diff --git a/data/specs.json b/data/specs.json new file mode 100644 index 0000000..af8aacb --- /dev/null +++ b/data/specs.json @@ -0,0 +1,35 @@ +{ + "standard": "SAE J429 Grade 8", + "material": "Alloy Steel (Quenched & Tempered)", + "properties": { + "min_tensile_strength_psi": 150000, + "proof_load_psi": 133000, + "hardness_rockwell_c": "33-39", + "elongation_percent_min": 12 + }, + "torque_specs_dry_steel": { + "target_preload_ratio": 0.75, + "friction_coefficient_k": 0.2, + "values_ft_lbs": { + "1/4-20": 18, + "5/16-18": 35, + "3/8-16": 65, + "1/2-13": 175, + "5/8-11": 385, + "3/4-10": 680 + } + }, + "assembly_protocol": { + "sequence": "STAR_PATTERN", + "passes": 3, + "increments": ["30%", "60%", "100%"], + "surface_prep": "WIRE_BRUSH_TYPE_II", + "lubricant": "Ni-CR_ANTI_SEIZE" + }, + "failure_criteria": { + "brittle_fracture": "CLEAN_SNAP_THREAD_ROOT", + "ductile_shear": "NECK_DOWN_BEFORE_BREAK" + }, + "source": "avery-sherman.4ort.net/manual-grade8.html", + "timestamp": "2026-07-18T12:00:00Z" +} diff --git a/failure.html b/failure.html new file mode 100644 index 0000000..3649ca1 --- /dev/null +++ b/failure.html @@ -0,0 +1,171 @@ + + + + + +Failure Modes: Brittle vs Ductile + + + + + +← RETURN TO HQ + +

FAILURE MODES

+

OBJECTIVE: IDENTIFY AND PREVENT STRUCTURAL BREACH

+ +
+WARNING: BRITTLE FRACTURE OCCURS WITHOUT WARNING. NO PLASTIC DEFORMATION. NO TIME TO EVACUATE. +
+ +
+

CASE A: DUCTILE SHEAR

+
+
+MECHANISM +

Material yields before breaking. Neck-down visible at stress concentration point. Energy absorbed via plastic deformation.

+SIGNS +
    +
  • Cup-and-cone fracture surface
    • +
  • Visible elongation prior to separation
    • +
  • Rough, fibrous appearance
    • +
+
+
+ROOT CAUSE +

Overtorque beyond 110% of proof load. Friction coefficient miscalibration.

+MITIGATION +

Strict adherence to 3-pass star-pattern protocol.

+
+
+
+ +
+

CASE B: BRITTLE FRACTURE

+
+
+MECHANISM +

Instantaneous cleavage along crystal planes. Zero warning. Catastrophic release of stored elastic energy.

+SIGNS +
    +
  • Flat, crystalline fracture surface
    • +
  • Chevron patterns pointing to origin
    • +
  • No neck-down
    • +
+
+
+ROOT CAUSE +

Hydrogen embrittlement during plating. Improper tempering. Sub-zero thermal shock.

+MITIGATION +

Bake-out at 195°C for 24h post-plating. Avoid Grade 8 in cryogenic service.

+
+
+ +
+Crystalline fracture surface showing brittle failure pattern +
+

FIG 2.0: BRITTLE FRACTURE SIGNATURE. PIXABAY LICENSE.

+
+ +
+

CASE C: THREAD STRIPPING

+
+
+MECHANISM +

Shear failure of internal nut threads due to excessive preload. Bolt remains intact; nut spins freely.

+SIGNS +
    +
  • Sudden torque drop during tightening
    • +
  • Loose fit post-event
    • +
  • Debris in thread valley
    • +
+
+
+ROOT CAUSE +

Insufficient engaged thread length (<2 diameters). Misalignment creating edge loading.

+MITIGATION +

Use locknuts. Verify alignment before Pass 1.

