Month: August 2024

Bugatti Recalled EUR 3 Million Chiron Due to Loose Screws

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Tsamouris, the Fastener Specialists©

In a striking reminder that even the most exclusive vehicles are not immune to fastener issues, Bugatti
recalled a single 2018 Chiron — with a jaw-dropping price tag of USD 3 million (EUR 2.7 million) — in April
2022 due to loose screws on the front frame.

Bugatti informed the US National Highway Traffic Safety Administration (NHTSA) that the loose screws could
compromise the Chiron’s structural integrity and increase the risk of injury in a crash.

While recalls are a common occurrence in the automotive industry, with the NHTSA seeing an average of
about 650 recalls involving 25 million cars annually, it is quite rare for a recall to involve a single vehicle —
Jaguar Land Rover, Mercedes-Benz, and Lamborghini have all issued similar recalls for single vehicles due to
missing or improperly tightened fasteners.

At Tsamouris, we are committed to supplying you with high quality fasteners, ensuring the integrity of your
infrastructure and machinery.

Smart Screws Detect When They’re Loose

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Tsamouris, the Fastener Specialists©

Researchers from the Fraunhofer Cluster of Excellence Cognitive Internet Technologies CCIT have
developed a groundbreaking smart screw system that significantly improves the safety and efficiency of
critical infrastructure monitoring. By combining advanced sensor technology and Internet of Things (IoT)
capabilities, these self-powered screws can detect when they become loose and automatically send alerts,
reducing the need for costly and time-consuming manual inspections.

The smart screw system is designed to address the common problem of screws loosening over time due to
various factors such as wear and tear, temperature fluctuations, and vibrations. This issue is particularly
critical in structures like bridges, wind turbines, cranes, scaffolding, and roller coasters, where loose screws
can have devastating consequences.

The innovative technology utilizes a screw fitted with a washer equipped with a pressure-sensitive thin film.
When the screw is tightened, the sensors register the preload force at three points. Any change in the
preload force alters the electrical resistance in the thin film, which is then reported to a radio module located
on the screw head. The radio module transmits the data to a base station, which collects information from all
relevant screws in the object.

Data transmission is handled by a low-power wide-area network (LPWAN) protocol capable of sending small
packets of data over long distances with minimal energy consumption. This allows the system to monitor
more than 100,000 sensors via a single base station located several hundred feet or even miles away. The
data is then displayed in a graphical overview, providing real-time information on the status of each screw
connection.

One of the key advantages of this remote monitoring system is its adaptability to a wide range of
applications. The smart screw technology can be configured for various scenarios, from flange connections
in industry to load-bearing parts of bridges and wind turbines.

The researchers have also addressed the issue of energy demand by incorporating energy harvesting
principles. The system can generate electricity from minute temperature differences between the screw
head and the environment or through solar cells, making it self-powered and resource-efficient.
Security is another crucial aspect of the smart screw system. Each screw is given an individual ID,
requirement profile, and encryption key during installation, ensuring that the system is protected against
hacking attempts and sabotage.

The technology is designed for commercially available DIN screws, with the system ready for use with M18
screws and versions for M20 and M36 screws in development.
At Tsamouris, as a leading supplier of high-quality fasteners, we are excited to see how this technology will
shape the future of infrastructure management and contribute to a safer, more efficient world.

Coney Island Boardwalk’s Loose Screws Sparked Lawsuits

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Tsamouris, the Fastener Specialists©

In March 2023, residents and elected officials expressed disappointment over the lack of new funding for
repairs to Coney Island’s iconic wooden boardwalk, in New York Mayor Eric Adams’ USD 100 billion (EUR 92
billion) budget. The historic landmark, which stretches nearly 3 miles (4.8 kilometers) from Coney Island to
Brighton Beach, has been plagued by loose screws, gaping holes, and uneven planks, posing a danger to
pedestrians and attracting lawsuits.

Former Mayor Bill de Blasio had allocated USD 115 million (EUR 106 million) for boardwalk reconstruction
starting in 2025, but this sum would only cover a portion of the necessary repairs.

Since 2012, dozens of lawsuits have been filed against the city due to alleged injuries on the boardwalk,
costing taxpayers hundreds of thousands of dollars in settlements. Residents have reported constant
vigilance while walking on the boardwalk, with some expressing concerns about tripping, rolled ankles, and
exposed nails.

