59_G-S901_0JRC1_SP_NULL_0001_NULL_NULL_0001_752_U_N_Y_N_N_Y_D.PDF

PCO LETTER REQUEST

A-10 TLPS

Legacy V 9/22/2015

Contract/Delivery Order Number: FA8202-09-D-0003-0012

Program Manager: Edie Messina

Letter Number: A10-CDM-0003-E-15-0077

Date of Letter: 9/10/2015

CDRL Number: A129

Document Title:

A–10 Aircraft Process Specification for Non-Destructive Inspection of Composite Laminates and Bonded Parts

Document/ Drawing Number: G-S901

NOT APPROVED (See comment below)

X APPROVED

APPROVED Subject to inclusion of attached comments

OTHER (please identify below)

Notes:

Program Manager Signature and Date:

X

MESSINA.CARRI

E.E.1023771388

Digitally signed by

MESSINA.CARRIE.E.1023771388

DN: c=US, o=U.S. Government, ou=DoD, ou=PKI, ou=USAF, cn=MESSINA.CARRIE.E.1023771388 Date: 2015.09.22 14:41:03 -06'00'

G-S901

11 August 2015 ii

TABLE OF REVISIONS

Revision Changes Reason for Change Approved

Original issue 08/11/2015

- - S. Miro iii

TABLE OF CONTENTS

TABLE OF REVISIONS .................................................................................................. ii

1.0 SCOPE

2.0 APPLICABLE DOCUMENTS

2.1 General

2.2 Documents

2.2.1 Government/Industry Specifications and Standards

2.2.2 A-10 Program Specifications and Other Documents

3.0 GENERAL REQUIREMENTS

4.0 PROCESSES

4.1 S-F502 Epoxy Resin Composite Laminate and Honeycomb Sandwich Parts

4.1.1 Acceptance Criteria

4.1.2 NDI Techniques

4.1.3 Equipment

4.2 S-F503 Polyester Resin and Glass Fabric Laminates

4.2.1 Acceptance Criteria

4.2.2 NDI Techniques

4.2.3 Equipment

APPENDIX: VALIDATION AND VERIFICATION PROCEDURES

A1.1 Basic NDI Level III Responsibilities

A1.2 Procedure Validation

A1.3 Procedure Verification

PHASE 1: VALIDATION CHECKLIST

PHASE 2: VERIFICATION CHECKLIST

1.0 SCOPE

This document establishes the minimum acceptance criteria and the non-destructive inspection techniques that shall be used on non-metallic laminates and bonded parts for A-10 program documents and drawings.

2.0 APPLICABLE DOCUMENTS

2.1 General

The documents listed below form a part of this document to the extent specified herein.

2.2 Documents

The following documents form a part of this specification to the extent specified herein. The revision level of these documents at the time of the contract will apply, unless otherwise specified. In the event of a conflict between the documents referenced herein and the contents of this specification, the contents of this specification shall be considered a superseding requirement.

2.2.1 Government/Industry Specifications and Standards

ASTM E1742 Standard Practice for Radiographic Examination

NAS410 Certification and Qualification of Non-Destructive Test Personnel

2.2.2 A-10 Program Specifications and Other Documents

S-F502 Fabrication of 250°F Curing Epoxy Resin Composite Laminate and Honeycomb Sandwich Parts

S-F503 Polyester Resin and Glass Fabric Laminate Bonding

3.0 GENERAL REQUIREMENTS

The supplier shall submit a non-destructive inspection plan to A-10 SPO Engineering for approval. This plan shall establish the policy and controls the application of non-destructive testing/inspection of all structural components for the A-10 aircraft. This plan shall include, but not be limited to, the following: NDI procedure development, acceptance criteria, NDI procedures, equipment, reference standards, personnel certifications, schedule, quality assurance provisions, equipment calibration, and validation and verification checklists.

Typical guidelines are as follows:

1. A-10 part number and description of part.

2. Proposed NDI techniques/methods that are required by the drawing or assembly.

NOTE: Internal company NDI process specifications may be used for this test plan provided they meet or exceed A-10 requirements and are vetted and approved by A-10 SPO Engineering.

