Unit

2 Fasteners

As you already know, an automobile is an assembly of a

large number of sub-assemblies and components, such
as engine, clutch, gearbox, differential wheels brakes,
etc. Automotive fasteners are a collection of products that
are used in automotive and vehicle assembly for joining
these components. Each of these assemblies is formed
by joining many components. Some of the components
or sub-assemblies may move together (kinematic joint),
some are physically fixed together, with zero motion
possible (rigid joint). Both types of joints are important
in manufacturing a vehicle. The process and methods
used for joining depend on the type of joint, the required
strength, the material of the components being joined,
the geometry of the components, and cost. The five most
common methods used for joining are:
1. Mechanical fastening
ƒ Screws
ƒ Bolts
ƒ Nuts
ƒ Rivets
2. Welding
3. Brazing

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 4. Soldering
5. Adhesive bonding

Mechanical Fasteners
A mechanical fastener is a device that is
used to mechanically join (fasten) two or
more objects together and the process
is called fastening. Bolts, nuts, screw,
stud, rivets, shins, pin, tie rods, etc., are
some examples of mechanical fasteners.
Mechanical fasteners are usually
made of stainless steel, iron, brass,
aluminium, nickel, etc.
In general, fasteners are used to
create non-permanent joints; that is,
joints that can be removed or dismantled Fig. 2.1: Fasteners

without damaging the joining components. The main

components of engine are joined by fasteners. Similarly,
there are many other sub-assemblies, which are joined
by the fasteners to make an engine.

Session 1: Automotive Bolts and Machine

Screws
Automotive bolts and machine screws are also known
as threaded fasteners. They are effective at joining
multiple objects. Fasteners have a threaded pin or rod
Bolt Screw
with a head at one end. An automotive bolt is inserted
through holes in the assembled parts and fixed firmly
with a mated nut with the help of a torque. The bolt and
nut are tightened by holding the bolt head stationary
and turning the nut for tightening.
Whereas, a machine screw is an outside threaded
fastener. On the top of a screw is a head, which is used
Fig. 2.2: Bolt and screw
to drive the screw into the object. An automotive bolt
with a common head can work as a screw, and can be
driven into a hole by the head (Fig.2.2). Usually, the
machine screws are fully threaded.
There are many types of automotive bolts, such as
connecting rod bolts, wheel bolts, hub bolts, U-bolts,
J-bolts, engine mounting bolts, suspension links and

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 bolts, lug bolts, radiator bolts,
thread nut runout shank radius head
motor mount bolts, all mounting
plates bolts, etc. The parts of a
standard bolt are shown in Fig.2.3.
A bolt is measured either in Inch
or Metric. A screw and bolt are
defined by length, type of head and
thread length grip length the thread.
nominal length
Thread on the Bolt
Fig. 2.3: Parts of standard bolt
A bolt thread is a ridge of uniform
section in the form of a helix on either the external or
internal surface of the cylinder. Internal threads refer
to those on nuts and tapped holes and external threads
are those on bolts, studs or screws. The helix of a thread
can twist in two possible directions — right hand (RH) or
left hand (LH) (Fig. 2.4). The number of screw threads
may vary from 2 to 20 starts or more. As illustrated in
Fig.2.5, if the end view is an offset circle, then the screw
is a single start.

Right Hand Thread

1 Start 2 Start

Left Hand Thread 3 Start 4 Start

Fig. 2.4: Threads on the bolt Fig. 2.5: Number of starts

Basic Thread Terms

The basic parts of thread as shown in Fig.2.6 have been
explained below:

Pitch Diameter
It is the effective diameter of a screw thread, approximately
halfway between the major and minor diameters.

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 Pitch

Major Crest
Diameter Angle

nk
Pitch

Fla
Diameter

Minor
Diameter Root

Pitch/2

Fig. 2.6: Basic parts of thread

Major Diameter
It is the largest diameter of a screw thread measured
at the crest of a male thread and at the root of a
female thread.

Minor Diameter
It is the smallest material diameter of a thread.

Crest
It is the major part of a thread internally or externally.

Flanks
They are the straight sides which connect the crest and
the root of the thread.

Root
The root is the bottom of the groove between the two
flanking surfaces of the thread whether internal
or external.

Thread Angle
It is the angle between the flanks.

Pitch
It is the distance between corresponding points on
adjacent surface of the thread, in the same axial plane.

