Extend Equipment Lifespan with the Right Fasteners
Fastener failures get a lot of attention on Melfast posts. And it’s not without good reason. Cutting corners on your selection of materials and coatings can have major consequences. It’s beyond simple inconvenience - it’s downtime, accelerated equipment wear and tear and safety problems.
And these failures can often be traced back to one overlooked detail: inappropriate or subpar fastener selection.
So let’s take a deeper dive into material, coating, and corrosion resistance - the main factors that directly affect performance over time.
Fasteners as a Hidden Driver of Long-Term Performance
Fasteners are not just about holding parts together. They influence alignment, vibration resistance, and long-term load integrity. In harsh environments (heat, chemicals, moisture, high load cycles), improper fastener choice accelerates wear and failure points elsewhere.
For instance, if a fastener stretches too much, it can throw off the alignment of parts like a flange. That misalignment puts uneven pressure on connected components, which can cause the gasket to fail or wear out bearings faster than expected.
Here’s a brief rundown of fastener basics that affect longevity of the fastener and structures made with them.
Material Selection: Match Properties to the Application
The first step in selecting the right fastener is choosing the correct material for your specific application. Each material has unique properties that make it a better fit for certain environments and mechanical requirements. Here’s a breakdown of commonly used fastener materials:
1. Carbon Steel
Strengths: Economical and strong, but limited corrosion resistance.
Best For: General-purpose use in controlled or dry environments.
Examples: Indoor equipment with limited exposure to moisture, cost-efficient structural applications.
2. Stainless Steel (304 and 316 Grades)
Strengths: Excellent corrosion resistance, though not as strong as alloy steel.
Best For: Corrosive or sanitary environments.
Examples:
304 Stainless: Food processing, indoor washdown areas.
316 Stainless: Marine applications, chemical plants, environments with salt or chlorides.
3. Alloy Steel
Strengths: High strength, often paired with protective coatings for improved durability.
Best For: High-stress, load-bearing applications.
Examples: Machinery under heavy vibration, automotive and aerospace components, or critical joints requiring maximum strength.
4. Non-Ferrous Metals (Brass, Aluminum, Copper)
Strengths: Excellent for specialized applications requiring electrical conductivity, non-magnetic properties, or thermal resistance.
Best For: Electrical enclosures, lightweight assemblies, or decorative hardware.
Examples:
Brass: Electrical components and plumbing hardware.
Aluminum: Aerospace and lightweight industrial assemblies.
Copper: High-conductivity electrical applications.
Matching the material to the application ensures that the fastener provides adequate strength, durability, and resistance to wear and tear.
Coatings and Finishes
Coating and finishes are literally your first line of protection. They affect corrosion resistance, torque-tension behavior (essential for the reliability of bolted joints) and chemical compatibility.
Common Coatings and Their Best Uses:
Zinc Plating: Cost-effective, provides basic corrosion resistance.
Best For: Indoor or low-humidity environments.
Hot-Dip Galvanized Coating: Superior for outdoor, heavy-duty applications.
Best For: Construction and marine hardware.
Phosphate Coating: Ensures torque/tension consistency in bolted joints.
Best For: Automotive and industrial equipment.
PTFE or Xylan® Coating: Reduces friction and resists chemical exposure.
Best For: Food processing and chemical facilities.
For applications exposed to corrosive chemicals, saltwater, or extreme heat, selecting the right coating can significantly extend fastener lifespans and reduce maintenance requirements.
Corrosion Resistance
Planning for the environment is crucial to prevent corrosion. Corrosion doesn’t just degrade the fastener. It also impacts structural connections and can result in costly reworking or disassembling.
Key Considerations:
Environmental Factors: High-moisture, chemical-rich, and salt-laden environments require fasteners with advanced corrosion resistance.
Galvanic Corrosion: When two different metals come into contact, such as a stainless steel bolt and an aluminum panel, galvanic corrosion can weaken the system if not properly managed.
Investing in fasteners that can withstand the environment where they’re installed can prevent costly downtime and ensure long-term reliability.
In a nutshell, longevity of your fasteners and your projects require prioritizing lifecycle costs over upfront price.
Consider the real cost of failure: lost production time, increased inspections, premature equipment replacement. The right fastener may cost more initially, but over time it reduces wear, maintenance, and downtime and saves you money in the long run.
Need help sourcing fasteners built for your application’s demands? The Melfast team can help you spec the right materials and coatings to optimize performance and minimize downtime. Contact us at [email protected] or at (973) 227-0045.
