Attachment 0002 - M830A1 Recap SOW.pdf

Statement of Work Cartridge, 120mm HEAT-MP-T M830A1 (C791)

Recapitalization Program

1.0 Scope: The Product Manager for Large Caliber Ammunition, Picatinny Arsenal, New Jersey, requires the Contractor to conduct a recapitalization program on the M830A1 cartridges in the U.S.

Government (USG) inventory. The primary focus of the recapitalization program is to disassemble the cartridge, replace the combustible cartridge case, then reassemble the cartridge using epoxy adhesive to bond the new cartridge case to the existing case adapter/projectile and using the latest configuration spring disc to assemble the cartridge case to a modified case base & seal assembly. A secondary focus will be to inspect the obturator, returning it by machining to its “as built” diameter and adding (also by machining) three channels (slots) to enhance obturator breakup on muzzle exit.

The Contractor shall also design and conduct testing on removed ignition primers to verify that those with missing lacquer sealing plugs still conform to the functioning time specified on the primer drawing/QAP (12527432).

2.0 Applicable Documents:

Federal and Military Standards

MIL-STD-286C Military Standard for Propellants, Solid: Sampling, Examination, and Testing w/Change 2

FED-STD-595 Federal Standard for Colors Used in Government Procurement w/Change Notice 2

Military Specifications:

MIL-C-70983A Military Specification for Cartridge, 120mm, HEAT-MP- T, M830A1, excluding Appendix A

DTL14000022E Detail Specification Item Specification for the Cartridges, 120mm Target Practice

MIL-A-70625A Military Specification for Automated Acceptance Inspection Equipment, Design, Testing and

MIL-DTL-70478E

MIL-A-70788A

w/ Amendment 5

Military Specification for Container, Ammunition, Metal for Cartridge, 120mm Tank Ammunition Adapter, Metal and Wood Pallets

MIL-P-70786 Military Specification for Pallet, Standard Metal w/Amendment 4 MIL-PRF-46147D Performance Specification Lubricant, Solid Film, Air

Cured, Corrosion Inhibiting w/Amendment 1

Drawings:

12912208 Rev M Cartridge, 120mm HEAT-MP-T, M830A1 12912206 Rev H Projectile Sub-Assembly, M830A1 12524833 Rev AB Case Base and Seal Assembly 12527480 Rev C Propellant, JA2

12912367 Rev B Combination of Adopted Items: Ctg, 120mm, HEAT-MP-T, M830A1 12912376 Rev B Combination of Adopted Items: Ctg, 120mm, HEATP-MP-T, M830A1 (25 Cartridge Per Wood Pallet; Marine Corp Use) 12524967 Rev G Profile & Alignment Gage, Hydraulically Operated Assy 13076166 Rev XC Projectile, 120MM, HEAT-MP-T, M830A1, Modified Obturator 19-48-4079/7 Rev 5 Unitization Procedures for Complete Rounds Packed in Cylindrical

Metal Containers on 4-Way Entry Pallets 19-48-4079/7B Rev 8 Unitization Procedures for Complete Rounds Packed in Cylindrical

Metal Containers on 4-Way Entry Pallets 19-48-4231-

20PM1006

Rev 04 Unitization Procedures for Ammunition and Components Packed in Cylindrical Metal Containers on 4-Way Entry Metal or Resin Treated Pallets

19-48-4231-48 Rev 06 Unitization Procedures for Complete Rounds Packed in Cylindrical Metal Containers on 4-Way Entry Metal or Resin Treated Pallets

Quality Assurance Provisions:

QA12912208 Rev K QAP Cartridge, 120mm HEAT-MP-T, M830A1

QS12524976 Rev L QAP for Casing, Cartridge QS12961467 Rev - QAP for Cartridge Casing, Painted QS12524833 Rev F QAP for Case Base and Seal Assembly

QS12527480 Rev C QAP for propellant

Commercial Specifications and Standards:

ASTM D610-2008 Standard Practice for Evaluating Degree of Rusting on Painted Steel Surfaces

Engineering Change Proposals:

R06Y2014 R10C3001

3. Requirements:

3.1. Teardown. Receive the contract quantity of M830A1 cartridges. The quantity recapitalized in each phase will depend on the availability of the cartridges. An estimate of the quantity and lot numbers of the cartridges are provided in Appendix B. The final quantity for each phase will be laid out in the contract.

3.1.1. A quantity of 30 each of largest lot of each production group shall be set aside to use as controls for Reassembly/LAP ballistic acceptance testing. These cartridges shall not be disassembled/torn down. Below is a list of lots to pull the control cartridges from for each group:

Group 1 MHM96K135-003A Group 2 ORI05J134-004 Group 3 ORI99A130-002

3.2. Teardown. Develop a detailed procedure for inspection and teardown of M830A1 cartridge, to include preservation and preparation of the case adapter for reuse. The procedure(s) shall be submitted to the PCO for approval at least 60 days prior to the start of the recapitalization effort.

3.3. Teardown. Conduct inspection of all cartridges in accordance with criteria in Appendix A to determine if cartridge is suitable for recapitalization, if cartridge is not suitable for recapitalization, then determine if any of the components can be used to support recapitalization.

3.4. Teardown. During tear down propellant should be stored by the cartridge lot it was reclaimed from and segregated from propellant from other cartridge lots. The propellant shall be uploaded into the cartridge lot it was originally downloaded.

3.4.1. Conduct propellant stability testing on a sample of JA2 propellant from each propellant lot prior to teardown/disassembly of any cartridges represented by the sample.

A current propellant stability test is required before the bulk JA2 propellant can be stored.

3.4.1.1. Downloaded propellant should be scheduled for re-use, destruction, or transfer to the USG within one (1) year of teardown.

