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Ultra Bolts

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The guide provides critical information for manufacturing and evaluating externally threaded fasteners with ultimate tensile strength of 1400 MPa or greater that have a bainite microstructure.

This guide is intended to provide information on expected material and mechanical properties for a bainitic, ultra-high strength steel fastener. It also provides precautions regarding processing and their possible effect on joint design. The guide is not a specification but provides a foundation for ongoing development.

The guide outlines property classes 14.8U, 15.8U and 16.8U and provides expected hardness values, proof loads, wedge tensile strengths, yield strengths, elongations and reductions of area for each class.

USCAR IFI GUIDE

for Ultra-high Strength Externally Threaded Fasteners


GUIDE Number: UHSFG-1416U-2014
1. Scope:
This USCAR IFI GUIDE provides critical information regarding the manufacturing and evaluation of
externally thread fasteners having the following characteristics:
a. Ultimate tensile strength of 1400 MPa and greater.
b. Having bainite micro-structure.
c. That meets the performance requirements of fasteners used in automobile applications.
d. That can be manufactured using existing fastener technology.
e. Meets the economic needs of both the end user and fastener manufacturer. The bolts and
screws covered by this GUIDE are M 6 through M20 that are suitable for use in service
temperature range of -50C to 200C.
Due to the high susceptibility of hydrogen induced delayed fractures, bolts and screws of tensile
strengths1400 MPa and higher should only be used in engine, transmissions, and axle
applications where the risk of corrosion is minimal.
2. Purpose:
This Guide is intended to provide information on expected material and mechanical properties for a
bainitic, ultra-high strength steel fastener. The Guide also provides some precautions regarding the
processing of ultra-high strength steel fastener products, as well as their possible effect on joint
design. This Guide is not a specification, but provides a foundation for ongoing development of ultrahigh strength fastener products.
3. Reference Documents:
a. ISO 898-1, Mechanical properties of fasteners made of carbon steel and alloy steel - Part 1:
Bolts, screws and studs with specified property classes - Coarse thread and fine pitch thread.
b. VDA 235-205, Ultra-high strength fasteners with bainitic heat treatment for automotive industry,
property classes 14.8 to 16.8.
c. FUNDAMENTALS OF HYDROGEN EMBRITTLEMENT IN STEEL FASTENERS, by Salim
Brahimi, July, 2014, http://www.indfast.org/info/free-technical-info.asp
4. Typical Mechanical Properties:
Tests
b

Hardness (HV)
b
Hardness (HRC)
Proof Load (90% YS)
c
Wedge Tensile (full size) MPa
Wedge test angle (threaded to head)
Wedge test angle (not threaded to head)
d
Yield Strength , minimum
d
Elongation , minimum
d
Reduction of area , minimum
a.
b.
c.

d.

14.8U
420 480
42 - 48
985 MPa
1400 - 1570
0
4
0
6
1120 MPa
10%
50%

Property Classes
15.8U
455 515
45 - 51
1050 MPa
1500 - 1670
0
4
0
6
1200 MPa
9%
48%

16.8U
490 - 550
49 - 52
1115 MPa
1600 - 1770
0
4
0
6
1280 MPa
8%
44%

Test methods shall comply with ISO 898-1.


In case of dispute the HV values prevail.
If a threaded bolt is tested As is to be applied as calculated on the mean dimension d2 and d3 of the
applied tolerance setting e.g. 6g, 6e etc.
These tests performed for PPAP and dispute resolution only. Material values established on turned
samples (measuring length L0 = 5d0; where d0 is the diameter of the turned screw diameter).

USCAR IFI GUIDE for Ultra-high Strength Externally Threaded Fasteners November 23, 2015

