AFML-TR-76-161

00 CID
1< RIVET QUALIFICATION OF ALUMINUM ALLOY 7050

ALUMINUM COMPANY OF AMERICA ALCOA TECHNICAL CENTER ALCOA CENTER, PA 15069

OCTOBER 1976

TECHNICAL REPORT AFML-TR-76-181 FINAL REPORT FOR PERIOD FEBRUARY 1975-JULY 1976

Approved for public release; distribution unlimited

[t

..

....

ri ..

AIR FORCE MATERIALS LABORATORY AIR FORCE WRIGHT AERONAUTICAL LABORATORIES AIR FORCE SYSTEMS COMMAND WRIGHT-PATTERSON AIR FORCE, OHIO 45433

NOTICES

When Government drawings, specifications, or other data are used for any purpose other than in connection with a definitely related Govet-ament procurement operation, the United States Government thereby incurs no responsibility nor any obligation whatsoever; and the fact that the Government may have formulated, fuinished, or in any way supplied the said drawings, specifications, or other data, is not to be regarded by implication or otherwise as in any manner licensing the holder or any other person or corporation, or conveying any rights or permission to manufacture, use, or sell any patented invention that may it any way be related thereto. Copies of this report should not be returned unless return is required by security considerations, contractual obligations, or notice on a specific document. This final report was submitted by the Aluminum Company of America, Alcoa Center, Pennsylvania, under Contract F33615-75-C-5117, Manufacturing Methods Project 808-5, "Rivet Qualification for Aluminum Alloy 7050." Mr. Kenneth L. Kojola, AFML/LTM, was the Program Mana-er. This echnical report has been reviewed and is approved for publication.

//

Kenneth L. Kojola Progr&m Manager FOR THE DIRECTOR

H. A., JOHNSON

Chief,' Metals Branch Manufacturing Technology Division

AIR FRGE I -MAKIf;77

I,!

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p

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SECURITY

UNCLASSIFIEDOF Sj 'kFICATION

THIS

-AiG F. Whonl Do)to !nt~red) (

()..,)REPORT DOCUMENTATION PAGE

TBEFOR,-

READ INSTRUCTIONS COMPLETING FORM

7AFIL

R-76"-1811 .............
-.............. . -

2-. GOVT ACCSIO" NO. N

'FNT'S CATALOG NUMBER

-. .

'FIna'

'chnical .e'65'
T.NUM
-

RIVET QUALIFICATION OF ALUMINUM ALLOY 7

ebvebwy W75-tun-AD76 ,
MING ORG. R

_W. J/Dewalt,.B" W./ifka.G. 'C

9.

"-

E./bNordmar /a 10.

F 3;=615- 7

117

PERFORMING ORGANIZATION NAME AND ADDRESS

PPOGPAM FLEMENT, PROJEC r, TASK

AREA A WORK UNIT NUMBERS

Aluminum Company of America Alcoa Laboratories Alcoa Center, Pa. 1506q

11. CONTROLLING OFFICE NAME AND ADDRESS

7RO11F, 808-5 MTP 10257

OZUW-AT E

Air Force Materials Laboratory (AFML/LT14)6/ Oct Air Force Systems Command Wright-Patterson Air Force Base, OH 4543 136
14. MONITORNG AGENCY NAME & ADDRESS(If different from Controlling Office) 15.

SECURITY CLASS

(of (hie report)

Unclassified
.15. DECLASSI FICATION/ DOWNGRADING SCHEDULE

RIBUION SAI'

4T (of this Report)

Approved for public release;

distribution unlimited

17.

DISTRIBUTION STATEMENT (of the obetrect entered In Block 20, It different from Reportl

18.

SUPPLEMENTARY NOTES

19.

KEY WORDS (Continue on reverse side if necessary and identify by block number)

:-2.

Aluminum Alloy 7050 Ingots

2 . 0. ABS-rrA

Casting Wire Rivets Tensile

Shear Fatigue Tests Joints

Ultimate Yield Load Analysis

Intergranular Stress-Corrosion Driving Formability

Heat Treatm nt Aging Pract cet Static Hole-Fill

(Continue on reverse side If neceeeev

and identify by block number)

anufacturing methods were established for the production of aluminum alloy 7050 aircraft-size rivets. ,_lloy 70 0 ingots were

cast to two purity lev~ls (iron and silicon con.yfeM2 both within
the chemical composition limits for alloy 7050.,> The ingots were converted into wire and the wire into rivets. 6Strength, formability and corrosion tests were conducted on wire to establish the aging practices to be applied to the rivets. The purity level had no noticeable 5ISOSLT effect on rivet fabrication, strength IO FORM

DD

1473

EDITION oF I NOV65,S OBSOLETE

Unclassified
SECURITY CLASSIr:CATION OF THIS PAGE ("one Deto Entered)

ILURITY

CLASSIFICATION

Entered) OF THIS PAGF(Whon Data

to stress-corrosion properties, foi'mability or resistance The rivets, in 3/32, 3/16 and cracking (SCC) of the wires. step agings of 8 hours 3/8-in. diameter sizes, were given second evaluations, Driving and hole-fill at 345V, 350w and 3551FF fatigue tests of high loadstatic tests of lap-shear joints, 7050 transfer joints and SCC tests were conducted using the quality, and hole-fill driving SCC for 7050 alloy rivets was found thate rivets.,_It the static strengEn ahna resistance to Driven rivets. equals or exceeds that of 2024-T31 ("ice-box") greater than shear strength values were at least 15 per cent The fatigue strength for 2024-T31 rivets. that typically found joints containof joints ,ith 7050 rivets was less than similar is recommended aging practice A production ing 2024-q3l rivets. T3tmp__ A small program he to place tu,:' 7050 jyta affect the that.iresidual stress around the rivet hole can showed cracking of the material being resistance t(-stress-corrosion joined.

UNCLASSIFIED
SECUPITY CLASSIFICATION Or THIr PAGr(When Dote Entered)

PREFACE

This final technical report submitted in

September 1976

covers the work performed under Cont10 February 1975 through 10 June 1976.

ct F33615-75-C-5117

from

This contract with the

Aluminum Company of America was performed under Rivet Qualification of Aluminum Alloy initiated 7050, Project

808-5.

The program was

with Lieutenanc

Joseph Hager,

and was completed under Kojola (AFML/LTM)

the technical direction of Mr. Manufacturing Technology

Kenneth L.

Division,

Air Force Materials Laboratory,

Wright-Patterson Air Force Base,

Ohio. Center.,

The program was accomplished at Alcoa Technical Aluminum Company manager was Mr. W. J. Dewalt, B. of America, W. J. Alcoa Center, PA.

The program

Dewalt and project

supervisors were Messrs. Mr. S. C. Ford

W. Lifka and R.

H. Stevens.

was project leader for tests Institute. Mr. J. V. J. E.

performed at Battelle Memorial

Jacoby supervised the casting of the ingots. for converting the ingots in(o

Mr. ]

Muncie was responsible and Mr. R. L.

rivet wires, Mr. J. T.

Dodson supervised the rivet production. the aging practices for the rivet wire program.

3taley developed Mr. G.

and riveus. Mr. F

E. Nordmark conducted the fatigue test analyses Sharp,

C. Ford corntributed to ,e and, along with Mr. Mr. D. M. L.

of the fatigue test to iThe analyses of the to the analysis Mr. R. H.

results, satic

tes'

results.

0. Sprowls contributed test results.

of the corrosion and stress-corrosion Stevens supervised the metallographic

examinations.

ii
i i i i b .

TABLE OF CONTENTS PAGE NO. ............... and Wire Screening ..................... ...... .i1

SECTION I. II. Introduction ........... Phase I - Rivet Production Tests .................... A.

3 3 3
4

Production of Wire and Rivets ...... 1. 2. 3. Ingots ............... Rivet Wires ............ Rivets ............... ................. .............. ................. ................

6 7 7
. . . . . .. .. Tests. ..

B.

Wire Screening Tests .... 1. 2. 3. 4.

Aging Practices .......... ............ Mechanical Property and Conductivity

Tests ....................
Accelerated Stress-Corrosion Tests. Drizing and Hole-Fill Tests ...... Briefing and Recommendations. ............. ............

9
11

C. III.

Phase I -

14
16 16 1 17 22 2o 32

Phase II A. B. C. D. E. F.

Rivet Tests ....

Aging and Anodizing .... Mechanical

Property and Conductivity

Joint Shear Strength Tests ........... Driving and Hole-Fill Evaluations Shear Joint Fatigue Tests ............... Accelerated Stress-Corrosion Tests ........ ................. ......

IV. V. VI. VII.

Conclusions ............ Recommendations ... Addendum .1.. . . . ........... . . .

37 ..
. . ... . . .

41
42 45

. .

References .......

.....................

Siv

LIST OF ILLUSTRATIONS Figure 1 Alcoa 181 Process ....... Alcoa Level Pour Mold. ...... 3 4I ................ ........... . .. . Page 85 86 87 88 89

Sketch Showing Principal Dimensions of the SCC Round Tension Specimen and the Stressing Frame

Intergranular Corrosion in Tension Specimen From .. 7050 Wire Aged 2 Hours at 35nF ........... Drivinv and Hole-Fill Test Specimen ....... Examples (Bottom) of "Good" (Top) and "Poor" Holes Drilled for Slug Driving Specimens. ...

5 6

90 91

7 8

Photograph of Subpress Setup in Testing Machine .. ................ for Driving Slugs ....... Typical Driving Test Specimen After All Slugs Upset to Form Flat Heads- 0.184-in. Diameter 7050 Slugs Driven in 0.190-in. 7075-T6 Sheet

92

Photograph of Some of the Completed Driving Specimens Containing 7050 Alloy 0.092, 0.184 and .. ............ 0.372-in. Diameter Slugs .... Driving Pressure versus Average Driven Flat Head 0.184 and 0.372-in. Diameter Curves for 0.092, Six Aging Practices. . Diameter 7050 Slugs Given Shear Crack in Driven Head of 7050 Alloy Slug.
.

93

10

94
95

11 12

Photomacrographs of Sectioned 0.092-in. Diameter (D) 7050 Slugs Driven With 1.5D Flat Head in Sheet ... ........... ... 0.090-in. 2024-T3 Photomacrographs of Sectioned 0.184-in. Diametev (D) 7050 Slugs Driven With 1.5D and 1.7D Diameter Flat Heads in 0.190-in. 7075-T6 Sheet . Photomacrographs of Sectioned 0.184-in. Diameter (D) 2024-T31 Slugs Driven (in the "Freshly" Quenched Condition) With 1.5D Diameter Flat .. Heads in 0.190-in. 2024-T3 Sheet .......... Photomacrographs of Sectioned 0.1 8 4-in. Diameter (D) 7050 Slugs Driven With 1.5D Diameter Flat Heads in Good-Poor Holes in 0.2 8 1-1n. 7075-T651 Plate Second Siep Aging: 12 Hrs. at 350 0 F ....

96

13

97

14

98

15

99

A
-

~...
V

.~

LIST OF ILLUSTRATIONS Figure

(CONTINUED) Page

16

Photomacrographs of Sectioned 0.184-in. Diameter (D) 2024-T31 Slugs Driven (in the "Freshly" Quenched Condition) With 1.5D Diameter Flat Heads in 0.2 8 1-in. 7075-r651 Plate ..... ........ Photomacrographs of Sectioned 0.372-in. Diameter (D) 7050 Slugs Driven With 1.5D Diameter Flat Heads Jn 0.375--in. 7075-T6 Plate - 2nd Step of A g ig was 8 Hrs at 350.F .......... ............ Preferred Test Lap Joint Specimen Configuration Photograph of Setup for Static Tests of Riveted
Lap-Joints ........... .................... Data for 7050-T7X Rivets ..

100

17

101
102

18 19

103

20

Average

(2nd Step of Aging = 8 Hrs at 3115'F) .........

21 Average Ultimate-Load Data (2nd Step of Aging = 8 Hrs for at

Ultimate-Load

..
..

10):

7050-T7X Rivets 3501F) ......... 7050-T7X Rivets 3551F) .........

105

22

Average Ultimate-Load Data for (2nd Scep of Aging = 8 Hrs at

..

106

23

Average Yie'ld-Load Data for 7050-TTX Rivets (2nd Step cf Aging = 8 Hrs at 3451F) ........ Average field-Load Data for 7050-T7X Rivets (2nd Step of Aging = 8 Hrs at 3501F) ......... Average Yield-Load Data ,or 7050-T7X Rivets (2nd Step of Aging = 8 Hrs at 3551F) .... ....... Driving Pressure Versus Average Driven Flat Diameter Curves for 3/32, 3/16 and 3/8-in. Diameter 7050-T7X Rivets Given Three Aging Practice,, ............ .................... Shear Cracks in Driven Head of 3/8-in. Dia. 7050-T7X Rivet - 2nd SZep of Aging: 8 Hrs at 345 0 F ............. ....................

...

107

24

..

108

25

109

26

Head

130

27

.I..il1

28

Phiotomaerographs of Sectioned 3/32-in. Diametor (D) 7050-T7X m-ivets Driven With 1.5D Flat Heads in 0.090-in. 202 1 1-T3 Sheet - 2nd Step of Aging: 8 lirs at 315PF ........ ................

112

29

Photomacr'ographs of Sectioned 3/1 6 -in. Diameter 2024-T31 Rlvets . . . . . . . . . . . . . . . . . R ...................

1 3 113

Ii

. .. ...

vl

LIST OF ILLUSTRATIONS

(CONTINUED)

Figure 30 Photomacrographs of Sectioned 3/16-in. Dia. 7050-T7X Rivets - 2nd Step Aging: 8 Hrs at 350F ................... ...................... Photomacrographs of Sectioned 3/16-in. Diameter (D) 7050-T7X Rivets Driven With 1.5D Flat in 0.2 8 1-in. 7075-T651 Plate - 2nd Step of Heads Aging: 8 Hrs. at 3551F ...... ............ . Photomacrographs of Sectioned 3/8-in. Diameter (D) 7050-T7X Rivets Driven With 1.55D Flat Heads in 0.375-in. 2024-T351 Plate - 2nd Step of Aging: 8 Hrs at 355 0 F .l. . . .................... Driving and'Hole-Fill Specimens for Pneumatic Hammer Driven Rivets ............ .............. Pneumatic Hammer Driven 3/32-in. Dia. 7050-T7X Rivets - Se-ond Step of Aging: 8 Hrs at 3500F. Photomacrograph of 3ectioned 3'16-in. Diameter 7050-T7X Rivet Driven in 0.190-in. Diameter Hole

Page

114

31

115

32

116
1J7

33
34

118

35

in ]/4-in.
36 37
38

8 Hrs at 35 0 F........

7075-T6 Plate - 2nd Step of Aging:

................. . .. 119
120

Shear JoInt Fatigue Specimen for 3/16-in. Dta. 1000 Flat Ctsk Head Rivets .. ........... Photograph of Setup for Fatigue Tests of Riveted Joints Using Restraining Fixture ........
Specimen Retaining Fixture (Sandwich Type) . .
.

121 12

39

Fatigue Results for 7050-T7X and 2024-T31 Rivets In High Load Transfer Lap Joints at Alcoa

Laboratories ..........
40

.................

..

123

Fatigue Results for 7050-T7X and 2024--T31 Rivets in High Load Transfer Lap Joints At Battelle Laboratories .......... .................. .. Effect of Rivet Alloy on Fatigue Strength of Load Transfer Joints ............... ...

124 125 126

SHigh
S42 S-

,41

Load-Strain Results for High-Load Transfer Joint Battelle .......... .................. ...

vii
A .---

--

--.-.

LIST OF ILLUSTRATIONS

(CONCLUDED)

Figure 43 44 115 Load-Strain Resu]ts - Alcoa .......... for High Load Transfer Joint ..................... ...

Page

127 128 129 130 131 132

Comparison of Strains in Alcoa and Battelle Tests .................... .................... Effect of Stress Ratio and Restraints on Fatigue Strength of High Load Transfer Joints ....... Two Sizes of Stressed Assemblies Used In Corrosion Tests of Rivets ............... Intergranular Corrosion and SCC in 2 Hours at 350F ....... ................ SCC In A 7050 Rivet ...

46 47 48 49 50

A 7050 Rivet ..
0

Aged 8 Hrs at 345 a 7050 Rivet ....................

F .....

....

Localized Corrosion in At 345 0 F...........

Aged 8 Hrs .... A Heated ..

133 134

Intergraiiular Corrosion and SCC In 2024-T31 Rivet ....... .................

Al A2

Orientation of the Longitudinal Slice Used In Testing 2124 Plate ..... ............... SCC In 2124-T351 Coupon Containing 2024-T31 Rivets ............. ....................

.. ..

135 136

LIST OF TABLES Table 1 2 Chemical Composition of 15-in. Diameter Ingots Cast for Plloy 7050 Rivet Program .......... . 7050-F13 Wires Produced and Shipped from Massena Works .......... ................. Results of Mechanical Property Tests on 7050-H13 Wire Produced At Massena Works ........... . Alloy 7050-F Rivet Items Manufactured Lancaster Works .......... ................... At the 49 Page 146

47

148

viii

LIST OF TABLES

(CONTINUED)

Table

Page Results of Tests to Determine Effect of Solution Heat Treating Practice on Tensile Properties of 7050 Wire .... ............ Results of Tensile Property Tests on Alloy 7050 Rivet Wires Using Six Aging Practices

..

50

6 7 8 9 10
11

51
52

Results of Shear Strength Tests On Alloy 7050 Rivet Wires Using Six Aging Practis.. ..... .. Results of Electrical Conductivity Tests On Alloy 7050 Rivet Wires ...... ...........

..

53 54 55

IScope of SCC Screening Tests on 0.372-in.

7050 Wire ................. ................... Resistance to SCC of 7050 Rivet Wire - 0.125in. Diameter Longitudinal Tension Specimens. Effect of "Low" and "High" Iron and Silicon Content on the Driving Pressure Requir':d to Form Flat Heads On 7050 Alloy Slugs ......

..

56

12

Average Driving Pressures Required to Form 1.5D Diameter X 0.5D Thick Flat Heads on 7050 Alloy Wires ............. ..................... .. Alloy 7050-F Rivets Solution Heat Treated and Aged for Phase II Portion of Program ..... Results of Tensile Property and Electrical Conductivity Tests on Alloy 7050 Wire Aged with Rivets ......... ................ ... Results of Shear Strength Tests On Undriven 7050 Alloy Rivets Using Three Aging Practices. Sheet and Plate Thicknesses for Specimens for Joint Yield and Ultimate Strength Tests. . . . Results of Tensile Property Tests of Alclad 2024 Sheet and Plate Items to be Used for Joint Shear Strength Tests .... ............. .. Computation of t/D and P/D 2 from Basic Data 3/32-in. Dia. Rivets, Second Step of' Aging:
-

57 58

13 14

59
60 61

15 16 17

62

18

8 lirs at 3451F ........

................

..

63

ix

LIST OF TABLES (CONTINUED)

Table 19 Computation of t/D and P/D 3/16-in. 20 Dia. Rivets,

2

Page from Basic Data

Second Step Aging:

8
-

Hrs At 345F ..............

..................

64

Computation of t/D and P/D 2 from Basic Data 3/8-in. Dia. Rivets, Second Step Aging: 8

Hrs at 345'F ................

21

................

65
-

Computation of t/D and P/D 2 from Basic Data 3/32-in. D~a. Rivets, Second Step Aging: 8 .................. Hrs at 350'F............. Computation of t/D and P/D 2 from Basic Data 3/16-in. Dia. Rivets, Second Step Aging: 8 .................. Hrs At 350'F ......... Computation of t/D and P/D 2 from Basic Data 3/8-in. Dia. Rivets, Second Step Aging: 8 .................. Hrs at 350.F ........ Comiputation of t/D and P/D 2 from Basic Data 3/-2-in. Dia. Rivets, Second Step Aging: 8

66
-

22

67
-

23

..
-

68

24

Hrs At 3551F ........