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 Basic Profile of Metric Thread

Fig. 2.7: Basic profile of ISO metric thread

In India, we use ISO metric threads and their basic

profile is shown in Fig.2.7, where
D= Major diameter of internal thread (nut)
d= Major diameter of external thread (bolt)
D2= Pitch diameter of internal thread
Hexagonal Bolt
d2= Pitch diameter of external thread
D1= Minor diameter of internal thread
d1= Minor diameter of external thread
P= Pitch
D
e

H= Height of fundamental triangle

d = D = nominal diameter
s k d1 = D1 = d - 1.0825 P
d2 = D2 = d - 0.6495 P
Non-structural Structural
P = Pitch
e = 1.6 D s = 1.8 D
H = 0.866 P
e = 1.8 D e=2D
r = 0.1443 P
k = 0.7 D k = 0.7 D
Bolt Head Dimensions
ISO metric bolts
Bolt head dimensions are related to
Fig. 2.8: Bolt head dimensions their diameter as follows (Fig.2.8):

Structural Bolts
A large, heavy-duty hex bolt designed for steel-to-steel
structural connections. They are used for structural

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 applications in buildings and bridges, ships, airplanes
and vehicles. Consequently, they are typically very short.

Non-structural Bolts
These are general duty hex bolts used in sheet metal
works and for fixing trims in vehicles.

Bolt Head Marking

The lines on the head of a bolt indicate its grade. Bolt
head markings for metric bolts have been given in the
table below.
Mechanical Properties
Class and Nominal Size Proof Min. Yield Min. Tensile
Head Marking
Material Range (mm) Load Strength Strength
(MPa) (MPa) (MPa)
Class 8.8 All Sizes 580 640 800
Medium below 16mm
Carbon Steel, 16mm – 600 660 830
Quenched and 72mm
8.8
Tempered
Class 10.9 5mm – 830 940 1040
Alloy Steel, 100mm
Quenched and
Tempered
10.9
Class 12.9 1.6mm – 970 1100 1220
Alloy Steel, 100mm
Quenched and
Tempered
12.9
Stainless A-2 Stainless All sizes 210 Min. 500 Min.
markings vary. Steel alloy 20mm 450 700 Typical
Most stainless is with 17–19% Typical
non-magnetic. Chromium and
Usually 8–13% Nickel
stamped A-2
Tensile Strength: The maximum load in tension (pulling apart) which a
material can withstand before breaking or fracturing.
Yield Strength: The load at which a material shows a specific deformation.
Proof Load: Load at which the product withstand without evidence of any
permanent set.
1MPa = 1N/mm2 = 145 pounds/inch2

Bolt and Machine Screw Material

Bolt and machine screw material can be important
when choosing a fastener due to its features.

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 Some of the material used to make these have been
given in the Table below.
Material Features
Aluminium Lightweight, resistant to oxidation, easy to manufacture and thermal
and electrical conductive.

Brass Strong, conductive and corrosion resistant

Copper alloy Higher load-carrying capacity, wear resistant

Plastic Inexpensive and corrosion resistant (for light loads)

Steel Strong, carbonated iron

Hardened steel Stronger than steel screws, but brittle

Stainless steel Chemical and corrosion resistant with an appealing finish

Super alloys Heavy mechanical strength, surface stability, corrosion resistant and
creep to resistant at high temperatures

Titanium Hard and strong, light weight and corrosion resistant

Types of Bolts
The table given below lists the different types of bolts
and their features.
Type Shape Features
Anchor bolt Available in roll as well as cut thread and is ‘J’
shaped.

Carriage bolt It is a threaded fastener used with wood. It comes

in an assortment of lengths, diameters and thread
pitches.

Elevator bolt Fastener used with wood, although it is used to

fasten metal components

Eye bolt It is a screw with a loop on one end and thread

on the other. Eye bolts are used to attach cables
to objects.

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 Flange bolt They are also known as frame bolts, hex frame
flange bolts and hex flange screws.

Frame bolt It is a one-piece hex-washer head bolt with a flat

bearing surface made of high alloy steel. It is used
in truck frames.

Hanger bolt They are threaded at both ends. Standard hanger

bolts are designed for insertion in a predrilled
pilot hole.
Heavy hex bolt A low carbon steel hex head bolt with a wider head
than that of a standard hex bolt.

Hex bolt These bolds have a hexagonal head. They are

available in different grades of stainless steel,
brass, silicon, bronze, etc.

Hex machine These bolts have a hexagonal head on one end, no

bolt washer face on the bearing surface and a threaded
shaft on the other end

Socket It is hex socket head screw with an enlarged,

shoulder bolt unthreaded and cylindrical shoulder under the
head.
Lag bolt It is a full-bodied bolt with a hex head. It used
for wood applications, such as in fences, patio
covers, etc.
Socket screws A hex socket head screw with an enlarged,
unthreaded, cylindrical shoulder under the head
for use as a bearing pin. Allen head wrench is
used for tightening the screw.

