BobbyD - Nice effort!
You wrote:
"For this test I put used a socket larger then the KeenSert diameter so I could draw it up into the socket. I slipped the bolt through a grade 8 washer and into the socket and started tightening in 5 pounds increments. When I hit 60 lbs of torque, the only thing I had accomplished was to suck the washer into the head of the socket to the point were I had very little bolt head left to grip"
<span style="color: #990000">This test procedure most resembles a true ASTM pull-out
test, except the screw is pulled vertically until it "pops"
at failure.
I suggest you use a longer shank screw, put a piece of 1/4" steel plate under the socket to more evenly distribute the load. A hole slightly larger than the diameter of the insert should be drilled.
Allow the bolt head to extend above the socket. Again, a piece of 1/4" steel sits on top of the socket with a hole
drilled only large enough for the bolt shank and thread to pass thru. Place a Grade #8 washer between bolt head and steel. Grease everything so the rotational friction is taken
out of the procedure as much as possible. Make sure your test bolt is long enough to pass thru all the pieces and embed the depth you desire into the aluminum.
Torque at 5# intervals until the bolt "pops", ie your
torque will drop to zero.
Just my take from doing hundreds of fastener pull-out tests.
We use a device manufactured specifically to pull screws.
The socket method will get you in the ballpark.
regards,
dale</span>