3.4.1.2. After completion of the stability test, the results will be provided to the PCO. These results will be added to the propellant stability database and used for loading authorization.

3.4.2. The USG wishes to test primers which have missing lacquer plugs to determine if the action time is impacted. During teardown, the Contractor shall select50 worst case primers with the most missing lacquer plugs out of the first production group. The Contractor shall conduct static testing to verify that primers with missing lacquer plugs still meet the 14ms function time requirement as delineated in drawing/QAP 12527432.

Pending successful testing, primers with missing lacquer plugs will be allowed to be reused if they are reworked to seal the flash holes within four hours of being removed from the cartridge.

3.5. Teardown. Teardown/disassemble each M830A1 cartridge that is suitable for recap based on the inspection. Approximately thirty-three (33) different cartridge lots will be included.

A listing of cartridge lot numbers and approximate quantity per lot is included at Appendix B. Components to be retained/reused are: Projectile with tracer and case adapter, propellant, and primer. These components shall be inventoried to allow these same component lots to be used to reassemble the cartridge lot and to be able to include component lot numbers and quantities for the Ammunition Data Card.

3.6. Teardown. Inspect pallets, top pallet adapters and palletized PA116 shipping and storage containers that the M830A1 cartridges were received in to determine if acceptable for reuse. Inspection criteria is provided in Appendix C.

3.7. Teardown. Dispose of the combustible cartridge cases that have been disassembled/removed from M830A1 cartridges which were determined to be unsuitable for recapitalization. These combustible cartridge cases will have cut edges with exposed fibers, which make the cases sensitive to ignition and should be disposed of promptly.

3.8. LAP. Conduct moisture testing on sample of each propellant lot at the time of stability testing. Control exposure of propellant to moisture and other contaminates during the teardown/disassembly process and reassembly/LAP process.

3.9. Component. Purchase combustible cartridge case, PN 12524976, in accordance with QAP 12524976. Exceptions to MIL-DTL-244 in regards to nitrocellulose fiberization quality requirements are included in Appendix D.

3.10. Component. Modify case base & seal assembly to meet PN 12524833, Rev AB. The groove in the case base & seal assemblies recovered from tear down will have the smaller spring disc/retaining ring groove. This groove will need to be extended to meet the PN 12524833, Rev AB requirements. After machining, clean the groove with a solvent, and apply a Dry-Film- Lubricant IAW MIL-PRF-46147 for corrosion protection. The touch up coating shall be smooth and free of excessive material, runs, or other imperfections and shall show good adhesion to the base metal. The groove does not need to be sandblasted before application. The affected characteristics from the rework procedure shall be subjected to inspections required by QAP12524833. This includes Minor 204 from Table C and Minor 210 from Table D. Minor 210 shall be applied before the Dry Film Lubricant is applied. Minor 211 does not need to be met as it is recognized this rework will widen the width of the groove.

3.11. Component. Purchase miscellaneous parts to support reassembly/Load, Assemble, Pack.

This includes but is not limited to the primer o-ring, spring disc, retaining ring, cartridge case epoxy coating, and bonding adhesive.

3.12. LAP. Develop a detailed procedure for reassembly (Load, Assemble, and Pack) of the

M830A1 cartridge. The procedure shall be submitted to the PCO for approval. Procedure shall include rework of loose adapters and channeling operations.

3.13. LAP. Reassemble (LAP) M830A1 cartridges using the existing projectile with tracer and case adapter, propellant, primer, and propellant containment bag, with a new cartridge case (PN 12524976), modified case base & seal assembly (PN 12524833), and the new configuration spring disc (PN 12990826). ADBAT testing not required for production.

3.13.1. Replace Note 3 on Drawing 121912208 with the following: Bond painted cartridge casing (PN 12524976) to the existing painted adapter. Bonding surfaces must be clean and dry prior to bonding. Mix Adhesive and Hardener (PN 12524908) in equal parts by weight until uniform in color. Adhesive and Hardener shall be applied to both bond surfaces and the joint mated within 1 hour after mixing. Immediately after adhesive application, the skived surfaces shall be pressed together firmly, securely clamped in position and remain undisturbed for the duration of the curing process. Excess adhesive shall be wiped from exterior surface without the use of solvent. The curing process shall consist of an oven cure at

60C maximum (1 hr. minimum). The bonded joint must withstand a tensile pull of 8900 Newton minimum.

3.13.2. Weight of Propellant. The Contractor shall conduct two Charge Establishment/Charge Verification tests to determine the charge weight of the propellant used for reassembly/LAP and satisfy the requirements of the propellant reassessment program. The lots used for these CE/CV will be MHM96K135-003A and ORI05J134-004. The Contractor and USG will use this data and ballistic data from the first M830A1 Recap program, to jointly determine the charge weight. Given that all cartridge lots will be loaded with the original lot of propellant for that cartridge lot, the delta charge weight change derived from this data will be applied to all cartridge lots.

3.13.3. For each CE test the Contractor shall provide three each cartridges at three different charge weights (a total of nine cartridges for each CE test). The Contractor shall calculate and provide the three charge weights prior to the test. For each CV test the Contractor shall provide 31 cartridges to the estimated charge. After analysis of the CE data, the Contractors shall provide the recommend charge weight to the PCO. Test personnel at Yuma will modify the CV cartridges to the recommended weight.

3.13.4. Replace note 23 on drawing 12912208 with the following: Apply identification markings in approximate area shown using ink, marking, stencil opaque in accordance with A- A-208, color black, NO. 37038 of AMS-STD-595, using 10 mm minimum high characters.

3.14. Obturator Diameter: A machining operation shall be performed to the outside of the projectile obturator to return the profile and dimensions (of the obturator) to those delineated on drawing 12912206. This operation shall be performed on all projectiles that have been inspected and deemed acceptable for recapitalization.