25

..................
-

..

69

Computation of t/D and P/D 2 from Basic Data 3/16-in. Dia. Hivets, Second Step Aging: 8 .................... Hrs At 355 0 F .......

26

Computation of t/D and P/D 2 from Basic Data 3/8-in. Dia. Rivets, Second Step Aging: 8

Hrs At 355 0 F ..............

27 28 29

.................
..

71
72

Average Shear Strength of Driven 7075-T7X .................... Rivets ............. Comparison of Shear Strengths of 2024-T31 and .... 7050-T7X Driven Rivets ............. Comparison of Driven and Undriven Shear

73 74

Strengths for 7050-T7X Rivets ...... 30

.........

Average Driving Pressures Required to Form 1.5D Diameter X 0.5 Thick Flat Heads on 7050-T7X .. ..................... Rivets ............. Largest Size Flat Head Formed Without Shear .................... Cracks .............

75 76

31

LIST OF TABLES (CONCLUDED)

Table 32 Tensile Properties of 0.090-in. Thick 2024-T3 Sheet Used for Lap-Joint Fatigue Specimens. . Fatigue Test Program for Lap Joints Containing .

Page 77

33
24

3/16-in.

Diameter 2024-T31 and 7050-T7X Rivets.

........ ......

78
79 80

Lap-Shear Fatigue Test Results

35
36 37

Scope of SCC Tests on Driven Rivets .... Results of Metallographic Exaiii!nacion of Corroded, As-Driven Rivets .............. Results of Metallographic Examination of Corroded Rivets from Assemblies That Were Heated After Driving But Prior to Exposure.

...

81

82

Al

SCC Tests of 1.5-in. 2124 Plate Stressed In the Short-Transverse Direction By Driven Rivets 36 Tests ........... .................... .. Results of Stress Corrosion Tests On 2124 Plate Containing Rivets. Hoop stress from Rivets In the Longitudinal to Short Transverse Grain

83

A2

Direction .................

..................

84

IX1

The Antodctoanoatre

conducted a pormto establish manu-

facturing methods for teproduction of hg-teghauiu alloy 7050 small diameter rivets. Included were tests of alloy

7050 rivet wire and rivets at different strength levels obtained through selected aging practices. In a previous small program to

demonstrate feasibility, a lot of rivets was made using alloy 7050 wire in which the iron (Fe) and silicon (Si) content were well below the limits specified for the alloy. Therefore, since it was

thought that the Fe and Si content may affect formability, two pui'ity levels were included in the test program; one with "low" Fe and Si content (duplicating the previous mater'ial) and the other with "high" Fe and Si content (both elements being within, but close to the maximums specified for alloy 7050). The work was completed in two phases. Phase I covered the

casting of the ingots, extrusion of billets, rolling of redraw rod, *drawing

* I

of wire, heat-treatment and aging of wires, screening tests of wires (formability, strength and corrosion studies), and rivet production. Optimum aging practices established in Phase I were

used for the rivets evaluated in Phase II. The primary objective for this project was to establish manu* I

facturing methods for the production of aluminum alloy 7050 rivets by determining a suitable aging practice and a range of purity level for which 7050 equals or exceeds the strength, heading and

hole-filling, and stress-corrosion resistance characteristics of

L.6,1...

of 2024-T31 acceptance achieved.

("ice-box")

rivets..

Preliminary qualification and

of 7050 alloy as a production rivet will be thereby

-I

I'!

j,_
A'

K7

II.

Phase I A.

-Rivet

Production and Wire Screening Tests

Proauction of Wire and Rivets 1. Ingots

All ingots required for the program were cast by the Ingot Casting Division of Alcoa Laboratories. The metal was melted and Primary metal,

alloyed Ini a ~4,000 pound gas fired ladle furnace.

pure alloying elements and master alloys were employed as charge components. casting. The molten metal was fluxed in the furnace prior to

It was also filtered and degassed during transfer A small addition

using the Alcoa A181 process* shown in Fig. 1.

of titanium and boron was made in the transfer system in the form of TIBOR rod to grain refine the ingot structure. The casting

procedure employed was Alcoa's level pour casting method shown in Fig. 2. An aluminum mold was used. The starting block was steel.

A device to remove the ingot cooling water (wiper) was located

6 in. below the mo1h.

Although some problems were initially

encountered with cracking, both purity levels (S. No. '420927-

~"low" Fe and Si and S. No. '420928

"high" Fe and Si) were

(I

successfully cast using idertical practices.

Both primary and backup ;.ngots, 120 in. long, were cast to each of the purity levels desired (see Table 1). They were

Immediately stress relieved by heating at 650OF overnight. Slices were cut 10 in. from the head end (top) of each ingot to evaluate the quality. The ingots were also checked ultrasoni-

cally and found to be free of cracks and gross porosity.

*US?

303986'4

The ingot confined to an

slices 8 in.

revealed center

some very

light

porosity which was No. S. No. The

circle circle

for primary ingot S. for primary ingot

420927C and to a 6 in. 420928J. slices structure This was

center

determined by dye penetrant techniques. the grain size,

were

also etched to reveal a 1 in.

and the macrograins at ingots. ingots

revealed

layer of twinned columnar equiaxed

the surface The was,

with the remainder

for both primary

layer of twinned in our opinion,

columnar grains on the not harmful for this

surface of the program.

rivet

The ingots were homogenized 860F followed minimize solidification constituent. A 72-in. in Table

(preheated)

for 16 hours at fabrication to

by 16 hours at 905OF prior of dendritic

to any

the effects

coring that all

occurs during of the AI

2

and to dissolve

virtually

CuMg

length of each of the two

primary ingots described were shipped to wires.

1, each weighing about (N.f.)

1

1,200 lb.,

Alcoa's Massena 2. The

Works for conversion to rivet

Rivet

iircs of 7050 rivet Alcoa's Massena (one with "low" cast wire required (N.Y.) Works for the

sizes and quantities

program were fab icated at two 15-in. diameter ingots content)

from the

a.-nd the other with Three

"high" Fe and Si sizes of rivet diameter

at the Alcoa Laboratories. 0.092, 0.184

wire were required: 3/16 and 3/8.-in.

and 0.372-in. respectively. to fabricate the

for 3/32,

diameter rivets,

Massena Works 7050 alloy rivet

used alloy wire.

7075 stanlard practices

-~

Each ingot was scalped to 14-1/4-in. extruded of 42-in. rod (starting rivet in. into 6x6-in. bloom stock. was rolled into

diameter and then in the form

The bloom stock, 3/8 and 7/16-in. arid 0.184-in.

long bars, stock).

diameter

Both the 0.092 from 3/8-in.

diameter

wires were diameter rivet

drawn

diameter rod,

and Ghe 0.372diameter rod. the

wires were drawn from 7/16-in. four bars (bloom stock) to roll the were

For each 3/8-in.

ingot,

used to roll rod.

rod and three bars

7/16-in.

No problems purity drawing

were encountered level to rods; the rods identicel. purity the

during rolling well. levels

of the bars of either The procedures

both rolled

used in

of both purity

to the finished wire

sizes were the two t,. 7075

No drawing differences levels, and it was found that

were noted between

7050 alloy draws well for drawing alloy

H13 temper using ,

-sting

procedures

to the H13 temper. Table of wire tion, 2 lists number of coils and totl weight (Pa.) of each size produc-. Alcoa total,

shipped to Alcoa's

Lancaster

Works for rivet

along with the amounts for the Phase I fabril-ated This amount

of each size of wire sent to screening tests of wire. In

Laboratories Massena Works rivet in wire.

and shipped is

1,467 lbs.

of 7050-H13 set forth for produced

quite close It was

to the amount

the program work statement. tests

more than sufficient of rivets to be

the Phase I j for use

and for the quantities II tests and to be

in the Phase Laboratory.

shipped to the Air Force

Materials

vs:1

S--"~

The results of the tensile property on samples taken from each coil in Table 3.

and shear strength tests

7050-H13 wire are given in the

The tensile strengths ranged from 39.6 to 43.5 ksi, As might be expected, these

overall average being 41.1 ksi. tensile strengths 36 and 46 ksi, in fall

between the minimum and maximum values of specified for alloy 7075-H13 wires "Aluminum Alloy Rod and Wire;

respectively,

Federal Specification QQ-A-430B,

for Riv-ts and Cold Heading". show io significant differences

The results of these tests also in the properties of the wires of

the two purity levels,

although metallographic

examinations showed

that the wires of the composition having the content had more constituent present in also be mentioned

"high" Fe and Si It should

the structure.

that the layer of twinned columnar grains

present at the surface of both ingots did not cause any fabrication problems and was ellininated in 3. Rivets Works, using the 7050-H13 wires the final product.

Alcoa's Lancaster (Pa.)

produced at the Massena Works, the 26 rivet items given in

manufactured the quantities of The manufactured head the 1000 Flat

Table 4.

styles included the Uniiv3rsal Head (MS20470), Countersunk Head (MS20426) (NAS1097).

and the 1000 Countersunk Shear Head

Normal manufacturing practices and production equipNo difficulties

ment were used to produce these rivet items. were encountered temper wires. in

producing the 7050-F rivets from the 1113 there was no apparent difference in producing

Also,

rivets from the wires of the two purity levels.

All items listed

in

Table 4 are within the dimensional rivets. In total,

tolerances required for 620 lbs of'

aircraft

Lancaster Works produced

7050-F rivets. B. Wire Screening Tests 1. Aging Practices Division of Alcoa Laboratories the solution heat treating and was

The Physical Metallurgy responsible artificial for recommending

aging practices to be applied to the 7050-H13 wires scheduled screening tests. A modest program was

for the various

conducted to establish a recommended tice for 7050 rivet 0.372-in. gire and rivets.

solution heat treating pracNine 16-in. lengths of

diameter 7050-H13 wire of the compsition having the (S. No. 420928J) were in soluticn heat Table 5. On the

"high" Fe and Si content treated and art~.i-lally

aged as described tests

basis of the results of tensile

conducted on these wires,

a solution heat treatment of 15 minutes at 900OF was selected for Ls- with 7050 rivet wire und rivets in The Physical Metallurgy previous test Division, this program.

after a review of some recommended in 6, 8,

results from a lot of 7050 rivet wire,

the following six agings for the the screening tests:

7050 wires to be evaluated (first step) + 2, 4,

4 hours at 2501F step).

10 and 12 hours at 350F (second tices, tensile strengths ranging Sufficient

Withthese 75 ksi

aging practo about 90

from about

ksi were expected. levels in all

quantities of wire of both purity treated, coldfor the

three diameters were solution heat (using the recommended An air circulatory

water, quenched and aged screening test this work. program.

six agings)

furnace was used for

Ij

I
"Mechanical Property and Conductivity Tests
Tensile tests, in duplicate, were conducted on all (a total 7050 wires The

with the six different results of these tests strengths ("low"

aging practices are given in

of 72 tests). Average tensile

Table 6.

ranged from about 73 kbi to 86 ksi, Fe and Si content)

with purity level

or "high"

having no effect on the tensileJ strengths for. 2024-T4 Since the tensile the wires heat employed for

properties.

The minimum and typical tensile respectively.

wires are 62 ksi and 68 ksi, properties obtained were

considered satisfactory, test

treated and aged wich the tensile the remaining screenIng tests.

samples were

Table 7 presents the results of shear tests three diameters aging practices.

made on all

of 7050 wire of both compositions given the six The average shear strengths obtained ranged with, again, the wire purity

from about 42 ksi to about 49 ksi, level having no effect practice. wires

on the shear strengths for a given aging for 2024.-T4

The minimum and typical shear strengths respectively.

are 37 ksi and 41 ksi,

The ratios of average condition

shear strength (purity level 0.56 to 0.58,

to average tensile and aging practice) which is

strength for each test

of the 7050 wires ranged from for aluminum alloys. were made using 16-in. from both ingot compoof 36 measurements).

about typical

Electrical

conductivity measurements

lengths of 7050 wire of all

three diameters (a total

sitions given the six aging practices fable 8 presents the readings obtained.

As the time at temperature

'

(3501F) hours,

for the second step ofL the aging increaspd, the conductivity, as expected,

from 2 to 12 Slightly

also increased.

lower conductivity readings were obtained for the wires having the "high" Fe and Si content. However, these slight differences

could be the result of differences ingots,

4rn the compositions of the two

Fe and Si being two of several possible e1er.ents

contributing. 3. Acce~lerated Stress Corrosioi (a) A4aterial diameser. 7050 rivet wires (SCC) Tests

The materials tested were 0.372 in. of both purity levels, artificielly

aged four hours at 250'F and 2, 4, 6, 8, 10 and 12

then by six second step aging practices; hours at 350 0 F. (b) Procedure

The scope of the SCC screening tests is

outlined in

Table 9.

SCC tests were made with 0.125 inch diameter longitudinal tension specimens stressed in Alcoa's stressing frames, as shown in Pig. te 3,

to 75 and 90 per cent of the actual yield strengths.

Tripli,

specimens were exposed for 90 days to two corrosive environments, as follows: (1) 3.5co NaC1 by alternate imiersion in accordance with

Federal Test otandard 151o, Method 823 and with ASTM Standard G44-.75. (2) Synthetic sea water by alter.:,.ie inmmersion solution in accordance with ASTM Method D-1-11 4 -"

J.1. other test conditions in .tho 823 and ASTM G414-75.

accordance with Feder-al Standard 151b,

(c)

Resu2ts

and Discussion

Nine of the 72 specimens exposed to the 3-1/2% NaCI solution failed in Table 10. 34 to 8h days. One specimen The results of these tests from each test are shown in

condition that incurred of each aging treatment The

failures,

plus one specimen representative

that did not incur

failure were examined metal-lographically.

examination showed that a sEcond step aging Lreatmcnt of two hours at 350 0 F resulted in corrosion. granular marked susceptibility to intergranular the susceptibility to inter-

Fcr both purity levels,

corrcsion decreased a6 the second step age wab lengthened

and only pIcting corrosion occurred with agings of eight or more hours at 350'F. granular The failed specimens showed rather deep inter-

corrosion with auxiliary

cracks emanating from this but a few Thus,

corrosion.

TVase cracks wer'e primarily transgranular, and intergranular is

were a mixture of transgranular

cracking.

some degree of susceptibility to SCC probably the short time agings. illustrate this Photomicrographs,

associated with Fig. 4,

contained in

condition. sea water

All 72 of the specimens exposed to the synthetic survived the 90 days of exposure. mild general corrosion. from this environment These specimens

incurred only

Metallographic

examination of specimens for material corrosion

showed pitting

intergranular corrosion

aged two hourcs at 350'F,

plus slight intergranular and only pitting

for the four hours at 350F aging,

corrosion for

agings of six or more hours at 350 0 F, having no effect.

with the level of Fe and Si

10

Susceptibility definitely is

to SCC and to intergranular corrosion Consequently, the following recommen-

undesirable.

dations were made regarding the second step aging practices to be evaluated in (1) (2) Phase II on rivets: 350 0 F,

The primary second step aging should be 8 hours at A more extensive aging,

involving longer time or slightly to

higher temperature, SCC,

should be included to assure high resistance

(3)

The 6 hours at 3501F age,

or the

equivalent

thereof,

should be included to establish whether this in an undesirabl.e 4. level

-..

indeed does result

intergranular corrosioDn on rivets.

Driving and Hole-Fill. Tests (a) Preparation tests were conducted using slugs

The driving and hole-fill

machined from 7050 rivet wires and the type of specimens shown in Fig.

5.

Slugs were machined from all

three wire diameters

(0.092,

0.1814 and 0.372-in.) practices. program. In total,

of' both purity levels with the s. x aig over 1000 slugs were prepared for the test from various thick-

The driving specimens were prepared

nesses of 2024-T3 and 7075-T6 about

sheet to provide grip lengths of as folcws:

1 and 1.5 times the nominal wire diameter, Slug Length, in. 0.20 Specimen Thickness, in. 'rilli Size, in.

Wire Diam., D, in.

Min, No. of Specimens* 2024-T3 7075-:T5

0.092 0.l184 0.. 84 0.372

0.40 0,50 0.80

0.090 0.190 0.281 0.375

3/32 3/16 3/16

24 24
---

3/8

24

24 24 24 24

IrIn~ each case, half of the specimens contained holes with a poor finish and rifling ("poor" holes). Examples of "good" and "poor" holes arc shown in Fig. 6.

11

The slug length for each wire diameter indicated in foregoing tabulation Is and to form a flat sufficient to fill the hole in

the

the specimen equal to

head having a diameter and thickness

1.5D and 0.5D,

respectively. 20 slugs were machined from a length of wire. These slugs were solution arid driven

For coffparison, 0.14-in.

diameter 2024-H13 rivet 20 min. at 9201F,

heat treated

cold-water quenched,

within 30 minutes. (b) A?.l as shown Various Proce-1.,.,; driven using a subpress with flat sets,

slugs werue squeeze in Fig.

7,

in

a 30,000-lb

capacity Satec testing machine.

loads were selected in

driving the slugs to produce flat ranging from about 1.3D to about After loading, each

driven heads having diameters 1.7D.

Each slug was loaded only one time. head was examined for defects The photograph in Fig.

driven flat measured.

and the diameter was

8 shows a typical specimen after and the photograph in Fig. 9

completion of the driving trials,

shows some of the completed driving specimens for all diameters. After completion of the driving tests,

three wire

certain examination

specimens were sectioned at midwidth for metallurgical of hole-fill. (c) Results

The comparative data in had no effect given size practice).

Table 11 shows that the purity level required to form a (i.e., flat head of a

on the pressures

for any set of conditions Therefore,

diameter and aging

the relationship between driving pressure

12

and driven flat

head diameter was the same for a given slug of purity level. Plots of three 10.

diameter and aging practice regardless driving pressure versus average sizes of slugs and the six It will be noted in fiat

head diameter for all

aging practices

are shown in Fig.

these plots that the driving pressure required head, for agtven slug diameter, (i.e., This is as the time consistent the as-

to drive a given size of flat decreases

as the material strength decreases

of the second step of the aging increases). with past experience rec'ived condition. to form 1.5D in

driving aluminum alloy rivets in

The approximate

driving pressures required three diameters Table 12. of slugs The

diameter flat

heads on all

given the six aging practices

are presented in flat

driving pressures to form the 1.5D diameter aged for 2 hours at 350F (2nd step) greater than those for the step). As shown in were

heads for slugs

abouit 25 per cunt ,2nd to

slugs aged for 12 hours at 3501F 10,

Table 12 and Fig.

the driving pressure diameter for the

form a 1.5D diameter flat slug was

head on a 2024-T31 0.184-in. less than that required

from 350 to 1600 lb.

7050 slugs.
A visual examination with a 2X magnifying glass was made in each case in I Fig. for the occurrence of shear cracks, the driven flat flat heads. heads in of the type shown

11, in

No shear cracks were slugs given a 2nd step

obtained in aging of 6,

1.5D diameter 8,

10 and 12 hours. heads,

When these slugs were driven slight

with larger flat

about 1.6D diameter or greater,

13

shear cracks program,

could be produced.

