A08 - NW Corrosion Prevention Control Plan.pdf

FOR OFFICIAL USE ONLY

ATTACHMENT 006

NW Corrosion Prevention and Control Plan

1.0 Introduction. The purpose of the Corrosion Prevention and Control Plan is to describe the corrosion control tasks and responsibilities for the NW system and NW field support equipment (if any required).

The level of corrosion control and mandated processes have been balanced against NW other program requirements such as the use of system performance specifications, intend use (integrated Soldier worn piece of equipment), lower unit cost, existing program funding, lower weight, expected field life of individual components, use of standard commercial industry processes and components for electronics and manufacturing.

Corrosion prevention and control (CPC) is defined as the application of engineering design and analysis, quality assurance (QA), nondestructive inspection (NDI), manufacturing, operations and support technologies to prevent the initiation of corrosion, avoid functional impairment due to corrosion, and define processes for the tracking and repair of corrosion problems. Corrosion prevention and control requires the coordinated efforts of numerous disciplines and organizations across the contractor teams and PdM Ground Soldier (PdM GS). The status of corrosion control efforts will be addressed during program and technical reviews.

2.0 Organization and Responsibilities. This section defines the team organization to establish and implement the corrosion prevention and control system. This section also assigns task responsibilities.

2.1 Team Coordination of Corrosion Control. A Corrosion Control Working Integrated Product Team (CC WIPT) will be formed consisting of members from the NW Systems Engineering IPT, Test and Evaluation IPT, Supportability IPT, representatives from any company with design responsibilities (as applicable), and chaired by the Corrosion Control lead for the NW program. This team will provide and coordinate a consistent corrosion prevention and control (CPC) policy taking into account the commercial nature of the NW planned procurement and its intended military usage. The following are among the responsibilities of this team:

• Develop, document, and maintain the Corrosion Prevention and Control Plan;

• Establish regular meetings and call special meetings if required;

• Document the NW corrosion design guidelines;

• Coordinate corrosion prevention policies and procedures with other team policies and practices;

• Review corrosion test results for process/finish material qualifications;

• Establish corrosion test requirements for procured items;

• Establish and maintain team-common process/finish requirements;

• Resolve any impasse in determining the preferred process/treatment method for corrosion control at any team site where the Government controls the corrosion process;

• Maintain a log of problems, action items, corrective actions, and status of each for all sites;

• Develop and update NW maintenance documentation to include inspections for signs of corrosion and corrective actions if corrosion issues are identified.

The CC WIPT will meet as required by the NW corrosion control lead to accomplish the responsibility of the team as stated in the above paragraph, resolve corrosion control issues and to ensure coordination of the corrosion requirements within NW program. Meetings, whether formal or informal will be documented by minutes distributed to all CC WIPT members. The CC WIPT chair will be the primary liaison with government personnel on matters relating to corrosion control. In the event that a specific company is not selected to have design responsibilities for the NW system or sub-components, corrosion control responsibilities detailed below will be responsibility of the CC WIPT.

2.2 Contractor Corrosion Teams (CCT).

A CCT will be established, except at non-DoD based companies (i.e., majority of their product is intented for the commercial market) and except other PM provided products (i.e., PM HMS is responsible for corrosion protection plan for Rifleman radio and its associated liberty battery), that has responsibility to provide coordination within the organization and technical disciplines responsible for or involved in corrosion control tasks for that company. Each effected company will have a team chair to manage the respective corrosion control team and to represent the company on the Government CC WIPT (as required). The CCT chair will be a member of their applicable company IPTs and lead in the area of corrosion. Each CCT will provide a forum, through the representatives of the affected disciplines, to establish engineering, manufacturing, and quality requirements that will be implemented by the responsible organizations at that company consistent with CCT direction and in compliance with the Government corrosion requirements stated in the associated NW sub-system specification / product description and statement of work. Any changes that are in conflict with higher system level contract requirements controlled by the Government shall be brought to the PdM GS configuration manager attention using the contract configuration management process.

Each CCT will consist of knowledgeable personnel who represent, at a minimum, the following disciplines necessary to implement the contract corrosion requirements:

• Materials and processes;

• Design;

• Reliability, maintainability, and supportability;

• Quality assurance;

• Manufacturing;

• Packaging & Preservation

• Hazardous materials.

2.2.1 Contractor Corrosion Team Responsibilities. The CC WIPT will guide the contractors on corrosion prevention and control measures and verify measures implemented on the program are necessary, adequate, timely, and cost effective. The CCT principal responsibilities are as follows:

• Review internal controls to ensure that corrosion prevention and control techniques are established, implemented, and maintained;

• Review procedures for interim protection during all phases of manufacture and during preparation for storage/packaging for shipment;

• Review training programs to ensure that the required corrosion prevention and control techniques (e.g., finishing, sealing, and drainage systems) are properly addressed;

• Provide technical input to corrosion control and other related technical publications on the associated contract;

• Review and recommend approval of cleaning materials, solutions, and chemicals not covered by approved specifications for use on the system, parts, and components;

• Conduct failure analyses and provide corrective action for corrosion problems and provide information to the CC WIPT;

• Conduct quarterly CCT meetings to ensure implementation of this plan and to coordinate solutions for problems that arise during the development and manufacturing phase;

• Close communication of the CCT chairperson and CC WIPT shall be maintained throughout the contract;

• Maintain a log of problems and solutions/actions covered;

• Incorporate environmental resistance requirements and verification methods into the testing and selection of materials to ensure system level compliance (Environment is defined as natural and man-made or operational environments. Materials include metallic and non-metallic materials);

• Ensure that a balance is maintained between electrical bonding/grounding needs and corrosion control approaches.

