Attachment 0015 - ECP R21A2038 - XM1128 Metal Parts Specification Release.pdf

DD FORM 1695, AUG 2019 (US ARMY CCDC-Armament Center VERSION) Microsoft Office WORD

DISTRIBUTION STATEMENT: D Distribution authorized to Department of Defense and U.S. DoD contractors only; Administrative or Operational Use, Specific Authority, Vulnerability Information, and Critical Technology; 27 July 2017. Other requests for this document shall be referred to CAD Division, PMCAS, Attn: SFAE-AA-CAS, B-162 North, Picatinny Arsenal, NJ 07806-5000.

NOTICE OF REVISION (NOR) OMB No. 0704-0188

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PLEASE DO NOT RETURN YOUR COMPLETED FORM TO THIS ADDRESS. RETURN COMPLETED FORM TO THE GOVERNMENT ISSUING CONTRACTING OFFICER FOR THE

CONTRACT/PROCURING ACTIVITY NUMBER LISTED IN ITEM 22 OF THIS FORM.

1. DATE PREPARED (DD-MON-YYYY)

27-OCT-2021

2. PROCURING ACTIVITY NO. (PAN)

R21A2038

3. ECP NO.

R21A2038

4. NOR NO. 1 OF

5. ORIGINATOR

a. CAGE CODE 19200

b. TYPED NAME (First, Middle Initial, Last)

Cameron S. Shackleford

c. ADDRESS (Street, City, State, Zip Code):

Bldg 62 Picatinny Arsenal Dover, NJ 07806-5000

d. TELEPHONE (Incl. Area Code)

973-724-3430

e. E-MAIL ADDRESS Cameron.s.shackleford.civ@army.mil

6. TITLE OF AFFECTED DOCUMENT:

Projectile 155 Millimeter: Extended Range, HE, Metal Parts Assembly, XM1128

7. DOCUMENT CAGE CODE

19200

8. DOCUMENT NO.

MIL-DTL-32692(AR)

9. REVISION 10. NOR SHEET

1 OF 43a. CURRENT b. OTHER UNINCORPORATED NORs

N/A

11. CONFIGURATION ITEM (OR SYSTEM) TO WHICH ECP APPLIES

Projectile, 155MM, Extended Range, HE, XM1128

12. DESCRIPTION OF REVISION

Creation of MIL-DTL-32692 in support of XM1128 Metal Parts Technical Data Package.

13. REMARKS/RATIONALE

This is required to release specification MIL-DTL-32692.

14. TO BE COMPLETED BY THE APPROVING ACTIVITY

a. (X one) (1) Existing document supplemented by this NOR may be used in manufacture.

(2) Revised document must be received before manufacturer may incorporate this change.

15.a. ACTIVITY AUTHORIZED TO APPROVE CHANGE

SFAE-AMO-CAS

b. NAME (First, Middle Initial, Last)

William G. Kuhnle

c. TITLE Associate for Programs, Plans & Integration

d. SIGNATURE e. DATE SIGNED

(DD-MON-YYYY)

16. THIS SECTION COMPLETED BY THE ACTIVITY ACCOMPLISHING REVISION UPON NEW REVISION RELEASE

a. NAME (First, Middle Initial, Last) b. TITLE c. REVISION COMPLETED (Signature): d. DATE SIGNED

(DD-MON-YYYY):

KUHNLE.WILLIA

M.G.1228820896

Digitally signed by

KUHNLE.WILLIAM.G.122882089

Date: 2021.11.29 14:07:25 -05'00' 29-Nov-2021

CUI

AMSC N/A FSC 1315

INCH-POUND

MIL-DTL-32692

27 October 2021

DETAIL SPECIFICATION

PROJECTILE 155 MILLIMETER:

EXTENDED RANGE, HE, METAL PARTS ASSEMBLY, XM1128

This specification is approved for use by the U.S. Army Armaments Center, and is available for use by all Departments and Agencies of the Department of Defense within the distribution limitations noted at the bottom of the page.

1. SCOPE

1.1 Scope. This specification covers requirements for the manufacturing and assembly of the metal parts for Projectile, 155MM, Extended Range, HE, XM1128 (see 6.1).

DISTRIBUTION STATEMENT D. Distribution authorized to the Department of Defense and U.S.

