Tag: #TsamourisFasteners

Supersonic Concorde’s Bolts

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United Airlines wants to bring back supersonic air travel, with plans to buy 15 Overture airliners from Boom
Supersonic, a start-up that could become the first to offer ultrafast commercial flights since the Concorde
stopped flying in 2003. But long before Boom’s ambitious plans, the Concorde’s innovative design, including
its unique bolt-together nozzles, pushed the boundaries of aviation technology.

The Concorde’s iconic rear power plant comprised a variable exhaust system with a primary nozzle and a
secondary nozzle, the latter featuring an arrangement of hinged ‘buckets’ or ‘clamshells’ that controlled the
exhaust flow during all stages of flight. This innovative design not only enhanced performance but also
helped reduce noise levels.

The primary nozzle, which formed the jet-pipe exit, consisted of 36 petals — 18 actuated and 18 followers —
moved by 18 pneumatic jacks. These jacks, connected by supply tubes and a manifold, allowed the nozzle’s
outlet area to be varied, optimizing engine efficiency throughout the flight envelope.

The flange of the primary nozzle’s convergent section had 90 holes to accommodate bolts, which secured
the section to the support ring and retained the petal hinge point yokes and double-yokes. Additionally, two
union bodies were riveted to the convergent section for fitting the pressure tapping tube of the re-heat
detection system.

Surrounding the primary nozzle, the secondary nozzle assembly served multiple functions, including
supporting the primary nozzles and buckets, channeling secondary air, and transmitting loads to the
airframe.

The buckets themselves were attached to the secondary nozzle via hinged points, with each bucket having
two such points. During takeoff, the buckets were set to 21 degrees, creating a ‘jet-pump’ effect that reduced
drag. As the Concorde accelerated through Mach 1.1, the buckets opened progressively to form a divergent
duct, optimizing thrust in supersonic flight. On landing, the buckets closed to deflect exhaust flow forwards,
acting as thrust reversers.

The Concorde’s bolt-together nozzles, along with its intake system, were responsible for approximately half
of the aircraft’s thrust at Mach 2, showcasing the critical role of these components in enabling supersonic
flight.

As United Airlines and Boom Supersonic work to bring supersonic travel back to the skies, they stand on the
shoulders of the Concorde’s designers, who crafted a marvel of engineering that pushed the limits of what
was possible in aviation. At Tsamouris, we understand the importance of precision and innovation in
fastening solutions.

Russian Tubular Home Held Together by Six Bolts

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In 2021, in a stunning display of architectural innovation, Moscow’s chief architect Sergey Kuznetsov
unveiled a pipe-shaped cabin that appeared to defy the laws of physics. The holiday home, located in
Russia’s Nikola-Lenivets Art Park, cantilevers over a hill, its sleek, stainless steel exterior reflecting the
surrounding forest. But perhaps the most astonishing aspect of this unique structure is that it is held
together using only six bolts.

Weighing twice as much as a fully-grown elephant and spanning 39.7 feet (12 meters) in length, the cabin
was conceived for the annual Archstoyanie festival, often referred to as Russia’s Burning Man. Drawing
inspiration from shipbuilding techniques, Kuznetsov and construction company Krost employed a method
known as transverse framing to create the cylindrical structure.

Instead of traditional wall studs, the cabin features a system of closely spaced, circular ribs running along its
entire length. These ribs, cut from sheets of stainless steel and connected by horizontal guides called
stringers, form a robust yet lightweight frame that can support itself without breaking.

The construction process involved simultaneously manufacturing six cylindrical modules before connecting
them together, much like the assembly of a ship’s hull. The biggest challenge was ensuring the cylinders
were joined with precision and virtually no tolerances.

To create the illusion of the cabin hanging in mid-air, the foundation is concealed inside a small hill that had
to be almost entirely demolished during excavation, then rebuilt and reinforced with sand cushions. A
concrete slab foundation extends underground in the opposite direction of the cabin, acting as a
counterweight and housing the plumbing and electricity.

Despite the complexity of the construction, no one on Kuznetsov’s team knew for certain whether the
structure would hold up in its cantilevered position until it was physically installed on-site. After removing the
supporting structures, the bottom of the console dropped by a mere 0.86 inches (22 millimeters), well within
the calculated maximum tolerance of 1.18 inches (30 millimeters), bringing a sense of joy and relief to
everyone involved.

