Weight Reduction Opportunities in

Bolted Joints

Mexico Fastener Fair 2017

Material & Design Considerations

Mark Mahaffy
Yair Diaz
Motivation – CO2 Regulations

Global Comparison CO2-limits

Empirical Daten1 Target values
220
Gültige Grenzwerte
210 Offizielle Vorschläge
200
190
CO2-Emissionen in NEFZ-
Äquivalenten [g CO2/km]

180
170
160
150
140
130
120
110
100

(2014), DOT (2011), METI (2011)

90

2010 2015 2020 2025

Emission regulations

1ICCT
Kxtreme – Ultra High Tensile Fasteners

KXtreme® - Overview, Property Classes & Target Applications

Ultra High Tensile Standards

Two relevant standards Description

 Conventional high strength bolts are described

up
- to property Schrauben
Ultrafeste class 12.9 in ISO
sind bis898-1. These
bolts must demonstrate a martensitic
Festigkeitsklasse 16.8 in VDA 235-205
microstructure.
und USCAR Guide UHSFG-1416U-2014
beschrieben. Diese Schrauben müssen
ein bainitisches Gefüge aufweisen.

15.10.2015 (c) KAMAX Automotive GmbH – confidential – technical data may be subject to change 5
KXtreme® Property Classes
1.800 1.700
1.600
1.600 1.500 1.500 8.8
Tensile strength [MPa]

1.400 1.400 10.9

1.400
1.220 12.9U
1.200 14.9U
1.040
1.000 1.040 15.9U /15.8 U
800 16.8U
800
17.8U

0
ISO 898-1 KXtreme - Chassis KXtreme - Engine

 12 14 15
KXtreme Chassis
Property Class 12.9U 14.9U 15.9U
Chassis

Tensile Strength [Mpa] 1250 - 1400 1400 - 1550 1500 - 1650

Yield Strength [Mpa] ≥ 1180 ≥ 1340 ≥ 1430
Application Engine external applications and Chassis applications
Coating Zinc Nickel / Zincflake

 14 15
KXtreme Engine 16 17
Engine

Property Class 14.8U 14.9U 15.8U 15.9U 16.8U 17.8U

Tensile Strength [Mpa] 1400 - 1550 1400 - 1550 1500 - 1650 1500 - 1650 1600 - 1750 1700 - 1850
Yield Strength [Mpa] ≥ 1200 ≥ 1340 ≥ 1290 ≥ 1430 ≥ 1400 ≥ 1450
Application Ultrahigh strength fasteners for engine internal applications (Downsizing, Uprating)
Coating KAPHOS® N / KAPHOS® L / polymeric coatings / oil treatment
KXtreme Mechanical Property Table

Property Class 14 15 16 17

Subcategory/ Designation 14.8U 14.9U 15.8U 15.9U 16.8U 17.8U

Tensile Strength Rm [MPa] 1,400 – 1,550 1,500 – 1,650 1,600 – 1,750 1,700 – 1,850
1)

Yield Strength Rp0,2 [MPa] ≥ ≥ ≥ ≥ ≥ ≥

1)
1,200 1,340 1,290 1,430 1,380 1,450

Yield to Tensile Strength ~ ~ ~ ~ ~ ~

Ratio Rp0,2/Rm 2) 0.86 0.96 0.86 0.95 0.86 0.86

Fracture elongation A5 2) ≥ 10% ≥ 9% ≥ 8% ≥ 8%

Necking Z 2) ≥ 50% ≥ 48% ≥ 46% ≥ 46%

1) Strength values measured on standard specimens 2) Ductility values (Toughness) on standard specimens
Subject to technical changes

15.10.2015 (c) KAMAX Automotive GmbH – confidential – technical data may be subject to change 7
Downsizing Potential
Comparison of 10.9 vs 15.9U fasteners at different sizes

Torque and angle

controlled
(yield controlled )

Torque controlled

 KXtreme® 15.9U allows downsizing to the next smaller bolt dimension

UHT Heat Treat Process

Bainitic austempering DIN EN 10052 Description

 Fundamental difference to
martensitic tempering is
the quenching and
Austenitizing Conventional holding at a temperature
Ac3 Heat Treatment greater than the
(Q&T) martensite start
Temperature

temperature (Ms)
UHT: Bainitic
Tempering Austempering

Isothermic transformation
Ms

RT
Time

Standard Oven Oil bath Oven Water bath

UHT Oven Salt bath Washing / Drying

15.10.2015 (c) KAMAX Automotive GmbH – confidential – technical data may be subject to change 9
KAMAX UHT – No Design Limitations up to M22