DoD contractors only to safeguard critical technology as determined on 21 October 2021. Other requests for this document shall be referred to the Office of the Project Manager for Combat Ammunition Systems, ATTN: SFAE-AA-CAS, Picatinny Arsenal, NJ 07806-5000.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure of contents or reconstruction of this document.

Comments, suggestions, or questions on this document should be addressed to: U.S. Army Armaments Center, ATTN: FCDD-ACE-QSA, Picatinny Arsenal, New Jersey 07806-5000 or emailed to usarmy.picatinny.ardec.list.ardec-stdzn-branch@mail.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https://assist.dla.mil.

Controlled by: DEVCOM AC Controlled by: FCDD-ACE-QSA CUI Category: CTI Distribution Statement: D POC: Standardization Office, Email usarmy.picatinny.ardec.list.ardec-stdzn-branch@mail.mil

ECP R21A2038

NOR 1 of 8 Sheet 2 of 43

MIL-DTL-32692

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to assure the completeness of this list, document users are cautioned that they must meet all requirements documents cited in sections 3 and 4 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards and handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

FEDERAL SPECIFICATIONS

TT-C-490 - Chemical Conversion Coatings and Pretreatments for Ferrous

Surfaces (Base for Organic Coatings)

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-1168 - Ammunition Lot Numbering and Ammunition Data Card MIL-STD-1916 - DoD Preferred Methods for Acceptance of Product MIL-STD-171 - Finishing of Metal and Wood Surfaces

(Copies of these documents are available online at https://quicksearch.dla.mil/.)

2.2.2 Other Government documents, drawings and publications. The following other Government documents, drawings and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation or contract

U.S. COMBAT CAPABILITIES DEVELOPMENT COMMAND � ARMAMENTS

CENTER (CCDC AC) DRAWINGS

13071704 - XM1128 Base Closure 13071724 - Envelope Drawing, Ultrasonic Inspection Equipment and Procedure for Body Machined, 155MM, XM1128 13071726 - XM1128 Body and Rotating Band Assembly 13071727 - XM1128 Body Machined 13071728 - Thread Protector 13071729 - Ultrasonic Inspection Standard, Wall Thickness, XM1128 13071730 - Ultrasonic Inspection Standard, Longitudinal and Radial Cracks, XM1128, Body 13071731 - Ultrasonic Inspection Standard, Circumferential and Piping Defects, 155MM, XM1128

ECP R21A2038

NOR 1 of 8 Sheet 3 of 43

DISTRIBUTION STATEMENT D: Distribution Authorized to DoD and U.S. DoD Contractors Only.

13071732 - XM1128 Metal Parts Assembly 13082825 - Envelope Drawing, Magnetic Particle Inspection, Band Area, 155MM, XM1128

13082826 - Envelope Drawing, Magnetic Particle Inspection, Base Closure, XM1128.

13082827 - Ultrasonic Inspection Standard, Longitudinal & Radial Under Band, XM1128

(Copies of these drawings and specifications are available via email usarmy.pica.ccdc-ac.list.drawing-request-help-desk@mail.mil).

2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

ASTM INTERNATIONAL (ASTM)

ASTM B117 - Standard Practice for Operating Salt Spray (Fog) Apparatus ASTM E8 - Standard Test Method for Tension Testing of Metallic Materials ASTM E10 - Standard Test Method for Brinell hardness of Metallic Materials ASTM E18 - Standard Test Method for Rockwell Hardness and Rockwell

Superficial Hardness of Metallic Materials ASTM E103 - Standard Test Method for Rapid Indentation Hardness Testing of

Metallic Materials ASTM E399 - Standard Test Method for Plane-Strain Fracture Toughness of

Metallic Materials ASTM E1444 - Standard Practice for Magnetic Particle Testing

(Copies of ASTM standards are available online at https://www.astm.org.)

2.4 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Required inspections.

3.1.1 First article. When specified (see 6.2), a sample shall be subjected to first article inspection in accordance with 4.2.

3.1.2 Conformance. A sample shall be subjected to conformance inspection in accordance with 4.3.

ECP R21A2038

Sheet 4 of 43

3.2 Components and assemblies. The components and assemblies shall comply with all requirements specified on Drawings 13071732 and 13071704.

3.3 Ammunition lot numbering. Ammunition lot numbers shall be assigned and ammunition data cards be accepted in accordance with MIL-STD-1168.