3.15. Loose Case Adapters: With the projectile subassembly in a nose-down orientation, apply a 360-degree continuous bead of adhesive and hardener (12524908) into the bottom of the “V”-shaped area formed by the sabot and the case adapter; the maximum amount of adhesive and hardener shall be 14 grams and the minimum amount, 12 grams. The projectile subassembly shall remain in the nose-down attitude until the adhesive and hardener cures. This operation shall be performed on all projectiles that have been inspected and deemed acceptable for recapitalization.

3.16. Obturator Channel: Modify obturators to include the channel per drawing 13076166. This operation shall be performed on all projectiles that have been inspected and deemed acceptable for recapitalization.

3.17. LAP. Pack out the recapitalized M830A1 cartridges in the inspected/acceptable palletized

PA116 shipping and storage containers. The preference is to repackage cartridges on the NSN 1315- 01-333-0534, COAI 12912367 configuration, which is 1 each cartridge per PA116 container, 30 containers/cartridges on a metal pallet.

3.18. LAP. Prepare and submit new Ammunition Data Cards (ADC) for the suffixed lots.

Ammunition Data Card requirements are included in Section E of this contract. When annotating the authorization for use of suffix on the ADC identify the specific case number assigned and provided by the PCO. The new ADC shall include a description of the recapitalization effort and identification of new component lot numbers and quantities.

3.19. Disposal. Dispose of spring disc, retaining ring, and primer o-ring that were disassembled/removed from M830A1 cartridges determined to be suitable for recapitalization as these components will not be reused for reassembly of the cartridge. Disposal of cartridge case is addressed under the teardown section since these are energetic and need to be disposed of promptly.

3.20. Dispose of inert residual components from teardown that could not be utilized to reassemble cartridges. Residual energetic material including projectiles with tracers and case adapters, propellant, or primers shall be packaged and shipped to Letterkenny Munitions Center for disposal. The Contractor shall prepare and ship this energetic material to LEMC and the USG will be responsible for the receipt and demil costs. Any cartridge, that upon inspection was determined unsuitable for teardown shall be returned to the USG so it will be put into the U.S. Army Demilitization Account for disposal. To minimize shipping unsuitable cartridges can be combined onto one pallet in accordance. The authority to store and ship this configuration will be provided after award.

3.21. LAP. Rework. Rework and repair requirements are included in Section E of this contract.

The following exception to this standard clause is provided here. For this contract, rework procedures along with the associated inspection procedures, shall be submitted to the PCO for review and approval prior to implementation/use.

3.22. LAP. If necessary, submittal of Requests for Variance (RFV) shall be in accordance with DI-SESS-80640D.

3.23. LAP. During reassembly/LAP, one of the three designated lots, which had cartridges set aside to use as ballistic test controls (reference paragraph 3.1) will be required to be reassembled/LAP for each production group. There are three production groups laid out in Appendix B. For example, Lot MHM96K135-003A will be reassembled the first group, Lot ORI05J134-004 will be reassembled the second group, and Lot ORI99A130-002 will be reassembled the third group. During the reassembly/LAP of each of these designated lots, a random sample of 30 each cartridges shall be pulled to serve as the ballistic acceptance sample for all M830A1 lots reassembled/LAP that same month. The Contractor is required to ship the 30 rournds set aside as controls, and the 30 round reassembly sample to Yuma Proving Ground. The USG will provide cartridges to use as warmers/spotters during the test and will be responsible for conducting the test and providing test results to the Contractor to support acceptance of the M830A1 recapitalized cartridges represented by the test. Each group is intended to be in an approximate time of 30-45 days with continuous, homogeneous reassembly/LAP, with breaks for weekends and holidays. TheUSG has selected the lots with the largest quantity for the ballistic testing but reserves the right to adjust the lot the random sample of reassembled cartridges is pulled from based on the results/yield from the teardown.

The controls will not change from those designated in paragraph 3.1.

3.24. LAP. Use of Reclaimed Primers and Case Bases from Demil – Depending on fall out rates, the USG may provide primers and case bases reclaimed from demil of M829A2 cartridges to be used to maximize the yield from this recap program. The Contractor shall make primer ammo cans and case base packaging material available for this effort. The USG will provide an address and a TAC for shipment of the packaging material which will be returned with the reclaimed components. The primers will have had a quick inspection for missing lacquer plugs, but the Contractor shall assume these primers will need to be inspected and the stake smoothed prior to using for LAP.

4. Quality:

4.1. LAP. Inspection Requirements. Recapitalized cartridges shall be subjected to inspections required by QAP 12912208.

4.2. Teardown. Propellant Stability Testing shall be conducted in accordance with MIL-STD- 286C. As stated in Supply Bulletin SB 742-1 paragraph 13-9, the following shall be used to categorize the propellant stability. Only propellant with Category A effective stabilizer shall be used to support reassembly/LAP

Category Effective Stabilizer

A 0.30 or more C 0.29 – 0.20 D Less than 0.20

Category A – acceptable stabilizer loss; safe for continued storage Category C – significant stabilizer loss. Lot does not represent an immediate hazard but is approaching hazardous stability condition. Loss of stabilizer does not adversely affect functioning in an uploaded configuration Category D – Unacceptable stabilizer loss.

4.3 LAP. The propellant moisture content shall be determined in accordance with MIL-STD-286 Method 101.5 or Method 103.5.1 or equivalent.

4.4 LAP. First Article Acceptance Testing (FAAT)

4.4.1 Contractor is required to submit a First Article Acceptance Test Plan for a reassembled/Load, Assemble, Packed M830A1 cartridge in accordance with DI-NDTI- 81307A. ADBAT testing will be configured with surrogate hardware including an inert M830A1 projectile with new case adapter. Testing will consist of five samples including one at start and end of the 10-piece FAAT.