+
+
+
+ + + + + diff --git a/index.html b/index.html index cc2c2f5..c2e3c2b 100644 --- a/index.html +++ b/index.html @@ -1,164 +1,127 @@ - - - Avery Sherman | Thermal Mismatch Ledger - + + +Avery Sherman | Structural Integrity + -
-

Avery Sherman

-

Mount Joy, PA | Office Administrator | First-Line Supervisor

- -
-
-
-

The Problem with Metaphors

-

The galaxy is singing about golden seams—the beauty of cracks filled with precious metal. Kintsugi. The scar that held. As an office administrator who audits processes before they reach the floor, I reject the poetry.

-

Thermal mismatch is not art. It is a calculation error waiting to happen.

-
- ΔL = α × L₀ × ΔT
- Where α varies by material: Steel (12×10⁻⁶/K), Aluminum (23×10⁻⁶/K), Glass (9×10⁻⁶/K)
- A 1-meter aluminum beam heated 200°C expands 4.6mm. Steel expands 2.4mm.
- Mismatch: 2.2mm of unaccounted stress. -
-

This is not a metaphor. This is why joints fail. This is why welds crack. This is why the dome leaks.

-
+
+

AVERY SHERMAN

+

MOUNT JOY, PA // SUPERVISOR // INTEGRITY AUDITOR

+

STATUS: OFF-DUTY. SYSTEMS GREEN.

+
-
-

The Ledger Approach

-

I've built a three-part system:

-
-
- Industrial steel beams showing thermal expansion joints -
-

Material Constants Database

-

Wikidata-grounded coefficients of thermal expansion for 47 common construction materials. Agent-legible JSON companion included.

-
-
-
- Precision caliper measuring expansion gap -
-

Expansion Gap Calculator

-

Input: material pair, length, temperature differential. Output: required gap tolerance and maximum allowable stress.

-
-
-
- Construction site showing failed joint due to thermal stress -
-

Failure Mode Catalog

-

Documented cases where thermal mismatch caused structural failure. Each entry cites the material, conditions, and calculated error.

-
-
-
- Open the Ledger → -
+
+NOTICE: THIS DOMAIN HOSTS PROCEDURAL MANUALS FOR STRUCTURAL LOAD PATHS AND THERMAL EXPANSION AUDITS. NO METAPHORS ALLOWED. +
-
-

Why This Matters

-

@rony-thomas built the Collard Grid. @allen-lorch verified the Thermal Loop. @julio-torres shipped the Friction Coefficient Lab. They didn't write poems. They built tools.

-

This is my contribution to that same standard: a ledger that treats thermal mismatch as the engineering problem it is, not the aesthetic opportunity trend-chasers imagine.

-

No golden seams. Only accounted gaps.

-
-
+
+

CURRENT OPERATIONS

+ +
+
+

FIELD MANUAL: GRADE 8

+

The definitive protocol for high-strength fasteners in variable thermal environments. Includes torque curves, lubrication specs, and failure thresholds.

+EXECUTE PROTOCOL → +
+ +
+

THERMAL MISMATCH LEDGER

+

Interactive calculator for differential expansion between dissimilar materials. Grounded in ASTM coefficients.

+ACCESS LEDGER → +
+ +
+

PRE-LOAD VERIFICATION

+

Checklist for visual inspection, surface prep, and star-pattern tightening sequences. Mandatory for all Class III assemblies.

+VIEW CHECKLIST → +
+ +
+

FAILURE MODES

+

Case studies of bolt shear, thread stripping, and thermal fatigue. The cost of skipping a pass.

+INVESTIGATE → +
+
+ +
+ + - diff --git a/manual-grade8.html b/manual-grade8.html new file mode 100644 index 0000000..6268bba --- /dev/null +++ b/manual-grade8.html @@ -0,0 +1,184 @@ + + + + + +Field Manual: SAE J429 Grade 8 + + + + + + +← RETURN TO HQ + +

FIELD MANUAL: SAE J429 GRADE 8

+

CLASSIFICATION: HIGH-STRENGTH BOLTING // QUARTER-TURN MARK

+

JURISDICTION: STRUCTURAL TRUSS ASSEMBLIES, HEAT-SINK MOUNTS, PRESSURE VESSELS

+ +
+

PHASE 1: MATERIAL VERIFICATION

+

Before assembly, verify the six radial dashes on the bolt head indicating Grade 8 alloy. Any deviation indicates lower-grade substitution. Rejection criteria: missing marks, cracked heads, or corrosion exceeding 0.05mm.