Of the 770 slugs headed in

the

a total of only 36 slugs were observed to actually have heads containing shear of the shear cracks observed

or even suspected to have driven flat cracks. in In every case, however, all

these tests would be considered "acceptable" on the basis of' Fig. 2 of Amendment 1 of MIL-R-5674C. There

the sketches shown in was no pronounced of purity level.

tendency for shear cracks to occur on the basis

Over 30 driven slugs,

including a few of the 2024-T31 slugs,

were sectioned and metallographically examined for defects and No def'ects were found in any of the sectioned quality. hole-fill slugs. Photomacrographs Figs. (6X) of some of the sectioned samples Examination of these phn'.om2the holes about as

are shown in crographs

'.2 through 17.

show that 7050 slugs appear to fill regardless

well as the 2024-T31 slugs, step of the aging.

of the time at the second

There does not appear to be any effect of It

purity level on the hole-filling ability of the 7050 slugs.

would be expected that the 7050 slugs will tend to have better hole filling qualities as the time of the second-step of the tensile and

aging increases because of the re-sulting decrease in yield strength properties. C. Phase I - Briefing and Recommendations it

On the *basis of the wire screening tests, that the 7050 rivets to be used in follows: Phase II

was recommended

of the program be as

14

[II
1. Be from the lots containing the "high" Fe and Si content, of future commercial as they will probably be more representative production lots of 7050 rivets. 2. Be solucion heat treated for 15 minutes at 900 0 F, cold8

water quenched and aged for 4 hours at 250F (1st hours at practices hours at

step) plus

3450,

3500

and 3551F (2nd

step).

These three aging the 6, tests

for the 2nd step are equivalentto 350F practices

8 and 10
of wires,

used for the Phase I in production,

and are recommended because, is the easiest to control. Both recommendations held at Wright-Patterson

the time variable

were accepted at the Phase I briefing AFB on December 10, 1975.

~~i

*15

1ii

III.

Phase II A.

Rivet Tests

Aging and Anodizing the approximate number of each of 13 rivet and ;i.ged for the Phase II emnloyed making

Table 13 lists

items that were solution heat-treated portion of the program. (second

Three aging practices were 350'

step agings of 8 hours at 3450,

and 355 0 F)*,

three batches of rivets for the test practices

program.

These three aging

were to optimize maximum strength along with miximum cracking. Therefore, rivets and

resistance to stress corrosion wires "T7X"

given these aging practices we.,e assigned the temporary temper designation for the remainder of the program. lengths of each diameter of rivet wire used to produce the rivets were if rivets. (0.092, 0.1841

Three 16-in. and 0.372-in.)

solution heat and

treated and aged with each batch

All rivet wires

rivets were from the same basic ingot, and Si content. After aging, rivets. Type II, B. the Alumilite** 205

which had the "high" Fe

finish was applied to all of the

The Alumilite Class 1 fi-ish

205 finish meets the requirements of MIL-A-8625.

Mechanical Property and Conductivity Tests were made on the wires solution heatand the results are presented

Tensile property tests

treated and aged with the rivets, in Table 14. The average tensile

strengths ranged from 75 ksi to

80 ksi.
* **

The average tensile

strength obtained for each aging at 9001F, step).

The rivets were

solution heat treated 15 minutes

cold-water quenched, aged 4 hours at 250OF (first Trade name of Aluminum Company of America.

16

condition was quite close to the target maximum difference being about 0.9 ksi. and typical tensile

tensile strength,

the

The published minimum

strengths for 2024-T4 wire are 62 ksi and

68 ksi,

respectively. conductivity measurements all were made on 16-in. three

Electrical lengths

of the 7050 wire in The results

three diameters for all of these measurements conductivity

aging practices. given in Table 14. consistently

are also

As expected the in

increased

with the increase

temperature

employed for the and 3550F). made on all Rivets 1000

second step of the aging

(8

hours at 3450,

3500

Table 15 presents the results three diameters of rivets given the

of shear tests

three aging practices. Universal and the of 18 lots

with both manufactured head styles (the Flat Countersunk) employed for these were utilized

making a total

for these tests. undriven rivets

The average

shear strength

obtained The

ranged from 44 ksi to 46 ksi.

minimum and typical are

shear strengths respectively.

for undriven 2024-T4 rivets The ratio of average to average shear

37 ksi and 41 ksi,

strength for the undriven 7050 rivets of the 7050 wires for each test

tensile strength which is

condition was 0.58,

about typical for aluminum alloys. C. Joint Shear Strength Tests 1. Materials and Preparation of riveted lap-joints were conducted Test 4, 18. in

Static strength tests accordance with the

requirements of MIL-STD-1312, configuration shown in Fig.

using the The tests

preferred two-fastener

17

were made using 3/32, sunk head (MS20426) practices. in

3/16 and 3/8.-in.

diameter 1000 Flat Counter-

alloy 7050-T7X rivets given the three aging machine colintersunk holes

The rivets were driven in

specimens prepared from Alclad 2024-T3 and T351 sheet and plate.

The sheet or plate thickness and rivet diameter combinations ("t/D" ratios) used in the program are shown in Table 16, Table 16.

As indicated in

tests were performed at both Alcoa The program called

Laboratories and Battelle Memorial Institute.

for tests on a total of 126 specimens by Alcoa, with Battelle duplicating 42 or one-third of the Alcoa tests. sheet, Battelle used

plate and rivets supplied by Alcoa to prepare their own

specimens for these tests. Table 17 notes the 11 thicknesses of Alclad 2024-T3 and T351 sheet and plate items acquired for the program. tensile property tests on specimens taken in direction for each item are also presented in tensile strength, in The results of

the longitudinal Table 17. All

yield strength and elongation values determined published in

these tests were above the minimum (A values)

MIL-HDB:(-5.
At both Alcoa and Battelle, the specimens were assembled by The follow-

squeeze driving the rivets to form flat driven heads. ing driving pressures were used: 2nd Step of Aging, 8 hrs. at 3457F 350OF 355 0 F Driving Pressure, lbs. Rivet Diameter, D, in. 3/8 3/32 3/16 25,300 6,100 1,510 24,000 5,750 1,460 23,000 1,420 5,650

18
[Af.

The lengths of the rivets used in above driving pressures, specimens sions: and to form flat were sufficient

each case, to fillthe

when using the holes in the

driven heads with the following dimendiameter and a

a diameter equal to 1.5 times the rivet from 0.5 to 0.6 times the rivet 2. Procedure at Alcoa Laboratories were

thickness

diameter.

All tests capacity

conducted in

a 30,000-lb

Satec testing machine using the appropriate The average loading rate in

load range each case

for each rivet diameter.

was 100,000 pounds per minute total in fastener shear area.

(10 per cent)

per square inch of were conducted for a

At Battelle,

the tests

appropriately

sized electrohydraulic

machines programmed inch of

loading rate of 100,000 pounds per minute per square fastener shear area. strain Nos. Joint deflection was determined (Model No.

using Instron

gage extensometers G51-13 and 231-1002

G51-13 at Battelle and Model Calibration of the testing to insure

at Alcoa).

machines

and extensometers at both Battelle and Alcoa, load-deflection Te~t is 4.

proper accuracy of the autographic were as specified in test MIL-STD-1312,

recordings, of the

A photograph Fig. 19.

setup at Alcoa Laboratories

shown in

Yield loads

were determined using the secondary modulus method and an offset at yield equal to 4 per cent of the nominal rivet hole diameter. 3. Results and Discussion (t), hole diameter (D), yield and (Py)

Specimen and ultimate P/D

2

shect thicknesses (Pu) loads,

along with computed t/D ratios, Tables

x104 load values

are presented in

18 through 26.

I9 19

Presented in accordance

Figs.

20 through 25 are nondimensional. plots Guidelines for Presentation fo;" each

(n

with MIL-HDBK-5

of Data) With

for the experimental a few exceptions,

data obtained

aging batch.

the results

of the tests

duplicated by Alcoa

and Battelle were in

good agreement. employing

The average ultimate load data obtained for joints 7050-T7X rivets given the three Figs. 20, 21 and 22. aging practices in

are plotted in is

For comparison,

each of these figures for 3/16 and l/4-in.

plotted the average

ultim1ate load curve

diameter 2024-T31 rivets driven in

clad 2024-T4 sheet. design values

This curve published

was obtained by multiplying the ultimate in MIL-HDBK-5 by a factor of 1.15,

since for design allowable data is divided by

loads the average curve 1.15. It

determined from test Figs. 20,

will be noted in

21 and 22 that nearly all.

of the plotted points obtained for the 7050-'YX riveted joints were above the average joints. On this basis, curve plotted for the 2024-T31 the data indicate riveted

that il.timate design

-allowables for 7050-T7X rivets should be slightly greater than those published for 2024-T31 rivets. lots of 7050-T7X rivets is establish design values. The average yield load data points for the joints diven with 7050-T7X rivets given the three aging practices are plotbed -n Figs. 23, 24 and 25. Again, forcmparison, in each of these three Additional testing of other

required to verify this trend and

figures are plotted the average yield load curves for both 3/16

20

and i/4-in,

diameter 2024-T31 rivets in

Clad 2024-T4 sheet. MIL-HDBK-5,

The but

curves are also the design values published in are based on the "old" yield criteria (i.e.,

the specified perfor hole

manent set value used to determine the yield load was, filling fasteners, the larger of 0.005-in. It

or 2.5 per cent of the

nominal shank diameter).

will be noted that the average yield Figs. 23,

2

load data points plotted in rivets generally fall 3/16 and i/4-in.

4 and 25 for the 7050-T7X

above the average yield curves for the Additional testing

diameter 2024-T31 rivets.

of other lots of 7050-T7X rivets is and to establish design values. At the high D/t ratios (0.64

required to verify this trend

and above)

all

failures in

these tests were by shearing of the rivets.

The average shear this program

strengths determined for the 7050-T7X driven rivets in ranged from 47.2 to 52.6 ksi.

The average shear strength values

for each rivet diarrieter given each of the three aging practices are shown in Table 2"7. As indicated in Table 28, the average shear

strengths for the 7050.-T7X rivets ranged from 15 to 21 per cent greater than the typical 2024-T31 rivets. shear strengths program. (B value) shear strength of 41 ksi for the driven versus the undriven in this

Table 29 compares

that were obtained for the 7050-T7X rivets

21

r1

D.

Driving and Hole-Fill Evaluations 1. Squeeze Driven Rivets (a) Materials and Preparation 7050-T7X with both the

All three rivet Universal and 1000

diameters of alloy

Flat Countersunk manufactured lead styles included in the test Fig. program. 5,

given the three aging practices were

The driving specimens were also of the type shown in and were parepared sheet and plate the nominal rivet Rivet Diam., D in. 3/32 3/16 3/16 3/8 Rivet Length, in. 13/64 7/16 9/16 13/16

from the thicknesses of 2024-T3 and 7075-T6 grip lengths of about 1 and 1.5 times

to provide

diameter as f-ilows: Specimen Thickness, in. 0.090 0.190 0.281 0.385 Hole Diam.n, :r. 0.o096 O.1.91 0.-191 0. 386 Min. N,. of Specimerns* 20241-T3 70 75-2-T 24 24
--

214 24

:12
2)4

24

each case, half of theSIn specimens finish and rifling ("poor" holes). holes are shown in Fig. 6. The length for each rivet tion Is sufficient to fil.).

contained holes with poor Examples of "good" and "poor" the foregoing tabula-

diameter given in the hole In

the specimen and to form a 1.5D and

fi.at head having a diameter and thickness equal to about 0.51), respec'tively. For comparison, ten 3/16-in.

diameter by were These

7/16-in. driven in

long 202':-f31 1000 Flat Countersunk Head rivets specimens made of 0.190-in. thick 2024-T3 at

sheet.

rivets were solution heat treated quenched,

20 minutes

920F,

cold-water

and driven within 20 minutes.

22

(b)

Procedure

All rivets were squeeze driven using a subpress with flat sets, as shown in Fig. 7, in a 30,000-lb capacity Satec testing driving the rivets to

machine.

Various loads were selected in

produce flat

driven heads having diameters ranging from about 1.4D Each rivet was loaded only one time for these each driven flat head was examined for

to about 1.7D. tests. defects driven.

After loading,

and the diameter measured.

Over 400 rivets were squeeze certain specimens examined for

After completion of the drLving tests,

were sectioned at midwidth and metallurgically defects and hole-fill. (c) Discussion and Results

Plots of driving pressure for all shown in

versus average flat

head diameter are

three sizes of rivets given the three aging practices Fig. 26. These plots show that the driving pressure head, fora given rivet (i.e., as

required to form a given size of flat diameter,

decreases as the rivet strength decreases

the temperature is

of the second step of the aging increases). in driving aluminum alloy The approximate driving

This

consistent with past experience

rivets in

the as-received condition.

pressures required to form 1.5D diameter flat Table 30. As notid in Table 30, only in

heads are given in

the case of the highest

strength 3/8-in. 345

0

diameter rivets

(second step aging of 8 hours at

F)

were severe shear cracks obtained when the driven flat The type of shear cracks Fig. 27. The largest

head diameter was equal to 1.5D. obtained for this condition is

shown in

23

diameter of driven flat cracks in

head that could be formed without

shear

the three sizes of rivets given the three aging practices Table 31. It should be mentioned that shear cracks Table 31 woulJA be classified Fig. 2 of

are listed in

obtained at the diameters indicated in

as "acceptable" on the basis of the sketches shown in Amendment I of MIL-R-5674C.

At least two rivets of each of the three rivet diameters given the three aging practices and driven in ness were sectioned for defects and hole filling defects were found in (6X) any of the driven rivets. each specimen thickqualities. No

Photomacrographs Figs. 28

of some of the sectioned samples are shown in 32. Examination of these photomacrographs fill

through

indicate that about as

the 7050-T7X rivets satisfactorily well as the 2024-T31 rivets. 2.

the rivet holes,

Pneumatic Hammer Driven Rivets Fig. 33 were prepared fo2 given only one aging were employed

Specimens of the type shown in these tests. practice Rivets in all

threedameters

(second

step aging of 8 hours at 3501F)

for these tests. pneumatic hammers.

About 90 psi air pressure was used for the

Flat driven heads were easily formed on the 3/32-in.

diameter

rivets using the lightest hammer available at Alcoa Laboratories. This gun weighed 2 pounds 7 ounces, bore. It and had a 0.403-in. diameter

was model F2 produced by the Reed Roller Bit Company.

The back-up bar weighed 1.5 lb.

24-

A standard Boyer No. the 3/16-in.

I riveting hammer was required to drive Some difficulty was encountered in

diameter rivets.

driving these rivets with flat drift off the rivet, making it

driven heads as the haimer tended to difficult to form a flat head type con-

concentric with the rivet hole.

A slight "cone-point"

figuration was machined into the driving set,

and this helped to A 1 5-lb.

obtain rivet heads concentric with the hole diameter. backup bar was used for these tests also. A standard Boyer No. the 3/8-in. rivets in

40 riveting hammer was required to drive and this was done by driving the (backup set in a stationary anvil).

diameter rivets,

a downhand position

As with the 3/16-in.

diameter rivets,

a small cone-point type of

configuration was machined into the end of the drawing set in order to Keeo the hammer centered on the rivet during the driving operation. Selected rivets of all defects and hole-fill three diameters were sectioned for Photomacrographs Figs. 34 and 35. (6X) of some of

qualities.

the selected samples are shown in these photomacrographs

Examination of

indicates that the hammer driven rivets are However, it is

not as well driven as the squeeze-driven rivets.

expected that this condition can be greatly improved by the use of more experi-nced aircraft riveters.

25

E.

Tests Shear Joint Fatigue 1. Materials and Preparation shown in Fig. 36,

Sixty lap-shear

joints with the dimensions

a 100 per cent load transfer joint, Laboratories using 3/16-in. 1000

were prepared at Alcoa Flat Countersunk head rivets.

Thirty-six of the joints

were assembled with 7050-T7X alloy rivets, alloy rivets. All specimens the

and the other 24 joints with 2024-T31

were taken from the same piece of 0.090-in. direction of rolling. specimens, shown in minmum Tests of triplicate

202 1h-T3 sheet in sheet-type tensile

also taken in 32.

the direction of rolling,

gave the values

Table values

These tensile properties

are above the specified

and are quite close to the typical values published

for 2024-T3

sheet. driven by means of a subpress in a

All rivets were squeeze 30,000 lb.

capacity Satec testing machine.

The specimens w(re rivets were

degreased prior to driving the rivets. driven in 15 min. at the "freshly-quenched" 9201F, immediately

The 2024-Tl4

condition

(solution heat treated placed aging, in and a

cold-water quenched, to retard natural quenching).

container surrounded by dry-ice driven within three hours after

The 7050-T7X alloy

rivets were driven at room temperature. step aging practice of 8 hours at employed were 5,450 7050 rivets. to lb. 350.F.

These rivets had the secondThe driving pressures for the

for the 2024 rivets and 5,750 lb. flat

At these pressures,

heads with a diameter equal obtained. Visual examination Qefects.

1.9 times the rivet

diameter were

indicated all

rivets to be free of shear cracks or other

26

L '77__ 77:*.-r

r-r

Static tension tests,

grips of the testing joints;

using 0.090-in.

thick doubles in

the

machine,

were made on four of the assembled and two with 7050-P7X failed rivets.

two with 2024-T31 rivets all four joints of these tests

As expected, The results Specimen Number 4211424-Fl -F2

by shearing of the rivets.

were as follows: breaking Load, lb. 4,720 4,625 Shear Strength,* Tensile Stress nri NSA at Breaking Load,** ps_ 53,000 52,000

Rivet Alloy and Temper 2024-T31 2024-T31

psi
41,200 40,00

Avg.
421367-BFI 7050-T7X

14,675
4,930

110,800
143,000

52,500
55)100

-P136

7050-T7X Avg.

5j030 14,980

143,900
43,500
holes,

b,500 i)6,000
0.11h';6 sq. In.

* **

Based on the area of four 0.191-in. diam. = 0.089 sq. in. Net Section Area (NSA) test results and in

On the basis of these

accordance

with Propused

Test 21 ("Shear Joint 1,at,.gue-Constant

the load Battelle levels for the Institute 33. fatiguc test arid Alcoa For this

Amplitude)

of M'I-STD-1312,
at both

p.rogram performed Laboratories Battelle and i7

Memorial Table

were seected was provided 28

as shown in

program, rivets

assembled joints; rivets. 2.

11 with

2021-T31

wil.h 7050-T7X

Procedure tests were conducted in 5000 lb. capacity at 18.3 Krouse

The fatigue

axial-load machines. the Battelle machines

The Alcoa machine operates at 30 Hz. As called Pig. 37, for in

H1z and

the specification, to each Both

a sandwich-type specimen

bending restraint, stresses

was applied

to reduce bending

at the

faying surface.

27

laboratories used restraints shown 1312. in Fig. 38, which is

made according to the dimensions Fig. 9 of Proposed Test 21 of MIL-STDthe restraints "T" by both spacers whereas

Teflon sheet was utilized in however,

laboratories;

Alcoa also used teflon

Battelle used aluminum. restraints was Battelle's

A significant difference

between the

use of locknuts under the wing nuts;

with locknuts

they were able to use a lower clamping torque on the The Battelle restraint such that was it was

nuts without having the nuts back off. tightened during initial could readily applied before more force fatigue

loading to a level

be moved with the thumbs. the specimen was installed it during the test.

The Alcoa restraint

and required considerably

to move

Alcoa tests specified in However,

were performed at a stress ratio* of -0.05 of MIL-STD-1312,

as

the March 1974 copy tests

Proposed Test 21. subsequent

Battelle's

were at R=0-I0 as

called for in

comnmittee notes of the Fastener Testing Development

Gro~ip (MIL-STD-

1312).
3. Discussion and Results at the two laboratories are

The results of the fatigue tests presented in Table 311 and Figs. for joints

39 and 40.