Square headed They are similar to hex cap screw in size and
bolt shape but the head is square instead of hexagonal.
They have the roll thread and also come in the lag
screw thread as well.
U-bolt It is a ‘U’ shaped bolt with two threaded arms.
U-bolts are used as framing fasteners for
foundations and pipe and conduit holders.

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 Knurled bolts This type of bolt is used in electrical switchboards.

Plough bolt It is used for making mechanical connections that

require a smooth, or flush, surface. It is used in
many heavy construction equipment, such as
snowplows, road graders and scoop shovels.

T-head bolt It is a bolt with a T-shaped head that matches

T-slots in a machine table. It is used for holding
parts on a machine table.

Machine Screws
Machine screws have threads for use with a nut
or in a tapped hole. Also referred to as a stove bolt.
The dimensions of metric machine screws are as
shown below.
2D 2D 2D 1.6 D
0.6 D

0.6 D
1.75 D 1.75 D
D/4
D/2
D/2
Length

Length

D D D D

Raised
Countersunk Panhead Cheesehead
Countersunk

Fig. 2.9: ISO metric machine screws

Different types of machine screws categorised on the

bases of head shape and features have been given in the
table below.
Type Head Shape Features
Phillips pan head It is slightly rounded with short vertical sides
and the head is ‘X’ shaped to fit into a phillips
screwdriver.
Slotted flat head Its head has a flat top. It has a simple slot for
a flat bladed screwdriver.

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 Slotted oval head It is countersunk with a rounded top.

Slotted truss It is wide with a low profile rounded top.

head

Slotted round Slotted drives have simple slots for a flat

head bladed screwdriver.

Torx pan head It is slightly rounded with short vertical

type F sides. Torx drives are designed for maximum
installation torque.
Slotted hex Slotted hex washer heads are six sided for
washer head type use with a wrench.
F

Phillips flat head Flat heads are countersunk with a flat. It is

X shaped for a Phillips screwdriver.

Phillips oval head Phillips drives are X shaped for a Phillips

screwdriver.

Phillips truss It is wide with a low profile rounded top.

head

Combo truss It is wide with a low profile rounded top.

head

Combo round It is domed and looks like half of a sphere.

head

Torx flat head Type F screws have a thread cutting tip.

type F

Set screw These screws have no head for screwing.

Sheet metal It is a screw with a self drilling point.

screw

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 Notes
Practical Exercise
1. List the different types of bolts used in a vehicle and state
their features.
S.No. Type of bolt Features
1.
2.
3.
4.

2. List the types of machine screws used in a vehicle and

state their features.
S.No. Type of bolt Features
1.
2.
3.
4.

3. Draw the basic profile of metric thread.

Check Your Progress

A. Fill in the blanks
1. A fastener is a hardware __________ that mechanically
joins or __________ two or more objects together.
2. Automotive fasteners are made up of a variety of
_____________.
3. A bolt is an externally threaded _________.
4. External threads are on the __________ or screws and
internal threads are on the __________.
5. In India we use ISO __________ thread.

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 Notes
B. Multiple choice questions
1. Which automotive fastener(s) is (are) used for holding or
connecting two or more objects in a machine?
(a) Nuts and bolts
(b) Wooden keel
(c) Fibre joint
(d) None of the above
2. What is the simple effective diameter of a screw thread?
(a) Pitch diameter
(b) Flank
(c) Root
(d) Threaded angle
3. What are the straight sides, which connect the crest
and the root called?
(a) Flank
(b) Root
(c) Minor diameter
(d) Pitch diameter
4. Match the following
(a) Eye bolt

(b) Flange bolt

(c) Frame bolt

(d) Hanger bolt

5. Choose sheet metal screw on the basis of the head shape

shown here

(a) (b)

(c) (d)

C. Answer the following questions

1. Describe the importance of bolts.
2. What are machine screws?
3. What is the importance of threads on bolt and machine
screws?
4. Differentiate between bolt and screw.
5. What do you understand by metric thread? Make a
profile of metric thread and state all the terminologies.

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 Session 2: Automotive Nuts
An automotive nut is a type of fastener
with a threaded hole. It is used opposite
a mating bolt to hold together temporary
or permanent structures. These nuts are
generally square or hexagonal shaped.
There are different types of automotive
nuts, such as simple nuts, collar nuts,
locking, etc. (Fig.2.10).

Thread Profile in Nut

Fig. 2.10: Different types of nuts A nut is screwed onto a bolt for joining two
metal parts. Therefore, the thread profile
of a bolt and nut must match and since we use metric
threads in India, the nut being used in conjunction with
the bolt must have metric threads as well. Mismatching
of the profile and forcible screwing may damage the
thread profile of a nut and bolt, and the nut will not fit
on the bolt. The nut may have left hand or right hand
internal threads.