2.2.2 Contractor Corrosion Team Functional Tasks. The CCT is responsible for assuring that the following functional tasks are accomplished on the contract:

2.2.2.1 Materials and Processes

• Write and maintain a process/finish specification for the contract item to ensure compliance with the establish corrosion prevention & control requirements in accordance with MIL-STD 7179;

• Serve as design consultant for the selection of materials, processes, and finishes;

• Review engineering drawings, system, and component specifications, and technical order manuals related to corrosion prevention and control;

• Assist in disposition of parts whose surface finish is damaged or defective;

• Initiate changes to material and process specifications and design as required;

• Assist procurement in the evaluation of subcontractor capabilities;

• Submit logs of corrosion problems and solutions/actions to the CC WIPT;

• Maintain records of all inputs from the CCT;

• Provide shop/manufacturing surveillance and support to assure compliance with specification requirements;

• Participate in or assist with, as applicable, the contractor Material Review Board for materials and processes technical disciplines.

2.2.2.2 Product Design.

• Recognize CCT decisions and incorporate these decisions into the product designs as appropriate;

• Coordinate corrosion-related design problems with the CCT;

• Ensure that protection and/or mitigation efforts for non-metallic outer surface material from microbial induced corrosion has been included in the requirements trade-offs and results of said trade-offs included in the requirements.

2.2.2.3 Reliability, Maintainability, and Supportability.

• Review drawings for conformance to standard corrosion prevention design practices;

• Ensure the incorporation of reliability, maintainability, and supportability (RM&S) considerations for material and finish selection;

• Document corrosion preventive & control maintenance procedures and applicable logistics resources.

2.2.2.4 Production Operations.

• Review and analyze corrosion-related problems across manufacturing departments;

• Request changes to engineering documentation to correct finishing procedures or implement new procedures.

2.2.2.5 Quality Assurance. The CCT Quality Assurance authority consists of process control and quality control items as described below.

2.2.2.5.1 Process Control.

• Audit incorporation of engineering specification or design changes;

• Perform tests on processing solutions and chemicals to monitor compliance of process parameters with applicable engineering or government specifications;

• Maintain records of scheduled processing solution tests and prepare test reports on specification compliance;

• Initiate corrective action for nonconforming processes upon proper direction.

2.2.2.5.2 Quality Control.

• Verify that parts and assemblies are properly protected from corrosion during manufacture, while in stock, and when packaged for shipment;

• Verify that parts are processed in accordance with the applicable specifications/standards;

• Verify that applied finishes conform to design and specification/standard requirements;

• Reject any material or part that has been damaged or has not been finished as required by applicable specification/standards.

2.2.2.6 Manufacturing (Planning).

• Translate processing and finishing requirements of engineering data on to planning documentation;

• Provide planning requirements to ensure in-process corrosion protection of the material or parts during manufacture;

• Revise planning documentation when changes to engineering design or specification requirements occur.

2.2.2.7 Packaging and Preservation.

• Translate corrosion protection/prevention requirements into required packaging and preservation instructions for shipping and storage;

• Revise packaging and preservation documentation when changes to engineering design or specification requirements occur.

2.2.2.7 Hazardous Materials.

• Ensure that materials and processes comply with all federal and state regulations;

• Serve as focal point for coordination and distribution of new regulations with the CCT, including new regulations regarding materials and processes.

3.0 Corrosion Prevention and Control Processes (CPCP).

3.1 General Requirements.

3.1.1 Contract Process/Finish Specification. The contractor, as stated in section 2.2, engineering document used to implement the contract’s corrosion protection and control is the process/finish specification, which should be incorporated into the released engineering/manufacturing dataset. The specification contains detailed finish instructions and guidelines, which are incorporated by design into engineering datasets and drawings. Materials and Processes will verify that these instructions and guidelines have been included in the datasets via the approval and sign off processes. The finish codes specify the material and process specifications, which are used to order material and by Manufacturing

(Planning) to incorporate into the manufacturing operation sheets. For commercial off the shelf (COTS) parts and equipment, the COTS vendor will ensure that all finishing materials should be used in conformance with Federal and State regulations.

3.1.2 Corrosion Testing. NW system (excluding the radio which is provided as an existing Government Furnished Property (GFP) item from a separate Government program management office) will be subjected to environmental testing as detailed in the NW system performance specification. These tests will include but not be limited to salt fog. Following testing the NW system will be visually inspected for signs of corrosion and executed corrective actions as required.

For situations where environmental conditions may be stressful to the COTS device, the PM’s approach would be to use protective packaging (case) or treat the component as expendable.

3.1.3 Dissimilar Metals. NW subsystems will be examined to ensure that dissimilar metals as defined in Table 1 are protected from galvanic corrosion. The CC WIPT and associated CCT will be responsible to ensure that the process/finish specification accurately reflects the requirements to provide corrosion protection.

Table 1. Grouping of Metals and Alloys

Group I Magnesium and its alloys (use requires approval), Aluminum alloy 5052, 5056, A356 (and other casting alloys), 6061 6013, and 6063 (and other 6000 series alloys) Group II Cadmium, zinc (use requires approval) 2000,7000 aluminum alloys Group III Iron, lead, and tin and their alloys (except corrosion-resistant steel) Group IV Copper, chromium, nickel, silver, gold, platinum, titanium, cobalt, and rhodium and their alloys; brass, corrosion-resistant steel, and graphite

Notes: Metals classified in the same groups are considered as similar metals. Materials classified in different groups are considered as dissimilar metals.