Tests at both

laborator-

ies showed longer lives

using 2024-T31 rivets compared

to those with 7050-T7X rivets. result from the difference in

It

is

believed that the longer lives

springback characteristics of the two The yield strength of the 2024 (fr,.shly heat treated) is much'

'kinds of rivets after driving. rivet in

* Stress S~Maximum

the driving condition

ratio, R

Mini-aun Stress M

Stress

28
-. Mod

lower than that Accordingly,

of the 7050 rivets recovery

driven

in

the T7X condition. rivet is stresses were on less after are obtained the

the elastic

of the 2024 residual

driving so higher beneficial retained around the rivet

compressive holes.

Similar results in an investigation

previously

at Alcoa Laboratories

fatigue strength of lap-joints rivets.(l) The failures of the of all

containing 2024-T31 and 7075-T73

of the 7050-T7X initiated

riveted joints in

and most

2024-T31 riveted joints

the region of the such failures failures the Alcoa greater than

knife edge produced by the countersink. initiated initiated tests at edges of the hole, at the surface of 2024-T31 riveted although rivet failures fietting occurred curves

Most

some fretting head. In

uncer the joints, at

at lives of the in

1,000,000

cycles initiated failures

faying surfaces; sheet. at the

two of the three such Figure two laboratories. in the tests,

the non-countersunk tests

4Il compares

average

representing the stress ratios

Because of the different the results strengths are plotted obtained

employed

on the basis

of load range. higher this resulted

The fatigue

at Alcoa are consistently It in was assumed that

than those reported by Battelle. primarily from the difference investigations

tightness

of the restraint.

Accnrdingly, relative

were made

at both laboratories

to the Battelle

load carried by the restraint. Micromeasurements faying surface from the edge strain gage (EA-13-031-

placed a

,c

CF-120)

centered on the 0.032 in.

and on a of the joint.

specimen edge at Evaluations

1a

distance of

29

were made with the restraint loadings. The load-strain

set both at 1000 plot, Fig. 42,

and 1490 lb the

fatigue

provides

following

observations: The load-strain a linear relationship at the faying surface is not

function

of applied load. at the sheet midthickness is is

The load-strain linear--indicating a function

relationship

that the faying surface nonlinearity of joint hending. data indicates in that restraint

The midthickness affects allows at any

adjustment condition tensile is strain only 1%

load transfer

as much as neither unrestrained

the application of full giver, load level. lb setting

However,

the reduction

for the 1490

and 6% for the 1000 lb setting. in bending strains variation with

The faying surface

data show reductions and little

from the unrestrained condition the two restraint adjustments.

Strain gage positioning on an Alcoa specimen Fig.

.both

is

indicated on

in

43.

To determine

bending

stresses,

gages were mounted to the Battelle

surfaces at and in

locations

comparable

locations restraint. produced shown at those

the section midway

between the grip and the bolts strains

Tightening of the restraint

by two technicians so only one set the effect

"negligible differences in
in Fig. 43. Figure

of data is

44 compares The

of the restraints supplement

the two laboratories. noted by Battelle:

following observations

30

In

the Alcoa tests

the restraints 80%,

reduced bending at much more than in

the

faying surface by about test, grips

the Battelle the

and produced some bending in and the restraints. at mid-thickness

the section between

Strains

were lowered only two to six per Thus, does not the proportion of load

cent by use of the restraintE. carried by the restraints significantly tests. Oscillograph dynamic the static strain readings greater in

appear to have been than in the Battelle

the Alcoa tests

for the Alcoa specimens

showed that the the same as

ranges

for the mid-thickness Thus,

gages were

svrain ranges. as that

the load transfer for the static

during fatigue readings

loading was the same shown in Fig. 43.

indicated

Fatigue tests tion of fatigue of specimens at life

of a

few additional

joints

confirmed the variaAlcoa tests are

with

clamping of the restraints.

R=0.10 and specimens

not having any restraints

plotted on Fig. riveted R=0.10, by Battelle joints

45 with the other Alcoa and Battelle on the, basis of load range. had a life and, et a In

data for 2024 at

Alcoa tests double

a specimen with restraints at the same stress without restraints The large reduction

those obtained an Alcoa

lower stress, half

specimen tested by Battelle. restraints

had a life in in life tests

those reported

for specimens without at R=-0.05.

was also demonstrated

Uj

.~31

.. ".

.. .. ..

"

..-

. . . ......

..... . . .

..

.. . ... .

.k ..

...

. ..

F.

Accelerated 1. Material

Stress-Corrosion

(SCC)

Tests of Rivets

The SCC tests (MS20426),

were made with 1000 diameter,

flat

countersunk

head

3/16 and 3/8 in.

rivets.

The primary test

material was 7050

rivets given a first

step age of four hours at 350 and

250F and then second step agings of eight hours at 345, 3551F. One lot of 2024-T31 rivets, 3/16 in. diameter,

was

included to provide a comparison in use. Finally, a reduced test

with the commercial material now program was conducted on 7050

rivets aged four hours at 250F plus two hours at 350OF to provide a control on The corrosive environments. With this aging, the

7050 rivets essentially and arc expected

are in

a peak strength,

T6 type temper, corrosion

to be susceptible

to intergranular

and to SCC.

Three sheet alloys,

202 11-T3,

7075-T73 and Ale.

7075-T73,

were

used to r-present the galvanic to be joined in service.

range of

aluminum materials

likely the

The galvanic relationship between shown below.

rivets and sheet alloys is Sheet Alloy

Galvanic Relationship of the Rivet to the Sheet 2024 Rivets 7050 Rivets Anodic - corrosion Similar Cathodic free corrosion

2024-T3 7075-T73 Alc. 7075-T73

accelerated
Similar - free corrosion Cathodic corrosion
-

corrosion corrosion

retarded
-

Cathodic

retarded

retarded

32

2.

Procedure on rivets is outlined in Table 35.

The scope of the SCC tests The rivets were driven in

an assembly designed tn apply a constant (5000 psi) on the rivet shank, super-

low level of tensile stress

imposed on the fo.-ming stresses from riveting. assist rivets; propagation of any cracking that initiated

The intent was to in susceptible

hopefully to a degree

that could be detected visually. of sheet with a spacer strip 46. The assembly was

The assembly consisted of two pieces of the same sheet at either end, clamped together at the center, clamps removed. Fig.

then the rivet was driven and the taken apart to verify as a result

Several assemblies were

that no relaxation of the rivet of plastic deformation (a) in

loading had occurred

the sheet.

As-Driven Rivets of each rivet-sheet environments combinations were exposed Phase I, namely:

Six assemblies to the two corrosivo

used in

3.5%

NaCl and synthetic sea water by alternate the assemblies were exposed for 90 days,

immersion.

Three of were

while the others

removed for metallographic of exposure. (b)

examination after 30,

50 and 65 days

Heated Assemblies containing 2024-T31 rivets and both sizes

Riveted assemblies

of 7050-r7X rivets second step aged for 8 hours at 3501F were heated for 72 hours at 3001F and for 1/2 hour at 4001F. heatings were selected from prior experience These

as being representative

of heatings that cause appreciable sensitization of 2024-T31 rivets

33
A

to intergranular

corrosion.

The

riveted assemblies were exposed immersion tests.

for 90 days to the two alternate 3. None cause Results and Discussion

of the rivets fracture

incurred SCC of sufficient of the rivet. Thus,

magnitude

to

complete

SCC had to be various periods of

detected by metallographic exposure. (a) The results driven rivets 7050-T6

examination after

As-Driven Rivets of the metallographic are listed in Table 36. examinations on the as-

Type Controls:

Both sizes of 7050-T6 type rivets 30 days exposure to 3.5% NaC1 A.I. sea water A.I. 47. An

showed evidence of SCC after and after 50 days of exposure SCC detected is

to synthetic shown in

example of the

Fig.

This verified 7050 rivet that

that both corrosion test was not aged sufficiently. 7050-T7X Rivets: examined

methods caused

SCC of a

Only three of the indications.

83 7050-T7X All

rivets

showed any adverse

eases were rivets

that had been second step 3.5% NaC1 A.I. inch rivet and in days. rivet a A stress

aged 8 hours at corrosion

345oF and exposed to in a 3/8 48)

crack was detected andexposed 7075-T73 30 days

driven in 3/8 inch rivet

2024-T3 sheet driven in

(Fig.

sheet

and exposed 90 on a 3/16 inch 49). only

Some intergranular driven in

corrosion was present

7075-T73 sheet and exposed corrosion on the

50 days rivet

(Fig.

The intergranular

3/16 inch

occurred

341

at a site

of rather seve.re

c.r'evice corrosion between the driven corrosion was found 350

head and the sheet.,

No SCC or intergranular

on any of the 7050 rivets

second step .aged for 8 hours at

and 3551F.
The evidence of SCC in at
3

7050 rivets second step aged 8 hours some susceptibility especially in if the when

451F was rather minimal but indicates

severe corrosive rivet is

conditions are encountered, a cathodic alloy. probably

driven in

The conditions is

both

accelerated tests expected in (1) time

grossly exaggerate what

to be

service because: of the

The specimens were wetted fbr the large majority with a good electrolyte

(80% or more)

that supports galvanic

corrosion, (2) The sheet materials and result in joined were exposed bare, a large cathodic area, thus freely

able to corrode

and

(3)

No effort

(such as wet priming of rivet

holes or painting

of faying surfaces) trical

was made to minimize corrosion or reduce elecand the sheet. that production rivets be given a to

contact between the rivet it is preferrable

None the less,

minimum second step age of 8 hours at 350F, assure high resistance to SCC.

or the equivalent,

The tendency towards susceptibility contacts a cathodic alloy is trend was noted in resulted in early

to SCC when the rivet This same which

not unique to 7050 alloy.

evaluations of 7075-T73 rivets,

development

of the more extensively aged 7075-T731

temper that eliminated the problem.

35

2024-T31 Rivets:

The particular lot of 3/16 in.

2024-T31

rivets did not incur SCC when evaluated in However,

the as-driven condition. variable, being

the resistance of 2024-T31 rivets is

dependent primarily on the cooling rate achieved during quenching. Other lots could be susceptible, inherently would cool somewhat particularly larger sizes that

slower during quenching and which

would incur higjer residual forming stresses during driving. (b) Heated Assemblies

The results of the metallographic examinations on rivets that were heated after driving are listed in Table 37.

7050-T7X Rivets: No adverse effect was noted on either size of 7050--T7X rivets that were heated for 72 hours at 3000F or 1/2 hour at 4001F prior to exposure. No evidence of SCC was detected all cases.

and the type of corrosion was pitting in

2024-T31 Rivets: Both of the heating periods used sensitized the 3/16 in. 2024-T31 rivets so that they became susceptible to 50).

intergranular corrosion and to SCC (Fig.

At the Phase I briefing, the question arose as to whether the residual stresses imposed around the rivet holes, beneficial to fatigue strength, being joined. taken in although

might cause SCC of the materials

The Addendum covers a small test program under-

this regard using 2024-T31 and 7075-TTX rivets driven 1P

2124 plate.

3b

IV.

Conclusions. The results of the test program warrant the following

conclusions: A. 1. Phase I - Rivet Production and Wire Screening Tests Alloy 7050-H13 rivet wire up to 0.372-in. in diameter

were produced using standard manufacturing methods and equipment. 2. Small diameter, aircraft-size (up to 3/8-in. diameter)

alloy 7050-F rivets with MS20426,

MS20470 and NAS1097 manufactured

head styles were produced using standard manufacturing methods and equipment. 3. The purity level of the cast ingots ("low" Fe and Si

content or "high" Fe and Si content, sition limits for alloy 7050 in

but within the chemical compohad no apparent effect or on the strength

either case)

on the production of the rivet wires and rivets, properties, formability characteristics

and resistance to stress-

corrosion cracking of rivet wires. 4. The solution heat treating practice for alloy 7050 rivet in diameter should be 15 minutes

wires and rivets up to 3/8-in. at 900 0 F, 5.

followed immediately with a cold-water quench. In corrosion tests of 7050 wire, it was determined that or the equivalent,

second step agings of 4 or less hours at 3501F, were insufficient corrosion and SCC.
6. Second step aging practices

to provide high resistance to intergranular

of 8 hours at

450,

3500 and

3551F should be applied to the 7050 rivets for the Phase II to attempt to optimize strength and resistance to SCC.

tests

37

B. 1. at 3450,

Phase II

Rivet Tests

Alloy 7050 rivets given the second step agings of 8 hours 3500 and 355 0 F developed average undriven shear strengths
0

ranging from 44 ksi (355

F)

to 46 ksi (345

F).

These values are

greater than the typical shear strength of 41 ksi for 2024-T4 undriven rivets. 2. Alloy 7050 rivet wires heat treated and aged with the ranging from 75 ksi (3551F)

rivets developed tensile strengths to 80 ksi (345

0 F).

These value2, are higher than the typical

tensile strength of 68 ksi published for 2024-T4 wire. 3. In lap-shear joints with high D/t ratios (0.64 and above)

the average driven shear strengths obtained for 7050-T7X rivets ranged from 47.2 ksi to 52.6 ksi. These values are from 15 to 22

per cent higher than the "B" value of 41 ksi given for 2024-T31 rivets in 4. MIL-HDBK-5. Average ultimate-load and yield-load data analysis of of Alclad 2024-T3 and T351 sheet

static test results on lap-joints

and plate at D/t ratios ranging from 0.38 to 1.0 indicate that design allowables for 7050-T7X rivets should be slightly greater

than those published for 2024-T31. rivets. 5. In squeeze driving tests of 7050-T7X rivets, ieads were 1.5D diameter in all

by 0.5D thick flat but one case.

formed without shear cracks

The exception was for the highest strength 3/8-in. which had the second step aging of 8 hours at

diameter rivets, 345 0 F.

38

6.

As would be expected, head in

driving pressures

to form a given

size of flat

a given rivet diameter will be greater for For 3/16-in. diameter

7050-T7X rivets than for 2024-T31 rivets. rivets the difference 7.

ranged from 150 to 600 lbs.

The 7050-T7X rivets were successfully driven with for a given rivet diameter, the

pneumatic hammers; however,

7050-T7X rivets will require a larger size pneumatic hammer than 2024-T31 rivets. 8. Metallographic examinations indicate that 7050-T7X about as well

driven rivets satisfactorily fill as the 2024-T31 rivets. 9.

the rivet holes,

The fatigue strength of high load-transfer

Joints using

7050-T7X rivets were 10 to 50 per cent less than those of similar joints using 2024-T31 rivets. 10. it In the fatigue tests of the high load-transfer joints, bending restraint

was found that the use of the sandwich-type

produced constant variation betw.een test results obtained by Alcoa Laboratories and Battelle because of differences pressure. 11. The corrosion test rerults showed that a minimum second at 35
0

in

clamping

step age of 8 hours of 7050-T7X rivets. 12.

1F will assure high resistance to SCC

The high resistance to SCC of 7050-T7X rivets is that sensitize

unaffected by exposure to elevated temperatures 2024-T31 rivets.

39

13. alloys,

Galvanic corrosion of 7050-T7X rivets driven in cathodic such as 2024-T3, is expected to be negligible in iervice

in view of the standard protective systems used on aircraft.

.4

41

Sii
aI

~4O

V.

Recommendations. On the basis of the foregoing conclusions, the 7050 alloy Further-

rivets have been assigned more, it 1. is

the T73 temper designation.

recommended that:

The tentative production practice for the second step or the equivalent. in

of the aging should be 8 hours at 355 5 0 F, 2. The 7050-T73 and 2024-T31

rivets should becompared

fatigue using low load-transfer joints, for most rivet applications. tories(2) advantage joints. 3. for in more, The use of the sandwich-type MIL-STD-1312, Test 21, scatter and Douglas Aircraft

which are more appropriate work at Alcoa Labora-

Some previous Company(3)

has indicated that the in such

found for 2024-T31 rivets may not be present

bending restraint

called produces

should be eliminated as it between laboratories.

rather than less,

.41

ACCELERATED STRESS CORROSION TESTS OF 2124 PLATE CONTAINING 7050-T7X AND 2024-T31 RIVETS

VI.

Addendum

I. In most applications,

Introduction rivets are inserted through the thickjoined, so that any hoop stress resulting grain

ness of the two materials from riveting acts in directions. legs However,

the longitudinal and long-transverse attachments

could be riveted to outstanding

of integrally

stiffened panels machined from thick plate, compo-

such that the resulting hoop stress has a short-transverse nent. Because of concern a small pilot

expressed by the Air Force at the Phase I to consider whether: and (b) how

Briefing, (a)

program was initiated

stresses

resulting from riveting could cause SCC,

t,1 e effects

of riveting with 7050-T7X rivets would compare to

tho3e of 2024-T31 rivets.

II.

Material

The plate material used was a lot of 1.5 inch thick 2124 plate in the naturally aged T351 temper and after artificial aging

to the T851 temper.

Previous tests susceptible tensile

by Alcoa had shown the T351 to SCC in the short-transverse after 4 to 13 In

t,3mper plate was quite direction, triplicate

specimens failing

days exposure to 3.3% NaCl A.I. contrast,

at a stress of 10 ksi.

the 2124-T851 plate had high resistance, tensile specimens

triplicate

short-transverse

surviving 90 days of exposure

at a stress of 32 ksi.

L42

The rivets used were the 3/16 and 3/8 inch 7050-T7X rivets second step aged 8 hours at 350'F and the 3/16 inch 2024-~T31 rivets. III. Procedure Short-

The scope of' the SCC tests is outlined in Table Al.

transverse by longitudinal coupons were machined from the plate (Fig. Al) and then three rivets were Inserted at the mid-plane of the plate. Hole spacing was proportional to the rivet diameter

(D) being 2D between the end rivet and edge of the coupon, and 4ID between rivets. The 12 coupons containing 36 rivets were exposed

to the two alternate immersion tLcsts. IV. Results and Discussion No crack-

Results of the SCC tests are listed in Table A2.

ing occurred in the highly resistant 21214-T851 plate, all six coupons surviving 90 days of exposure. Likewise, no cracking

occurred in the less resistant 21241-T351 coupons that contained 7050-T7X rivets. Cracking did occur In both the 212!4-T351 coupons that contained 2024-T31 rivets. The cracks were visible after 13 In the 3.5% NaCl A.I.

dayq exposure in either environment.

test, a crack developed near one of the end rivets that eventually propagated to the edge of the coupon. A second crack

also developed between the same end rivet and the center rivet. In the synthetic sea water test only one crack developed between an end rivet and the edge of the coupon.

U4

The two 2124-T351 coupons containing 3/16 inch rivets and exposed to 3.5% NaCi A.I. for metallographic were removed from test after 45 days The coupon containing the 7050while the cracks A2).

examination.

T7X rivets was verified to be free of cracks, caused by the 2024-T31 rivets were

shown to be SCC (Fig.

No attempt had been made to try to measure the stress induced in the plate by the rivets. However, it is believed that the main that they had

reason the 7050-T7X rivets did not cause cracking is more spring back (elastic recovery) than the 2024-T31 rivets.

and thus induced a lower stress however, is that the

Another factor,

7050-T7X rivets are anodic to the 2124-T351 plate by about 140 my and reduced corrosion of the plate for a distance of about 1/16 inch around the rivet heads. V. Conclusions is concluded that:

Based on these results it 1.

A short-transverse stress from rivets can cause SCC in

susceptible plate alloys. 2. (a) The propensity for SCC in the plate depends on the: (b) Magnitude of stress

Inherent resistance of the plate, (c)

induced, alloys. 3.

Galvanic relationship between plate and rivet

7050-T7X rivets appear less likely to cause cracking

than 2024-T31 rivets because they induce less stress and are more anodic.

44

References

1.