Faulty Bolt Caused SpaceX Falcon 9 Explosion

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A NASA investigation into the June 2015 SpaceX Falcon 9 rocket failure has concluded that a single bolt,
rather than a manufacturing defect, was behind the catastrophic event.

The unmanned mission, known as CRS-7, was supposed to deliver a Dragon cargo spacecraft to the
International Space Station when disaster struck just 139 seconds after liftoff. The rocket’s second stage
liquid oxygen tank suffered an “anomalous event,” causing the vehicle to disintegrate in the blink of an eye.

While SpaceX’s own investigation pointed to a faulty rod end bolt that broke due to a material defect, freeing
a helium-filled composite overwrapped pressure vessel (COPV) to wreak havoc, NASA’s independent review
team found the evidence less conclusive. They suggested that manufacturing damage, improper installation,
or other equally plausible scenarios could have led to the bolt’s failure.

However, the NASA probe went a step further, identifying a critical design flaw: the use of industrial grade
instead of aerospace grade stainless steel for the rod end. This material choice, which lacked proper
modeling and testing for the application, fell short of the manufacturer’s recommended 4:1 safety factor.

The report also highlighted other issues, such as the potential for increased latency in the rocket’s telemetry
system and the risks associated with using commercial parts in flight-critical applications. NASA urged
SpaceX to pay closer attention to manufacturers’ recommendations when sourcing components for their
vehicles.

In response, SpaceX maintained that all credible causes, including those identified by NASA, were
addressed before the Falcon 9’s return to flight.

As a the Fasteners Specialists©, Tsamouris is committed to quality and adherence to the highest standards
to help prevent bolt oversights that could lead to catastrophic failures.

China’s Bullet Train Defies Extreme Cold with Chromium-Molybdenum Bolts

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In January 2021, China unveiled the CR400AF-G, a high-speed bullet train designed to operate in
temperatures as low as -40°F (-40°C). The train, part of the Fuxing series developed by the China State
Railway Group, can reach speeds of 217 mph (350 km/h) and connects Beijing with northeastern cities like
Shenyang and Harbin, the latter famous for its annual snow and ice festival.

The CR400AF-G boasts several cutting-edge features that enable it to withstand extreme cold:

🚄 Chromium-molybdenum alloy bolts that endure ultra-low temperatures

🚄 Silicone sealing strips to prevent snow and ice from entering the train body

🚄 Temperature-resistant brake control devices

🚄 Stainless-steel pipes with built-in heating devices

The train’s streamlined, low-resistance design and lightweight aluminum alloy body also contribute to
reduced energy consumption.

One standout feature is the brake system, which prevents freezing even when the train stops for extended
periods. The new system enables the brakes to move from time to time even if the train stops, like a person
who stamps their feet to keep warm in cold weather.

With the launch of the CR400AF-G, China further solidified its position as a global leader in high-speed rail
technology. The country boasts the world’s largest high-speed rail network, spanning over 22,991 miles
(37,000 km), and the fastest commercially operating train – the Shanghai maglev, which reaches speeds of
268 mph (431 km/h).

Just as China’s new bullet train pushes the boundaries of what’s possible in extreme cold, at Tsamouris, we
strive to provide fastening solutions that excel in even the most demanding environments.

Masks Made of Bolts and Screws

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Ontario-based artist Dale Dunning has found a truly unique way to express the power of communication and
knowledge. His mesmerizing bronze and aluminum sculptures combine the art of typography with the
intricacy of welding and fasteners, resulting in a series of captivating metallic masks.

Each androgynous face is meticulously crafted from hundreds of typefaces, creating a figurative stamp that
symbolizes the essence of human interaction. But Dunning doesn’t stop there; he pushes the boundaries of
texture by incorporating thousands of bolts, screws, and washers into his creations, adding a layer of
industrial charm to these already stunning pieces.

For Dunning, the head is the perfect canvas to explore the depths of the human mind. “We live in our heads,
see, feel, and experience the world in our head,” he explains. By focusing solely on the head, he eliminates
the distraction of limbs and the rest of the body, allowing the viewer to fully immerse themselves in the
sculpture’s message.