At Tsamouris, we understand the important role that quality fasteners play in ensuring the safety and
structural integrity of public spaces.

Screws Coming Loose on Jet Wing Mid-Air

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Tsamouris, the Fastener Specialists©

In March 2023, a video surfaced on social media showing three screws visibly shaking on the left wing of a
TAAG Angola Airlines Boeing 737-700 aircraft during flight.

The video, which quickly went viral, raised serious questions about the maintenance and safety standards of
the state-owned airline, which serves as the flag carrier of Angola. TAAG Angola Airlines, headquartered in
Luanda, operates domestic flights within Angola, as well as medium-haul services in Africa and long-haul
routes to Brazil, Cuba, and Portugal.

The incident highlighted the critical importance of proper maintenance and regular inspections of aircraft,
particularly in areas that are subject to high stress and vibration, such as the wings. Loose or missing
fasteners can potentially lead to structural issues, compromising the safety of passengers and crew.

How a Loose Bolt Led to China Airlines Boeing 737 Explosion

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Tsamouris, the Fastener Specialists©

In August 2007, a seemingly minor maintenance oversight led to a near-fatal accident during China Airlines
Flight 120. Fortunately, there were no casualties. The Boeing 737-800, carrying 157 passengers and 8 crew
members, caught fire and exploded at Naha Airport in Japan shortly after landing safely from Taipei and after
all passengers had evacuated.

The incident unfolded as the crew prepared for disembarkation, having taxied the aircraft to the gate and
shut off the engines. Suddenly, ground crew members noticed flames emanating from one of the engines
and promptly informed air traffic control. The captain, upon being alerted, ordered an emergency evacuation.
Miraculously, all passengers and crew managed to evacuate the aircraft through the four hatches using
slides, just moments before the plane exploded. The pilots, having ensured everyone’s safety, exited through
the cockpit window. Despite the harrowing experience, only minor injuries were reported.

The on-site investigation revealed that fuel had leaked from a puncture hole in a slat’s track. Further inquiry
uncovered that an incorrectly installed bolt in the right-wing of the aircraft’s slat down-stop had worked itself
loose. The bolt had been torqued without the requisite washer during scheduled maintenance six weeks
prior. Consequently, the nut came loose, causing the entire down-stop assembly to detach and fall onto the
slat-can assembly track during ground movement.

As the slat retracted, it pushed the detached assembly, eventually forcing the downstop bolt through the
slat-can wall, puncturing the fuel tank. The leaking fuel ignited upon contact with high-temperature areas on
the right engine, leading to the fire and explosions.

Shockingly, the cause of this near-disaster was traced back to a single missing washer, which was found
lying just below the opening in the wing forward spar.

In the aftermath of the incident, the Republic of China Civil Aeronautics Administration grounded the entire
fleet of Boeing 737-800s operated by China Airlines, Mandarin Airlines, and the Republic of China Air Force
for fuel system inspections. The Japanese Civil Aviation Bureau followed suit, requesting inspections of
aircraft of the same type operated by Japanese carriers.

Why it Takes Less Torque to Loosen a Bolt Than to Tighten It

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Tsamouris, the Fastener Specialists©

Have you ever struggled with a stubborn bolt, only to find that loosening it requires less effort than
tightening it? This phenomenon, which may seem counterintuitive at first, has a scientific explanation that
lies in the design of threaded fasteners.

YouTuber AvE delved into this topic (watch at YouTube), providing an in-depth demonstration and
explanation of why it takes less torque to loosen a bolt than to tighten it. Using an oscilloscope rigged as an
ad-hoc torque-strain gauge, AvE showcased that loosening a bolt requires approximately 10% less torque
than what was initially applied during tightening.

The key to understanding this difference lies in the pitched threads of the bolt, which act like an inclined
plane. When tightening a bolt, it’s akin to pushing an object uphill, requiring more effort to overcome the
incline. Conversely, loosening the bolt is like pulling an object downhill, which requires less force due to the
assistance of gravity.