G. E. Nordmark and W. J. Dewalt, "Comparative Axial-Load Fatigue Tests Of Lap Joints Riveted With 2024-T31 and 7075-T73 Rivets", Alcoa Laboratories Report No. 12-67-26. Unpublished research. Aluminum Company of America, November 16, 1967. G. E. Nordmark and W. J. Dewalt, "Comparative Flexural Fatigue Tests Of Box Beams Riveted With 2024-T31 and 7075T73 Rivets", Alcoa Laboratories Report No. 12-69-19. Unpublished research. Aluminum Company of America, July 9, 1969. E. L. Pampy, "7050-(XXX) AlumInum Rivet Material", Lab. Report No. LR-7031. Unpublished research. Douglas Aircraft Corporation. February 15, 1974.

2.

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(2H

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) 4) p cd rI

0.
r-"

0O3bGr0 D~

~0

(4E- 4

>

4) 0) Cd

bo 1'-4 4.
C

0HR.

UH
.

cd 4jj lj 0 0PQ 0 0

E-

C)~~'-

--

~j

4'~

C0 C)

0-

:1 >

zC

0U
0 -I 0 IN C al

13

0
0 N )

0)
0j Q

4 4 4

0
V) ;U) 4-4 4V)

4V)

0 0.

ob
'-

-H)4
. 0 H.ri -40
****

00

H- 4l .3AO

4)
tic V)

)
r.

E V)
0. V-0
CO .

0.

0.

0)

o
1-4-

0 2
t4i

(di
I C

:j
CI

nl
Clij

.011 c ) 4) r-

0O'J

1j)-40
N* C)

o4

(I

-.-.

-.

r-fE m :% ('0 2:

C) Nm
4 N

C3 (N
N

NJ

0 (NJ
(J

0 (\J
(N

0 N

4 0'

-46-

TABLE 21 7050-H13 WIRES PRODUCED AND SHIPPED FROM MASSENA WORKS

Wire Diameter, in.

Iron and Silicon( 1 ) Content

Coils Shipped to Lancaster Works Total No. Weight, lb 2 3 6 6 6 6 103 ill 325 288 294 338

No. of 8-ft Lengths Sent to Alcoa (2) Labcratories

0.092 0.092 0.184 0.184 0.372 0;372

Low High Low High Low High

15 15 15 15 20 20

Notes:

(1) Low = Ingot S. No. 429027C (0.05% Fe, 0.04% Si). High = Ingot S. No. 429028J (0.15% Fe, 0.10% Si). (2) Totalnet weight for all items was 60 lb.

iI
-47-

K-9.~n-.-. '--.-

W V"'jWI

-.

vw~w-.rr

.1

N.

--

-.

n oc-t.e~ec-c

UeX'enC-

04.4e"N'C.

cejCto

C~ c

"

tv~~-c

0CC.I1M

C)

Ii.

VEL

InC

(CCL

c0

I-

(.1
CC

H1~12C)CLHCJ14
003 C

r0)

~jHCPN
.

LCCinC

CC

CC.

CCj

CN

11 C11

I-c.C 0

1jC

CC.

4.

c-

ece

..

ii

W-cC

C2CLC

~ ~~~(j.
CCCC -

14'C

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12

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4-'

A
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Lr f' r\(TU"\L0000

0000

va D

i ct

cb

I I

2~~~B~~t R;
Cd0)00-0-

~ 2r3~
0 0

414O-O irIr l r3-! COOCDC)

N>C.-I -1ta;'.0

rrUH.-h-{H~~

COXC

~0
00 0

NC)))

C)C

(-I

00

C\Jcu

:5

V C-ri

C\C\

Q00-Q-)

t-t-40zC-V

00C

N
41

0.0 0
E

,)03

IS

(lU)
0

H-

000 H

0) -1

00

tfL(tfr\\ltl' OO0 UN \ -I-

0)q

I-li-sN .r

Vs3C) (D. F-.CJHC~ 01 GO

00 C U

&s40HCII
4

C)D "V (1O Vs H

dw.

BdrI -- H0 _j4 , -4Z,4

3

0000

000

00

0:I

W144 d

34

-40

H bo In 4:11 110 CCCC N t- t\CC' 00CC CC' (\I m tl- (_ H 0C 0- l EHH (Nl(CW(C'(C'l(C"'\
-a'0

C')

;',

TABLE 5 RESULTS OF TESTS TO DETERMINE EFFECj OF SOLUTION HEAT TREATING PRACTICE ON TENSILE PROPERTIES OF 7050 WIRE

Solution Heat Specimen Number 420928-1-1 -2 -3 Temp., OF 890 890 890

Treatments Ti at Temp., min. 15 30 60 Avg.

Tensile Properties Elongation Tensile Yield in 4D, Strength, Strength, ksi % ksi 78.9 79.1 9 79.1 79.9 80.3 80.1 80.1 79.9 80.0 79.9 79.9 72.2 72.2 72.4 73.6 73.5 73.8 73.6 73.1 73.4 73.1 73.2 16.7 19.3 18.0 18.0 18.0 16.7 1_93 18.0 18.7 17.3 1-7.3 17.8

420928-2-1 -2 -3

900 900 900

15 30 60 Avg.

420928-3-1 -2 -3

910 910 910

15 30 60 Avg.

Notes:

(1)

All specimens were 16-in. lengths of 0.372-in. diameter Wire was obtained from Ingot ",.No. 7050-H13 wire. 1420928J at Massena Works. Following solution heat treatments indicated, all specimens were immediately cold-water quenched and aged 4 hours at 2501F and 6 hours at 350 0 F.

(2)

S~-50-

rr-w
rHi H O -t -,4 f-

0jC kD

Qz. )

t-H 0)

00

UE -i

0 w

0()N-aHC4 H
4 -

-tC -,i

- H
.-

-zt4-0

01

.-

00

% t-

OC Mo

N O H

OP4

V)0

',
-o

tQ~~- L 0 0 41
.[

cOO (,j

r--H

co*
9

0q

co

*D *

C~

W)

(Y

t-"'

00a-p
Q) 't j

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t

0"

o ko
HUf

o- CO co C)
cr0

m
.r

N-" 0)~

kot(C\I)

Lnc

OH()a c CC coc CC CD
4-)

O~)
1-0 w Y)-'

4o :i

jy

4-

ri)Ou
C.~~f -L

Y)
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U0\ O O~
4) a

d)C.

.a)
( ) c N)

0Y
(;-40

(Y-

0d
W. co coC~ 00C)Ln

+
CQ I-C

00

H
U) *c-1

0)

nc-

C) 4-3

+)

mco

HHm~
9

nc

w-

*
0--~~r .

--

0.0

.0

- 1 H- 0 f)

::j.

U) 0Cl) 4-)

d4.3 C'JC O'JC\ C ON 00 0)01 t -lO oji t' -c 0c C) 00 t-- 0 C'4(V G'm \ 00 M
00J

) ;-i

9
0

~I ~

~C00
(\J N CU

t- Oc D CCJCIJ mC 00 \001

co j \jili 01\ ,*
o4-

11~ $

'\ 43

r0 Q) 4-)' 0 * H a)

H ---

4.4-

.00

.51

TABLE 7
RESULTS OF SHEAR STRENGTH TESTS ON ALLOY 7050 RIVET WIRES USING SIX AGING PRACTICES(')

2nd Step of Aging, hrs. at 3500F 2 S1120927C

Basic Lot S.No. 420927C 420928J 1420928J

Iror. and Silicn Level,02) Low HIgh Low High Low High Low High Low High Low l1Igh

Shear Strength, 3 i Wire -Iain . 2 ) In. 0.092 0.1lb4 0.372 Avg.

Avg Tensil Strength,,) ksi

(6)
Ratio

148.5
448.5 147.44 446.6 411.8 44I4. 9 413.5 143.1 142.9 4P.2 142.5 142.1

117.9 117.8 417.5 117.1 145.2 45.0

47.6 149.1 147.2 4 .4 445.5 445.9

48.0 118.5 147.4

17,711

85.14
85.5 83.2 83.5 79.2 79.4 77.2 76.44 75.1 711.6 73.7 73.6

0.56;
0.57 0. 57

0. 1'l
0.57 0.57 0.5"7 0.57 0.58 0.57 0.58 0.58

420927C 1420928J 420927C 4120928J 11209270 4120928J 1420927C 420928J

45.2 115. 1 404.0 43.6 43.3 112.9 442.6 112.8

8 10 12

43.9 1444.7 113.44 1 44-14 113.7

412.8
442.7 413.0

113.2 143.6 142.7 443.44

Notes:

(1) All wires solution heat treated 15 min. at 9001, immediately coldwater quenched and aged 14 hrs. at 250F (1st step) + number of hours shown in table at 3500F (2nd step). (2) Low = 0.05% Fe, Double-shear tests 0.011% Si and High = 0.15% Fe, 0.10% Si. ASTM B565-72.

(3)

made using fixtures

specified in

(11) Each value shown is (5)

the average of three tests. from tensile tests on all three wire diameters.

Values are the average See Table 6.

(6)

Average shear strength divided by average

tensile

strength.

-52-

TABLE 8 HESULTS OF ELECTRICAL CONDUCTIVITY TESTS ON ALLOY 7050 RIVET WIRES(

1

2nd Step of Aging, hvs. at 350 0 1' P

Basic Lot S.No. 1120927C 1420928j

Iron and Silicon Level( 2 ) Low High

Electrical Conductivit, in Wire Diam. 0-.18140.37 0.092 36.6 36.2 36.6 36.1 36.5 36.0

(3) Avg. 36.6 36.1

IACS

120927C
420928J 6 8 10 12 142092'/C I120928J 1420927C 1120928J 142092C l20928J 420927C 1120928J
()

Low
H1igh Low HI gh Low HIgh Low High Low High

38.7
38.5 40.3 39.8 I41.1 110.9 142.0 141.6 142.5 41.7

38.8
38.2 40.4 39.9 141.2 140.9 42.1 141.6 112.6 41.8

38.6
38.0 140.3 39.6 141. 1 110.9
141.8

38.7
38.2 140.3 39.8 41.1. 140.9 442.0 '41. 6 142.14 141.7

41.5 142.2 141.7

Note's:

All wires ,solution heat treated 15 min. at 900 0 F, immediately cold-water quenched and aged 4 hours at 250OF (ist step) + number of hours shown in table at 350 0 F (2nd step). Low = 0.05% IPe, 0.014% S8 and H1igh 0. 5% Fe and 0.10% S1.

2)

(3) Mea;tured at

201C.

-53-

Table

SCOPE OF SCC SCREENING TESTS ON 0.372 IN.

7050 WIRE

1/8" Dia.

Tension Slecimens

Test Variables: Two Compositions

Six Agings
-

High and low purity

4/250 + 2, 4, 6, 8,

10, 12/350eF

Test Procedures:
Replication Two Stresses Two Environments
-

Triplicate 75 and 90% Y. S.

3.5% NaCI - A.I. Synthetic Sea Water

A.I.

Total Tests

144 Specimens

. ..

- -54--

10 N 0 C) 00 0 C)0 CP0 000D Ln

0
-LI

C0000oo

000000

0)0

JJLC

(N>D4

0 04) 4.)OO(

0 (Nj)~

(n
Z
Z~~~~-

o I-)1
r0 fi

0 -O a
P4> N

x n0)a

o 0 X
11 T
m) C) rn (Y )m

4 -r
f-Im

. x
ZP
mO))mU)

J 14t 0) -4~
w

'1)

a)

Z Co
7;F:

H D

z
r--

0
44

V55-

4I
L

TABLE 11 EFFECT OF "LOW" OR "HIGH" IRON AND SILICON CONTENT ON YTHE G DRIVING PRESSURE REQUIRED TO FORM FLAT HEADS ON 7050 ALLOY SLUGS(I)

1<

Ratio of Driven Flat Head Diameter Drivingt35 Pressure,

to Slug Diameter(2) Fe and Si (4)

4 hr at
"Low"

~ ~(13) hr at 350F((3)_______12 hr at 350OF((3)________ 3) 3) 50OF( 8 30F

Fe and Si(4)

Fe and Si

lb.

"High"

"Low"

"High"

"Low"

"High"

Slug Diameter=0.092-in.
1,000 1,200 1,300 .... 1.35 .... 1.34 1.29 .... 1.46 1.30 1.45 1.33 1.43 1.33

1,500
1,600

1.47
1.50

1.46
1.51

1.52
1.54

1.50
1.56

1.48 1.56
....

1.44 1.19 1.55

Slug Diameter=0.184-in.

5,000
5,500

1.37
1.42

1.36
1.42

1.42
1.149

1.42
1.48

1.46
1.50

1.46
1.51

6,000 6,500 6,900

1.47 1.48 1.51

1.49 1.48 1.52

1.53 1.55 1.58

1.52 1.56 1.58

1.54 1.58 1.61

1.56 1.58 1.60

Slug Diameter=0.372-in. 18,000 20,000 24,000 26,000 28,000 1.30 1.35 1.45 1.49 1.52' 1.29 1.35 1.45 1.49 1.52 1.37 1.41 1.49 1.37 1.42 1.50 1.55 1.57 .... 1.46 .... .... .... 1.46

1.54
1.57

Notes:

(1)

Slugs were machined from wires solution heat treated 1. min. at 900 0 F, immediately cold-water quenched and aged 4 hours at 250'F (1st step) + 2, 4, 6, 8, 10 and 12 hours at 350OF (2nd step). Each value is the average of four tests.

(2)

(3)
(4)

Second step of aging. Low=0.05% Fe, 0.04% Si and High=0.15% Fe and 0.10% Si.

-56-

TABLE

12

AVERAGE DRIVING PRESSURES REQUIRED TO FORM 1.5D DIAMETER X 0.5D THICK FLAT HEADS ON 7050 ALLOY WIRES

2nd Step (2 ) of Aging, hrs at 350F 2

Driving Pressure, Wire Diameter, D, 0.092 0.184 1730 1610 1510 1460 1420 1360 6800

lb. in. 0.372 27700 26800 25300 24000 23100 22400

'4
-

6550
6100 5750 5650 5550 5200

6 8 10 12

2024-T31(

Notes:

(1) Tests conducted using specimens machined from wire as shown in Fig. 5. The wire composition ("low" or "high" iron and silicon content) had no effect on driving pressures (see Table 11). (2) All 7050 alloy wires were
0

solution heat

treated

15 min. at 900 F, immediately cold-water quenched and aged 4 hrs at 250F (1st step) + number of hours shown in table at 350OF (2nd step). (3) Specimens were machined from 0.184-in. c ,. eter 2024-H13 rivet wire. These specimens were solution heat treated for 20 min. at 9201F, immediately cold-water quenched and driven within 30 min. (in the freshly quenched condition).

-57-

TABLE 13 ALLOY 7mi0-F RIVETS SOLUTION HEAT TREATED AND AGED FOR PHASE II PORTION OF PROGRAM(O)

Rivet Lot Specimen No.

Manufactured Head 2 8tyle( )

Rivet Diam., in.

Rivet Length, in.

Total Quantity Aged(3) Approx. No. lbs. of PCs.

421362

h21363
1121364 1121365 421366 1421368 1121369 421370 1121371 1121372 421373 11213711
4121367

MS201470 MS201126 MS20426 MS201470

MS20470

3/32 3/32
3/32

1/4 1/4

5/16

0.3 0.3
0.3

3/32 3/16
3/16

5/16 7/16
7/16

0.3 3.0
3.0

1200 1400 1000 1200 1700

2000

PS 20 1426

NAS109( MS20 1170 MS20426 M320470 MS20 1126 MS20470 MS20426

3/16 3/16 3/16 3/8 3/8 3/8 3/8

7/16 9/16 9/16 7/8 7/8 1-1/"1 1-1/4

3.0 3.0 3.0 4.5 4.5 4.5

11.5

2100 1600 1700 330 390 250 290

Notes:

(1) (2)

All rivets from same basic ingot (5'. No. 420928J), having the "High" iron and silicon content (0.15% Fe and 0.10% Si). MS201126 = 100-degree Flat Countersunk Head

MS20470 = Universal Head NAS1097 = 100-degree Countersunk Shear Head (3) All rivets solution heat treated 15 min. at 900 0 F, immediately cold-water quenched and aged 4 hrs. at 250F (1st step); then one-third of each of the 13 rivets lots aged, respectively,
8 hrs. at 3145, 3500 and 3551F (2nd step).

-58-

-.

>0

'

II

..

0' 0

wV

0'

-'
.' In

00
v4 0

101

WE'

en

'0D4-C

C- 0 C-v

Jt
0 6

>01

tl

1. 4 tifl 61~4
00 V4

V '0

x:
-. 4

-0 10r

dO

'ii~~d -

3d0

.?

a 0

V) E -K

4~0

1-59

TABLE 15 RESULTS OF SHEAR STRENGTH TESTS ON UNDRIVEN 7050 ALLOYS RIVETS

USING THREE AGING PRACTICES(1)

2nd Step of Aging, 8 hrs at 345

0

Rivet Head Style(

Shear Strengt (3) . R--ivtDam.,4) In. 3/32 3/16 3/87 45.5 45.2 45.3 44.1 44.6 44.3 43.0 42.9 47.1 47.3 47.1 43.9 44.6 44.3 a3.9 44.8 46.4 46.2 46.3 44.2 44.6 44.4 44.0 44.2

Avg.

Avg. Tenstle Strength,-5) ksi

Ratio(

MS20426 MS20470 Avg.

46.2

79.9

0.58

350F

MS20426 MS20470 Avg.

44.3

76.6

0.58

355 0 F

MS20426 MS20470

Avg.
Notes: (1)

42.9

44.4

44.1
ingot

43.8
(S.No.

74.9
1420928J),

0.58
having the

All rivets from same basic

"High" iron and silicon content. All rivets solution heat treated 15 min. at 900 0 F, immediately cold-water quenched and aged 4 hrs at 250OF (1st step) + 8 hrs at temperatures shown in table (2nd step). (2) MS20426 = 100-degree Flat Countersunk Head MS20470 (3)
-

Universal Head tests made using fixtures specified in ASTM

Double-shear

B565-72.

(4)

Each value shown is

the average

of 4 or 5 tests. tests on all three wire

Values are the average from tensile diameters (see Table 14).

(6)

Average shear strength divided by average tensile strength.

-60-

Table 16 SHEET AND PLATE THICKNIESSES FOR SPECIMENIS FOR JOINT YIELD AND ULTIMATE STRENGTH TESTS(l)

Sheet or Plate (2)t

Thickness 2),t,I in.

Ratio of Sheet or Plate Thickness to Rivet Diameter., D, (t/D) D=3/32" D=3/16" D-3/6"

0.040
0.050

0.043 (3)
53 (3)-

0.071 0.080 0.090

0.125

0-76 0.85 0.96

0.38(3) " 0.483'

0.67
0.86 -

043)

0.160 0.190

0.43 0.51

0.250 0.313 0.375

Notes:

0.67 0.84 1.00

(1) At least triplicate tests made in all cases, using rivets given the second step agings of 8 hours at 0
3450, 3500 and 355 F. 1090 Flat-Countersunk Head

(MS2o426) 7050-T7X rivets driven in type shown in Fig. 18. (2) (3)

specimens of the

Alclad 2024-T3 sheet and Alclad 2024-T351 plate. In these cases, triplicate tests were also performed at Battelle using 7050-T7X rivets given second step agings of 8 hours at 3450 and 355 0 F. Battelle prepared specimens using same sheet, plate and rivets employed at Alcoa Laboratories.

-61-

H~~~QQC(V *N~~~ A r-i,H

C'C~LC ao.O H~ -4 CJ ojJHH

O C\~V j

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nh RN Ci

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a)j-4.)4.W

E-4

bH .4 z HO)

LC \lC'.