3.4 Mechanical properties. Heat treatment or stress relief applied shall be uniform throughout each lot of projectiles and base closures and shall be performed and controlled as to produce in the projectile and base closure the mechanical properties specified in Drawing 13071726 or Drawing 13071704 as applicable.

3.5 Projectile plane-strain fracture toughness. The fracture toughness (Kic) in the side wall shall not be less than 25 KSI in. (thousand pounds per square inch square root inch). The fracture toughness (Kic) in the base shall not be less than 22.5 KSI in. Independent verification of fracture toughness shall be conducted in accordance with this specification.

3.6 Material defects.

3.6.1 Projectile body and base closure metal defects. The projectile body and base closure shall be free from cracks, splits, bursts, cold shuts, pipes, porosity, inclusions, folds, seams and other metal defects. The interior of the body and base closure shall also be free of sharp edges.

3.6.2 Projectile cavity surface defects. In addition to the requirements of 3.6.1 the projectile cavity shall be free from scale, fins, burrs, draw marks, laminations, imbedded foreign matter, and pits. As specified in the contract, visual standards for evaluation of surface defects may be established for each production line after the first month of production for each contract, if applicable. Visual standards for scale or pits will only be evaluated or established in the base of the projectile. Visual standards shall not preclude the requirement for compliance with 3.9 (see 6.4).

3.7 Welded rotating band.

3.7.1 Foreign matter on band seat. Prior to banding, the band seat shall be free from any contaminants that would be detrimental to the adhesion of the band to the band seat.

3.7.2 Rotating band seat control. Body material (steel) under the rotating band shall not be visible in the cannelure diameter. Body material (steel) under the rotating band shall not extend above the finished bourrelet surface.

3.7.3 Minimum melting of steel. Upon removal of the rotating band material, the steel band seat shall demonstrate visual evidence of minimum melting due to gilding metal adhesion during application of the rotating band.

3.7.4 Band seat subsurface defects. There shall be no evidence of intergranular penetration of gilding metal, weld arc cratering (except for the starting weld pass), or cracks

ECP R21A2038

NOR 1 of 8 Sheet 5 of 43 when the body band seat is turned down to 5.795 inches plus or minus 0.010 inches diameter and tested as specified. There shall be no evidence of intergranular penetration of gilding metal, weld arc cratering, or cracks when the body band seat is turned down to 5.695 inches plus or minus

0.010 inches diameter and tested as specified.

3.7.5 Band welding stress relief. The projectile shall be stress relieved within 4 hours of overlay band welding using either quench and temper or induction. Stress relief shall be at a temperature not less than 1000°F. The peak temperature at any point in the steel body shall not exceed the lower austenite transformation temperature or cause melting of the gilding metal.

3.7.5.1 Quench and temper stress relief. If quench and temper heat treatment is utilized for stress relief, heat treatment shall be for not less than 1 hour.

3.7.5.2 Induction stress relief. If induction is employed for stress relieving the maximum hardness of the heat affected zone after tempering shall be Rockwell C39 Validation that the stress relief process does not contribute to hydrogen embrittlement shall satisfy TT-C-490 and

MIL-STD-171.

3.7.6 Rotating band surface defects. The surface of the rotating band shall free of surface defects, damage and contamination in accordance with the following requirements.

a. On the forward land, there shall be no evidence of raised copper due to nicks, dings or damage of any kind and there shall be no paint or foreign matter on the outer diameter.

b. The aft three lands shall not have any nicks or digs extending greater than ½ the land width, nor shall they exceed the maximum band diameter.

c. On the surface of the overlay band the number of cavities equal to or less than 5/32 inch in the greatest dimension shall not exceed one per 45 degree segment of the band and no single cavity greater than 5/32 inch on the entirety of the band. The allowable cavity on the forward or aft bands shall not exceed 3/32 inch in the greatest dimension. Any cavity greater than 3/32 inch shall be filled with Government approved filler/hardener. However one inch square area per band is allowed a maximum of four (4) cavities, none of which exceeds 3/32 inch in the largest dimension.

d. One tightly closed seam in the area of the weld start stop zone is allowed on the surface of the overlay band.

e. Disbond (pick out) as indicated by a ragged appearance forward or aft of the rotating band is allowed.

f. The overlay rotating band and band seat areas shall have no other discontinuities, cracks, lack of bonding, lack of fill or other metal defects other than those herein defined.

