE

MONEL

49,000 PSI

M

A286

90,000 PSI

C

1100F - NON-STRUCTURAL

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XZK-6 = BACR15BB6D

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Fast. Shear

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Example of Shear Strength Usage

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P = F\ X 4 = 1050 LBS Fast. 3 * Shear ~ 38,000 psi

* NOTE: USE FRACTIONAL VALUES FOR ALL JOINT CALCULATIONS INVOLVING SHANK DIAMETERS FASTENERS - RIVET ALLOYS

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777 TRAINING MANUAL FASTENERS -- HEX-DRIVE, LOCKBOLTS AND RADIUS LEAD-IN BOLTS Hex-Drive BoLts Hex-drive boLts (Hi-Loks) have externaLly threaded pins with no wrenching feature on the head. There is a hexagon recess in the threaded end to prevent the pin from rotating during instaLLation. The coLLar is internaL threaded and seLf-Locking. The instaLLation force is controlLed by a groove in the collar, which shears off during installation. SpeciaL power tooLs are often used for hex-drive bolt instalLation. A hex key and standard wrench can aLso be used for manuaL instaLLation. Hex-drives are used when: soLid rivets do not have sufficient shear strength, joint cLamp-up is necessary or collar rotation provides manufacturing advantage. Hexagon or twelve point seLf-Locking nuts may be instaLled instead of hex-drive coLLars when: there is not enough cLearance for colLar instaLlation, the use of seal nuts is necessary or re-torque is necessary due to seaLant squeeze out. Lockbolts

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The LockboLt pin has paralleL grooves instead of threads with no wrenching features on the head. The coLlar has a smooth cyLindricaL bore that is swaged into the grooves of the pin.

pneumatic puLLing gun, which puLLs the shank of the bolt through the hole and simultaneously swages a collar into the pin grooves. The pin-tail breaks off at a predetermined Load. The stump type LockboLt is driven with a conventionaL riveting gun, fitted with a lockbolt die set, and a bucking bar. NOTE: When a stump type is required and onLy the corresponding puLL type is avaiLabLe, the pintail may be removed and fastener gun driven. LockboLts are used when: soLid rivets do not have sufficient shear strength, joint cLamp-up is necessary or instalLation speed provides manufacturing advantage. Lockbolt instalLation is fast and easy, but requires open access to the parts. Where access is limited, other fastener types are used. Radius Lead-In BoLts Titanium radius lead-in boLts are used for their good fatigue properties in aluminum alloys. These fasteners have a shank diameter that is 0.006 inches Larger than the diameter of the hoLe in which they are to be instaLLed, to provide a interference fit. There are two oversizes availabLe for each nominaL size, for use in repair work.

There are two types of lockbolts: pull and stump. The pull type lockboLt is instalLed with a special


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777 TRAINING MANUAL COLLAR

STEP 1 HEX-DRIVE PIN IS INSERTED IN THE HOLE AND THE COLLAR IS MANUALLY THREADED ON TO THE PIN. SERRATED STEM TOOL\

1-.-__

9,

1---r=J

BREAK . - NECK

STEP 2 POWER TOOL ENGAGES COLLAR. ALLEN KEY ENGAGES THE END OF THE PIN TO PREVENT ROTATION OF THE PIN.

STEP 1

STEP 2

STEP 3

STEP 4

CHUCK JAW PULLER

-~-~

STEP 3 THE FRANGIBLE NUT OF THE COLLAR IS TWISTED OFF AND DISCARDED. INSTALLATION IS COMPLETE.

