What is a significant risk of improper torque settings during assembly?

Improper torque settings during assembly pose a significant risk of structural failure under load because the fasteners, such as bolts and nuts, are critical in holding components together securely. When torque is not applied correctly, it can either lead to over-tightening or under-tightening of these fasteners.

If fasteners are under-tightened, they may not adequately hold the assembly together, resulting in components shifting or coming apart when subjected to operational stresses, such as turbulence or sudden maneuvers. Conversely, over-tightening can also compromise the integrity of the materials, potentially causing them to deform or crack. Both scenarios can lead to serious failures during flight, risking the safety of the aircraft and its occupants. Such structural failures are particularly concerning in high-stress areas where safety is paramount, making the understanding of proper torque settings critical in aircraft assembly and rigging practices.