Dimensions of Nut
All the dimensions of ISO metric nut are related to the
internal diameter of the nut.

Material of Nuts
Nuts and bolts are made of the same material these
include everything from aluminium to brass, copper
alloy, plastic, steel, hardened steel, stainless steel,
super alloys, titanium, etc.

Types of Nuts
The table given below lists the different types of nuts as
per their type shape, and features.
Type Shape Features
Hex It is a type of metal fastener that has six sides. They are
used to fasten a bolt to another object.

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 Heavy hex These nuts are larger and thicker than hex nuts. Heavy
hex nuts are used for large diameter and high strength
bolt applications.

Nylon insert Some nuts use nylon as a locking feature. The nylon is
lock inserted to seal the bolt thread against seepage of liquid
material.

Jam It is a thin nut used to lock a thicker nut. A thin nut

is placed adjacent to the joint surface and tightened
against the thick nut.

Nylon insert It is low profile locknut which is fastened a bolt for

jam lock mechanically joining material together. The nylon insert
located at the top of the nut prevents loosening caused
due to vibration.
Wing It is a type of nut with two large metal ‘wings’, on each
side. It can be easily tightened and loosened with hand.

Cap These nuts cover the exposed portion of a threaded stud,

rod and bolt ends. It is shaped like a dome.

Acorn It is a nut fitted with a domed top. The external thread

cannot be touched due to domed top.

Flange It is a plate or ring used for connecting pipes, valves,

pumps and other equipment, to form a piping system.

Tee It is an internally threaded fasteners which is used for

tightening wood, particle board, etc.

Square It is a four-sided nut and has a greater surface.

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 Prevailing It is a type of locknut, which resists loosening caused by
torque lock shock, vibration and other dynamic forces.

K-lock or Kep It is a nut with an attached free-spinning washer. It is

used to make assembly more convenient.

Coupling It is used to join two externally threaded rods together.

Slotted Hex These nuts are used in many applications, but

Nuts specifically in automotive bearing or wheel hub to
spindle assemblies.

Castle nut With nut slots (notches) cut into one end, it is a positive
locking device. These nuts are used in low-torque
applications, such as holding a wheel bearing in place.

Practical Exercise
1. List the types of nuts used in a vehicle and state their
features.
S. No. Type of bolt Features
1.
2.
3.
4.

2. Draw the profile of ISO metric thread.

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 Check Your Progress Notes
A. Fill in the blanks
1. A nut is a type of fastener with a _____________ hole.
2. For joining two metal parts, the nut is screwed onto the
_____________.
3. The _____________ of the bolt and nut must be same else
the nut cannot be _____________ on the bolt.
4. A nut can have left hand or right hand _______________
threads.
5. A hexagonal nut is a type of metal fastener that has
_____________ sides.

B. Multiple choice questions

1. Which factor of the bolt and nut must be same for the
nut to be screwed on the bolt?
(a) Pitch
(b) Minor diameter
(c) Root
(d) Flank
2. Which of the following is a hexagonal nut?

(a)

(b)

(c)

(d)

3. Which nut is used to join two externally threaded rods

together?
(a) Coupling
(b) K-lock or Kep
(c) Square
(d) None of the above
4. Which nut is used specifically in automotive bearing or
wheel hub to spindle assemblies?
(a) Slotted Hex Nuts
(b) Prevailing torque lock
(c) K-lock or Kep
(d) Square

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 C. Answer the following questions
1. Describe the importance of nuts.
2. Why are nuts made of four or six faces?
3. What is the importance of threads in a nut?
4. What do you understand by ISO metric thread?
5. Name the different types of nuts.
6. Name the different types of machine screws.

Session 3: Automotive Studs

Automotive studs also known as double-
ended automobile fastener has threaded on
both the ends. One end of the stud is fixed
to an object while the other end is typically
mated with a nut. With the growing automotive
parts industry, various automotive fasteners
manufacturers and suppliers are coming up
with new materials to manufacture a variety
of auto studs.
Studs (Fig.2.11) are used for joining of
parts. Due to low tensile strength of cast iron,
cast iron thread gets damaged in excessive
Fig. 2.11: Different types of studs
tightening process. It leads to permanent
damage of the casting. They are also used in
gas and water-tight joints in applications, where heavy
pressures are created. In automobile, studs are used
for holding down the cylinder head on a cylinder block
of motor car engine. The joint between the cylinder and
the head should be a temporary one.
On the basis of their usage, automotive studs can be
categorised as engine studs, wheel studs and stainless
steel studs.
Automobile studs are manufactured from brass,
copper, plastic, nylon, aluminium, bronze and titanium.