\FRANGIBLE NUT NOTES: SELECT CORRECT GRIP LENGTH FASTENERS FOR COMPOSITES HAVE LOW TORQUE GROOVE, LARGE FOOTPRINT PROTRUDING HEADS, AND LARGER FLANGED COLLARS. REMOVAL REQUIRES SPLITTING COLLAR, OR UNTHREADING COLLAR WITH SPECIAL TOOL

I

_ _ FRANGIBLE NUT

FINAL INSTALLATION SEQUENCE OF A PULL TYPE LOCKBOLT

FASTENERS - HEX-DRIVE, LOCKBOLTS AND RADIUS LEAD-IN BOLTS

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AITEDN A BOEING COMPANY

777 TRAINING MANUAL FASTENERS -- TENSION AND SHEAR General The 'Shear' head fasteners are used in applications where shear and not axial tension is the primary mode of load transfer. The 'tension' head systems are for shear applications where higher tensile pre-load and axial tensile capability are required. Tension protruding head fasteners have a larger diameter heads and more threads of engagement into their collars than shear fasteners. Tension flush head fasteners have larger diameter heads and deeper countersinks than shear flush fasteners. See the SRM chapter 51 in the fastener section for head dimensions. Do not substitute shear nuts or collars for tension nuts and collars. The shear nuts or collars do not have the same diameter or number of threads of engagement.

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SHEAR JOINT

TENSION - PROTRUDING HEAD

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TENSION - PROTRUDING HEAD

SHEAR - PROTRUDING HEAD TENSION - FLUSH HEAD

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II SHEAR - FLUSH HEAD

SHEAR - PROTRUDING HEAD LOCKBOLTS

HI-LOKS

FASTENERS - TENSION AND SHEAR



777 TRAINING MANUAL FASTENERS -- BLIND GeneraL BLind boLts and rivets are permanent fastener that are avaiLabLe in aLuminum, MoneL, aLLoy steeL and A286 CRES. The fasteners are muLtipLe piece and have the advantage of being instaLLed from one side.

SpeciaL bLind boLts are used for composite assembLies. AppLications of bLind boLts are for assembLy of eLevators and rudders, and for some of the boLted repairs of 777 empennage structuraL boxes.

BLind BoLts

Removing bLind boLts can be difficuLt. The drive screw must be driLLed out. TooLs are avaiLabLe from the fastener manufacturer to assist in bLind boLt removaL.

There are two types of bLind boLts:

BLind Rivets

Threaded Pu LL. The tooL that instaLLs the threaded type rivet TURNS the core stem, whiLe reacting against the fastener head. The bLind head then forms and the joint components are drawn together. FinaLLy, the core stem breaks away compLeting the instaLLation. The tooL that instaLLs the puLL type PULLS the core stem instead of turning the stem. Since blind bolts are used for Limited far-side access, the formed head is difficuLt or impossibLe to inspect. Therefore, it is important to exactLy foLLow the BAC 5004-3 instaLLation procedures. These incLude:

BLind rivets are not the same as bLind boLts. BLind rivets are Lower in strength and cannot be substituted for bLind boLts. They shouLd never be used in areas of tension Loading, vibration or where the head is subjected to prying. BLind rivets are poor in fatigue because they do not fiLL the hoLe Like soLid rivets. If bLind rivets are used in a repair, the repair is considered time Limited or interim and shouLd be inspected at frequent intervaLs for Looseness. The repairs showing blind rivets in structuraL repair manuaL have FAA approvaL provided the inspections are accompLished at the intervaLs stated.

Correct hoLe size Correct grip length and diameter bolt Using correct tooLs and technique

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AlTEDN 777 TRAINING MANUAL

A BOEING COMPANY

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BLIND BOLT INSTALLATION

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NOTES: SELECT CORRECT GRIP LENGTH INSPECTION OF FORMED HEAD REQUIRED

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REMOVAL REQUIRES DRILLING OUT CENTER STEM (DRILL GUIDES AVAILABLE)

BLIND RIVETS FASTENERS - BLIND



777 TRAINING MANUAL FASTENERS -- OVERSIZE FASTENERS Genera l Oversize fasteners are generally used in repair applications to clean up damage to a hole and to provide the same fastener fit as was provided in the original design. Occasionally, oversize fasteners are used to provide an alternate load path. As a general rule, if original rivets are replaced by hex-drives or lockbolts, a 1/32 oversize fastener is used in the repair. If original hex-drives or lockbolts are replaced with hex-drives or lockbolts, a minimum of 1/64 oversize fastener is used. If rivets are replaced with rivets then the same diameter can generally be used. Briles Rivets When Briles Rivets are replaced, the next larger diameter should always be used. Briles rivets are available in 1/32 diameter increments up to 5/16" (Ref BAC R15FV Series). Oversizing of holes and counterbore is required to fit the appropriate size rivet. In the event that use of an oversize Briles Rivet would result in a knife-edge condition on thin skin, the countersink depth of the original rivet may be maintained and the rivet shaved flush after installation. In many cases it would probably be preferable to replace the Briles rivet with an OVERSIZE protruding head rivet.