Lr\ '\0 OH,8 o NNH

O LA~\n NO'i0 O r-4 ('JH -

0LC't\ C RIN li

~) PQ
C :E'2

0 H 0

0
-

0100%1 c-

r-i -U-I

Cd

4.) 4-)O H

E-L4

Hb r-4HrW C/I

H aU\L m
. ..

ON m U

0\CT \

O\L0 \ C

4) -1)

HH.Q) (:Y\ O\ C)

ILI H\J ) a.

FI 5
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1 ld

~ H \0

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U\ -

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*4. H~~ bOb4H)C

4)

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C-~~~~~~.

00L'\H _: _.zr Inu --

~-z-J TU'\

C)\LU\C\N

H -:Tr( U'\Lflnfl NORI

000 _-~r r\ I (C)

lrIHO) a) r0 j 1t--0 W 4.) C: 221 0) O H Q H- W~ m C/3-. X.0. -1 Ix.~ 0)

0)
1 H Cd >u 0 0H4C

2l

0)' bl
>-(2

E-'E<4 prH

In U-

t-) , ,X0 ,

tLzJ-ffl l \

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zrcU V) a0 4--l'~. 0)-O~ Cd

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C- ;CY\C .ru \.0 O'O '0O

1-1 )\-

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Cd rf)11 CJ MCD12 000 j

H0)~
oa\c' U--LcuCD v OOH i rCXj _:N CiCY

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b LIa Cd tQ) >QH 00)r.) SLC Q)0) 4-) (11 C)

0C~ 4-) z N.OC O m %O

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04~

14
H It) 140)4
0~~~~0)-

OIODf 000 C D Cj 00

CDC\ 00CD 0 C 0

0 \10 U-4r-% \10 00i11rC C 0 1 a C

N(I 00 Y C HH r\ j
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Z w

F- r0)0q%
)C 0) U)

0)U HOR.H

KC

Cd I Ez 0)
rt'0 0 C CD 0 00a \ C C) r-4 C n
CV) C-C1

a Q : >r-40 C 4 0) H l

0 0)\

iI'Dt,(\H 00(J 0 C~)C~

E-

zi'~

HH
0)

H,-

;1

C Hl

4H-H)~d2
w 3

2
00

H
1

H)(

W)

H.-4 CJ\i0 O\O\O 02~~~c 000 000 r-IH NNN NNN Q~~U.:-.r.J Cl)m nr,)r) IEI I &l 4F P--

()() -.-

..)H >II 0 C -4 Z o a) r)m

r-NR 0 H4
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kj c

ll) I

TABLE 18 COMPUTATION OF t/D AND P/D

Second Step of Aging :8 Hrs. at 345F
2

FROM BASIC DATA-

3/32 IN. DIA. RIVETS

Sheet : Alded 2024-T3

Test Specimen No. 420967-3A1 -3A2

-U -3A5

Hole Dia., D,

D12 sq. in. .0098 .0098 .0098 .oo98_.0_0 .0098

.0098 Average .0089 .0089 .0089

Sheet Thick., t, in. .o406 .0403

o04 .. .040 .0404 .0401 .0401 .0401

t/D

Yield Load, pyl Ib/ Fastener

0-4

Ultimate Load, Pui,

10 Pu 2

Type Of Fai(2) A A
A

in.
.0988 .0988
.400988 .0988 .o988 .0988

D 1040
1.714

b/Fastener
315 329
339

102 3.214 3.57

3. 59 3.122 3.245 3.279

.411 .408 4og 40

.409 .409 .42 .423 .424

168

178
-

1.6 1.429 1.653

306

140

.318

3-1-0-A-2(3) -2

.0945 .0945 .0945

2018 186

.0945 420968-3AI
-3A2 -3A3

.0089 .0097
.0097

.0402

.425
.424

2.258 2.020 2.146

17 24
3uq9i 234

2.101

282 285 283

3.168 3.202 3.180

3.222 3.2
3.8A4 7

A A A

A A
A A

AVeroee

.0401

2.1h9

3.188

.0987
.0987 .0987

.0520
.0521 .0521 .0521

.52
55o .528 .528

2.619
2.05 2.412 2.512

363
370 362

Average

3.763

3-050-A-1(3) -2 -3 1120976-3A1 -3A2 -3A3

3 3-070-A-1( ) -2 -3

.0948 .0948 .0948 .0981 .0981 .0981 .0948 ,0948 o0948 ,0980 .0980 .0980 .0976
.0976

.0090 .0090 .0090

AveraSe

.0515 .0516 .0511 .0514 069c :0698 .02_L .0697 .0691 .0690 20_ .0690 .0796 .0793 0 .07911 .092h
.0922

.54 .544 .539

.542

250 250 253 313 360 346 343 343 340 347 372 369 359
372

2.778 2.7u8 2.11

2.789

33 334 338 406 400 401 369 374 371 389 397 399 390 3 00

3.744 3.711 3.756

3.737

A A A B B B B B B B B B B
B

.0096 .0096 .0096 Average '0090 .0090 .0090 Average .0096 .0096 .0096 Avsrage .0095
.0095

.708 .712 J.12 .711 .729 .728 .728 .728 .812 .809 _o .810 .947
.945

3.260 3.750 3.6o4 3.538 3.811 3.811 3.778 3.600 3.615 3.875 3.844 3.778 3.779
3.916

4.229 4.167 4.177 4.191 4.100 4.1;6 4.12 4.126 4.052 4.135 4.156 4.1i4 4.105
4.105

42o969-3Al -. A2 3 -3A3 420970-3A1

-3A2

-3A3

.0976

.0095
Average

.0922
,0923

9
.946

366

65
3.849

4.211
l.140

Notes:

load determined at the permanent set of 0.04D. jfl 2A . earing deformation of hole followed by shear-tension failure of countersunk head. n hear of rivets. I : These specimens prepared and tested at Battelle.

-63-

TABLE 19 COMPUTATION OF t/D AND P/D

Second Step of Aging Test Specimen No.
1

FROM BASIC DATA-

3/16 IN. DIA. RIVETS

Sheet
Ultimate

8 Hra. at 345SF D, sq. inn. 0.0368 0.0368 0.0368

0.0368 Average Sheet Yield

Alclad 2024-T3
Pu Type

Hole

Die., D. in. O.1918 0.1910 0.1918

0.1918

Thick., t, n. .0698 .0699 .0696

C697

t/D 360 .364 .363

.363

Load, py7 1 . Ib/ Fastener 665 780 791

613

PY 2 104 D I.80r 2.120 2.158

1.666

Loadt U Pu, lb/Fastener 1 ?96 1 478 1 290

1 125
-

i04

D2

Teof Failure (2)

A

120976-6AI -6A2 -6A3

-6A11

3.7?3 3.9 3 .O16

3.505

A A A

.0698 .0695 . .0695

.06911 .0920 .0925 .0925 .0920 .0923 .0920 .0916

.364 .370 .370

.370 .881 .484 .484 .481 .483 .488 .486 860 910 887
-

1.938 740 70735 865 928 935 2.o68 2.096

-

3.814 1 200 3.399

-

3.187

6-070-A-1(3)
-2 -3 820970-6Al -6A2 -6A3 -

0.1878 O.1878

0.1878

0.0353 0. 0353 0.0353

Average

A
A

2.C82 2.363 2.536 2. 555 2.485 2.423 2.563

1 165

3.293 1 35 1 375 1 3 1 335

0.1912 0.1912 0.1912 0 . 1912

0.0366 0.0366 0.0366 O. 0366 Average

3.697

3.683 3.757 3.6 8 3.696

A A A,
A

6-090-A-1(3)
-2

0.1885 0.1885

-3
420971-6Al -6A2 -6A -6A2

0.1885
.1909 .1909 .1909

0.0355 0.0355

1 220

3.282 3.437

0.0355
Average

.0918
.0918 .1230 .1230 .1228 .1230 .1559 .1555 .1558

.887

.-507 2_
2.1198
-

1 215

L.

A A

A
Is 1 ! "

.487 .64)t .6L-L .610t ._.6L3 .6 i4 .016 .8

1

3.380 1 829 1 413 ! 446 1 1115 3.926 3.9611 3. "3 i -3 7 3.938 1 838 18 3.980 3.959 B
31

.0364 .0364

.0364 -0364

1320 1238 1,263

3.626 3.1101 3.47o 3.499

Average 12l253-6A1 -6A3 .1911 .1911 .0365 .0365

1380

-6A3

.1911

.0365

.817
.816

1465

3.671 3.780

3.640
3.692

1 85

Average

3.959 3.9116

Uotes:

lead determined at the permanent set of 0.04D. A =earing deformation of hole followed by ahear-tenrslon failure of cnuntersunk head. *1I Shear of rivets. (3) These speelmens prepared and tested at Pattelle. (1$ 2

64-

TABLE 20 COMPUTATION OF t/D AND P/D Second Step of Aging : 8 Hr. at345F Test
Specimer
2

FROM BASIC DATA-

3/8 IN. DIA. RIVETS Sheet : Aiclad 2024-T3, T351

Hole
Dia.. D.

D2 sq. in.
0.1504

Sheet
Thick., t,

Yielo t/D
.403

py
-

Ultimate
Load, Pu,

Pu 02
3.324

Type
of

Load. Py,(1 lb/ Fastener

No.
421253-12A1

in.
0.3878

in.
.1562

02
2.161

ener tener
5 000

Failure(2)
" A

-12A2 -12A3

0.3878 0.3878
0.3864 0.3864 0.3864

0.1504 0.1504
Average 0.1493 o.1493 o.1493 Average 0.1505 0.1505 0.1505 Average

.1561 1.4
.1561 .1560 .1563 .1560 .1561 .1789 .1788 .1788 .1788

.403

3 250

3 ?60 3 2Ji 25
3 230 3 310 2 930

2.367 2.277
2.268

5 140 5 115

3.418

A A
A A A

.403 .404 .40 .404 .4l5 .461 .461 .461 4 225 3 900 3 950

3.381 4 420 4 44o 4 950 2.960 2.974 . 3.083 5 575 45 5 5 550 3.704 3.352 _ 3.581 A A A

12-160-A-4(3 -5 -6

.405

2.163 2.217 L 2.114 2.807 2.1-91 2.2 2.674

421271-12A1 -12A2 -12A3

0.3879 0.3879 0.3879

].2-180-A-4( 3
-5

0.3865
0 3865

0.14914
0.1494

.1796
.1798

.465
.465

3 6'0
3

2.456
2.490

4 910

3.286
3.374 3.358

A
A

-6
4

0o3865
0.3873 0.3873

0.1il94
.1500

.17911

.46

3 80

20

5.414 100

5040

A
B B

Average 21272A-12AI

.176 .2h'9

.1165 .640

2,470 5 I4C0

-12A2

0.38730383 150 .1500 08. -2

.1500 Average

.21 a 241
.2_81__ .2480 .3189 .3186 .3185 .3186 .379? .379 .3797 .3795

.640 .11
.641 .641 .824 .823 .823 .823

5 625 IC
1 9:0

3.600 .

3.750 363
3.571

5 925

5 55

3.9 0

3.910 3.900
3Q91 3.927

B B

-1221

5 875

4213q9-12Ah -12A5 -12A6

0.3870 0.3870 0.3870

.1498 .1498 .1498 Average

050 1 750 It 925

3.371 3.171 3.288 3.277

5 850 5 950 5 950

3.905 3.972 3.972 3.950

B B

421330-12AI -12A2 -12A3

0.3861 0.3861 0.3861

.1491 .1491 .1491 Average

.983
.983 9 .983

5 090 5 160 5 355

3.414 3.-461 3.592 3.489

5 825 5 855 5 995

3.907 3.927 ?021. 0 3.945

B B

Notes

(1) Load deternined at the permanent act of 0.04). 2 A - Bearing deformation of hole followed by shear-failure of countersunk head. B = Shear of rivets. (3) These specimens prepared and tested at Battelle.

-65-

TABLE 21 COMPUTATION OF t/D AND P/D 2 FROM BASIC DATASecond Stop of Aging : 8 Hrs. at 350OF Test Specimen NO. 420967-301 -3B2 -31 3
-3 -35

3/32 IN. DIA. RIVETS Sheet : Alcild 2024-T3

Hole Die.. D, in. .0988

.0988

0, sq. in. .0098 .0098 .0098

.0098 0098
.0097 .0097 Average

Sheet Thick., t, in. 0w404 .0404 .01102

.0403 .0403 .0403
.0521 .0524

t/D .409 .409 4 .40,, .408

.1408 .528 .531

Yield Load, Pyl' lb/ Fastener

162

10

02

Ultimate Load, Pu, b/Festarerr 321 320 317

306

Pu 04 D2 3.276 3.265 3.235

3.122

Type of Filkre() A A A
A

157
150 161 2?16
2-3

.0988 .0988

0988

1.653 1.602 1.316

1.531 1.642
1.653 2.536 2.608

294
364 362

3.000
3.184 3.753 3.732

A A
A

420968-3BI -3B2

.0987 .0987 .0987

-3B

"-35
420976-3B1
-312 -3B3 420969-3131 -3B2 -3B3 420970-311 -3B2 -31B

0987 0987

.0097 .0097
.0097 Average

.0520 .0522
02 .0522

.527 .529

N5 200
178

2.526 2.062
1.835 2.309

358
3 2

3.691 3.701
)t526 3.680

A A A

.529

.0981
.0981 .0981 .0980 .0980 .0980 .0976 .0976 .0976

.oo96
.0096 .0096 Average .0096 .0096 .0096 Average .0095 .0095 .0095

.0695
.0696 .0696 .0696 .0795 .0792 .0796 .0794 .0921 .0922 .0921

.709
.709 .709 .709 .811 .808 .812 .810 .944 .95

343
338 336 344 343 3511 328 341 320

3.573
3.521 3.500 3.531 3.583 3.5.5 3 3.615 3.4r3 3.59g 3.36

385
386 379 37O 387 381 360 372 362

4.010
4.021 3.948 3.990
3.854

tj
1B B1 B B P
B

3.969
3.948

0.031

3.789 3. 916 3.811

B
13

-3N

.0976

.0095
Average

-.0920
.0921

3
.944

338

5
3-.495

375

3
3.863

Notes:

(1) T.oad determined at the permanent set of 0.04L. 2 A = Bearing deformation at hole followed by shear-tension failure of countersunk head.

I 3

Shear of' rivets.

-66-

TABLE 22 COMPUTATION OF t/D AND P/D Second Step of Aging : 8 Hrs. at 360*F Test
SpecWmen Hole D2 Sheet Thick., t, "/, Yield Load, PV'(2

FROM BASIC DATA- 3/16 IN. DIA. RIVETS Sheet : Alcled 2024-T3
Ultimate Load, Pu,
-

Type of

No.
420976-6In

Dia., D. in.
.1918

sq. in.
.0368

in.
.0696

Ib/ Fastener :361 .365

.3611

/astener 1.853 1.753

1.853 1

Faikire
3.2I2

-6P2 -6132

.1918 .1918 .1912

.1912 .1912 .1912

.0368 .0368

.0698 .0700
.0699

36

682 6105

20

1 30 1 213

193

3.342 3.2296
3.293

A A A
A A A

Average

420970-6BI
-6u3 -613l

.o366
.0366 .0366 .0366 Average

.0924
.0921 .o919 9 .0921 .1229 .1226

.483
.482 .481

843
788 780 712

2.303
2.153 2.131 i.o! 5 2.1J4l

1 245
1 253 1 235 1 250

3.402
3.42? 3.:371 3.2t15 3.404

-632

.4181

.482 .64)t .6142 .64114 1 215 1 225

-

420971-6BI

-6132

.1909 .1905

.0361, .0364

3.420 3365
-

13 34

3 3.703

-6B

1909
19

.03611
.03611 Average .0365 .0365 0365 :0365 Average

.1230
.1232 .1229 .1560 .1566 .1567 .1560 .1563

13?12
1 338

.6115
.61111 .816 .820 .820 . 816 .818

1155

.13 3.319

3.687 3.__676
3.690 3.726 3.:63 .671 A30 8.88 3.767

p
13

3121253-601 -612

-63

-B'

.1911 .1911 .1911 .1911

1 290 1 313 1 265 -

3.5311 3197

3-466
3.532

1 460 1 51lO

1 34

13 P B B

Notes: (L1 Load determined at the permanent set of 0.04D. ABearing deformation of hole followed by shear-tension 2)A failure of countersunk head. !3 ',;hear of rivets.

-67-

TABLE 23 COMPUTATION OF t/D AND P/D? FROM BASIC DATASecond Step of Aging : 8 Hrs. at 350 F Test Specimen No. 421253-1211
-12D2 -12113

3/8 IN. DIA. RIVETS Sheet : Alclad 2024-T3, T351

Hole Dia., D. in. .3878 .3878

.3878
.3879 .3879 .3879 .3879

D2 sq. in.