3.8 Protection of rotating band. The rotating band shall be protected with a flexible rotating band cover (FRBC) per Drawing 13071732 prior to shipment.

ECP R21A2038

NOR 1 of 8 Sheet 6 of 43

3.9 Non-destructive testing. Projectiles and base closures shall be inspected using Non

Destructive Testing methods as outlined below.

3.9.1 Ultrasonic defect testing. Projectiles shall be free of any discontinuities equal to or in excess of the requirements outlined in 13071724. The calibration criteria are notches and holes in the standards (see Drawings 13071730, 13071731 and 13082827), which simulate cracks and piping defects. Projectiles that comply shall be stamped with the letter �U� as specified on the Drawing 13071726.

3.9.2 Ultrasonic wall thickness testing. Projectiles shall be free of wall variation and undersized wall thickness equal to or in excess of the calibration criteria for the respective zones.

The calibration criteria are holes and machined bands in the standard (see Drawing 13071729), which defines wall thickness and variation.

3.9.3 Magnetic particle test of base closure. The base closure shall be free from all metal defects including cracks, splits, bursts, cold shuts, pipes, porosity, inclusions, and other metal defects when subjected to magnetic particle inspection. Sensitivity of magnetic particle inspection shall be established per the requirements in Drawing 13082826.

3.10 Interior cavity finish. The interior cavity after painting shall be free from grease, dirt and other foreign matter. There shall be no pool of paint in the bottom of the cavity. The coating shall be a smooth, uniform, continuous film, provide complete coverage, and be free from dried overspray, runs, sags, blisters, orange peel, bare spots, or other imperfections.

3.11 Ballistic test. Upon gun launch, the projectile assembly shall reveal no evidence of metal parts failure. Metal parts failure shall be defined as:

3.11.1 Breakup. Loss or breakup of metal parts components in the gun bore or in flight.

3.11.2 Rotating band failure. Loss or fanning of the rotating band.

3.11.3 Shearing of rotating band. Shear of rotating band as evidenced by complete lack of engraving.

3.12 Workmanship. Components shall be free of burrs, sharp edges, cracks, dirt, grease, corrosion, and other foreign matter. Cleaning methods used shall not be injurious to any parts, nor shall the cleaning agents contaminate the parts. All required marking and stamping shall be neat and sharply defined. All painted parts shall be dry to the touch before inspection and/or gaging. The paint shall be considered dry when the soft tacky condition no longer exists and the paint feels firm when touched with a finger using moderate pressure.

Sheet 7 of 43

4. VERIFICATION

TABLE I. Requirement/verification cross reference matrix.

Methods of Verification Classes of Verification 1- Examination 2- Test

A- First Article B- Acceptance

Section 3 Requirements

Description Verification Method

Verification Class

Section 4 Verification

1 2 A B

3.1.1 First article X X X 4.2

3.1.2 Conformance X X X 4.3

3.2 Components and assemblies X X X X 4.3.2.1 - 4.3.2.10

3.3 Ammunition lot numbering X X X 4.3.2.6, 4.3.2.9

3.4 Mechanical Properties X X X 4.4.3

3.5 Plane strain fracture toughness X X X 4.4.3.3

3.6.1 Projectile body and base closure

metal defects X X X 4.3.2.6, 4.3.2.9

3.6.2 Projectile cavity surface defects X X X 4.3.2.3, 4.3.2.7

3.7.1 Foreign matter on band seat X X X 4.3.2.4

3.7.2 Rotating band seat control X X X 4.3.2.6

3.7.3 Minimum melting of steel X X X 4.4.4.3.2

3.7.4 Band seat subsurface defects X X X 4.4.4.3.3, 4.4.5.4

3.7.5 Band welding stress relief X X X 4.4.4.3.4

3.7.6 Rotating band surface defects X X X 4.3.2.6

3.8 Protection of rotating band X X X 4.3.2.8

3.9.1 Ultrasonic defect test X X X 4.4.5.1

3.9.2 Ultrasonic wall thickness test X X X 4.4.5.2

3.9.3 Magnetic particle test of base

closure X X X 4.4.5.3

3.10 Interior cavity finish X X X 4.3.2.7

3.11 Ballistics test X X X 4.4.8

3.12 Workmanship X X X 4.3.2.1 - 4.3.2.10

Sheet 8 of 43

4.1 Classification of verification. The verification requirements specified herein are classified as follows:

a. First article inspection (see 4.2).

b. Conformance inspection (see 4.3).