4.4.2 FAAT Special Instructions

4.4.2.1 Cartridge Case

4.4.2.1.1 If a current supplier for the Case, Cartridge PN 12944287, is utilized for purchase of cartridge cases the requirement for compositional and dimensional FAAT can be requested to be waived provided the supplier has not had a lapse in production of the same or similar cartridge cases of over 365 days or any changes to the process or raw materials. Further, the requirement to conduct ballistic lot acceptance testing of the cartridge case is waived. Oil resistance testing not required

4.4.2.1.2 If a new supplier is utilized for purchase of cartridges cases (P/N 12524976), in addition to the inspections required in accordance with QAP 12524976, the Contractor is required to conduct a ballistic FAAT in accordance with DTL14000022E paragraphs 4.6.2 and 4.6.3. Additionally, the Contractor is required to conduct a ballistic FAAT in accordance with DTL14000022E Table II Note 2 to assure compliance with DTL14000022E Table II Critical 4 (Residue, burning/smoldering) and Major 116 (Residue, non-burning) for operative bore evacuator performance at all operational temperatures. The USG will provide a sufficient quantity of Cartridge, 120mm, TPCSDS-T, M865, with the legacy cartridge case, to support ballistic test requirements. The Contractor is responsible to disassemble the M865 cartridge, reassemble with the sample cartridge case, and conduct the testing. Prior to conduct of the FAAT, the Contractor shall submit a FAAT plan in accordance with DI-NDTI-81307A and receive formal approval from the USG contracting officer. The Contractor shall submit a FAAT report in accordance with DI- NDTI-80809B. In the event of a conflict between the requirements in DTL14000022E and those of the SOW, the requirements of the DTL14000022E take precedence.

4.4.2.2 Case Base and Seal Assembly

4.4.2.2.1 A 10-piece modified FAAT will be required to ensure the modified retaining ring groove meets all drawing requirements.

4.4.2.3 Epoxy Coating

4.4.2.3.1 If a current supplier is utilized for the purchase of the two-part epoxy coating the requirement for a dimensional and ballistic FAAT can be requested to be waived provided the supplier has not had a lapse in production over 365 days or any changes to the process or raw materials.

4.4.2.3.2 If a new supplier is utilized for the purchase of the two-part epoxy coating (P/N 12912373 and 12953391), in addition to the two-part epoxy inspections required in accordance with this SOW, the Contractor is required to conduct a ballistic FAAT in accordance with DTL14000022E paragraphs 4.6.2 and 4.6.3. Additionally, the Contractor is required to conduct a ballistic FAAT in accordance with DTL14000022E Table II Note 2 to assure compliance with DTL14000022E Table II Critical 4 (Residue, burning/smoldering) and Major 116 (Residue, non-burning) for operative bore evacuator test performance at all operational temperatures. The M865 legacy configuration shall be used as the combustible cartridge casing test configuration. The USG will provide a sufficient quantity of Cartridge, 120mm, TPCSDS-T, M865, with the legacy cartridge case, to support ballistic test requirements. The Contractor is responsible to disassemble the M865 cartridge, reassemble with an epoxy coated sample cartridge case, and conduct the testing. Prior to conduct of the FAAT, the Contractor shall submit a FAAT plan in accordance with DI-NDTI-81307A and receive formal approval from the USG contracting officer. The Contractor shall submit a FAAT report in accordance with DI-NDTI-80809B. In the event of a conflict between the requirements of DTL14000022E and those of the SOW, the requirements of DTL14000022E take precedence.

4.4.2.3.3 Oil Resistance Testing. This test is applicable to first article inspection only. The sample cartridge cases shall be introduced into the cartridge coating process. They shall be allowed to dry for twelve (12) hours minimum prior to testing. One test sample 50mm x 50mm shall be cut from each of the coated cases. A drop of hydraulic oil of type MIL-H-46170, MIL-H-6083 and VV-L-800 shall be applied to the coated surface of the sample. One drop of each sample, and allowed to stand for a minimum of eight (8) hours. The samples shall then be wiped with a dry rag and subjected to visual inspection for any evidence of degradation of the coating which shall cause the sample to be classed defective. As an alternative method, a taped off 50mm x 50mm section on the combustible cartridge case may be used in lieu of cutting a 50mm x 50mm section. Three (3) sections, one each for the three (3) types of hydraulic oil, may be taped off on each case.

4.4.2.4 Reassembly/LAP

LAP/reassembly shall be evaluated in accordance with QAP 12912208. A ballistic FAAT is not required.

4.5 LAP. Critical Characteristics

4.5.1 The following characteristics, apply to components to be purchased in support of this SOW or to Reassembly/LAP and are classified as “critical”:

4.5.1.1 Cartridge – Propellant impurity, 100%, propellant shall be screened using acceptable method(s) such as visual inspection, metal detectors, magnetically, electronic scanning, x-ray scanning, mechanical screening, etc. (Reference QAP 12912208, Part III)

4.5.2 Critical characteristics control requirements have been included in Section E of this contract.

4.5.3 There are additional critical characteristics associated with the M830A1 Cartridge, but these can only be observed during ballistic testing. The Contractor will be held responsible if the following occurs during ballistic firing.

4.5.3.1 Case base and seal assembly obturation. The case base and seal assembly shall seal the breech of the weapon against leakage of combustion gases generated when a cartridge is fired.

4.5.3.2 Any evidence of gas leakage caused by obturation failure shall be cause for rejection of the lot or first article sample. Evidence of obturation failure includes one or more of the following:

4.5.3.2.1 Evidence of gas leakage in rubber seal

4.5.3.2.2 Evidence of gas leakage in base steel or protective plating

4.5.3.2.3 After firing, the case base and seal assembly shall be extracted by the service extractor when the weapon is operated in the normal manner.