Sheet Thick., t, in. .1561

.1560 .1562

t/D .403
.1102 .1103

Yield Load, Pyl) lb/ Fastener

3 1211
3 505 It 250 it 025 905 -

104 2.360
2.277 233

Ultimate Load, Pu, Ib/Fastener l2 4 905

4 00 4 905 5 5 5 5 150 250 175 325

Pu 104 D 3.261
3.191 1.261-

Type of 42 Failure2) A
A A A A A A

.1504,
.15011 .1504

3 ?50

Averagc
1I21271-12131 -12I12 -12P13 -12tIS .1505 .1505 .1505 .1505

.1kl
.1790

.1103
.h162 .1462 .116 3 .01 61

2.322
2.8214 2.6714 2.595
-

3.238
3.1-2

.1793
.95

3.4188
3.439 1.53t

.1801

Average
)2127'(2A-12111 -1212 -1211 -121PI .3873 .3873 .3873 .3873 .1500 .1500 .1500 .1500 Average 4121329-12 .3870 .3870 .3870 .11,98 .1198 .1,198

.1795
.21179 .2479 .21179 29 .21179 .3185 .3186 .3181

.J163
.640 .64o0 .64o0 .640 .640 4 875 1 650 1 655 1t 705

2.698
3.250 3.100 3.103 1 3.147 3.-98 3.238 3.178 5l700 5 625 5 550 5 625

3.1172
3.800 3.750 3.700 35 3.750 3.808 B 1t 13 1 1. 13
3

.823
.823 .82

It 940 It850 I 760

5 705 5 735
5 655

3.88
3.7

Average
1I21330-12131 -121-2 -1-113 .3861 .3861 .3861 .14191 .11191 .I1191

.3184
.3806 .3792 .310

.823
.986 .982 .987 4 925 5 025 5 000

3.238
3.303 3.370 3.353 5 540 5 595 5 650

3.80h1
3.716 3.753 11 13
3

Average

.3803

.985

3.342

3l 3.753

Noter:

oaddetermined at the permanent set of o.o41). !en~ring deformatlon of hole followed by shear-tension A failure of countersunk head. Shear of rivetr. V

-68-

TABLE 24 COMPUTATION OF t/D AND P/D Second Step of Aging : 8 Hrs. at 355'F Test
Specimen
2

FROM BASIC DATA- 3/32 IN. DIA. RIVETS Sheet : Aiclad 2024-T3

Hole
Die, D,

D sq. in.
.0098 0098 .0098 0098
0098 Average

Sheet
Thick., t, t/D '1

Yield
Load, py(1

py

Ultimate
Load, Pu, 31 5 334

PU
4

Type
of

No.
4120967-3cI -3C2
-3C5

in.
.0988 .0988

in.
.o'o3 .01o4 .04 02
.o8

lb/ Fastener
.109
.407 ..o07 t09 .408 .325 170

D20 LJ1U4 t/Fastener

4 1.766 1,439
1.643

D2

Failure(2
A A
A A

:0988 o3 .0988

.0988

o0o0 .01104

175 141
-

3.108

311 309
267

3.173 3.153
3.235 ;?.97 3.111 3.000 3.01-2

. 0403
.040? .o4o2 .O40:? .0l402 .0520 .0520 .0521 .05.9

12_0lL0-C_.I(3 -2 -3

.o9146 o9116 .09416

.0090 .0090 .0090 Average .0097 .0097 .0097 .0097

.425
.425 .425 .527 .52 .528

174
185

1.889 1.933 2.056 1.956

280
270

A A A

420968-3CI -3-2 -3c -3TA

.0987 .0987 .0987 .0987

250 250 265

P.577 2.577 2.732

-3c5

.0987

.0097

.05n1

."6

*598
.546 .518

2'0

191

2270268

.1j99

350 360 35 3 1

33)

3.608 3.711 3.660 3. 515

A
A

3. 12r:?
3.577
3.573 3.618

A A

A
A A A A 4, I'

Average 3-050-C-1(3)
-P

.0520 .0515 .0517 .0515

.527 jI4i 253 242

24423 2.P742 2.843 2.719 2.761t :5411 311 318 322 318

-3

.09101i .09114 .09144

.0089 .0089 .0089 Average .0096 .0096

.54U'
.516 .7,(4 .7(7

3.573
3.588 4.052 4.083 .938

.0516
.0700 .o69g'

4;2097(6-3Cl -3C2

-3c, -3c

.0981 .0981

.o981 .o981

.oo-9 oo96
Average .0090 .0090

.07oo .o6911
.0697 .0690

.(lT :

5 3f17

3-583 3.271

:.6115 3.65
1.021 3.27) 3.522 3.611

389 392 W 8

3'1
341 1 342

,.oo0

.711 .721 .727 317 325

3-070-c-1(3) -2

-3

.09419 .0o9119

3.488
3. 00
4

.0999

.0090

0689
.0690
.0793 .079 .0793 .079Lh

Average
'420969-3CI -3r2 -3(3 .0980 .0930 .0980 .0096 oo96 .0096 Average

.726 .727
.803 8:1

327

3.633 3.599
3.594 3.615 3.583

310

3.822 2
3.800 3

345
3471

.807
.810

372 378

3.875 3.938 3.885

4120970-3Ci -3C2 -IC3

.0976 .0976 .0976

.0095 .0095 .0095

Average

.0923 .0922 .0920 .0922

.9426 i.145

309 333 321365

3.253 3.505 1.923

362 367

3.811 3.863 .8

945

3. 379

3.842

Notes.

fll load determined at the permanent set of 0.01). = earing deformation of hole followea by shear-tension 2A at' countersunk head. IShear of rivets. (3) 'hee specimens pre;ared and tested at Battelle.

failure

1'
I;
-,

-69-

,..1~.~

K
Test
Specimen No. 4120976-601 -6C2 -603 6-070-c-1(3) -2

TABLE 25
COMPUTATION OF t/D AND P/D2 FROM BASIC DATA- 3/16 IN. DIA. RIVETS Sheet :AlIded 2024-T3
Sheet
Thick., t, in. .0698 .0699 .oug6 .0698 .0692 .o695 .0692 .0(62 .0693
s,,naag.a. .0925 .0922

Second Step of Agirw2 : 8 Hrs. at 355*F

Hole
Dia.. D, in,. .1918 .1918 .1918 .1886 1i886 .1L886
.1886

D2
sq. in. .0368 .0368 .0368 Averag .0356 .0356 .0356
o,036

Yield
t/O Load, Py'))T lb/ Fastener 786 788 788 645 655
74t0 700

Py
D
2

ultimate
u

PU

Type
ak

lb/Fastener 1 371 1 330 1 305 1 115 1 065

1 040 1 090

.36~4 .361k .363 .364 .367 .369 .367 .367 .367 4U .1482 .487 .484 .485 .485 EUL5 .6)1c .646 .644 .816 86
' .18 8-70

2.1? 21,1 2.141 2.139 1.812 1.8140

2.079 :L.966

3.726 3.614 3.546 3.628 3.132 2.992

2.921A 3.062

A A A A A
A

I
--

Avereg
.

1.924

3.025 1 275 1 238 1 300 1 205 1 1o 155 1 350 1 390 1 368 1 363 1 360
1 360

4120970-oci [a .t.uee...

-6C3

.11o36 -C .1912 1889 .1889 .1889 .1909 .1909 .1909 .1911 .1911
.1911

.1912

.36

094

-0

.0366 .0357 .0357 .0357 Averag .0364 o0364 .0364, Averag .0365 .65
.03 65

00o 970 825 8L;5

8u5

2.377 2459 2.650 2.11 2.5

_I2.11

3.481" 3.383A 3.552 3.375 3.2935

3.235

A A A A

) 6-ogo-o-1(T -2 -3
420971-601 -6G2 -603 421253-6c1

.0920 .0915 .09.16 .0917 .1232 .1226 .1233 .1230 .1559 .16
.15603

2.415 1 238 1 238 1 250 1 270 1 285

1 280

3.269 3.709 3.709 .813 3.7145 3.73k' 3.72( 3.72B 3.729 B3 !3 B3 B 8

3.401 3i.401 L.414 3.412 3.479 3.521

3.507

4IAveraA

-1-'2 -C23

.1561

.81,

3.501

>1,Notes:
*1(3)

(1' Load determiined at the permanent set or 0.04D. (2) Ao- Bearing defarmc.tion of hole followied by s~hear-tension failure of countersunk head. S 'hear of rivets. These specrimens prepared and tested at Battelle.

P9, I

TABLE 26 COMPUTATION OF t/D AND P/D

Second Step of Aging : 8 Hrs. at 355F Test Specimen No. Hole Dia., D, in. sq. in. D, Sheet Thick., t, in. t/D Yield Load, py,(1 lb/ Fastener 10 2
2

FROM BASIC DATA-

3/8 IN. DIA. RIVETS

Sheet Alclad 2024-T3 T351

py

Ultimate Load, Pu, tb/Fastener

Fu 10 2

Type of Failure ( )
2

421253-2C1
-12C2 -12C3 12-160-C-5(3) -6 -7 421271-12CI -12C2 -12C3

.3878
.3878 .3878 .3862 .3862 .3862 .3879 .3879 .3879

.1504
.1504 .1504 Average .1492 .1492

.1559
.1561 .1561 .1560 .1562 .1558 .1560 .1560 .797 .1795 .1793 .1795 .1795 .1797 .1797 .1796 .2479 .2449 .24 u0 .2479

.402
.403 .403 .403 .401 4o .404 .404 .463 .463 .462 .463 .464 .465 .465 .465 .64o .6ho .64o .640

3 475
3 650 32675 2 975 2 99 3080 4 300 4 150 3975

2.11
2.N27 2.943 2.394 l.994 1.99g 2 6 2.018 2.857 2.757 2.641 2.686 2.426 2.69 2.420 2.1405 5 5

030
10

3344
3.411 3. 3.384 3.029 2:.55 2.948 3.425 3.455 3.369 3.423 3.231 3.311 3.301 3.281

A A A A

h ?20 4213

.192
Average .1505 .1505 .1505 Average .1492 .1492 .1492 Average

5 155 5 200 5 100

A A A

12-180-c-4(3 -5

-6
1121272A-12C1 -1202 -12C3

.3863 .3863 .3863

3620 3 530 3 610

4 820 4 940 4 925

A A A

.3873 .3873 .3873

.1500 .1500 .1500 Average

4 610 4 650 4 705

3.073 3.100 3.137 3.093

5.525 5 525 5 575

3.683 3.683 3.717 3.695

t 13 B

421329-12C!
-12C2 -12C3 421330-12C1 -12C2 -12C3

.3870
3870 .3870 .3861 .3861 .3861

1498
.1498 .1498 Average .1491 .1491 .1491 Average

.3186
.3184 .3184 .3185 .3803 .3802 .3806 .3804

.823
.823 .823 .823 .985

4 725
4 b05 4 510 005 960 4 990
r

3.154
3.208 3.011 3.124 3.357 3.327 3.347 3.343

5 575
5 545 5 5140 5 545 5 575 5 550

3.T)2
3.702 3.698 3.707 3.719 3.739 3.722 3.727

11
F B

.985
.986 .986

il 14 B

Notes:

M) 2 (3)

Load determined at the permanent set of O.04D. A Bearing deformation of hole followed by shear-tension failure of countersunk head. B = Shear of rivets. These opecimens prepared and tested at Battelle.

TABLE 27 AVERAGE SHEAR STRENGTH OF DRIVEN 7050-T7X RIVETS

2nd Step of hrs. at. 8 Aging, 345

0F

Average Shear Strength,(') ksi 3/32 Rivet Diameter, in. 3/16 3/32 52.6 50.0 50.0 f-0.1I 47.4 47.5 50.2 48.o
.4

350F 355 0 F

47.2

Note:

(1)

From static tests of lap joints of the type shown in Fig. 18 prepared from Alclad 2024-T3 sheet and Alclad 2024-T351 plate. Ratio of sheet or plate thickness (t) to rivet diameter (D) was 0.64 and above. Average values are for tests of at least 7 specimens (14 rivets). Shear areas were based on measured hole diameter.

I.

-72-

TABLE 28 COMPARISON OF SHEAR STRENGTHS OF 2024-T31 AND 7050-T7X DRIVEN RIVETS(l)

2nd Step of Aging, 8 hrs. at 345 0 F 350F 3550F

Rivet Diameter, in. 3/16 3/32 1.28 1.22 1.22 1.22 1.16 1.16

ILL 1.22 1.17 1.15

Notes:

(1) The averae shear strength determined for the ?050-T7X rivets (see Table 27) divided by 41 ksi, the B-value shear strength for 2024-T31 rivets in MIL-HDBK-5.

'-73

TABLE 29
COMPARISON OF DRIVEN AND UNDRIVEN SHEAR STRENGTHS FOR 7050-T7X RIVETS(l)

2nd Step of Aging, 8 hrs. at

-45

Rivet Diamter, in. 3/16

16 1.06

3/8

0o,

1.o8
1.08

350F

1.13

1.07

355 0 F

1.17

1.07

1.07

Notes:

(1) The average driven rivet shear strength (see Table 27) divided by the average
undriven i'ivet shear strength

(see Table 15).

01

.-74-

'
TABLE 30 AVERAGE DRIVING PRESSURES REQUIRED TO FORM i.5D DIAMETER X 0.5D THICK FLAT HEADS ON 7050-T7X RIVETS

2nd Step of Aging,

Average Driving Pressure, Rivet Diamter, D, in.

lb.

8 hrs. at 345 0 F 350F 355 0 F

2024-T31(
2

3/32
1 550 1 500 1 1150
)

3/16 6 100 5 800 5 650

5 500

3/8 25 000(l) 24 000 23 500

Notes:

(1) Shear cracks occurred. (2) These rivets were solution neat treated for 20 minutes at 920 0 F, immediately cold-water quenched and driven within 20 minutes (in the "freshly" quenched condition).

-75-

TABLE 31

LARGEST SIZE FLAT HEAD FORMED WITHOUT SHEAR CRACKS(1)

2nd Step
of Aging,

Rivet Diameter,
in.

D,

8 hrs.
0 34r5 F

at

3/32
1.61 1.65 1.64

3/1-6
1.55 1.59 1.64

3/1.43 1.49(2) 1.54

350OF 355 0 F Notes: (1)

(2)

head diameter divided The average measured flat Shank protrusion by the nominal rivet diameter (D). the rivet hole was sufficient, in each case, to fill head. and to form a 1.5D diameter x 0.5D thick flat MIL-R-5674C0 requires minimum 1.4D diameter and minimum 0.3D thickness. Flat head diameters up to 1.56D formed without shear cracks.

-76i
.. f*ll t

..

7n....nc

.anf..

Lcn.

tAG

TABLE 32 TENSILE PROPERTIES OF 0.090-IN. THICK 2024-T USED FOR LAP-JOINT FATIGUE SPECIMENSM SHEET

Specimen Number 420963-Ll -L2 -L3 Avg. Minimum(2) Typical(3)

Tensile Strength, ksi 71.3 71.1 71.2 71.2 64 70

Yield Strength, ksi 53.9 53.6 53.4 53.6 47 50

Elongation in 2 in., % 17.5 17.8 18.5 17.7 15 18

Notes:

(1) Standard 1/2-in. sheet-type tensile specimens taken in thC direction of rolling (longitudinal). Minimum longitudinal tensile properties (A values) published in MTL-HDBK-5. Typical tensile properties published in the Aluminum Association's "Aluminum Standards and Data, 1974-1975".

-77-

-1

TABLE 33 FATIGUE TEST PROGRAM1 FOR LA? JOIiATS CONTAINING 3/16-IN. DIMAETER 2024-T31 AND 7075-T7X RIVETS

Tensile Type of Test Static Fatigue Fatigue Fatigue Fatigue Fatigue ILocation of Test Alcoa Alcoa Battelle Alcoa Battelle Alcoa Battelle Alcoa Battelle Alcoa Battelle LoadI Level,(l) lb. 4,980(3) 3340 3340 2490 2490 1490 1490 A A B B Percent of Static Failure 2 Load( ) 100 67 67 50 50 30 30 No. of Tests 2024 7050 Rivets Rivets 2 3 3 3 3 3 3 3 3 3 3 2 3 3 3 3 Stress Avg. Shear on Net Stress on Section Area) Rivets, psi psi 43,500 29,100 29,100 21,700 21,700 13,000 13,000 56,000 37,500 37,500 28,000 28,000 16,700 16,700

3
-

Notes:(1)

A = I ad level chosen which does not cause failure at less !han 3,000,000 cycles. B = Load level "as-nece-3sary" to establish S-N curve. be mutually agreeable between Alcoa and Battelle. Will

(2) (3)

As specified

in

MIL-STD-1312,

Proposed Test No.

21.

lap-joints to fail Average load for two tests Lap-joints made of 0.090-in. 7050 rivets. sheet (see Figure 36).

containing thick 2024-T3

-78-

0 (/4-3) 4-2'

0000 000 0.

00)o0 0''O )J00 0 C c~co

00 000

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1-4 0:

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(I

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0 00 000
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000 00
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4-

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\13 -1

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-- C\ij~ -2t Fr q~ ,t Frjr(')M

O)---IHO qCOF.

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mmm

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lkm fr

C/) 0000 0- CD) 00000D E-1 to'.=~~'J~ rJ 32 C\HH-(\ 00000C00(D

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0 Q 20 >0) F-i -IJH 0 0w- -42)2 0 0 000 0 j000C~ Q)2.0~ (Y) \3 r0H C. O HHH IrnY) -Ir A (Y) f)'. D0 00 30, 0 'I [C/C O'.) MCo0 C00 0 tOC. OC Hd 0 0 0 0 oo C- 0J-'. H3 O o 'r0.i %f-j (D HO . A 0.

0
0 0 (NJ) C '.r 2

Oz

0-)C))

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(/24 / 0) U 4--l

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C 1) )\0o 0)\ 0. tOi (1)~~~~~) )0 cc

4-~-I V)

lu /

CJ j

CcO C O2 /

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U)*H-4> 0 C) C)0 m0 0 00 tOC) If) 0 0 '.D --r C:) C: 0 0)0I 0 4) -30 ,q 4 0) :5 0

-79-

Table

35

SCOPE OF SCC TESTS ON DRIVEN RIVETS TRIPLICATE RIVETS IN TWO ENVIRONMENTS: 3.5% NaCI & SYNTHETIC SEA WATER - ALT. IMMERSION I. As-Driven Assemblies A. 7050-T7X Rivets 3/16 & 3/8 in. 8 hrs. at .45, 350, 355*F 7075-T73 2024-T3, 7075-T73 & Alc. 30 and 90 days 276 Tests

2 sizes 3 agings 3 sheet alloys 2 periods B.

2024-T31 Rivets 3/16 in. 2024-T3, 7075-T73 & Alc. 30 and 90 days 7075-T73

36 Tests

1 size 3 sheet alloys 2 periods C. 7050-T6 Rivets

24 Tests 3/16 and 3/8 in.

2 sizes

2 sheet alloys
1 period II. Heated Assemblies A.

2024-T3 & 7075-T73

90 days 60 Tests

7050-T7X Rivets 3/16 & 3/8 in. 8 hrs. 72 hrs. at 350OF at 300F & 1/2 hr at 400F

2 sizes 1 aging 2 heatings 2 sheet alloys

2024-T.3 & 7075-T73

1 period
B.

90 days
12 Tests at 300*F & 1/2 hr. at 400*F

2024-T31 Rivets 3/16 in. 72 hrs. 2024-T3 90 days

1 size 2 heatings 1 sheet alloy 1 period

-80-

4.)

111

11

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4-' 9 001001111001001111 00 1 0000

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Table

Al

SCC TESTS OF 1.5 IN. 2124 PLATE STRESSED IN THE SHORTTRANSVERSE DIRECTION BY DRIVEN RIVETS - 36 TESTS TRIPLICATE RIVETS, 90 DAY EXPOSURE TO 3.5% NaCi AI

Al & SYNTHETIC SEA WATER

I.

7050-T7X Rivets

24 Tests

2 rivet sizes
1 rivet age 2 plate tempers A. B. II. low resistance high resistance

3/16 & 3/8 in.

8 hrs. at 350*F

(*): (+):

T351 T851 12 Tests

2024-T31 Rivets 1 rivet size 2 plate tempets 3/16 in. T351 & T851

(*) (+)

1/8 in.
stress.

tensile specimens failed in

4-13 days at 10 ksi

,

1/8 in.

tensile specimens survived 90 days at 32 ksi stress.

-83-

> II1 >1 11(

M)
U) Lo U t)0
00 0j ra d Hd 0~ U2A 0 C

0)0

4-0 r

) d

EHZP~ 4 H' IxOC

rlr 44J~> 0' (n' 0 >4

rt

~
0 z 0 zc 0 z

0 a'

C 0H4*

Cd

0 0
4U)E00 V)

0 Z Z1
rd 4.1Y

(0

>

E-1

C -

PZE-4~ Cd
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di

p-

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~
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to (a

dI Cxn

U) roU)o(a

4) 0J

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In

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z4

Hu

-i)

0 Z4 E-4

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-84-

cm

LUJ

tz

IWe
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K00-%
100
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0 000

C-,

/'\I

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Iw
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0

-86-

I!I
'/2

G.L.

ROUND TENSION SPECIVIEN

311

63~ ALL S% AL

.,
0.688" .9

OVER

'

4!

Ii

().688"

"-

STRESSING HRAME

'1

Figure 3 Sketch Showing Principal Dim nsions of the SCC Round Tension Specimen and the St-essing Frame --

Figure 4A

S. No. 420927-1-L4 Neg. 200035A

Mag: lOOX Keller's Etch

Section through tension specimen that failed after 51 days at a streiss of 75% V.S. showing intergranular corrosion of surface and two auxiliamy cracks.

lop

41

Fig..re

4B

S. No. 420927-1-L4 Neg. 200036A

Meg: 5001, Keller's Etch

Higher magnification of the shorter auxiliary crack showing cracking is primarily transgranular and not typical of SCC.

Figure 4 Intergranular Croinin TninSpecimen From 7050 Wire Aged 2 Hours at 350"F

M.

02
en
Ij
zL

~
CO

Ca)

Hn l,
a,

000

4DuJi
LL

LeJ

CL NH
>1
C'C',

(0

I;-

-89
LIJ m U

CU) 0~

o .E

0)0 (1)

0 0 LO0

00

17

CL 0

0~

0E

C2

co

UU-

c~0

-90-I

co

CL

41

CL

4-.