4.2 First article inspection.

4.2.1 First article quantity. First article verification shall be performed on the quantity of items as indicated in Table II.

4.2.2 Inspections to be performed. The first article verification shall be performed in accordance with Table II.

4.2.3 First article rejection. If any item fails to comply with requirements, the first article shall be rejected.

Sheet 9 of 43

TABLE II. First article inspection.

Number of FAT Samples

REQUIREMENT

PARAGRAPH

INSPECTION

METHOD

REFERENCE

Thread protector 13071728 Examination for defects 25 3.2 4.3.2.1

XM1128 body machined (mult) 13071727 Temperature of mult, max. (Note 1) 3 3.2 4.4.1 Chemical composition certification (Note 4) 1 3.2 Certification

XM1128 body machined (prior to nosing) 13071727 Examination for defects 25 3.2 4.3.2.3

XM1128 body machined (forward of rear shoulder) 13071727

Examination for defects 25 3.2 4.3.2.4

XM1128 body machined (rearward of shoulder) 13071727 Examination for defects 25 3.2 4.3.2.5

XM1128 body and rotating band assembly (prior to painting) 13071726

Examination for defects 25 3.2 4.3.2.6 Ultrasonic defect inspection 25 3.9.1 4.4.5.1 Hardness test 25 3.4 4.4.3.1.1 Yield strength and elongation of body (Notes 2-3) 2 3.4 4.4.3.2 Plane-Strain Fracture Toughness test (Notes 2-3) 1 3.5 4.4.3.3.1 Magnetic particle test, band area (Note 3) 5 3.7.4 4.4.5.4 Rotating band chemical analysis (Note 3) 5 3.2 4.4.4.3.1 Rotating band welding stress relief (Note 3) 2 3.7.5 4.4.4.3.4

XM1128 body and rotating band assembly (after painting) 13071726

Examination for defects 25 3.2 4.3.2.7 Salt Spray test (Note 3) 5 3.2 4.4.7

Note 1: Check temperature of first, middle and last mult to be used in the First Article sample. This reading is to be taken during processing of First Article samples.

Note 2: Verification by an independent lab is required per 4.4.3.2.3 and 4.4.3.3.2.

Note 3: These samples are in addition to samples used for examination of characteristics as well as the examination for defects.

Note 4: Verification by an independent lab is required.

Sheet 10 of 43

CUI

TABLE II. First article inspection - continued.

Number of

FAT

Samples

REQUIREMENT

PARAGRAPH

INSPECTION

METHOD

REFERENCE

XM1128 Metal Parts Assembly 13071732

Examine for defects Ballistic performance for structural integrity (Note 3)

XM1128 Base Closure 13071704

3.2 3.11

4.3.2.8 4.4.8

Examination for defects 25 3.2 4.3.2.9 Yield strength and elongation of base closure (Notes 2-3)

2 3.4 4.4.3.2

Salt Spray test (Note 3) 5 3.2 4.4.7 Ballistic performance for structural integrity (Note 3)

23 3.11 4.4.8

Note 2: Verification by an independent lab is required per 4.4.3.2.3.

Note 3: These samples are in addition to samples used for examination of characteristics as well as the examination for defects.

ECP R21A2038

NOR 1 of 8 Sheet 11 of 43

4.3 Conformance inspection.

4.3.1 Lot formation. Lot formation shall be in accordance with lot formation requirement of MIL-STD-1916.

4.3.1.1 Heat treatment inspection lot. Heat treatment inspection lots shall not exceed one mill heat of steel or 2500 components, whichever is smallest. Whenever a break in heat treating of eight (8) hours or more occurs or a furnace is shut down for any length of time, the heat treatment inspection lot will be terminated and a new lot shall start. Additionally, heat treatment inspection lots shall be restricted to components heat treated in the same heat treating equipment, at the same temperature, for the same length of time and in one unchanged process. When a batch type furnace is used, the heat treatment inspection lot shall be further restricted to those components heat treated at the same time in one batch. Test samples shall be selected from the heat treatment inspection lot after final heat treatment. Components in heat treatment inspection lots shall remain grouped together and identified by inspection lot until mechanical property tests have been completed. Components from heat treatment inspection lots which comply with applicable requirements may be subsequently regrouped into final assembly lots provided they are documented and traceable to the final assembly lot.