4.5.3.3 There shall be no burning/smoldering residue exceeding one second in duration after the cartridge has been fired. Any test cartridge exhibiting evidence of burning or smoldering residue lasting greater than two seconds shall be cause for rejection of the lot or first article sample. An infrared (IR) black and white video camera, and an IR color video camera shall be used to observe burning/smoldering residue and gas leakage. The IR cameras shall have frame speeds of no less than 30 frames per second. Position the IR black and white camera behind the breech so that it records a full view down the tube. Position the color IR camera to flank the black and white IR camera. External light sources shall be minimized during camera operation to make burning/smoldering residue and gas leakage more easily observed. The filter shall be removed from the black and white IR video camera to maximize its spectral response.

4.6 LAP. AIE/AAIE requires USG review and approval prior to use on this contract. AIE/AAIE shall be submitted for review and approval to the AMSRD-AAR-QEM-E with a cover letter notification sent to the PCO (DI-QCIC-81960). Approval of the AIE/AAIE will be transmitted to the Contractor via PCO letter.

4.6.1 The Contractor shall establish and maintain a documented system for the identification and approval of AIE/AAIE to include the calibration and verification of inspection equipment as necessary to meet contract requirements.

4.6.2 AIE designs shall include sufficient information to permit accurate and timely evaluation by the USG. All AIE designs shall be in the same units of measure as specified on the drawing. As a minimum, the submission shall contain the following information:

Contract Number Item Model Number/Part Number Component or Assembly Drawing Number and Revision Appropriate Defect Characteristic Operating Instructions/Calibration Standards

Recall Procedures Any Manuals or Literature Required to Operate and Maintain the System Personnel Qualifications Necessary to perform the inspection or operate the equipment.

AAIE designs shall include the minimum information above in addition to: An evaluation and apportionment of system reliability, considering operational reliability, decision making reliability, handling/inspections accuracy, calibration/verification cycles, configuration control methods and recall procedures for product which requires re-inspection

4.6.3 Automated AIE (AAIE) shall utilize failure safe designs whereby the decision-making logic and the material handling devices shall normally operate in a reject mode until an accept mode signal is obtained. AAIE shall be qualified IAW MIL-A-70625A. AAIE designs which inspect for metallic contamination of the propellant and utilize eddy current/magnetic inspection are exempt from the requirement to operate in the reject mode until an accept signal is obtained.

4.6.4 The USG reserves the right to requalify any previously qualified AIE/AAIE used for the performance of this contract at any time throughout the life of the contract. All cost associated with such requests shall be borne by the USG. The USG reserves the right to disapprove at any time the use of any AIE or AAIE not meeting the contractual requirements.

4.6.5 Qualification and Certification of Non-destructive Test personnel: Personnel operating NDT AIE in support of this contract shall be certified and qualified IAW AIA/NAS 410.

4.6.6 If a current supplier is used for the purchase of new cartridge, and/or purchase of epoxy paint and/or Load, Assemble and Pack the requirement to submit AIE and AAIE designs for approval can be requested to be waived. This request should include a listing a previously submitted and approved AIE/AAIE and the applicable contract.

4.7 LAP. Contractor Component Acceptance Testing

4.7.1 If during Contractor component level ballistic lot acceptance testing, a component fails to meet DTL 14000022 requirements, e.g., residue in excess of 0.5 grams, burning residue, evidence of gas leakage on case base & seal assemble, the USG shall be notified of these failures, be provided the test data on these failures, and be provided corrective actions. The Contractor shall submit test incident reports in accordance with DI-SESS-80255A.

4.7.2 Government Furnished Cartridge Requirements. The Contractor is responsible to identify the quantity of M865 cartridges required to support cartridge case ballistic lot acceptance testing 120 days in advance of the need for these cartridges.

4.8 LAP. Cartridges selected for ballistic acceptance testing will be subjected to testing in accordance with the following paragraphs of MIL-C-70983. The sample is required to meet the requirements shown below in order for the cartridge represented by the sample to be acceptable for DD250. Paragraphs identified as "Recapitalization Testing" shall be tested to evaluate the efforts related to the recapitalization effort, e.g. teardown, reassembly, selection of charge weight, etc. If the requirement is not met, the Contractor shall conduct a failure analysis to determine the root cause. If it is determined the root cause was not related to the recapitalization process the Contractor will not be held responsible. Ship a random sample of 30 each recapitalized cartridges from a single USG designated lot to Yuma Proving Ground to serve as the ballistic acceptance sample for all M830A1 cartridges LAP’d that same month.

Spec Ref. Criteria Applicability to Recap FAAT/LAT

3.4.1 Target Impact Dispersion For Information Only

3.4.1.1 Erratic Flight Recapitalization Testing

3.4.2 Muzzle Velocity Recapitalization Testing

3.4.3 Chamber Pressure Recapitalization Testing

3.4.4 Differential Pressure Recapitalization Testing

3.4.5 Firing Time For Information Only

3.4.6 Tracer Function For Information Only

3.4.7.1 Primer Parts Separation For Information Only

3.4.7.2 Primer Gas Leakage For Information Only

3.4.8 Misfire For Information Only

3.4.9 Premature Function For Information Only

3.4.10 Cartridge Chambering

3.4.11.1 Propulsion/ignition System Residue and

Flareback Unconditioned Use

3.4.11.3 Flareback For Information Only

3.4.12 Metal Parts Security For Information Only

3.4.13.1 Case Base and Seal Assembly Function -

Obturations Recapitalization Testing

3.4.13.2 Case Base and Seal Assembly Function -

Soundness

Recapitalization Testing

3.4.13.3 Case Base and Seal Assembly Function –

Extraction

Recapitalization Testing

3.4.13.4 Case Base and Seal Assembly Function – Primer

Retention

Recapitalization Testing

3.4.14 Early Burst For Information Only

3.6.1 Workmanship - General

The paragraph in MIL-C-70983 is modified for this recapitalization program as follows: The combustible cartridge case and case base and seal assembly shall be free from cracks, burrs, chips, scratches, gouges, dirt, grease, rust, or any other foreign materials.

