853363_QUALASSURANCE.pdf

This document is a U.S. Air Force quality assurance requirements specification for first article test plans and reports for F100 engine parts.

The specification establishes guidelines for preparing first article test plans (FATP) and first article test reports (FATR) for F100 engine components where first article data is referenced within a contract. All first articles must be serialized and undergo comprehensive testing including: dimensional conformance with finish requirements, non-destructive inspections (FPI, ultrasonic, eddy current, x-ray, and visual), material property conformance (mechanical, metallurgical, and chemical), and compliance with all applicable processes, specifications, and standards. Dimensional inspection requires 100% measurement of all dimensions on assembly and detail drawings with results presented in tabular format including drawing dimensions, tolerances, actual readings, and instrument serial numbers. All tooling and gaging used must have NIST-traceable calibrations per ISO 10012-1. Non-destructive inspections must be performed on 100% of first articles per the Quality Assurance Deficiency (QAD) list with results documented in tables showing features inspected, acceptance/rejection criteria, and gage serial numbers. Material properties testing shall include composition, heat treat condition, metallurgical microanalysis (with photomicrographs), and mechanical testing per manufacturing specifications. The FATP must provide detailed description of specific testing instructions, while the FATR must include all laboratory test results from contractor facilities and sub-vendors. Remnants from destructive testing and one non-destructively tested article shall be delivered per contract requirements, with one article marked as "UNSERVICEABLE - Condition Code R" and delivered with the FATR. All first articles must be newly manufactured under the current contract without prior contract items, and subcontractors previously identified for testing shall remain the only sources used unless OEM-approved alternatives are substantiated with OC-ALC/LPFR authorization. Engineering Instructions take precedence over all other technical instructions.