Wheel Studs
Wheel studs are threaded fasteners that are used for
holding the wheels of automobiles. These wheel studs
are semi-permanently fixed directly to the vehicle hub.
Lug nuts are used over the wheel stud for tightening

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 the wheel (Fig.2.12). When a wheel is
removed for tyre change, etc., the stud
remains in the hub. Many automobiles
use bolts instead, where removable
bolts are screwed into the wheel hub.
Wheels that use bolts have one or
more small locator pins to assist this.
The wheel is lifted onto the pins, and
then the bolts are inserted. Once the
bolts are tightened and the wheel is
fully installed, the pins have no further
function whilst the vehicle is driven. Fig. 2.12: Wheel stud

Types of Wheel Studs

Wheel studs are replaceable and come in two basic
kinds:
(a) Screw-in and
(b) Press-in
Screw-in
Screw-in studs (Fig.2.13) are simply screwed into the
existing threaded bolt hole in the hub. The end that
screws into the hub is usually either threaded with
a higher tolerance fit or installed with a chemical
thread-locking fluid to keep it from backing out from
the hub when the lag nut is removed.
Press-in Fig. 2.13: Screw-in type stud
Press-in studs (Fig.2.14) are installed from the back
side of the disc or drum hub and may require removal
of the hub from the vehicle for installation or removal.
They consist of a threaded portion and a larger diameter
section, called the knurl, which is splined to prevent
rotation. The diameter of the knurl is larger than the
hole in the hub requiring a press fit to seat the stud.
The stud is prevented from being pulled through the
hub by a larger diameter stop on the end.

Engine Studs
Main Studs
Main studs are used for heavy-duty application Fig. 2.14: Press-in type stud

(Fig.2.15). It can replace main cap bolts. Main studs

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 provide the ability to obtain more accurate torque
values. Studs do not twist during tightening. As bolts,
the studs stretch in one axis alone. Use of studs results
in less wear to the block’s threads. Life of the threaded
holes increases in the block over periods of servicing
or rebuilding. The use of studs also eases main cap
installation, and contributes to main cap alignment.

Fig. 2.15: Main studs in engine block

Cylinder Head Studs

The use of head studs, (Fig.2.16) help in cylinder head
installation, simply from a standpoint of gasket and
head alignment.
Use of studs provides much more accurate and
consistent torque loading. When a bolt is installed, the
act of tightening results in both twisting (torsional load)
and stretching (vertical or axial load). This results in
the bolt being exposed to two forces at the same time,
as well as experiencing frictional loads at the thread
engagement. When the nut is tightened on a stud, the
stud stretches on its vertical axis only. The exposed
end (top) of the stud features ‘fine’ threads, which allow
more precise and therefore accurate, torque readings
when the nut is torqued (or torque or angle tightened)
to specifications.
Fig. 2.16: Cylinder head studs

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 Notes
Practical Exercise
1. List the types of studs used in a vehicle.
S.No. Type of studs
1.
2.
3.
4.

2. Draw different types of studs used in automobile.

Check Your Progress

A. Fill in the blanks
1. Studs are mechanical ___________ which are ____________
on one or both ends.
2. Automotive studs are _______________________ at both
the ends.
3. Wheel studs are the threaded fasteners that hold on the
____________ of automobiles.
4. Press-in studs are installed from the back side of the
____________ or ____________.
5. For a performance or ____________ application, the use
of ____________ is preferred whenever possible instead of
main cap bolts.

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 Notes
B. Multiple choice questions
1. Fasteners which are threaded on one or both ends are
known as _____________.
(a) studs
(b) welding
(c) casting
(d) rivets
2. On the basis of their usage, automotive studs can be
categorised as __________________.
(a) engine studs
(b) wheel studs
(c) stainless steel studs
(d) All of the above
3. Wheel studs are used in automobiles for ____________
_____________.
(a) holding the wheels
(b) holding the chassis
(c) holding the frame
(d) All of the above
4. Main studs can replace ____________________.
(a) main cap bolts
(b) screw-in
(c) press-in
(d) All of the above
5. Which wheel stud can be replaced if broken?
(a) Screw-in and press-in
(b) Engine studs
(c) Stainless steel
(d) All of the above

C. Answer the following questions

1. What are the advantages of studs over bolts?
2. In what conditions should studs be used in place
of bolts?
3. Differentiate between bolt and stud.
4. Name the different types of studs.

Session 4: Automotive Washers and Rivets

A washer is a thin plate with a hole. It is normally
used to distribute the load of a screw or nut. It acts
as a spring, locking device, spacer, wear pad and also
reduces vibration. A washer’s, outer diameter (OD) is
twice the width of its inner diameter (ID).