4.3.2 Classification of characteristics. Conformance examinations and tests are specified in the following Classification of Characteristics paragraphs. When cited herein, attributes sampling inspection shall be conducted in accordance with MIL-STD-1916, using the inspection levels cited in the Classification of Characteristic paragraphs. Definitions of Critical, Major and Minor shall be as defined in MIL-STD-1916. Acceptance criteria shall be in accordance with MIL-STD-1916. Dimensions marked tool control shall be gaged at the beginning of production and whenever tooling is replaced. Where destruction of components is necessary to inspect these dimensions, measurements of the tool may be substituted provided there is an established correlation between the tool dimensions and the component dimensions prior to the start of production. There shall be adequate documented surveillance to assure that drawing requirements are being met throughout the life of the tool.

Sheet 12 of 43

CUI

4.3.2.1 Thread protector.

Drawing Number

13071728 Next Higher Assembly 13071732

Classification Examination Or Test Conformance Criteria

Requirement Paragraph

Inspection Method

Critical None defined

Major 101 Pitch diameter of threads Level IV 3.2 Acceptance

Inspection Equipment

(AIE)

102 Major diameter of threads, max Level IV 3.2 AIE 103 Outside diameter of o-ring groove Level IV 3.2 AIE 104 Width of o-ring groove Level IV 3.2 AIE 105 Depth of o-ring groove Level IV 3.2 AIE 106 Diameter of inner cavity Level IV 3.2 AIE 107 Material certification Note 1 3.2 Certification

Minor 201 Total height Level II 3.2 AIE 202 Evidence of poor workmanship Level II 3.12 Visual

Note 1. With each lot of material.

ECP R21A2038

NOR 1 of 8 Sheet 13 of 43

4.3.2.2

XM1128 body machined (mult).

Drawing

13071727 Next Higher

Assembly

Classification

Examination Or Test

Conformance

Criteria

Requirement

Paragraph

Inspection

Method Critical None defined

Major 101 Chemical composition certification

(Note 1) Lot of steel 3.2 Certification

102 Temperature of mult, max. 4.4.1 3.2 AIE

Minor None defined

Note 1. Independent verification of chemical composition. Beginning with the first heat of material and once per year thereafter as a minimum, a sample of the material being used for production of the projectile body shall be sent to a lab for independent analysis of chemical composition. If the independent analysis indicates that any sample fails to meet any requirement for correct chemical composition of the alloy, all material represented by the sample and all applicable components made since the last successful analysis shall be rejected.

Sheet 14 of 43

4.3.2.3

XM1128 body machined (prior to nosing).

13071727 Next Higher

101 Presence of surface defects in projectile cavity 100% 3.6.2 4.4.2 /

Visual / dedicated light source

Sheet 15 of 43

4.3.2.4

XM1128 body machined (forward of rear shoulder).

13071727 Next Higher

101 Cleanliness of rotating band seat Level IV 3.7.1 Visual 102 Diameter of rotating band seat Level IV 3.2 AIE 103 Runout of rotating band seat Level IV 3.2 AIE 104 Location of rotating band seat Level IV 3.2 AIE 105 Width of rotating band seat Level IV 3.2 AIE 106 Thickness through the base Level IV 3.2 AIE 107 Runout of pitch diameter of nose thread with bourrelet and front face Level IV 3.2 AIE

108 Runout of ogive with bourrelet (two locations)

Level IV 3.2 AIE

109 Runout of bourrelet relief with bourrelet Level IV 3.2 AIE 110 Diameter of bourrelet, min Level IV 3.2 AIE 111 Diameter of bourrelet relief Level IV 3.2 AIE 112 Diameter to first basic length from front face Level IV 3.2 AIE

113 Diameter to second basic length from front face

Level IV 3.2 AIE

114 Diameter of ogive at shorter basic length Level IV 3.2 AIE 115 Length from front face to relief of bourrelet Level IV 3.2 AIE

116 Length from front face to rear of bourrelet relief

Level IV 3.2 AIE

117 Thickness of body wall in ogive area min. (2 locations)

100% 3.9.2 4.4.5.2

118 Variation of wall thickness in ogive area 100% 3.9.2 4.4.5.2 119 Variation of wall thickness in bourrelet area 100% 3.9.2 4.4.5.2

120 Pitch diameter of nose threads Level IV 3.2 AIE 121 Minor diameter of nose threads, max Level IV 3.2 AIE

Sheet 16 of 43

4.3.2.4 (Cont.)