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777 TRAINING MANUAL

I A

-H

PART NUMBER

DESCRIPTION

A

0

H

TO

BACB30MY6K()

3/16 HEX DRIVE

.295-.315

.1885-.1895

.045-.055

.181-.184

BACB30MY6K()X

1/64 OVERSIZE

.295-.315

.2016-.2026

.045-.055

.181-.184

BACB30MY6K()Y

1/32 OVERSIZE

.295-.315

.2168-.2182

.045-.055

.181-.184

FACTORY FASTENER

REPAIR FASTENER TYPE

TYPICAL REPAIR FASTENER SIZE

RIVET

RIVET

SAME DIAMETER

RIVET

HEX-DRIVE OR LOCKBOLT

1/32 OVERSIZE



1/64 OVERSIZE

FASTENERS - OVERSIZE FASTENERS



777 TRAINING MANUAL FASTENERS -- REMOVABLE FASTENERS Bolts

Tension and Shear Bolts

A bolt, generally, has a smooth cylindrical shank and is intended to be installed by turning the mating nut.

Tension and shear-rated bolts may have hexagonal, 12 point, or countersunk heads with long threads for tension joint installations, or short threads for shear applications. Material options are the same as for fatigue-rated bolts. Wherever possible, bolts should be installed with the head uppermost or forward as applicable, except as noted in relevant maintenance documents or engineering drawings.

Removable bolts are used for the following conditions: Permanent fasteners that require sufficient shear, axial tension or fatigue performance Joint clamp-up is necessary Occasional disassembly is required

Bolt Threads Removable bolts can be categorized as fatigue, tension, or shear rated. Fatigue-rated Bolts Fatigue-rated bolts are used for high strength applications in critical joints and have 12 point protruding heads with long threads. They are available in a tension strength range of 160 to 220 KSI, and are typically made from Alloy Steel, A 286 (CRES), Inconel 718 and 6AL-4V Titanium. (Note: Because of stress corrosion cracking problems, H-11 steel bolts (BACB20MT) are no longer used for design or recommended as replacement fasteners).

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All Boeing standard bolts have rolled threads after heat treatment, not machined threads. Rolled threads have a smooth uniform root radius which blends with the thread flanks to provide improved fatigue life through lower stress concentrations.

Countersunk washers should always be used under the head of fatigue-rated bolts. Otherwise, the washer will ride in the radius under the bolt head.

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777 TRAINING MANUAL

SHORT THREADS\

SHORT THREADS \

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-E+-+ -

..

1~1t-

v COUNTERSUNK HEAD BOLT

r-

--+-+-

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LONG THREAD (TENSION) BACB30LH SHORT THREAD (SHEAR) BACB30LU

12 POINT HEAD BOLT LONG THREAD TENSION BACB30NJ SHORT THREAD BACB30LT

LONG THREADS\

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HEX HEAD BOLTS LONG THREAD (TENSION) BACB30NE SHORT THREAD (SHEAR) BACB30NF

12 POINT HEAD FATIGUE TENSION BOLT BACB30US

ALL "BAC" BOLTS ARE PURCHASED WITH ROLLED THREADS

FASTENERS - REMOVABLE FASTENERS



777 TRAINING MANUAL FASTENERS -- BOLT STRENGTHS Fastener Alloys Mechanical fastener strength properties for the fastener alloys summarized in the table are independent of the materials in which they are installed, and apply only when the fastened materials are sufficient in strength and thickness to develop the full strength of the fastener. Boeing part standards should be referred to for fastener dimensions, materials, finishes and qualification requirements. For fastener installation requirements, see the applicable Boeing process specification.