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 Automotive washers are
small flat dishes with a hole in
the center. The main function of
an automotive washer is to hold
or bear the load of a threaded
fastener or bolt. Washers are
put below a nut, axle bearing
or joint with the main purpose
of preventing leakage and
distributing pressure. The
automotive washers include
Fig. 2.17: Different types of washers
bolt lock washers, cylinder
head washers, lug nut washers, radiator washers and
hardened washers. These essential auto fasteners are
generally made of metal, leather, plastic or rubber.
The table given below lists the different types of
washers as per their type, shape and features.
Type Shape Features
Flat They are kept under the head of a bolt or nut for
providing a smooth bearing surface as well as to
distribute the fastener load over a wider surface area.

Fender It is a flat washer with a large outer diameter in

proportion to its central hole. It is commonly used to
spread the load on thin sheet metal.

Finishing It is designed to accommodate the heads of a

countersunk screw in order to provide a finished
appearance.

Split lock It is a split type of spring washer whose purpose is to

prevent self loosening of the nut or the bolt.

External tooth It is also known as a serrated washer or star washer,

lock has serrations that extend radially inward and/or
outward to bite into the bearing surface.

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 Internal tooth It has serrations along the inner edge of the washer,
lock which makes it aesthetically pleasing

Square plate It is made from low carbon steel and has a larger
surface area than round washers. This type of washer
is used in timber construction.

Dock It has an outside diameter measuring up to a 100mm.

Dock washer is used for heavy duty load bearing
applications.

Ogee It is typically used in dock and wood construction.

These oversized washers have a large bearing surface
designed to prevent bolt heads and nuts from pulling
into the wood.

Sealing It is made from a silicone rubber section, molded

and bonded to a stainless steel formed washer. It is
vibration-resistant. They are designed for use with
regular screws, bolts or studs for sealing panels and
enclosures having large or irregular clearance.

Rivets
Rivets are semi-permanent mechanical fasteners. Before
being installed, a rivet consists of a smooth cylindrical
shaft with a head on one end. Rivets are used as
automobile fasteners in a wide number of applications
like vehicle bodies, aircraft, bridges, cranes, building

Fig. 2.18: Different types of rivets and rivet joint

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 frames, etc. Rivet is held in place and the metal parts
are joined. The joint can be opened by removing the
deformed end of the rivet by chisel or grinding. Rivets
and riveted joint are shown in Fig.2.18.

Types of Rivets
Rivets are usually categorised
on the basis of their heads as
shown in Fig.2.19. The material
of the rivets must be tough and Universal
Cone Round Top Button Truss
Head Countersunk Head Head Head
ductile. They are usually made
of steel (low carbon steel or
nickel steel), brass, aluminium
or copper, etc. However, when
strength and fluid tight joint is AN456
Pan Flat Top Flat Tinners’
Head Countersunk Head Head Rivet
the main consideration.
Fig. 2.19: Common types of rivets
Making rivet heads with
hand rivet set
The rivet head on the rivet is made using a hand rivet
set as shown in Fig.2.20. The sheet metal to be joined
by riveting is drilled according to the size of the rivet
shank. The holes are aligned and the rivet is inserted
into the holes. The deep hole of the rivet set is used to
draw the sheets and rivet together and also the rivet
directly through thin sheeting. The rivet set selected
should have a hole, slightly larger than the diameter
of the rivet. The rivet shank is hammered keeping the
shallow cone hole of the rivet set on the protruding end
of the rivet. A good job of riveting can be done with not
more than six normal blows of the hammer, and after a
little practice this number can be cut by half.

Deep
Outlet Hole
on Side
Shallow
Concave
Hole
Hand rivet set Drawing rivet in joint Hammering rivet Forming head
Fig. 2.20: Forming rivet heads

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 Other Important Fasteners
There is a vast array of different types of fasteners
used in the automobile industry. Some other important
fasteners have been given below.

Circlip
A circlip, is a type of fastener consisting of a semi-flexible
metal ring with open ends. It can be snapped into place,
into a machined groove on a dowel pin or other part to
permit rotation but to prevent lateral movement. Circlips
are often used to secure pinned connections. These are
used to retain piston wrist pins or gudgeon pins, the
clips are known as wrist pin clips or wrist pin retainers
or gudgeon pin clips. The most commonly used circlip
for this application is a simple spring steel circlip (snap
ring), or plain wire ring. A circlip and circlip plier are
Fig. 2.21: Circlip and
circlip plier
shown in Fig.2.21.