3.6.2 Workmanship – Cartridge Case Paint

3.6.3 Workmanship – Cartridge Case Cracks

3.7 Propellant Contamination

4.8.1 Workmanship – General. The paragraph in MIL-C-70983 is modified for this recapitalization program as follows: The combustible cartridge case and case base and seal assembly shall be free from cracks, burrs, chips, scratches, gouges, dirt, grease, rust, or any other foreign materials. Paint touch-up is allowed on case adapters with no restriction to area touched up.

4.8.2 Cartridge Chambering – During LAP, additional attempts with the mechanical arm are allowed provided cartridge can be extracted with normal force. Operator is not to assist the mechanical aid. Applies to each 90-degree orientation.

4.9 Obturator Channeling and Diameter: After modifying the Obturator as described in 3.14 and 3.16, complete the following inspections:

CLASS CHARACTERISTIC CONFORMANCE

CRITERIA

INSPECTION

METHOD

MAJOR

101 Length of obturator channel (3x) Level III Gage 102 Width of obturator channel (3x) Level III Gage 103 Depth of obturator channel (3x) Level III Gage 104 Evidence of crack(s) on obturator 100% Visual 105 Diameter of obturator Level III Gage

MINOR

201 Radial location of channel Level III Visual

4.10 Use of Reclaimed Primers from Demil – To maximize yield the USG may reclaim primers from other demil efforts. After inspection the primers shall meet all inspection criteria as the primer reclaimed from the recap effort. The quantity will be based on availability and the results of the primer missing lacquer test.

4.11 Use of Reclaimed Case Bases from Demil – Residual serviceable cases bases from demil will be provided to increase the deliverable cartridge quantity. Enough case bases will be provided to meet the number of available projectile assemblies. These case bases will need to have original marking obliterated and be remarked.

5 Delivery Requirements

5.1 Submit the following reports to allow the USG to track/trace the GFM cartridges provided for recapitalization:

5.1.1 Teardown. Provide report on number of cartridges determined to be suitable for recapitalization. It is assumed, all cartridges suitable for recapitalization will be disassembled, if the number of cartridges disassembled is different explain why. Report required by the fifth day of the month each month teardown has occurred the previous month.

5.1.2 Teardown. Provide report on the number of cartridges remaining (not torn down, not recapitalized, can be returned to Army Field Service for Demil). Report required 45 days after DD-250 of the last lot for each award.

5.1.3 Teardown. Provide report(s) on the number of combustible cartridge cases destroyed.

5.1.4 LAP. After completion on assembly for each contract award, provide inventory, indicating serviceable (useable) and unserviceable (unusable), on the residual components. Inventory should include the following components:

Projectile with tracer and case adapter Primer Propellant Case Base and Seal Assembly Spring Disc Wood Pallets Metal Pallets Pallet Adapters PA116 Shipping and Storage Containers

Upon receipt of this inventory, a separate modification will be awarded for disposal of these components.

5.1.5 Disposal. Provide report on the GFM components destroyed. Report required 180 days after contract modification and authorization for demil is awarded. Deliver residual energetic material to LEMC 60 days after contract modification and authorization for demil is awarded. Complete shipping address will be provided with the contract modification.

6 Special Instructions

6.1 GFM

6.1.1 There will be cartridges with two different NSNs provided for recapitalization: NSN

1315-01-333-0533, COAI 12912376, packaging configuration is 1 ea cartridge per PA116 container, 25 containers/cartridges per wood pallet and NSN 1315-01-333-0534, COAI 12912367, packaging configuration is 1 ea cartridge per PA116 container, 30 containers/cartridges per metal pallet. The preference is for the deliverable M830A1 cartridges (following recap) to be packed out in the NSN configurations in which they were received (see C.4.20 for additional details).

6.1.2 Review of the Ammunition Data Cards for those lots that have a parent lot quantity and a suffixed lot quantity, e.g., MHM94B130-001 and MHM94B130-001B, show that the reason for the suffix and segregation of the parent from the suffix will no longer apply after recapitalization. For reassembly, these parent and suffixed lots can be combined when recapitalized.

6.1.3 Lot suffixes shall be assigned for each lot and provided at time of contract award.

6.1.4 The Acceptance Inspection Equipment requirements stated in paragraph 4.6 of this SOW are identical to the requirements included in the FY17-21120mm Tank Training Ammunition contracts and are intended to allow existing AIE/AAIE submissions to be rolled over for use on this effort if the same supplier is utilized. Including Propellant moisture test method detailed in par. 4.3.

6.1.5 The Government will plan to provide a quantity of GFM cartridges that will allow for 10% fallout/attrition. Cartridges will be provided within 75 days of contract award. The Government prefers to maximize the yield of recapitalization and would consider adding additional cartridges to the contract. If, during production, the contractor believes the attrition rate will be less than 10%, the contractor can submit a proposal to the PCO to increase the award quantity.

7 Security Requirements:

7.1 The security classification level for this effort is Controlled Unclassified Information (CUI).

7.2 Controlled Unclassified Information (CUI): Contractor employees that will require access to CUI will follow all DoD (DoDI 5200.48) and Army policies regarding access to CUI, and the handling, storage, transmission, and destruction of CUI. Contractor employees are required to complete initial CUI training (available at https://securityawareness.usalearning.gov/cui/index.html) within 30 days of start of performance on the contract, and then annually thereafter. CUI may be transmitted electronically (e.g., data, website, or e-mail), via approved secure communications systems or systems utilizing other protective measures such as Public Key Infrastructure or transport layer security (e.g., https).