63-05-00 - 154 ALTEON PROPRIETARY - Copyright

(c) -

See title page for

'.5


777 TRAINING MANUAL

MINIMUM RATED STRENGTH - ksi

ALLOYS

SHEAR (Fsu)

TENSION

(F tu)

STEEL 8740/4340

95

160

CL>

125

220

95/110

160/200

PH 13-8 MO

125

220

INCONEL 718

125

220

95

160

H-11 CRES A286

TITANIUM 6AL-4V

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H-11 IS NOT RECOMMENDED DUE TO STRESS CORROSION SUSCEPTIBILITY

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FASTENERS - BOLT STRENGTHS



777 TRAINING MANUAL FASTENERS -- BOLT TORQUE REQUIREMENTS Bolt Torque Requirements Pre loaded bolts improve both the fatigue resistance and the locking characteristics of the nut and bolt installation. They also introduce a beneficial compressive stress around the rim of the hole which counteracts the tendency for stress concentration cracks to occur at the edge of the hole caused by applying a shear load to an unpreloaded bolt.

Re-application of torque to removable bolts is recommended if the joint uses faying surface sealant in any interface. Fay surface sealant may squeeze out of the joint when bolts are tightened, resulting in partial loss of bolt preload, unless torque is then reapplied to the fastener. It is important that torque application be completed within 60 minutes of the squeeze-out life remaining in the fay surface and fastener sealant.

It is important that the maximum allowable torque value is not exceeded as torque values are based on the proof load for the fastener material which is approximately equivalent to the yield strength. For CRES steel nuts, use torque values given for shear type nuts. Use BAC (Boeing Airplane Company) standard torque tables as a guide whenever specific torque values are not called out on the engineering drawing or in approved maintenance documents such as the structural repair or maintenance manuals. Torque wrenches should be used when engineering drawings or maintenance documents indicate that specific torque values are to g be applied. ~

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In cases where space ;s limited, the head end of the ~ bolt instead of the nut, may need to be rotated to ~

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obtain the necessary torque. When the fastener head is used for this purpose, the high side of the torque range should b e use d .

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777 TRAINING MANUAL 1I1111NII 7 . 7 757-200 STRUCTURAL REPAIR MANUAL NUT PART NO. BOLT PART NO.

I B/ ./

,

FASTENER DIAMETER AND THREAD SIZE

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A/'

:~SING

ADAPTER IN LINE WITH WRENCH. CORRECTION REQUIRED T1 - T x A

- A+ B

T T1

= ACTUAL = TORQUE

TORQUE ON NUT WRENCH READING

BACN10GW, BACN10JA, BACN10B, BACN10JB, BACN10RM,NAS577, BACN10JD,(7/16 THRU 1-1/4 ONLY), NAS1805 BACB30NG, BACB30NH, BACB30MT, BACB30FD, BACB30MR, BACB30L~~. BACB30PN, BACB30NE, BACB30LM, BACB30US BACB30NM, BACB30LN, BACB30NS, BACB30EM, BACB30LP, BACB30LU, BACB30LR, BACB30MS, BACB30NN, NAS6603 THRU NAS6620, NAS6703 THRU NAS6720 NUT TIGHTENING TORQUE RANGE (POUND-INCH)~

BACN10HR, BACN10JG, BACN10HC

DRY BOLT

0>

--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

0>

--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

-----

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



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.

Q

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.

Q

~

N

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. '"

r=;

* ~


ts


777 TRAINING MANUAL

~A

-t- -{}A-A

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

-

~iiiiiijj

TOOL HOLES (3) 120· APART (APPROXIMATE)

()

v

(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



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).