*0

0 l0d m0
CL

',

w.m

cm

00

[.I.

C-

-92-

a)

CE
0

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z cr <
01L 00
C) Vi 0

(D-

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00 0-VI'

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0(

-------------------------------------------

Figure 11 Shear Crack in Driven Head of 7050 Alloy Slug

-95-

2ND STEP OF AGING: 2 HR AT 150F GOOD HOLE DRIVING PRESSURE: 1,800 LB POOR

HOLE

-E
GOOD HOLE

2ND STEP OF AGING: 12 HR AT 350F

DRIVING PRESSURE: 1,400 LB POOR HOLE

(MAG: 6X)

Figure 12 Photomacrographs of Sectioned 0.092-in. Diameter (D) 7050 Slugs Driven With 1.5D Flat Head in 0.090-in. 2024-T3 Sheet

"-96-

GOOD H01OF

DRIVING PRESSURE: 5,750 LB

GOOD HOLE

DRIVING PRESSURE: 8,000 LB

POOR HOLE

DRIVING PRESSURE: 5,750 LB

,.1

"POOR
HOLE
P

DRIVING PRESSURE: 8,000 LB

....

. I

ai

Mag: 6X Figure 13 Photomacrographs of Sectioned 0.184-in. Diameter (D) 7050 Slugs Driven With 1.5D and 17D Diameter Flat Heads in 0.190-in, 7075-T6 Sheet. Second Step Aging 8 Hrs. at 350F
-97I1*

GOOD HOLE

DRIVING PRESSURE: 5,500 LB

HOLE

DRIVING HOLE IPRESSURE: , 5,300 LB

(MAG: 6X)

Figure 14 Photornacrographs of Sectioned 0.184-in. Diameter (D?,

2024-T31 Slugs Driven (in the "Freshly" Quenched Condition) With 1.5D Diameter Flat Heads in 0.190-in.
2024-T3 Sheet

-98a1

GOOD HOLE

DRIVING PRESSURE: 5,500 LB

DRIVING PRESSURE:
* POR5.500 LB

HOLE

(MAG" 6X) Figure 15 Photomaciographs of Sectioned 0.184-in. Diar-,eter (D) 7050 Slugs Driven With 1.5D Diameter Flat Heads in Good-Poor Holes in 0.281-in. 7075-T651 Plate Second Step Aging: 12 Hrs. at 3b0F

Lk.,6-9

A6

GOOD HOLE

DRIVING PRESSURE: 5,300 LB

"HOL
SHOLPRESSURE:

SPOOP,

DRIVING 5,200 LB

"i I (MAG: 6X)

Figure 16 Photomacrographs of Sectioned 0.184-in. Diameter (0) 2024-T31 Slugs Driven (in the "Freshly" Quenched Condition) With 1.5D Diameter Flat Heads in 0.281-in. 7075-T651 Plate

, ' ,. .

,:.-

100-

GOOD HOLE DRIVING PRESSURE: 24.000 LB

POOR HOLE

DRIVING

PRESSURE24,000 LB

.I:

(MAG: 6X)

"Figure 17 Photomacrocraphs of Sectioned 0.372-in. Diameter (D)

.i.

7050 Slugs Driven With 1.5D Diameter Flat Heads in 0.375-in. 7075-T6 "late 2nd Step of Aging was 8 Hrs. at 350T
-101-

cz
0

Q-

.4r.

0
0r

-u

aN
0 00 w w
4a

q2

ac
I

-U

I"H
4-.

00

-102-

W
2
Ii

vi

-c C) o
U) U)

-J

C)

(
t F ' I

tr.

p
is
-703-- n-----

-4

7.0
SYMBOL 0 C3 RIVET DIA. -IN. SHEAR FAILURE 3/32 3/16 I

6.0 5.0

3/8

SLASHED (/) POINTS INDICATE BATTELLE DATA SHEET AND PLATE: ALCLAD 2024-T AND T351 BEARING ULTIMATE STRENGTH 115 KSI AT e/D =2.0

4.0

tA

.
S~AVERAGE

.0
CURVE FOR 3/16 AND 1/4 -IN. DIAM. 2024-T31 RIVETS IN CLAD 2024-T4 SHEET.

1.0

0.2

0.4

0.6
t/D

0.8

1.0

1.2

Figure 20 Average Ultimate-Load Data for 7050-T7X Rivets (2nd Step of Aging = 8 Hrs at 3451F)
-

104-

1..

H7'.0

*-rRIVET DIA. -IN. SHEAR FAILURE 3/32 0

SYMBOL

6.0

0
A

3/16
3/8

SHEET AND PLATE: ALCLAD 2024-T3 AND 1351

BEARING ULTIMAIE Sr(IENGTH, 115 KSI AT e/D = 2,0

4.0
10

3.0
AVERAGE CURVE FOR 3/16 AND 1/4 -IN.

2.0
1.0

DIAM. 2024-T31 RIVETS INCLAD

2024-74 SHEET.

0I

L_______

0.2

0A

0.6

0.

. .O

1.2

Figure 21 Average Ultirnate-Load Data for 7O'50-T7X R. (2nd Step of Aoing 8 Hrs at 350 0 F)

1,

1 .

7.0 ...

1"
SYMBOL 0 RIVET DIA. -IN. SHEAR FAILURE 3/32

I
0

6.0

3/16
3/8

U A

SLASHED (I) POINTS INDICATE BATTELLE DATA SHEET AND PLATE: ALCLAD 2024-T3 AND T351

5.0

BEARING ULTIMATE. STRENGTH, 115 KSI AT e/D = 2.U

4.0

3.0
"AVERAGE CURVE FOR 3/16 AND 1/4 -I1..
DIAM. 2024-T31 RIVETS IN CLAD "2024-T4SHEET.

1.0

0.2

0.4

0.6 t/D

0.8

1.0

1.2

Figure 22 Average Ultimate-Load Data for 7050-T7X Rivets (2nd Step of Aging 8 Hrs at 355F)
-106-

7.0
0

1
SYMBOL RIVET DIA. -IN. 3/32

1
3P,6
3/8

"

6.0

0
A

SLASHED (/) POINTS INDICATE BATTELLE DATA SHEET AND PLATE: ALCLAD 2024-T3 AND T351

5.0
BEARING YIELD STRENGTH 82 KSI AT e/D = 2.0

4.00

3.0
r

0
#_003/16

'

1/4 -IN. DIA.

-IN.DL6..

2.0
MIL-HDBK-5 DESIGN ALLOWABLE LOADS FOR 2024-T31 RIVETS INCLAD 2024-'14 SHEET,

I .0

BASED ON "OLD" YIELD CRTE-RIA.

0" .

0.2

0.4

0.6 t/D

0.8

1.0

1.2

Figure 23 Average Yield-Load Data for 7050-T7X Rivets (2nd Step of Aging = 8 Hrs at 345TF)
-

107-

7 .0
60
.

!
bYMBOI_ --

....-

. . .. .. ..
3/32 3 / 16

RIV/ET DIA. -IN.

3/8
SHEET AND PLATE: ALCLAD 2024-T3 AND T351

5.0

BEARING YIELD STRENGTH 82 KSI AT e/D 2.0

4.0
CL.

0 3.0

0'
1/4 -IN. DIA. RIVETS

3/16 -IN. DIA. RIVETS

2.04

1.0-

MIL-HDBK-5 DESIGN ALLOWABLE LOADS FOR 2024-T31 RIVETS IN CLAD 2024-T4 SHEL iBASED ON "OLD" YIELD CRITERIA-

0I--

---

0.2

0.4

0.6 t/0D

0.8

1.0

1.2

Figure 24 Average Yield-Load Analysis for 7O50-rT7X Rivets (2nd Step of Aging 8 Hrs at 350F)

-108-

7.0i
SYMBOL 0 -3/16 SA 3/32 3/8

-i
,IVET DIA. -IN.

6.0

SLASHED (/) POINTS INDICATE BATIELLE DATA SHEET AND PLATE: ALCLAD 2024-T3 AND T351

5.0 4.0 3.0

BEIr. "1 YIELD STRENGTH

82 K5,i AT e/D =2.0

0
A
1/4 -IN. RIVETS .0 3/16 -IN. RIVETS

3A

2. 0
-MIL-HDBK-5 DESIGN ALLOWABLE LOADS FOR 2024-T31 RIVETS IN CLAD 2024-T4 SHEET, BASED ON "OLD" YIELD CRITERIA

1.0

0
S~t/D

0.2

0.4

0.6

0.8

1.0

1.2

jI

Figure 25 Average Yield-Load Analysis for 7050-T7X Rivets (2nd Step of Aging = 8 Hrs at 355 0 F)
_-109-

U.LL

t
0(0

IC
LL%

4
V(

a.
LA. CL

0)-

00
1j 0

8
00

E F0
N
0

15 x

V)S(

oN

1.0 W)j nLUco

U-

oJ

V
a00

> 0

r0
0'

0
Nr

0
0 N

0 C4

14

0 (N

0 OD

0 <

91 IflSI~dDNIAJHG

L-110

Ii

Figure 27 Shear Cracks in Driven Head of 3/8-IN. Dia. 7050-T7X Rivet 2nd Step of Aging: 8 Hrs. at 345F

111-

,.-

GOOD HOLE

POOR HOLE DRIVING PRESSURE: 1550 LB GOOD HOLE

POOR

HOLE

(MAG: 6X)

Figure 28 Photomacrograph7, of Sectioned 3/32-in. Diameter (D) 7050-T7X Rivets Driven With 1.5D Flat Heads in 0.090-in. 2024-T3 Sheet 2nd Step of Aging: 8 Hrs. at 345F

112_a

.-

GOOD

"1

HOLE

DRIVING PRESSURE: 5,500 LB

POOR HOLE

(MAG 6X)

S,

Figure 29 Photomacroqraphs of Sectioned 3/16-in. Diameter 2024-T31 Rivets

-113-

1:.

GOOD HOLE

,,

DRIVING PRESSURE: 5,500 LB

POOR HOLE

ItI

,,

(MAG: 6X)

i2nd

Dia. 7050-T7X Rivets igure 30 Photomacrographs of Sectioned 3/16-in. Step Aging: 8 Hrs. at 350'F

-114-

GOOD HOLE

DRIVING E SURE:
40LB

HOLE

Figure 31 Photomacrographs of Sectioned 3/16-in. Diameter (D) 7050-T7X Rivets Driven With 1.5D Flat Heads in
0.281-in. 7075-T651 Plate

2nd Step of Aging: 8 Hrs. at 355F

-115-

DRIVING GOOD HOOPRESSURE 26,000 LB

POOR
HOLE

DRIVING
PRE4SURE

26,000 LB

(MAG: 6X)

Figure 32 Photomacrographs of Sectioned 3/8-in. Diameter (D) 7050-TTX Rivets Driven With 1.55D Flat Heads in 0.375-in. 2024-T351 Plate 2nd Step of Aging: 8 Hrs. at 355F
-116-

MY

Lo 0 cw, tt

Lo co C

OD)
N

0
DN

0n

00)

to Cl*)

U))CY

-o 0C

v,..

II

(MAG

6X)

"Figure

34 Pneuatic Hammer Driven 3/32-in. Dia. 7050-T7X Rivets

Second Step of Aging 8 Hrs. at 350"F

-118-

I~

(Mag 6X) Rivet driven with Boyer No. 1 Pneumatic Hammer. Note that fairl,, good hole filling was obtained, even though buck-up set did not fit properly on manufactured head

K
,I

Figure 35 Photom,'crograph of Sectioned 3/16-in. Diameter 7050-T7X Rivet Driven in 0.190-in. Diameter Hole in 1/4-in. 7075-T6 Plate 2nd Step of Aging 8 Hrs. at 350F

.J! ,i i - " "-

119-

w
0 4 W U) U

o z

40 o

co8

0<

z
-:z

LU

+1

CO
WI.

re))
CY
4-4t,

~-90 c0
.44-J
-

<

<Q

Iiwc
_j

CL r 0

0 ..1. 4

LLj

C~

120-tc

-121-

Figure 37 Photograph of Setup for Fatigue Tests of Riveted -Joints Using Restraining Fixture

3.0-

SINGLE LAP JOINT FATIGUE SPECIMEN

9 MIN. 9/32" MN

"T" SPACER (2 PLACES)

l)

1/4 "COMMERCIAL BOLT AND WING NUT .260/ 267 HOLE (G DRILL)TYPICAL 8 PLACE,;

STIFFENER PLATE (2 REQ. PER ASSEMBLY)

15/3 DtA HOLES TYPICAL 4 PLACES i

11/2"

21/4" MIN

"17/8 'MI

3/4

REF

NOTE

41/8"-

1
2 3

D t ,MINAL FASTENER DIAMETER UNDER TEST .3/16- N STIFFENr. PLATE AND BOLT MATERIAL -- MILD STEEL 1/32 -4N TEFLON SHEET INTERFACED BETWEEN STIFFENER PLATES AND TEST SPECIMEN SUf'FACES

4 TIGHTEN WING NUTS ONLY FINGER TIGHT

Figure 38 Specimen Restraining Fixture

(Sandwich Type)

-122-

CU

00
0CNC

coo 8J coj

Cu)

I
o

0
.14 04

00 0~~ oO 0 0

80
8B1

0
'3-103) NI OVO-1

8
vflbyixvvqi
123-

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00

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00

oc
ClQ)
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4
II

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00

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i)

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00

97 '-103A3

NI

aVOi

vqnfv'IIXVy4

-124-

ItU)

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0 0o

0
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<
0

01

441

CV0 0

a:

cc

*1

1~~~~~

'39N~J

46

0:

-1250

28001
! i/

2400/
STRAIN GAGES
r

z
I-

MIDTHICKNESS

800GGGAGES
800

S1200

440

NO RESTRAINT RESTRAINT SET FOR

1490 LB LOAD RESTRAINT SET FOR 1000 LB LOAD

400

800

600 1200 a TrnfrJ 2000tel 2400 itB I -L

P-APPLIED LOAD, LBS

Figure 42 Load-Str;'in Results for High-Load Transfer Joint-Battelle
1

-126-

00 0

H N
0 ~0000

11

0
0 LO

0 0 0

000 Nm

o~X~ N
0N

C,

2
00

0
0
0

Nq cv) LIDC)

00

avoli
-

127-

Ic

C/0)

L)

oL
LL

00 0 0 00 0' 01
'

sgi

avo

-128-

2
K
4CL

04-0

411

c-c
C14-

C-

(9
wn
x. o

F(n L

U8 M

oC)U

4
0

L)O

.1)

Ii-

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0)

-E

-129-

3/16 IN.RIVET WITH 0.090 x 1.5 x 2.75 IN.SHEET

i.

3/8 IN.RIVET WITH 0.190 x 2.25 x 5.5 -IN. SHEET

Figure 46 Two Sizes of Stressed Assemblies

Used in Corrosion Tests of Rivets -130-

.".

S No 420964-1" Neg. No 202302A

Mag. l.OX As Polished

Section through a 3/8 -in. diam., 7050-T6 type rivet (Aged 4 hrs/250F + 2 hrs/350F)
driven in 2024-T3 sheet and exposed 30 days to 3.5% NaC"
-

A.l. Photomicrograph

shows a 0.033 inch long intergranular stress -corro sion crack initiating at the base of the manufactured head and some intergranular corrosion on the shank of the rivet. No other cracks were detected. The maximum reduction in cross-section area as a result of cracking was estimated at 8%.

S-cracks

A replicate rivet examined after 50 days of exposure showed two diametrically located
at the base of the manufactured head, each &bout 0.063 inch long. The maximum

reduction in cross-section area in this rivet was estimated at 28%.

Figure 47 Intergranular Corrosion and SCC in a 7050 Rivet Aged 2 Hours at 350*F

-131-

-*

--

-..

--

-"-.

4...

'...

4,.,, ,

-,

. N

As

polished

,
.,

."5'

"
. -

..

S.

'

,. ,

I.
-" .

-S;

-2024-T3

-0
' ,,

-.
head.
. . -

' ,." 5
= I .,,

.
o o

" setio thrug a 3/8in dim 700- "r/2O rie

"4'
(Ae 4

5 + 8 hr F driven

,. i

S .No. 4.20964-7 Neg]. No. 202301A

Mag. lOOX As polished

"i
i' i

Section through a 3/8-in, diem. 7050-17X rivet (Aged 4 hrs/250F + 8 hrW/345F) driven in 2024-T3 sheet and exposed 30 days to 3.5% NeC' - A.I. Photomicrographofshows a the manufactured 0.020 inch bong intergranular stress-corrosion crack initiating at the base maximum reduction in cross.-sectior, area as a head. No other cracks were detected. The result of cracking was estimated at 5%.

Figure 48 SCC in a 7050 Rivet Aged 8 Hours at 3450 F

-L'

132-

'.

'It

S. No. 420974-9

Mag. 1OOX

Neg. No. 202466A

As PolishedI

-driven

Section through a 3/16-in, diem. 7050 -'7X rivet (aged 4 hrs at 250F plus 8 hrs at 345F) in 7075-T73 sheet and exposed 50 days vu 3.5% Nsed - A. I. Section is at a site of rather severe crevice corrosion between the sheet and the driven head that would not cause a localized, highly acidic envirnonment. This condition was .a. present on any of a i ~ Aa ~ ~ a , --- . a~4 at the other 7050 rivets examined. Photomicrograph tJiowe severe pitting of the 7075 -T73 sheet and pitting plus intergranular corrosion of the 7050-17X rivet. At other locations (surface of the driven head, shank and manufactured head )the Corrosion on this rivet was much loes extensive and only pitting in nature.

~:

-. -.

- ..

.-

Figure 49 Localized Corrosion in a 7050 Rivet Aged 8 Hours at 345*F

-133-

~~1
*.0

. .4

Figure 60

S. No. 420963-75 Neg. No. 202860A

Mag. 10OX As Polished , .,

Cross-sectin through the manufactured head of the 2024-T31 0 rivet that was heated 1/2 hour at 400 F and exposed 90 days to 3.5% NaCI - A. I. showing intergranular corrosion.

Vy

.q-.,.-

:'

H
."-.

Figure B0A

S. No. 420963-75 Neg. No. 202861A

Mag. 10OX As Polished

Cross-section through above rivet showirg stress corrosion

cracking in the fillet area and shank of the heated 2024-T31 rivet.

Figure 50 Intergranular Corrosion and SCC in a Heated 2024-T31 Rivet

-134-

#-T

1.5 IN.
THICK

0/

3/16 IN. RIVLr: 1/4 x 3/4 x 2-1/4 IN. SLICE 3/8 IN.RIVET: 1/2 x 1-1/2 x 4-1/2 IN. SUCE RIVETS WERE DRIVEN INTHE LT DIRECTION SO THAT THE RESULTANT HOOP STRESS INTHE PLATE WOULD HAVE A ST COMPONENT

Figure Al Orientation of the Longitudinal Slice Used in Testing 2124 Plate

-135-135-.

K;

.1k

4RI

S.No.446596-1 Neg. No. 202267A

Mag. 10OX Etch Keller's

Photomicrograph of a section from the 2124-T351 plate coupon containing 2024-T31 rivets after 45 days exposure to 3.5% NaCI - A. 1.The intergranutar nature of the cracks verified SCC as the cause of cracking.

7050-T7X rivets was also sectioned after 45 days exposure to 3.5% NaCI and was verified free of any cracking.

The 2124-T351 plate coupon, S. No. 446596-3, containing 3/16-in. diam.

-

A. I.

Figure A2 SCC in 2124-T351 Coupon Containing 2024-T31 Rivets

-136-

.xriy