3. Personnel performing nondestructive testing such as ultrasonic, radiography, etc., shall be qualified in accordance with NAS 410. NDI staff certifications including staff names and their expiration dates with all that apply to the NDI inspections are required.

NOTE: If the parts are to be sent out for NDI inspections, describe how the subcontractor is qualified and explain how the subcontractor will perform to A- 10 test plan requirements. This is the responsibility of the prime contractor and his subcontractor.

4. Required NDI equipment and other materials. The equipment used shall be capable of detecting the minimum-size defect allowed by the acceptance criteria. The equipment description should include the manufacturer, model number and serial number for each piece of equipment that may be used.

5. The procedure on how the NDI equipment is calibrated and maintained in accordance with the manufacturer’s recommendations.

6. Descriptions and schedule of representative NDI manufactured standards. The design or type of NDI standards used shall be coordinated with the Level III individual representing the supplier performing the inspection. Standards shall be documented on an engineering drawing and include an identification number, material types and thicknesses, and size, type and location of defects.

7. Documented procedure to validate NDI manufactured test standards.

8. NDI part inspection methods and description of all zone(s) or areas to be inspected.

9. Typical NDI product/part inspection procedures detailed on operation sheets approved by a Level III individual.

10. NDI test report with typical certifications.

11. Validation and verification of NDI procedures shall be performed and documented as described in Appendix I.

4.0 PROCESSES

The following sections establish the acceptance criteria and the non-destructive techniques for processes used on the A-10 aircraft program.

4.1 S-F502 Epoxy Resin Composite Laminate and Honeycomb Sandwich Parts

4.1.1 Acceptance Criteria

4.1.1.1 Material Inclusions – Reference Section 4 in S-F502.

4.1.1.2 Voids – Reference Section 4 in S-F502.

4.1.1.3 Wrinkling or Reinforcement Distortion – Reference Section 4 in S-F502.

4.1.1.4 Node Separation – Reference Section 3 in S-F502.

4.1.2 NDI Techniques

NDI examination of the laminate and honeycomb sandwich components shall consider, but not be limited to, ultrasonic inspection, radiography, visual inspection and tap testing as required by the supplier’s test plan. The purpose of ultrasonic testing shall be to detect defects in laminates and adhesive bonded areas. The purpose of radiography testing shall be to detect defects in radius areas, honeycomb areas, closures, foam ties, etc.

4.1.3 Equipment

Test equipment such as Olympus Bondmaster 1000e+, Sonotest 410D, QMI Scanner, Sonic 1200M, USN-60, USM-Go or equivalents, shall be used to inspect the parts. This equipment shall be used to produce ultrasonic scans of the parts and shall be specified in the NDI plan that is submitted to A-10 SPO Engineering. Radiographic equipment shall meet the requirements of ASTM E1742.

4.2 S-F503 Polyester Resin and Glass Fabric Laminates

4.2.1 Acceptance Criteria

4.2.1.1 The laminates must be properly cured. Cracks, delaminations, resin starved areas, soft spots, and areas of uncured resin are prohibited.

4.2.1.2 No voids due to air leakage or failure to remove air present during processing shall be permitted. This type of void is distinguished by excessive whiteness, surface tackiness, or a “crowfoot” pattern of voids.

4.2.1.3 Areas that are critical structurally, aerodynamically, or electrically, shall be uniform, smooth, free from uncured or unbonded areas, resin-starved areas, tackiness, excess resin, laps, wrinkles, delamination, air or gas pockets, patches, porosity, and other similar defects.

To permit visual inspection with a light source laminates shall be essentially void free and translucent, except for those over 1/4 in. thick. Critical structural, aerodynamic, and electrical areas shall be specified in the drawings, specifications, or purchase orders for the part. If not specified, the part shall be considered critical.

4.2.1.4 The following defects are permitted within the limits specified:

4.2.1.4.1 Voids due to volatized styrene, provided these voids—tiny bubble-like hollows of

0.01 – 0.02-inch diameter or less—do not appear on the exterior of the laminate, but may be evident over the whole part, provided that the laminate does not appear to have excessively uneven translucency.