's

AITEON A BOEING COMPANY

777 TRAINING MANUAL

SHEAR NUT BACN10JC

TENSION NUT BACN10HR

CLIP-ON

DEFORMABLE THREADS

BACN10KB

BACN10KF

BACN10KA

BACN10YD

NUTPLATES

FASTENERS - NUTS / NUTPLATES



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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63-05-00 - 162 AlTEON PROPRIETARY - Copyright (c) - See title page for

s


777 TRAINING MANUAL

BACS12FA

BACS12ER

-6--+-1NAS 623

15 o ~

, .... o

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J:

$",

--1--

N

-

$

'"

I

NAS 517

-It /"=-------t.

-

--

-.

--

.or: ------0

NAS 1801

9 '"

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FASTENERS - SCREWS



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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63-05-00 - 164 ALTEON PROPRIETARY - Copyright (c) - See title page f o r ' s


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 <4 FASTENERS IN THE JOINT

CLASS I

STANDARD BOLTS AND CLOSE TOLERANCE BOLTS WITH 4 OR MORE FASTENERS IN THE JOINT

CLASS II

BOLTS ATTACHING REMOVABLE PANELS

CLASS III

BOLTS ATTACHING REMOVABLE PANELS WHICH ARE NOT INTENDED TO PICK UP ANY STRUCTURAL LOADS

>

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FASTENERS - HOLE FIT CLASSIFICATION AND APPLICATION



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.

~

'"

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.

o N

9o ~ 9

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ls


777 TRAINING MANUAL

~

III' fj7Qfj7

STRUCTURAL REPAIR

o not substitute cadmium plated fasteners ~ 0f or bare or BMS 10-85 coated fasteners when

REPAIR FASTENER

OItJ6INAL OR SPECIFIED CODE

PART NUI18ER

XCI

BACB30FMO-()

m

DESCRIPTIONI!I

[!]

AllO)' STEEL, CAD

PLATED, 95 I
EQUIVALENT

'" "'*r

HI-SMEAR

HUBPS

::~:~~:=i ~;~:

SPS VOl-SHAN

MUBPS Nl18PS

BACB10fM()AK() BACB1OMB()-()

OEUTSCH

HL18PS

BAtB1OM8( )A()

IIEST COAST Nl18PS VEST COAST 11(22-

8,1.(830611( I-() IIACB3061HlAO

HI-SHEAR

NUOVAP

HI-SHEAR HI-SMEAR

H110VAZ

HI-SHEAR

HSTlOA6 HST10AP HST10AZ

HI-SHEAR HI-SHEAR YHU

BACB10FHOk()

[!]

VHY

AllOY STEEL, BMS 10-85 COATED, 95 KSI SHEAR, CETYL ALCOHOL LUSRICATED, 150°F MAXIMUM TEMPERATURE

DEUTSCH

SPS HI-SHEAR VOl-SHAN HI-SHEAR

BACBJOFMOA()

XNJ Y6E

A286 CRES, CAl) PLATEI), 95 I(SI SHEAR, CETYL ALCOHOL LUBRICATED, 450°F MAXIMUM TEMPERATURE

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

HL10VAP HL10VAZ HL440UC HL440UC HL440UC HL440UC Hl440UC HSnOA6 HST10AP HSnOAZ wcno-

A286 CRES, BMS 10-85 COATED, 95KSI SHEAR, CETYl ALCOHOL LUBUCATED, HooF MAXIMUM TEMPERATURE

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

HL10VAP H110VAZ Hl440AP Hl440AZ HL440AZ HL440AZ HL440AZ HST10A6 HST10AP HsnOAZ

BACBJOFM()AK()

XTC

BACBJOMY()C{)[!J 6AL-4V TITANIUM, CAl) PLATEO,95I(SI SHEAR, CETYL ALCOHOL LUBRICATED, 450°F MAXIMUM TEMPERATURE

BACBlODX()-() BACB1ODX()A() BACB1OHC()-()

Il!II!lI!l

...

[8J

[!J!) ImJ

i nstalled through titanium structure. 0 o not substitute lockbolts for hex drive b olts when installed through composite S

tructure.