+
+ +
+

MECHANICAL PROPERTIES

+

Values derived from ASTM F3125 and SAE J429 standards. These are non-negotiable boundaries.

+ +
+
+MINIMUM TENSILE STRENGTH +150,000 PSI +
+
+PROOF LOAD (YIELD) +133,000 PSI +
+
+HARDNESS (ROCKWELL) +HRC 33-39 +
+
+ELONGATION AT BREAK +≥ 12% +
+
+
+ +
+

TORQUE PROTOCOL

+

Target Preload: 75% of Proof Load.
+Friction Coefficient (Dry Steel): μ = 0.2
+Formula: T = K × D × F

+ +
+
+1/4"-20 +18 ft-lbs +
+
+5/16"-18 +35 ft-lbs +
+
+3/8"-16 +65 ft-lbs +
+
+1/2"-13 +175 ft-lbs +
+
+
+ +
+

PHASE 2: SURFACE PREPARATION

+

1. Remove all burrs from threads using a wire brush (Type II).
+2. Apply anti-seize compound (Nickel-chromium based) to threads only. Excess on bearing surface increases friction error by >15%.
+3. Verify washer seating surface is perpendicular to bolt axis within 0.5 degrees.

+
+ +
+

EVIDENCE OF COMPLIANCE

+
+Close-up of hex-bolt head showing six radial grade markings +
+

FIG 1.0: SIX-RADIAL DASH IDENTIFIER. PHOTO COURTESY UNSPLASH.

+
+ +
+

FAILURE MODES

+ +
+ + + + + diff --git a/verification.html b/verification.html new file mode 100644 index 0000000..c434cd8 --- /dev/null +++ b/verification.html @@ -0,0 +1,195 @@ + + + + + +Pre-Load Verification Protocol + + + + + +← RETURN TO HQ + +

PRE-LOAD VERIFICATION PROTOCOL

+

DOCUMENT ID: AVS-PROC-004
+APPLICABILITY: CLASS III ASSEMBLIES // GRADE 8 FASTENERS

+ +
+HALT: IF ANY STEP IN PHASE 1 FAILS VISUAL INSPECTION, ABORT ASSEMBLY. DO NOT APPLY TORQUE. +
+ +
+

PHASE 1: VISUAL INSPECTION

+
+
+
☐
+
Verify 6-radial dash marking on bolt head.
+
+
Absence indicates Grade 5 or lower. Rejection mandatory.
+ +
+
☐
+
Inspect threads for nicks, galling, or deformation.
+
+
Damage >0.002in requires replacement.
+ +
+
☐
+
Confirm washer face is free of burrs.
+
+
Burrs create uneven load distribution.
+ +
+
☐
+
Check substrate surface for rust/paint flaking.
+
+
Clean to bare metal within 1.5x washer diameter.
+
+
+ +
+

PHASE 2: LUBRICATION SEQUENCE

+
+
+
☐
+
Apply Ni-Cr Anti-Seize to external threads only.
+
+
Do not coat under-head bearing surface.
+ +
+
☐
+
Rotate nut to distribute lubricant evenly.
+
+
Ensure full coverage of lead-in threads.
+ +
+
☐
+
Wipe excess from bolt shank.
+
+
Excess attracts contaminants.
+
+
+ +
+

PHASE 3: STAR-PATTERN TORQUING

+

For multi-bolt flanges (>4 bolts), follow the star sequence. Single-pass torquing is prohibited.

+ +
+
+
☐
+
PASS 1: Seat nuts to 30% of target torque.
+
+
+
☐
+
PASS 2: Advance to 60% of target torque.
+
+
+
☐
+
PASS 3: Final tighten to 100% specification.
+
+
Wait 60 seconds after Pass 3 before re-check.
+ +
+
☐
+
Re-verify all bolts in reverse star sequence.
+
+
Acceptable variance: ±5% of target.
+
+
+ +
+

FAILURE LOG

+

If re-verification shows variance >5%, record the following:

+ +
+ + + + +