4.2.1.4.2 Resin pultrusions, surface cavities, or other blemishes on non-critical surfaces provided:

4.2.1.4.2.1 That no more than one such blemish appears in any square foot (12 in. by 12 in.)

of surface nor exceeds 3/4 of a square inch in area.

4.2.1.4.2.2 That no blemish extends through any ply of fabric nor exceeds a depth or height equivalent to one ply of the particular fabric employed.

4.2.1.4.3 A wrinkle shall be interpreted as a raised fold of cloth through one or more plies of the layup, generally giving a greater overall thickness to the part than its maximum specified tolerance. Such wrinkles are not permissible and must be repaired.

4.2.1.4.4 Fraying or delamination around drilled holes or along trimmed edges shall be kept to a practical minimum. Delamination, characterized by an area of whiteness, is allowed up to 1/16 inch from the trimmed edge of a drilled hole.

4.2.2 NDI Techniques

NDI examination of the laminate components shall include, but not be limited to, ultrasonic inspection, visual inspection and tap testing. The purpose of ultrasonic testing shall be to detect defects in laminates and adhesive bonded areas.

4.2.3 Equipment

Test equipment referenced in Section 4.1.3 shall be used to inspect the parts. This equipment shall be used to produce ultrasonic scans of the parts and shall be specified in the NDI plan that is submitted to A-10 SPO Engineering. Radiographic equipment shall meet the requirements of ASTM E1742.

Appendix

APPENDIX: VALIDATION AND VERIFICATION PROCEDURES

A1.1 Basic NDI Level III Responsibilities

A1.1.1 Ensure that procedure validation and verifications are conducted.

A1.1.2 Provide subject matter expert support throughout all phases of procedure development, validation and verification.

A1.1.3 Determine skill level required to perform inspection.

A1.1.4 Determine if task-specific training is required to perform inspection.

A1.1.5 Review and approve developed NDI procedures.

A1.1.6 Ensure that inspection procedures are properly validated and verified and the results properly documented per the attached checklists.

A1.2 Procedure Validation

Procedure validation is the responsibility of the seller. During validation, the NDI technique is expected to progress from initial concept to a written draft procedure. Validation concludes with successful procedure performance on simulated or actual component. Procedure validation shall, as a minimum, accomplish the following objectives. The objectives are general in scope and are intended to guide the validation process, not to dictate how results are obtained.

A1.2.1 Collect and analyze supporting data such as material, defect type, defect location, defect orientation, capability desired, etc.

A1.2.2 Determine the appropriate method, equipment and technique required to fulfill the inspection requirements.

A1.2.3 Design/manufacture prototype support equipment as necessary.

A1.2.4 Determine reference standards requirements to effectively control setup and inspection sensitivity.

A1.2.5 Determine surface preparation requirements as necessary.

A1.2.6 Determine the required technician certification level and inspector for reliable procedure performance.

A1.2.7 Determine and document defect sizing and reporting requirements.

A1.2.8 Produce a clearly written and complete draft inspection procedure.

A1.2.9 Design/manufacture test specimens containing actual or simulated discontinuities as necessary.

A1.2.10 Conduct necessary tests and evaluations to demonstrate procedure feasibility to meet engineering expectations for detection capability.

A1.2.11 Perform and document validation per the Phase 1: Procedure Validation checklist.

A1.3 Procedure Verification

During procedure verification the validated procedure is given to a production inspector to verify that the procedure can be accomplished as written. The verification process must prove the suitability of an NDI procedure to perform its intended purpose to the satisfaction of the verification witnesses, inspectors, and the NDI Level 3. All new or modified procedures shall be verified.

A1.3.1 Ensure that the procedure is thorough, understandable and logically written.

A1.3.2 Ensure that the procedure is understood and executable by the lowest-certification-level technician expected to be approved to utilize the procedure.

A1.3.3 Ensure that the specified equipment performs as expected.

A1.3.4 Ensure that part or assembly preparation requirements are adequate and can be accomplished as written.