I!I!I I!I!I [!(!J

BA(830"(( IA()

::~:~~~~~:~~: }rnm BACB10NE()-O BACB30lH()-( )

I!I!l

'UO"} I!l :~~:~~:::!~:: }[!!I!J

MUIIKD

HI-SHEAR HI-SHEAR HI-SHEAR

YMY YMS

XTJ VAX

Hl44D

HL181(D HL181(D H110VA H110VAZ H5nOA6 HSnOAP HST10AZ

HI-SHEAI!

'"

ALTERNATIVE

BACB1OLJ()-()

,,,",.NF()-()

BACB10FI)O-() BACBJOFI)OPO BACBJOVT()I«) BACBJOVN()I«)

BOLT - HEX DR IVE - PROTRUD ING HEAD -

I

REPAIR FASTENER ORIGINAL OR SPECIFIED CODE XCZ YEF

YHU YHY

PART NUMBER BACB30FM()-()

BACB30FM( lK( l

DESCR IPTION

[!)

[!)

[!!]

EQUIVALENT

AL LOY STEEL, CAD PL ATED, 95 KSI SHEAR, CE TYL ALCOHOL LUBRICA TED, 4500F MAXIMUM TE MPERATURE

AL LOY STEEL, BMS 10-85 CO ATED, 95 KSI SHEAR, CE TYL ALCOHOL LUBRICATED, 3500F MAXIMUM TE "PERATURE

SHEAR

TABLE V XEK XNJ YGE

Fastener Substitution F; gure 1 ( Sheet 11>

BACB30FM()A()

>

:.

51-30-03

Page 14 Mar 15/94

747 SRM

L----

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

~t~:~u I!J

HLl8KD HL18KD HL10V HL 10VAZ HSTIOAG HSTIOAP HSTI OAZ

HI-SHEAR HI-SHEAR HI-SHEAR SPS DEUTSCH

HLIOVAP HL 10VAZ HL440UC HL440UC HL440UC

[!!] [!9 ~

ALTERNATIVE

I!m

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() - ()

I::!rn I::!rn I::!rn I::!rn

I

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

I"!I'1'Y1

l.!!L!..J

T W T Y

-<--

SUBSTITUTION



777 TRAINING MANUAL FASTENERS -- FASTENER FINISH REQUIREMENTS THIS PAGE INTENTIONALLY LEFT BLANK



777 TRAINING MANUAL FASTENERS -- FASTENER FINISH REQUIREMENTS Fastener Finish Requirements The fastener finish requirements for use with various aircraft materials are shown. These recommendations should be followed so as to minimize the potential for corrosion resulting from rework operations. The recommended fasteners in aluminum structure are BMS 10-85 (aluminum-pigmented coating) coated titanium, BMS 10-85 coated A-286, or cadmium-plated A-286. Cadmiumplated alloy-steel fasteners are a structurally satisfactory alternative. However, in a corrosive environment the cadmium plating, which is a sacrificial coating, may disappear allowing the alloy-steel fastener to corrode. This may result in the ruststreaking of the surrounding structure and/or the start of corrosion of any adjacent aluminum structure. All steel and titanium fasteners must be installed wet with BMS 5-95 or equivalent sealant. With the exception of 5056 rivets installed in aluminum structure, it is recommended that all rivets are installed dry. Fay surface sealant does not need to be removed from the fastener holes before rivet installation. However, because of their head geometry. Briles rivets (BACR15FV) should never be installed wet with sealant, since the reduction in hole filling ability wiLL degrade the fatigue quality of the joint. See the StructuraL Repair Manual for the latest information.



777 TRAINING MANUAL

FASTENER AND FASTENER HARDWARE INSTALLATION DETERMINE THE METAL GROUP OF EACH ALLOY USED IN THE ASSEMBLY, THE LOCATION OF EACH ALLOY AND THE LOCATION WITHIN THE AIRPLANE, THEN SELECT THE LOCATION WITHIN THE AIRPLANE, THEN SELECT THE INSTALLATION PROTECTION FINISH CODE FROM TABLE. METAL GROUP