As you gaze upon these masks, you can’t help but feel a sense of awe at the level of detail and craftsmanship
that goes into each piece. The juxtaposition of delicate typefaces and rugged bolts creates a visual
symphony that is both thought-provoking and aesthetically pleasing.

Composer John Cage — a Symphony of Bolts

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When avant-garde composer John Cage found himself confined by the traditional piano’s limitations, he
refused to accept defeat. Instead, he embarked on a journey that would revolutionize the world of music,
armed with nothing more than his creativity and a handful of screws.

It all began in 1940 when Cage was working as an accompanist for a dance class in Seattle. Faced with the
challenge of composing for dancer Syvilla Fort in a cramped performance space, Cage had an epiphany: “I
decided that what was wrong was not me but the piano.”

With that realization, Cage set out to reinvent the instrument. He began by placing screws and bolts between
the piano strings, creating his first prepared piano composition, “Bacchanale.” The result was a mesmerizing
blend of percussive, otherworldly sounds that defied convention and ignited the imagination.

Emboldened by the success of “Bacchanale,” Cage’s ambitions grew. He expanded his palette of
preparations, incorporating an array of objects such as rubber, plastic, and nuts in his most famous prepared
piano work, “Sonatas and Interludes.” Each object was meticulously chosen and placed according to Cage’s
precise instructions, transforming the piano into a veritable orchestra of unexpected timbres.

As Cage’s prepared piano compositions gained recognition, he remained deeply involved in the
performance process. He would often attend rehearsals, guiding pianists in the art of preparation and finetuning
the placement of objects to achieve the perfect balance of sound.

Today, Cage’s legacy lives on through contemporary composers like Kelly Moran and Hauschka, who
continue to push the boundaries of the prepared piano. Moran’s preparations evoke a hypnotic, bell-like
quality, while Hauschka’s eclectic mix of objects conjures the illusion of a sprawling, unconventional
ensemble.

At Tsamouris, we draw inspiration from visionaries like John Cage, who dared to challenge the status quo
and unlock new possibilities through innovation. Just as Cage transformed the piano with screws and bolts,
we strive to revolutionize industries by offering cutting-edge fastening solutions that defy expectations and
inspire creativity.

Tiny Radioactive Capsule Get Lost in the Australian Desert Due to Loose Bolts

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Seeking a Needle in a Haystack? A tiny capsule, no larger than a penny, managed to cause a stir that
reverberated across Australia. This was no ordinary capsule; it was a highly radioactive Caesium-137 device,
used as part of a sensor in mining operations by the giant Rio Tinto. When the capsule went missing in
January 2023, somewhere along a 870-mile (1,400 kilometers) stretch of desert highway, authorities found
themselves in a race against time to locate the potentially lethal object.

The capsule had fallen off the back of a truck during its journey from a mine near the remote town of
Newman to the state capital, Perth. It is believed a bolt securing the lead-lined gauge containing the capsule
worked loose somewhere on the journey – potentially shaken loose by the vibrations of the truck – and the
capsule fell through a hole left by the missing bolt.

The severity of the situation quickly became apparent: a mere hour of exposure at a distance of one meter
was equivalent to receiving ten X-rays, and prolonged contact could lead to skin burns, acute radiation
sickness, and even cancer.

Faced with the daunting task of finding a needle in a haystack, or in this case, a minuscule radioactive
capsule in the vast Outback, authorities deployed specialized radiation detectors to locate the gamma rays
emitted by the device. Search teams meticulously combed the truck’s GPS route, with a particular focus on
the densely populated areas near Perth.

As the days turned into weeks without any sign of the capsule, the urgency of the situation grew. The federal
government stepped in, providing additional resources such as radiation portal monitors and gamma-ray
spectrometers to aid in the search. The hunt for the missing capsule had become a national priority, with the
safety of the public hanging in the balance.

Just as hope began to wane, a breakthrough occurred on February 1st. A vehicle equipped with specialized
detection equipment picked up traces of radiation while traveling at 44 mph (70 km/h) along the search
route. Portable detectors were swiftly deployed, and the capsule was pinpointed a mere two meters off the
side of the road.