Split Pin
A split pin is a metal fastener with two tines that
are bent during installation. Split pins are generally
made of soft metal, making them easy to install and
remove. Common materials used in its manufacture
may be mild steel, brass, bronze, stainless steel and
aluminium. A new split pin (see Fig. 2.22 A) has its
flat inner surfaces touching for most of its length so
that it appears to be a split cylinder (Fig.2.22 D). Once
inserted, the two ends of the pin are bent apart, locking
it in place (Fig.2.22 B). When they are removed they
are supposed to be discarded and replaced, because of
fatigue from bending.

Fig. 2.22: Split pin in shaft. A-new, B-installed, C-spring type, D-cross-section

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 Spring Pin
A spring pin (Fig.2.23) is a mechanical fastener that
joins two or more parts of a machine relative to each
other. Spring pins have a body diameter which is larger
than the hole diameter, and a chamfer on either one
or both ends to facilitate starting the pin into the hole.
The spring action of the pin allows it to compress as
it assumes the diameter of the hole. The radial force
exerted by the pin against the hole wall retains it in
the hole, therefore a spring pin is considered a self Fig. 2.23: Slotted spring
retaining fastener. pin (1) and washer (2)
used to secure a shaft (3)

Practical Exercise
1. List the different types of washers used in a vehicle and
state their features.
Sr. No. Type Features
1.
2.
3.
4.

2. Draw different types of rivets used in an automobile.

Check Your Progress

A. Fill in the blanks
1. A washer is a thin ____________ with a hole that is
normally used to ____________ the load of a threaded
____________.
2. Automotive washers are small flat ____________ with a
____________ in the center.
3. Rivets are ____________ mechanical fasteners.

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 Notes
4. Rivets are categorised on the basis of their ____________.
5. Circlips are often used to secure _____________.
6. Split pins are typically made of ____________ metal,
making them easy to ____________ and remove.
7. Spring pins have a body diameter which is larger than
the ____________ diameter, and a ____________ on either
one or both ends to facilitate ____________ the pin into
the hole.

B. Multiple choice questions

1. A washer is used to distribute the load of a ___________.
(a) screw or nut
(b) chassis
(c) wheel
(d) None of the above
2. A washer’s outer diameter (OD) is twice the width of their
____________.
(a) inner diameter
(b) pitch
(c) flank
(d) None of the above
3. Which of these is a f lat washer?

(a)

(b)

(c)

(d)

4. Which of the following type of washers is used in timber

construction?
(a) Square
(b) Dock
(c) Ogee
(d) Split lock
5. Which of the following is a semi-permanent mechanical
fastener?
(a) Rivet
(b) Nut and bolt
(c) Studs
(d) None of the above

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 C. Answer the following questions
1. Describe the importance of washers.
2. What is the importance of rivets?
3. What are the advantages of using washers as fasteners?
4. In what conditions should rivets be used as fasteners?
5. What are the advantages of using split pin as fastener?
6. What are the advantages of using spring pin as fastener?
7. Name different types of washers.
8. Name different types of rivets.
9. List the uses of circlip.

Session 5: Removal and Replacement of

Damaged Fasteners
Removal of Broken or Spoiled Headed Screw
In automobiles, jerk, vibration and corrosion can
cause the screw to break. This leads to dislocation of
the assembly. Therefore, it should be removed and
replaced. Similarly improper use of screw drivers with
its snap head can spoil the screw head, which makes it
difficult to tighten, loosen or remove the screw from the
assembly. Fig.2.24 shows broken and spoiled screws.

Fig. 2.24: Broken and spoiled screws

Method of Removal of Damaged Screw

Case 1: Removal of spoiled headed screw
If the screwdriver keeps slipping, due to widening of the
groove or screw way:
• Use a hacksaw blade and dress the groove.
• Then use a screwdriver with a thick snap, place it
on the screw head and turn it anti-clockwise.
• This removes the screw, if it is not responded.
• Take a prick punch and hammer. Give a light blow
in anti clockwise direction. This loosens the screw.

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 • If it does not work use a drill machine with a drill
bit smaller than the size of the screw.
• Now drill it at the centre of screw, the screw will
get removed.
Case 2: Removal of unheaded screw
If the screw is broken at the top of the assembly
Fig. 2.25: Unheaded screw • remove the other screw and separate the assembly,
• hold the jaws of the clipper on broken screw,
• lock the clipper and turn it anti-clockwise and
• the screw will come out.
Case 3: Removal of unheaded screw broken in the
assembly
• Use a drill machine with drill bit smaller than the
size of screw.
• Now drill it at the centre of the screw. The screw
will get removed.
• Dress the threads before fixing a new screw.

Broken Nut or Bolts

Jerky movement and vibration cause loosening of nuts
and bolts in automobiles and also spoil their internal and
external threads. Also, this slackens the assembly unit
and changes its alignment. Improper use of spanners
or socket may lead to spoiling of edges of their edges.
It is necessary that broken nuts and bolts are removed
or replaced else it becomes difficult to tighten, loosen
Fig. 2.26: Broken bolt
or remove the nut or bolt from the assembly. Fig.2.26
shows a broken bolt.