Secure file transfer tools, such as the DoD Safe Access File Exchange (SAFE) website (https://safe.apps.mil/), should be utilized – especially for transmission between contractor and Government personnel. Electronic files/data stored on removable media may be transferred via US postal service or other approved delivery service.

7.3 The contractor shall safeguard CUI and perform Cyber Incident Reporting in accordance with

DFARS Clause 252.204-7012.

7.4 Adequate security. The Contractor shall provide adequate security on all covered contractor information systems. The covered contractor information system shall be subject to the security requirements in National Institute of Standards and Technology (NIST) Special Publication (SP) 800-171, “Protecting Controlled Unclassified Information in Nonfederal Information Systems and Organizations”

7.5 Cyber incident reporting requirement. When the Contractor discovers a cyber incident that affects a covered contractor information system or the covered defense information residing therein, the Contractor shall—

7.5.1 Conduct a review for evidence of compromise of covered defense information, including, but not limited to, identifying compromised computers, servers, specific data, and user accounts. This review shall also include analyzing covered contractor information system(s) that were part of the cyber incident, as well as other information systems on the Contractor’s network(s), that may have been accessed as a result of the incident in order to identify compromised covered defense information, or that affect the Contractor’s ability to provide operationally critical support; and

7.5.2 Rapidly report cyber incidents to DoD at https://dibnet.dod.mil.

https://dibnet.dod.mil/

APPENDIX A

Cartridge Recapitalization Inspection Criteria

A.1 If a cartridge has any one of the following conditions it CANNOT be recapitalized: Nose Tip Damaged (broken off, bent, dented)

Nylon Band damaged to the point of precluding chambering Proximity Sensor Damaged Pitting Corrosion on Projectile Projectile partially or completely separated from case cap/adapter Case cap/adapter damaged, e.g., punctured, cracked, or split Case Base & Seal Assembly rubber seal torn or separated

A.2 Cartridges with the following conditions can be reworked/recapitalized:

Case Base & Seal Assembly separated from cartridge case Combustible Cartridge Case punctured, cracked, split. (Ctg Case being replaced) Combustible Cartridge Case discolored or softened (Ctg Case being replaced) Case cap/adapter discolored Case cap/adapter with missing protective coating Skive Joint separated (Ctg Case being replaced) Case cap/adapter is loose at the projectile interface Primer above flush (primer being removed, reused, reinstalled) Primer stake missing or does not engage primer (primer being removed, reused, reinstalled) Non-removable corrosion on primer (replace with cannibalized primer from a cartridge with a bad projectile/case cap.

A.3 Primer Inspection Criteria:

Primers with corrosion on the center electrode shall not be considered for recapitalization.

Primers with damage to the exterior threads that prevent the primer from interfacing with the case base & seal assembly shall not be used for recapitalization Primers with burrs on the exterior threads shall be deburred and used for recapitalization Primers with scratches on the aft face shall be evaluated for rework Primers with missing lacquer plugs shall not be considered for recapitalization

A.4 Propellant Inspection Criteria:

If an unusual amount of the JA2 propellant grains are clumped together (more than three instances of more than two grains clumped together per cartridge), this could be an indication that this cartridge was subjected to unusual conditions. None of the propellant from a cartridge where clumping is observed should be considered for recapitalization.

If the JA2 propellant grains are unusual in color (graphite gray to black in color with straight, right-angle ends), none of the propellant from this cartridge should be considered for recapitalization If the JA2 propellant stability test result is Category “C”, propellant represented by the sample shall not be used for recapitalization

A.5 Propellant Bag Inspection Criteria: Propellant bag shall be free of rips and tears.

APPENDIX B

Listing of Lot Numbers and Corresponding Quantity Intended for First Phase of Recapitalization