Remarkably, it appeared that the capsule had not caused any harm during its time in the wilderness, having
seemingly remained undisturbed where it had initially fallen. An investigation was immediately launched by
the chair of Australia’s Radiological Council to determine how such a dangerous object could have been
misplaced, with the possibility of charges being laid against Rio Tinto.

The case of the missing radioactive capsule serves as a stark reminder of the importance of proper handling
and transportation of even the smallest, most unassuming objects when they possess the potential for harm.

Missing Bolts on Qantas’ Boeing 737 Engine

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A pilot with the Australian airline Qantas raised concerns about the airline’s maintenance standards after
sharing shocking footage of a Boeing 737 plane missing three out of four bolts and a seal on an engine air
duct. The video, tweeted by journalist Michael West in September 2023, showed that the missing pieces had
fallen into the plane’s cowl.

According to West, the maintenance work on the plane was carried out in Brisbane, and the issue was
identified by engineers on a Saturday. While the missing bolts could have potentially led to a fire onboard,
West admitted that suggesting the plane could have crashed would be too alarmist.

Qantas stated that safety had always been their top priority and that an investigation was underway to
determine how the defects occurred. The airline also emphasized that the air duct takes air away from the
engine and does not impact its operation.

West has raised concerns about Qantas’ cost-cutting measures and outsourcing, suggesting that these
factors may be contributing to mounting problems with the airline’s planes. He also pointed out that
regulators inspect Qantas planes before takeoff to ensure their safety.

Artist Drills Thousands of Screws to Nail Perfect Portraits

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In 2011, California-based artist Andrew Myers took portraiture to a whole new level by creating stunning
three-dimensional images using thousands of everyday screws. Myers’ unique approach involves drilling
holes into wooden planks and meticulously placing screws to form the likeness of his subjects.

Each portrait takes Myers over six months to complete, with some larger pieces requiring up to 10,000
screws. The artist starts by studying a photograph of his subject and meeting them in person to ensure he
captures their facial features accurately. He then painstakingly drills the screws into the pre-drilled holes and
hand-paints each screw head to achieve the desired effect.

Myers’ screw portraits, ranging from 23.6 by 23.6 inches (60 by 60 centimeters) to 4 by 4 feet (1.2 by 1.2
meters), have garnered significant attention from art collectors, with smaller pieces selling for USD 9,000
(EUR 7,650) and larger ones expected to fetch up to USD 35,000 (EUR 29,750). However, despite the high
price tags, Myers insists that the portraits are more a labor of love than a lucrative endeavor, as the cost of
purchasing thousands of screws adds up quickly.

At Tsamouris, we admire the dedication and precision that artists like Andrew Myers bring to their craft. Just
as Myers carefully selects and places each screw to create a masterpiece, we are committed to providing
high-quality fasteners that ensure the integrity and longevity of the projects they hold together.

New York City’s Hidden Randel Bolt

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In the early 1800s, surveyor John Randel Jr. embarked on a monumental task: transforming New York City
into the orderly, gridded metropolis we know today. Armed with metal bolts and marble slabs, Randel Jr.
traversed the island, marking nearly 1,000 proposed intersections. Despite facing opposition from angry
landowners and enduring countless setbacks, his vision laid the foundation for modern Manhattan.
Today, finding Randel Jr.’s original bolts has become a treasure hunt for history buffs and surveying
enthusiasts. The only authenticated bolt, discovered in Central Park in 2004 by geography professor Reuben
Rose-Redwood and surveyor J. R. Lemuel Morrison, remains a closely guarded secret to protect it from theft
or damage.

These bolts represent more than just historical artifacts; they symbolize the “politics of mapping” and the
complex relationship between progress and personal loss. While the grid system ushered in a new era for
New York City, it also meant the destruction of homes and livelihoods for many Manhattanites.
Intrepid explorers continue to scour the city’s parks, armed with Randel Jr.’s old maps and a keen eye for the
unusual. Rumors of additional bolts and even a surviving marble monument circulate among the surveying
community, but the Central Park bolt remains the only officially recognized relic.

At Tsamouris, we highlight the significance of these hidden treasures and the stories they tell about the
evolution of our cities. Our commitment to providing high-quality fasteners is rooted in the belief that even
the smallest components can play a crucial role in shaping the world around us.