Method of Removal of Spoiled Headed Nut or Bolts

Case 1: Removal of nut or Bolts
• Use spanner of smaller size, fix it on the nut or
bolt and turn anti-clockwise. It will come out.
• If it does not come out take a prick
punch and hammer at the face of nut or
bolt. Give a light blow in anti-clockwise
direction. This loosens the nut or bolt.
• If this also does not work, use a drill
machine with drill bit smaller than the
size of nut or bolt.
Fig. 2.27: Broken thread

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 • Now drill it at the centre of nut or bolt and remove
the edges of the nut, in the case of a bolt, remove
the bolt head by using a clipper and remove the
remaining part of the bolt from the assembly.
Case 2: Dress the internal threads of the bolts by
using a tap of appropriate size
• In the case of nut, use a die to rethread the stud
threaded portion and use a new nut.

Broken or Spoiled Threaded Studs

A stud is stronger than a bolt, if installed
correctly. The stud is screwed into the
threaded hole without applying pressure
to or galling the threads. After stud
installation, the parts are slipped over the
stud and the washer is installed.
The stud is stronger as the thread
contact at the stud and the threaded hole
Fig. 2.28: Removal of thread
is stationary, when pressure is applied
(while tightening the fastener). But when a bolt is used
to mount a part, the bolt is rotated in the threaded hole
during tightening, which can tear out weak threads.
There will be times when clearance problems will
make it impossible to use a stud instead of a bolt.
Sometimes there is no room to slip a large part over a
stud, but rather the part has to be slipped into place
from the side. But if a stud is used instead of a bolt, the
studs will result in better fastener strength than a bolt.

Method of Removal of Broken or Spoiled

Threaded Studs
Case 1: Removal of spoiled threaded studs
• To remove a spoiled threaded stud, apply gentle
pressure on the assembly with a screwdriver.
This will lift the spoiled portion of the stud
threads upward.
• Turn the nut anti-clockwise, turn the stud
assembly and gently press the screw driver inside
for the stud to come out.

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 • If the nut threads, i.e., internal threads of the
nut or external threads of the studs are spoiled,
then weld the spot to nut and stud. Now turn the
assembly anti-clockwise, a the stud will come out.
Case 2: Removal of broken studs above the casing
• If the stud above the assembly unit is broken,
separate the assembly by removing other nuts.
• Fix the stud extractor on the broken stud and
lock it.
• Now turn the stud extractor slowly, the stud will
come out.
Case 3: Removal of broken studs inside the casing
• Take a prick punch and hammer on the face of
broken stud. Give a light blow in anti-clockwise
direction. This will loosen the remaining portion
of the stud.
• If it does not work, use a drill machine with drill
bit smaller than the size of the stud.
• Now drill it at the centre of the stud. Remove the
burr from the casing.
• Use an appropriate tap and redress the internal
thread.
• Fix the new stud using a stud extractor.

Use of Anti-rust Solution

Anti-rust solution is used for dissolving the dust and
rust on the fastener. This solution makes the process
of removing or changing fasteners easier. Nowadays
Indian as well as imported anti-rust solution or sprays
are available in the market. Fig.2.29 shows anti-rust.

Check Your Progress

A. Fill in the blanks

1. In automobile screws get broken due to ____________,
vibration and ____________.
2. To remove a spoiled headed screw use hacksaw
____________ and dress the ____________.
3. In automobile, due to ____________ movement and
vibration, nuts and bolt get ____________.
Fig. 2.29: Anti-rust solution

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 Notes
4. A stud is stronger than a ____________.
5. Anti-rust solution is used for dissolving the ____________
in the fastener.

B. Multiple choice questions

1. For removing a spoiled headed screw _______________.
(a) use hacksaw blade and dress the groove.
(b) remove the screw, if it does not respond
(c) Both of the above
(d) None of the above
2. Remove unheaded screw if _______________________.
(a) the screw is broken at the top of the assembly
(b) the other screw and separate the assembly
(c) comes out
(d) All of the above
3. How to remove an unheaded screw broken in
the assembly?
(a) Dress the threads before fixing new screw
(b) Drill in to the centre of screw, it will be removed
(c) Use drill machine with a smaller drill bit than that
of the screw
(d) All of the above

C. Answer the following questions

1. Give the process of removing screw with spoiled head.
2. How is a screw without head removed?
3. List the steps to remove unheaded screw broken in the
assembly.
4. Give the steps to remove broken or spoiled
threaded studs.

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