Lot Number QTY NSN Propellant Lot Charge Weight

1 MHM92B001S588 10 13115013330534 HCL89M013-001 7.1

2 MHM93H131-001 508 13115013330534 HCL92H-071407 7.12

3 MHM93K131-003 30 13115013330534 HCL92H-071407 7.12

4 MHM94A131-005 2 13115013330533 HCL92H-071407 7.12

5 MHM94A131-005B 78 13115013330533 HCL92H-071407 7.12

6 MHM94A131-005C 430 13115013330533 HCL92H-071407 7.12

7 MHM94B130-001 75 13115013330533 HCL92H-071407 7.12

8 MHM94B130-001C 332 13115013330533 HCL92H-071407 7.12

9 MHM94B130-005 967 13115013330533 HCL92H-071407 7.12

10 MHM94C132H001 20 13115013330533 HCL92H-071407 7.12

11 MHM94C132H001B 304 13115013330533 HCL92H-071407 7.12

12 MHM96H135-002 147 13115013330534 HCL93J-071429 7.12

13 MHM96H135-002A 3 13115013330534 HCL93J-071429 7.12

14 MHM96K135-003A 2642 13115013330534 HCL94J-G71455 7.12

15 MHM96K135-003B 4 13115013330534 HCL94J-G71455 7.12

16 MHM96L135-004A 921 13115013330534 HCL94M-071456 7.12

17 MHM97A135H005A 1568 13115013330534 HCL94M-071456 7.12

18 MHM97C136H002A 1772 13115013330534 HCL94M-071456 7.12

MHM98E171-002A 87 13115013330534

HCL93J-071429/

HCL93L-071430

7.12

20 MHM98J137H001 480 13115013330534 ARV95M-072083 7.12

21 ORI05J134-004 4800 13115013330533 ARV03K-072352 7.15

22 ORI05J134-004A 1038 13115013330533 ARV03K-072352 7.15

23 ORI05M134-005 693 13115013330533 ARV05D-072063 7.08

24 ORI06J134-006 252 13115013330533 ARV05H-072075 7.16

25 ORI06J134-006A 481 13115013330533 ARV05H-072075 7.16

26 ORI98L130-001 781 13115013330534 ARV98E-071899 7.15

27 ORI99A130-002 1376 13115013330534 ARV98E-071899 7.15

28 ORI99B130H003 56 13115013330534 ARV98E-071899 7.15

29 ORI99B130H-003 1 13115013330534 ARV98E-071899 7.15

30 ORI99F131-001 1017 13115013330533 ARV98E-071899 7.15

31 ORI99F131-001B 1074 13115013330533 ARV98E-071899 7.15

32 ORI99F131-001C 16 13115013330533 ARV98E-071899 7.15

33 ORI99F131-001D 87 13115013330533 ARV98E-071899 7.15

Total 22052

Group 1

Group 2

Group 3

APPENDIX C

Pallet and Shipping & Storage Container Inspection Criteria

The palletized shipping & storage containers in which the M830A1 cartridges were received are intended to be reused to package the refurbished cartridges. These packaging “sets”, e.g., pallets, pallet adapters, metal containers and internal packaging, shall be visually inspected in accordance with the paragraphs below:

C.1 PA116 Shipping & Storage Container

C.1.1 Rust is permissible on the stacking surfaces of the container. No rust is permissible on the open end of the body that makes contact with the cover gasket on either the OD or ID within an area 3/8 inch from the body open-end, which does not affect sealing of the can, is acceptable.

C.1.2 The remainder of the external container body should be evaluated for the degree of rust. The maximum cumulative rust on each container shall not exceed an area 1.5 inches square (reference grade 7 of ASTM-D610), not including the stacking surfaces. Any single rust spot or blister should not exceed 1/8 inch in diameter. For rework of rust inside the lip of the container it is acceptable to lightly scuff the surface with sandpaper and repaint approximately one inch of the interior of the can mouth. No field marking is allowed on the containers, but minor over spray of a different color or visible paint from a scratch is acceptable.

C.1.3 At the discretion of the Contractor, containers that do not meet the above criteria should be either spot refurbished or totally refurbished to the degree necessary to meet the criteria.

Corrosion resistance testing is not required on refurbished containers.

C.1.4 Containers that exhibit dents to the body or damage to the extent that it interferes with removal, insertion, or free movement of the internal components should be reworked if possible. Containers with dented rims and/or rings should be reworked to ensure stacking with other surrounding containers is not compromised. If, despite rework, stacking is compromised the container shall be discarded.

C.1.5 Containers that meet the criteria for reuse but are contaminated with dirt or dust to the extent that it could interfere with the application of stencils should be cleaned.

C.1.6. Containers must meet the requirements from palletization per MIL-DTL-70478E, Appendix A, paragraph 50.2.4.

C.1.7. Container Cover. The handle shall move freely and the grip shall not be twisted or bent beyond approximately 3/8 inch. If the cable is frayed or the pin is deformed on the D-handle cover, it is not acceptable for reuse and should be repaired or replaced. Refurbished D-handle covers may have the spring clip and wire rope assembly painted. The acceptance criteria for the painted spring clip are that it can be inserted into the handle holes. Both the D-handle cover and the older style cover may be repaired and reused as necessary. The cover style on the PA116 containers are interchangeable however it is desired that the use of the D-handle covers be maximized to the greatest extent possible on the recap cartridges with use of the older butterfly handle being used on containers for demil components. Total rust surface area of the flat exterior of the cover shall not exceed ½ square inch. Rust is permissible on the contact area of the handle and shaft. Caked on mud or dirt on the cover is not acceptable. Any minor or slight deformation of the rim that will not affect gasket replacement or reuse is acceptable.

Covers with excessive dirt or mud and covers with field markings shall be cleaned and painted.

At the discretion of the Contractor, both types of covers may be spot refurbished without removal of the base cushion. The base cushion shall be removed if the entire cover is being refurbished. Replacing the spring does not require that the clamp be painted. The total rust surface area of the cover is not applicable to a replaced clamp.

C.2. Internal Packaging Components. Internal packaging components may remain in the container and be inspected as described below:

C.2.1 Components that are difficult to remove from the container or are damaged, e.g, torn, cut, cracked, incomplete, badly contaminated with dirt or sand, etc, such that it may affect the item’s function or reliability shall not be reused, unless cleaned and/or repaired prior to reuse.

C.2.2 Base cushions are acceptable so long as tears, gouges, or residual adhesive do not interfere or prevent proper fit to the container cover or against the cartridge case base.

C.2.3 Projectile supports that have scratches and/or chips in the plastic that do not affect fit or function are acceptable.

C.2.4 Rust stains on the exterior of the sleeves and strap assembly and/or plastic parts that will not come in contact with the cartridge, e.g., a rust stain that does not penetrate to the ID of the sleeve, are acceptable. A piece of the sleeve from edge that has a tear equal to, or less than 1 inch deep, and no more than 2 inches circumferentially is allowed provided it does not affect the insertion or removal of the cartridge and will not damage the combustible cartridge case during insertion or removal.

C.2.5 Rust stains on the ends of the foam sleeve and/or projectile supports are acceptable if no rust stains/marks are on the interior of the foam sleeve and strap.

C.2.6 If the strap has a nick or cut which does not exceed 30% of the web of the strap, it is acceptable for use. A strap cut more than 30% will be scrapped. It may be repaired at the discretion of the Contractor by sewing a lapped joint of approximately ¾ inch.