Head types Bolt lengths, shapes

All current bolt lengths, thread

All current head shapes types and external shapes (center
collar, grooves)

03.11.2015 (c) KAMAX Automotive GmbH – confidential – technical data may be subject to change 10
UHT Summary
KXtreme
 Up to property 17.8U
 Bainitic Microstructure
 No size limitation
 Engine Applications:
 Production up to PC17.8U
 Connecting Rod Bolts
 Cylinder Head Bolts
 Bearing Cap Bolts
 Fly Wheel Bolts
 Damper Bolts
 Chassis Applications
 PC12.8U in Production
 PC14.8U first applications in customer
testing. Production July 2017.
 Using selected material and special
processing data shows risk for hydrogen
induced failure is similar to PC10.9
 System cost & weight savings when designed
up front

19.06.2017 (c) KAMAX Automotive GmbH – confidential – technical data may be subject to change 11
KX – Lightweight Bolt

T. Schmitt
M. Kellner
Weight Reduction & Increased Function

Weight Reduction

Head weight reduction up to 34%

Inner Hex Extrusion adds Value to the Weight Reduction

• Hex flange head and internal

hex drive are adjusted to the
next standard size

19.06.2017 (c) KAMAX Automotive GmbH – confidential – technical data may be subject to change 13
Wedge Tensile Results

Wedge Tensile Test (10°)

• According to DIN EN ISO 898

10°

Tension [MPa]

Elongation [%]
Results
 All specimens fail in threaded section.
 Lightweight-head has no negative impact on the ultimate tensile strength.

19.06.2017 (c) KAMAX Automotive GmbH – confidential – technical data may be subject to change 14
Lightweight Bolt Summary

KX - Lightweight Bolt
 Reduction of head weight up to 34 %.

 Additional functionality through internal hex

drive.

 Non proprietary design, no patent required.

 Possible application to every size and head

shape.

 Lightweight head is independent of shaft and

thread length.

 Available with all coating systems.

 Selected as lightweight head for 2 global

automotive OEMs

19.06.2017 (c) KAMAX Automotive GmbH – confidential – technical data may be subject to change 15
KXact – Precision Clamp Load
Typical Clamp Load Variation Contributors

Factors of influence*

14.13
FM, max 8%
Thread tolerance

ΔFM
FM, min
52.46
2% Tensile strength tolerance
Clamp load FM

33.36
2%
Friction window

Tightening angle 𝜗 𝐹𝑀,𝑚𝑎𝑥 −𝐹𝑀,𝑚𝑖𝑛

∆𝐹𝑀 = 𝐹𝑀,𝑚𝑖𝑛
[%]

* Averaged for M6 – M20 u. 8.8 – 16.8

19.06.2017 (c) KAMAX Automotive GmbH – confidential – technical data may be subject to change 17
KAMAX Optimized Bolt

Example M12x1.75 10.9

30% Gewindetoleranzen Tensile strength
Vergütungsstreuung Reibwertfenster
Friction window
Thread tolerance
tolerance Thread tolerance
Current: 6g
13% Optimized for reduced clamp load
25%
spread: 4g
Clamp load spread
reduced by 59%
Clamp load spread

20%

Tensile strength tolerance

56% Current: 1040-1190 MPa
15%
Optimzed for reduced clamp load
spread: 50 MPa

10% 9%

18%
Friction window
5% 31% Current: Δµ = 0.06
Optimzed for reduced clamp load
14% spread: Δµ = 0.03
0%
Stand der Technik KX-Vorspannkraftoptimierte Schraube
Current PC 10.9 bolt KX optimized bolt

19.06.2017 (c) KAMAX Automotive GmbH – confidential – technical data may be subject to change 18
 Reduced Clamp Load Variation

Reduced: tensile strength tolerance + thread tolerance + friction window

Tensile strength: 50 MPa
Thread tolerance: DIN13 / KN5602 / 4g
Friction window: Δµ = 0.03

50%

45%

40%
Clamp load variation

35%
16.8
30%
14.8
25%
12.9
20% 10.9
15% 8.8

10%

5%

0%
M6x1 4g M8x1,25 4g M10x1,5 4g M12x1,75 4g M16x2 4g M20x2,5 4g

19.06.2017 (c) KAMAX Automotive GmbH – confidential – technical data may be subject to change 19
Summary

 Precise installation of clamp load

 For special applications a clamp load

spread of ± 5 % possible

 Light weight potential due to reduced max.

loads and reduced surface pressure.

Clamp load FM
 For applications with narrow clamp load
requirements

Tightening angle 𝜗

19.06.2017 (c) KAMAX Automotive GmbH – confidential – technical data may be subject to change 20