XM1128 body machined (forward of rear shoulder).

13071727 Next Higher

Major 122 Length of effective thread, min. Level IV 3.2 AIE 123 Total length Level IV 3.2 AIE 124 Runout aft of band seat Level IV 3.2 AIE 125 Diameter aft of band seat Level IV 3.2 AIE

Minor 201 Radii or chamfers missing Level II 3.2 Visual 202 Surface finish improper Level II 3.2 Visual 203 Evidence of poor workmanship Level II 3.12 Visual

Sheet 17 of 43

4.3.2.5

XM1128 body machined (rearward of shoulder).

13071727 Next Higher

Critical

Major diameter of closure threads, min, projectile body Pitch diameter of closure threads, min, projectile body

100% + VL-

VII

100% + VL-

VII

3.2

AIE

Pitch diameter of closure threads, max, projectile body Pitch diameter of external boss threads

Level IV

103 Major diameter of external boss threads Level IV 3.2 AIE 104 Pitch diameter of internal boss threads Level IV 3.2 AIE 105 Minor diameter of internal boss threads Level IV 3.2 AIE 106 Rear diameter Level IV 3.2 AIE 107 Depth of cavity recess Level IV 3.2 AIE 108 Diameter of rear o-ring groove Level IV 3.2 AIE 109 Length from shoulder to rear face Level IV 3.2 AIE 110 Length from rear face to rear o-ring groove Level IV 3.2 AIE

111 Width of o-ring groove Level IV 3.2 AIE 112 Length from rear of closure threads to shoulder Level IV 3.2 AIE

113 Length from front of closure thread to shoulder

Level IV 3.2 AIE

114 Depth of cavity Level IV 3.2 AIE 115 Projected runout of closure thread pitch diameter Level IV 3.2 AIE

116 Minimum length of internal boss thread Level IV 3.2 AIE 117 Minimum length of external boss thread Level IV 3.2 AIE 118 Runout of inside diameter Level IV 3.2 AIE 119 Runout of rear diameter Level IV 3.2 AIE 120 Flatness of shoulder Level IV 3.2 AIE 121 Perpendicularity of shoulder Level IV 3.2 AIE

Sheet 18 of 43

4.3.2.5

XM1128 body machined (rearward of shoulder).

13071727 (Cont.)

Next Higher

Minor 201 Surface finish improper Level II 3.2 Visual 202 Evidence of poor workmanship Level II 3.12 Visual

Sheet 19 of 43

4.3.2.6

XM1128 body and rotating band assembly (prior to painting).

13071726 Next Higher

13071732

Critical

1 Ultrasonic defect test, projectile body 100% 3.9.1 4.4.5.1 2 Magnetic particle inspection, band area 4.4.5.4 3.7.4 4.4.5.4

101 Hardness Test 100% 3.4 4.4.3.1 102 Yield strength and elongation of body, Note 1

4.4.3.2 3.4 4.4.3.2.2

103 Plane-Strain Fracture Toughness test, Note 2

4.4.3.3 3.5 4.4.3.3.1

104 Rotating band min melt 4.4.4.3 3.7.3 4.4.4.3 105 Rotating band chemical analysis 4.4.4.3.1 3.2 4.4.4.3.1 106 Diameter of rotating band Level IV 3.2 AIE 107 Runout of rotating band with bourrelet Level IV 3.2 AIE 108 Location of cannelure (3 locations) Level IV 3.2 AIE 109 Diameter of rotating band cannelure (3 locations) Level IV 3.2 AIE

110 Location of rotating band Level IV 3.2 AIE 111 Location of basic diameter (rotating band) Level IV 3.2 AIE

112 Rotating band surface defective Level IV 3.7.2, 3.7.6 Visual 113 Weight Level IV 3.2 AIE 114 Ultrasonic test stamp missing, Note 3 100% 3.9.1 Visual 115 Presence of metal defects in projectile body 100% 3.6.1 Visual / dedicated light source

116 Foreign matter in cavity 100% 3.12 Visual / dedicated light source Note 1. Independent verification of this characteristic is required per 4.4.3.2.3.

Note 2. Independent verification of this characteristic is required per 4.4.3.3.2.

Note 3. Any part found without the required test stamp shall be tested to determine if the part fails the critical test. If the part fails the critical test it shall be treated as a Critical Nonconformance. If the part passes the critical test it shall be treated as a Major Nonconformance.