A1.3.5 Demonstrate that the procedure meets engineering expectations for detection capability, if applicable.

A1.3.6 Determine if the inspection capability is significantly affected by multiple human factor-induced variances.

A1.3.7 Determine the need for task-specific training or certification. If it is determined that task-specific training is required, task-specific training must be developed.

A1.3.8 Ensure that human factors and environmental variables are accounted for in the procedure as necessary.

A1.3.9 Document verification per the Phase 2: Procedure Verification checklist.

A1.3.10 Approve the procedure for distribution and use.

PHASE 1: VALIDATION CHECKLIST

1. Procedure Name/Description/Purpose: ______________________________________________________

2. Inspection Area Description and Figures (attach figures as required).

3. Detection Capability Requirements: _________________________________________________________

4. Inspection Criticality:

a. Identified as 1A fatigue and fracture critical structure? Yes ___ No ___

b. If 1A structure, is it identified as a 1A inspection in the procedure? Yes ___ No ___

5. Inspection Procedure Considerations:

a. Initial procedure complete and clearly written? Yes ___ No ___

b. Method, equipment, kits, reference standards and technique appropriate? Yes ___ No ___

c. Inspection location clearly and correctly identified? Yes ___ No ___

d. Part preparation defined? Yes ___ No ___

e. Inspector certification level appropriate? Yes ___ No ___

f. Human factors addressed and incorporated in procedure? Yes ___ No ___

g. Defect mapping/defect recording criteria defined? Yes ___ No ___

h. Inspection successfully demonstrated on representative structure or coupons with actual or simulated discontinuities? Yes ___ No ___

i. NDI Level 3 and engineering oversight provided during procedure development? Yes ___ No ___

Comments (provide a summary of any element marked “No” above): __________________________________

6. Personnel Qualification Recommendation:

a. NAS 410: Level 2 ___ Level 1 ___

b. Task-specific training requirements identified? Yes ___ No ___

The following endorsement attests that the validation of the subject procedure has been completed and documented such that the results support continuation to Phase 2 Verification.

NDI Level 3

Name: _________________________________________________________ Date: _____________________

Signature: ________________________________________________________________________________

PHASE 2: VERIFICATION CHECKLIST

1. Procedure Name/Description/Purpose: ______________________________________________________

2. Criticality: Identified as 1A fatigue and fracture critical structure? Yes ___ No ___

3. Summary of Verification Activities:

a. Inspection method (Ref. NAS 410): MT ___ PT ___ RT ___ UT ___ ET ___ Other _________________

b. Lowest skill level defined and appropriate? Yes ___ No ___

c. Equipment/kit requirements clearly identified in the procedure and appropriate? Yes ___ No ___

d. Part preparation techniques defined and appropriate? Yes ___ No ___

e. Describe specimens or calibration standards used during verification: ___________________________

f. Human factors (e.g., non-direct line of site access, inspector comfort, etc.) and environmental issues (e.g., temperature, chemical vapors, etc.) adequately addressed in the procedure and are appropriate? Yes ___ No ___

Describe the human factors/ environmental issues encountered during verification: ________________

4. Inspection Results:

a. Inspector was able to effectively perform inspection? Yes ___ No ___

b. Target defects (if used) were detected as required? Yes ___ No ___

5. Inspection Capability:

a. Capability has been assessed and is appropriate for the requirement? Yes ___ No ___

b. Human factors considerations have been taken into account in capability estimates? Yes ___ No ___

Describe the method for establishing capability: __________________________________________________

Comments (provide a summary of any element marked “No” in items 3 through 5) _______________________

(continues)

PHASE 2: VERIFICATION CHECKLIST (continued)

Verification Inspector(s):

Certification: Level 2 ____ Level 1 ____ Other _____________

Name: _________________________________________________________ Date: _____________________

Signature: ________________________________________________________________________________

Comments: _______________________________________________________________________________

NDI Level 3

Name: _________________________________________________________ Date: _____________________

Signature: ________________________________________________________________________________

Comments: _______________________________________________________________________________