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5. Material:
Material shall meet the requirements of alloy steel defined in ISO 898-1. Material hardenability shall be such
that a 90% lower bainitic transformation is achievable.
Appropriate steel materials have to be chosen and agreed between bolt manufacturer and purchaser.
Note: SAE J403, grade 8640 steel has been found to be a suitable material. (see Appendix A)
6. Microscopic Analysis:
The microstructure of the fasteners is lower bainite. The core of the threaded portion of the fastener shall
consist of a minimum of 90% lower bainite. The balance of the microstructure may be martensite
incorporated as islands, but shall not be present in cohesive areas. The islands must not exceed a size of
80m in any direction (assessment at a minimum magnification of 500:1).
7. Heat Treat Process (hardening by austempering):
a. The fasteners shall be austenized in a controlled atmosphere furnace adjusted for the carbon
content of the material or in the presence of protective gas.
b. If the fastener raw material was phosphate coated the fasteners shall be processed to remove
surface phosphate before hardening.
c. Ultra-high-strength fasteners with tensile strength values Rm 1400 MPa are susceptible to
hydrogen-induced brittle failures. Great care must be exercised in properly applying the
austempering heat treat process to obtain primarily a lower bainite microstructure to achieve
high strength and a desirable degree of ductility.
8. Carburization:
a. Carburization is not permissible. When assessing carburization by hardness measurement,
care shall be taken to differentiate between a hardness increase due to carburization during
heat treatment and that resulting from cold working after hardening (e.g. thread rolling after
heat treatment).
b. In case of complete decarburization, partial decarburization, or reduction of carbon contents as
defined in section 9.10 of ISO 898-1(2009) the following limit values shall apply:
14.8U, 15.8U, 16.8U
Height of non - decarburized thread zone E
7/8 H1
Maximum depth of complete decarburization G in mm 0.015
H1: Height of external thread in maximum material condition, mm
9. Surface finishes:
a. Ultra-high strength fasteners to be used in engine applications (in oil circulation) are to be
coated preferentially with solid film lubricant / polymer or with zinc phosphate + solid film
lubricant or polymer.
Zinc-phosphated fasteners shall not be installed for at least 7 days after phosphate (quarantine
time for hydrogen effusion).
b. Parts to be coated with zinc flake coating according to ISO 10683 shall be cleaned with
mechanical or alkaline procedures before coating. If chemical cleaning is needed for functional
reasons, only acids with suitable acid pickling inhibitors shall be used for pre-treatment cleaning
to minimize the absorption of residual hydrogen.
Note: To avoid hydrogen induced brittle failures, zinc and zinc alloy electroplated finishes are not permissible for
ultra-high strength fasteners. The removal of existing surface coatings with electrochemical processes is not
permissible.

USCAR IFI GUIDE for Ultra-high Strength Externally Threaded Fasteners November 23, 2015

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10. Design Considerations for fasteners used in fatigue applications:


For fasteners intended for use in fatigue applications the designer should consider specifying oversize
fillet radius and/or an undercut in the bearing surface adjacent to the shank, and the MJ thread design.
Thread rolling after hardening will improve fatigue life results (see Appendix).
11. Surface discontinuities:
Surface discontinuities shall comply with the requirements of ISO 6157-3.

12. Marking Requirements:


The property classes associated with this GUIDE shall be designated 14.8U, 15.8U, or 16.8U depending
on the tensile strength and yield strength requirements. The U is added to signify a lower bainite
metallurgical structure.
The manufacturers identification mark shall be on all fasteners.

APPENDIX
General Information and considerations

1. Development fasteners: The requirements in this document were derived from tests performed on MJ8
X 1.25 hex flange head screws roll threaded after heat treatment made from 8640 material. The
fasteners were separated into several lots and heat treated to various hardness levels. Approximately
half had martensitic microstructure and half lower bainitic microstructures.
2. Joint design considerations: The under-head compression and thread flank pressures of 14.8U and
higher strength fasteners are substantially greater than property class 10.9. The higher pressures
associated with properly loaded 14.8U and higher strength fasteners should be carefully considered
during the joint design process.
3. Installation tool considerations: Properly loaded property class 14.8U and higher strength fasteners
usually require significantly higher tightening values than do property class 10.9 fasteners. Because of
this thin-walled and unhardened driver sockets should not be used in the installation of these fasteners.
Six point sockets are preferred for use compared to twelve point sockets to minimize screw corner
rounding and rapid socket wear and/or breakage.
4. Thread rolling after hardening considerations:
a. Thread rolling after hardening increases fatigue life and helps to minimize thread nicking during
handling.
b. Thread rolling after hardening reduces the susceptibility to hydrogen embrittlement.
c. When fasteners are roll threaded after hardening M42 tool steel thread rolling dies are
recommended to prolong die life and minimize the creation of thread laps.
d. Thread rolling fasteners after hardening is more difficult than thread rolling before hardening
which usually results in higher associated manufacturing costs.

USCAR IFI GUIDE for Ultra-high Strength Externally Threaded Fasteners November 23, 2015

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Representative
Adam Kotlarek
Adrian Cockman
Al Dapoz
Brett Gibson
Duane Drobnich
Fadi Saliby
Horst Dieterle
Joe Greenslade
John Fragnoli
John Reiff
Kurt McKinney
M. Murphy
Mike Holly
R. Talbott
Ralph White
Salim Brahimi
T. Knott

Working Group Members


Company Affiliation
General Motors
Ford Motor
ITW Automotive
Chrysler
Ford Motor
Bossard/McGill University
KAMAX and VDA
Industrial Fasteners Institute
General Fasteners
General Motors
SBD Inc.
Ford Motor
General Motors
Ford Motor
Chrysler
Industrial Fasteners Institute/McGill University
Ford Motor

COMMENTS AND QUESTIONS:


Please address comments and questions regarding this document to mark.mahaffy@fcagroup.com.

USCAR IFI GUIDE for Ultra-high Strength Externally Threaded Fasteners November 23, 2015

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