This principle doesn’t account for external factors that may affect the bolt between installation and removal,
such as rust, corrosion, or seized threads. These issues can significantly increase the torque required to
remove a fastener, sometimes necessitating the use of additional tools or techniques.
By providing fasteners and torque tools from Bahco and Irimo that meet the highest standards of quality and
performance, at Tsamouris, we aim to support engineers and mechanics in their projects, whether they’re
tightening or loosening bolts.

Loose Wing Screw on Air China Boeing 737 Flight

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Tsamouris, the Fastener Specialists©

In July 2022, Air China found itself in the spotlight after a passenger on flight CA1921 from Beijing to
Hengyang noticed and recorded a loose wing screw on the Boeing 737NG aircraft. The video, which was
shared widely on Chinese social media platform Weibo, prompted the airline to take swift action and issue a
statement addressing the incident.

According to the statement, Air China “attached great importance” to the loose screw in the inboard canoe
fairing of the left flap and immediately inspected the relevant parts of the aircraft, repaired the loose screws,
and checked the entire fleet for similar issues.

The inboard canoe fairing, where the loose screw was located, is primarily used to regulate airflow, reduce
drag, and save fuel. The screws in question are responsible for fixing the flap track fairing tail cones, which
are a part of the inboard canoe fairing.

While there was no official explanation for the cause of the loose screw or its potential impact on flight
safety, aviation experts weighed in on the matter. Qiu Qing, an aviation blogger with over 300,000 followers
on Weibo, suggested that the issue could be attributed to either a broken supporting target in the fairing or
long-term vibration at the screw’s position.

According to the configuration deviation list (CDL) of the Boeing 737NG, it is acceptable for the aircraft to
take off without up to two flap track fairing tail cones. Veteran pilot Chen Jianguo told the Beijing Youth Daily
that one or two loose screws on the fairing would not affect safety, even if the fairing itself were missing.

Loose Screw Causes Gas Meter Leak

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Tsamouris, the Fastener Specialists©

In September 2022, a gas meter in the Kincaidston Ayr, Ayrshire, Scotland, was found to be ‘bubbling’ due to
a loose screw, raising concerns among residents still reeling from a devastating house explosion in the area
just months earlier.

Rikki Bell, a 34-year-old qualified plumber and heating engineer, captured shocking footage of the gas leak at
his parents’ home on Sorrel Drive. Bell’s parents had noticed the smell of gas near their front door and porch,
prompting their son to investigate.

Using leak detector fluid, Bell discovered that a nut on the meter, which had been installed just nine months
earlier as part of major replacement works following the Gorse Park explosion, had not been properly
tightened. “It was basically tightened by hand,” Bell explained, adding that it took about four full turns with a
spanner to stop the leak.

Rikki’s mum, Tracy Bell, contacted SGN, the gas network operator, but was disappointed by their response.
She felt that the customer service agent and engineer downplayed the severity of the issue, stating, “To be
told it is just a loose screw is not good enough… It does not fill you with confidence — I do not understand
how it could have happened, and it is gas, it is dangerous and it is not a water tap. Things like this should be
checked and checked again.”

This incident emphasizes the critical importance of properly installed and maintained gas fittings and the
potential consequences of even seemingly minor issues like loose screws.

Loose Screw from Air Canada Propeller Smashes into Passenger’s Window Mid-Flight

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In December 2017, an Air Canada passenger experienced a terrifying moment when a screw from the
plane’s propeller came loose mid-flight and smashed into the window by his seat. The passenger shared
images on Reddit of the alarming incident, which occurred on a flight to Vancouver.

He described hearing a loud “pop” and then noticing that a screw had embedded itself in the outer pane of
the window. The noise caused concern among passengers, and the flight attendant promptly notified the
pilot. The pilot, who had over 25 years of flying experience, stated that he had never encountered such an
incident before.

Upon landing, the pilot spoke with the “lucky” passenger at length, revealing that even the aircraft
manufacturer, Bombardier, had never seen a case of a screw coming loose and embedding itself in a
window.

An Air Canada spokesperson confirmed the incident, stating that one of the twelve one-inch bolts on the
“prop spinner” had come loose during the descent into Vancouver. The bolt struck the exterior pane of the
two acrylic window panes, resulting in a small hole. Fortunately, the interior pane was not impacted, and the
aircraft landed safely without further incident.

Events like these highlight the critical importance of proper maintenance and the use of high-quality
fasteners in the aviation industry.