. 0

LOCATION IN THE AIRPLANE INT FASTENER OR HARDWARE t ALUMINUM 1 ALLOY STEEL, CAD PLATED 1a X CRES, PASSIVATED OR DRY FILM LUBED CRES, CAD PLATED or BMS10-85 COATED 1a X TITANIUM TITANIUM, BMS 10-85 COATED 1 X: 1: 2:

a: b: INT: EXT:

IT]

IV III III IV y,: IV /< Xv ~ ~ EXT INT EXT INT EXT INT EXT INT EXT INT EXT II

1 X X 2 X 2

2 1a X 2 X 2

2 X X 2 X 2

X X X 2b X 2

X X X 2b X 2

X 2 X 2 X 2

X X X 2 X 2

X X X 2b X 2

X X X 2b X 2

X X 1 1b 1 1

X X 1 1b 1 1

DO NOT USE NO FINISH (DRY INSTALLATION) FOR PERMANENTLY INSTALLED FASTENERS, WET INSTALL WITH BMS5-95 SEALANT. FOR REMOVABLE BOLTS/NUT COMBINATIONS, INSTALL WITH BMS3-27. FOR FASTENERS, INSTALLED INTO NUT PLATES, PRIME HOLE WITH BMS10-11 TYPE I PRIMER AND INSTALL WIH MIL-C-11796, CLASS3. FOR BLIND FASTENERS, WET INSTALL WITH BMS5-95 CADMIUM-PLATED FASTENERS AND FASTENER HARDWARE SHALL NOT BE USED IN CONTACT WITH TITANIUM OR CFRP INTERIOR (NOT EXPOSED TO OUTSIDE ENVIRONMENT) EXTERIOR (EXPOSED TO OUTSIDE ENVIRONMENT)

[] METAL GROUP: I MAGNESIUM AND ITS ALLOYS II CADMIUM-TITANIUM PLATE AND CADMIUM ZINC,ALUMINUM AND THEIR ALLOYS III IRON, STEELS (EXCEPT CORROSION-RESISTANT STEELS), LEAD, TIN AND THEIR ALLOYS IV COPPER, BRASS, BRONZE, (ALUMINUM BRONZE OR ALUMINUM NICKEL BRONZE), COPPER-NICKEL, COPPER BERYLLIUM, CHROMIUM, MOLYBDENUM. NICKEL AND NICKEL BASE ALLOYS, COBALT ALLOYS, TITANIUM AND TITANIUM ALLOYS, TUNGSTEN, CRES, CARBON, CFRP, SILVER AND GOLD

FASTENERS - FASTENER FINISH REQUIREMENTS

'.s


777 TRAINING MANUAL

FASTENER SELECTION (CONTINUED) COMPATIBLE MATERIAL--FASTENERS FASTENER MATERIAL

STRUCTURE MATERIAL ALLOY STEEL, OR ALUMINUM + STEEL

ALUMINUM + TITANIUM

ALUMINUM

FASTENER FINISH

ALLOY STEEL

CADMIUM OR ALUMINUM

CRES

CADMIUM

TITANIUM

ALUMINUM

OJ

ALLOY STEEL

ALUMINUM

IT]

CRES

ALUMINUM

TITANIUM

ALUMINUM

OJ OJ

ALUMINUM

ANODIZE

ALLOY STEEL CRES TITANIUM

CADMIUM OR ALUMINUM CADMIUM OR ALUMINUM ALUMINUM ANODIZE

OJ

MAGNESIUM

5052 ALUMINUM

ANY EXCEPT TITANIUM

H-11 ALLOY STEEL

NICKEL-CADMIUM (INSTALL WITH WET PRIMER OR SEALANT) OR ALUMINUM

TITANIUM OR CRES

CRES TITANIUM

COMPOS ITEI AL

TITANIUM CRES

PASSIVATE IT] PHOSPHATE FLUORIDE OR ALUMINUM ALUMINUM

OJ

OJ

DO NOT USE CADMIUM PLATED FASTENERS

FASTENERS - FASTENER FINISH REQUIREMENTS



777 TRAINING MANUAL FASTENERS -- FASTENERS SECTION QUIZ THIS PAGE INTENTIONALLY LEFT BLANK

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Is

Boeing Fasteners

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