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Two 38 mm (1.5 in.) diam threaded stud bolts that were part of a steel mold die assembly from a plastics molding operation were examined to determine their serviceability. Chemical analysis showed the material to be a plain carbon steel that approximated 1045. Visual examination revealed evidence of severe hammer blows to the clevis and boss areas and a gap between the die and the underside of the boss. Magnetic particle inspection showed cracks at the thread roots that, when examined metallographically, were found to contain MnS stringers. The cracking of the threads was attributed to a poor stud bolt design, which allowed a high stress concentration to occur at the base of the threads upon application of a lateral load. It was recommended that bolts of a new design that incorporated a stress-relieving groove be used. Threading of the bolt to eliminate the gap between the lower face of the boss and the die and an improved method of inserting or removing the bolt to avoid hammering (use of a wrench on a square or hexagonal boss) were also recommended.

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