What percentage of clamping force drop-off may occur when reusing bolts on spade terminals?

When reusing bolts on spade terminals, a significant concern is the reduction in clamping force due to factors like wear, fatigue, and the potential for the bolts to no longer create a tight fit. Studies and industry practices indicate that a clamping force drop-off of up to 30 percent can occur with reused bolts. This drop-off is primarily attributed to the deformation of the bolt threads and the material fatigue that can happen over time, leading to less effective torque and a weaker bond when the bolts are reinstalled.

This level of clamping force reduction is particularly critical in electrical applications because it can lead to poor connections, increased resistance, and even potential failure of the electrical system. Understanding the impact of reusing bolts can guide professionals to either replace the bolts or employ additional methods to ensure that the necessary force is maintained, ultimately preserving the integrity and safety of the electrical connection. Thus, recognizing that a 30 percent drop-off is a realistic expectation helps in planning maintenance and replacement strategies effectively.