Custom Metal Washer Precise Stainless Steel Extra Thick Flat Washers

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What is a Metal Washer?

A metal washer is a small, flat metal disc with a central hole designed to distribute the load of threaded fasteners like bolts, screws, or nuts over a larger surface area. These components serve multiple purposes in mechanical, architectural, and industrial applications:

• Load distribution: Prevents surface stress and material deformation by evenly spreading fastener pressure

• Spacing: Acts as a spacer when fastener length exceeds material depth

• Vibration absorption: Certain types help dampen vibrations in machinery

• Sealing: Specialized versions with bonded materials prevent leaks in plumbing/HVAC systems

• Corrosion prevention: Insulates dissimilar metals to prevent galvanic corrosion

Metal washers are manufactured through precision stamping or CNC machining processes from various metals including carbon steel, stainless steel, brass, copper, and specialized alloys.

Metal Washer – Extra Thick Flat Washers

Materials

Extra thick flat washers (3-18mm thickness) are typically made from high-strength materials including:

• AISI 4140 alloy steel: Offers excellent strength and toughness

• Stainless steel 316: Provides superior corrosion resistance

• Carbon steel: Cost-effective option for heavy-duty applications

• Inconel: For extreme temperature environments

• Titanium: When high strength-to-weight ratio is required

Surface Treatments

These washers undergo specialized surface treatments to enhance performance:

• Black oxide coating: Improves corrosion resistance and reduces light reflection

• Zinc-nickel plating: Provides superior protection against rust

• Quenching and tempering: Achieves Rockwell hardness ratings of HRC 38-42

• Precision grinding: Ensures tight tolerances (±0.02mm)

Specifications

Key specifications for extra thick flat washers include:

• Thickness: 3-18mm (compared to standard washers at 0.5-3mm)

• Load capacity: 1,200-2,400 kN (substantially higher than standard washers)

• Standards compliance: ASTM F436, ISO 7085, ASME B18.22.1

• Tolerances: ±0.02mm for precision applications

• Temperature resistance: Up to 1,800°F (982°C) for high-temperature variants

Application Fields

Extra thick flat washers are critical in industries requiring extreme durability:

• Renewable energy: Wind turbine tower flange connections

• Heavy construction: Bridge building and infrastructure projects

• Mining equipment: High-vibration, high-load environments

• Railway systems: For track and bridge maintenance

• Offshore drilling: Saltwater-resistant applications

• Aerospace: Where precision and reliability are paramount

Excellent Case: Wind Turbine Assembly

Challenge: A wind energy company was experiencing frequent bolt failures (63% failure rate) in their turbine tower flange connections due to extreme weather conditions and constant vibration10.

Solution: The company switched to 14mm thick extra flat washers made from quenched and tempered AISI 4140 alloy steel with zinc-nickel plating.

Results:

1. 63% reduction in bolt failure rates due to improved load distribution

2. Extended maintenance intervals from 6 months to 2 years

3. Improved safety by preventing catastrophic joint failures

4. Cost savings from reduced downtime and replacement part requirements

5. Better performance in corrosive coastal environments due to specialized plating

The extra thick washers provided the necessary durability to withstand the tremendous forces and environmental challenges faced by offshore wind turbines, demonstrating how specialized washer solutions can solve critical engineering problems.