Deformation of Allen Head Screws: Impact or Wear?

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SUMMARY

The deformation of Allen head screws primarily results from over-torquing and improper tool usage rather than wear. Specifically, using an incorrect size Allen key, such as a metric key on an inch bolt, can lead to rounding of the screw head. Additionally, the use of impact wrenches on Allen head bolts can exacerbate this issue, causing damage to both the screw and the key. Larger Allen headed cap screws (1/4 inch and above) are less prone to this deformation.

PREREQUISITES
  • Understanding of Allen head screw specifications
  • Knowledge of torque specifications and their impact on fasteners
  • Familiarity with the differences between metric and inch tools
  • Basic principles of wear and deformation in materials
NEXT STEPS
  • Research the effects of over-torquing on fastener integrity
  • Learn about proper tool selection for Allen head screws
  • Investigate the impact of using impact wrenches on various fastener types
  • Study material properties related to deformation and wear resistance
USEFUL FOR

Mechanical engineers, automotive technicians, and anyone involved in assembly or maintenance of machinery using Allen head screws.

drag88
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Hi all just a simple question about the hole of the Allen head screw becoming round/circular after repeated use of a Allen key on it. From what I read so far it should be a form of wear. I am thinking of abrasive or impact wear, but not sure which is it. Can anyone answer this? Thanks.
 
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no way would hardened spec allen bolt round out IF you use the proper wrench..i have rounded allens i found on the original race car simply because it was not known if the bolt was inch or metric..ifin you got a metric allen and use an INCH wrench, you can round them..especially if they are rusted
 
I've seen many Allen set screws get rounded when using the proper key. They have been over torqued and the metal has deformed, not worn. I suspect that the deformation is happening to both the key and the screw's recess. I've not seen it happen in larger size Allen headed cap screws (say 1/4 in. and larger bolt size).

I don't have any experience (or at least much) with use of an impact wrench with Allen head bolts. I can imagine that an impact wrench could readily do damage to the head.
 

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