Sheet 20 of 43

4.3.2.6

XM1128 body and rotating band assembly (prior to painting).

13071726 (Cont.) Next Higher

Minor 201 Evidence of poor workmanship Level II 3.12 Visual 202 Presence of burrs Level II 3.2 Visual 203 Nomenclature marking missing, incorrect or illegible Level II 3.2 Visual

204 Ammunition lot number missing, incorrect or illegible

Level II 3.3 Visual

205 Welding machine stamp missing, incorrect or illegible

Level II 3.2 Visual

Sheet 21 of 43

4.3.2.7

XM1128 body and rotating band assembly (after painting).

13071726 Next Higher

101 Diameter of bourrelet, max. 100% 3.2 Ring Gage 102 Foreign material in cavity 100% 3.10 Visual / dedicated light source

103 Paint on threads 100% 3.10 Visual 104 Pool of paint in cavity 100% 3.10 Visual / dedicated light source

105 Incomplete coverage in cavity 100% 3.10 Visual / dedicated light source 106 Salt spray test 4.4.7 3.2 4.4.7

Rotating band surface defective Projectile cavity surface defects

100% 100%

3.7.6 3.6.2

Visual Visual / dedicated light source

201 Evidence of poor workmanship Level II 3.12 Visual 202 Exterior protective coating thickness 4.4.6 3.2 AIE

Sheet 22 of 43

4.3.2.8

XM1128 metal parts assembly.

13071732 Next Higher n/a

Major None defined

201 Evidence of poor workmanship Level II 3.12 Visual 202 Plug, shock attenuating missing Level II 3.2 Visual 203 Flexible rotating band cover missing or installed incorrectly Level II 3.8 Visual

204 Thread protector o-ring missing or installed incorrectly

Level II 3.2 Visual

205 Base thread protector missing or installed incorrectly

Sheet 23 of 43

4.3.2.9

XM1128 base closure.

13071704 Next Higher

Critical

Magnetic particle test, base closure.

Thread minor diameter, max, base closure.

Pitch diameter of threads, max, base closure.

4.4.5.3.2

100% + VL-

VII

100% + VL-

VII

3.9.3

4.4.5.3

Pitch diameter of threads, min, base closure Total length

103 Location of forward basic outside diameter Level IV 3.2 AIE

104 Location of rear basic outside diameter Level IV 3.2 AIE 105 Diameter of thread pilot Level IV 3.2 AIE 106 Depth of cavity Level IV 3.2 AIE

107 Depth of largest rear cavity basic diameter Level IV 3.2 AIE

108 Web thickness at hole Level IV 3.2 AIE 109 Diameter of burner orifice Level IV 3.2 AIE 110 Forward runout of boat tail Level IV 3.2 AIE 111 Rear runout of boat tail Level IV 3.2 AIE 112 Flatness of forward face Level IV 3.2 AIE 113 Wall thickness at basic diameter Level IV 3.2 AIE 114 Distance between basic diameters on exterior aft cavity Level IV 3.2 AIE

115 Depth from forward interior basic diameter to rear-most interior cavity surface

Level IV 3.2 AIE

116 Runout of large rear cavity diameter Level IV 3.2 AIE 117 Runout of base closure orifice Level IV 3.2 AIE 118 Perpendicularity of forward face Level IV 3.2 AIE 119 Salt Spray 4.4.7 3.2 4.4.7

Sheet 24 of 43

4.3.2.9

XM1128 base closure.

13071704 (Cont.) Next Higher

Presence of metal defects in base closure

Yield strength and elongation, Note 1

100%

4.4.3.2

3.6.1

3.4

Visual/dedic ated light source 4.4.3.2.2

122 Magnetic particle stamp missing, Note 2 100% 3.2 AIE 123 Paint thickness 4.4.7 3.2 AIE

201 Diameter of thread relief Level II 3.2 AIE 202 Width of thread relief Level II 3.2 AIE 203 Depth from forward face to threads Level II 3.2 AIE 204 Diameter of counterbore rear of thread relief Level II 3.2 AIE

205 Depth to rear of thread relief Level II 3.2 AIE 206 True Position of notches Level II 3.2 AIE 207 Radius of notches, 4 places Level II 3.2 AIE 208 Depth of notches (4 places) Level II 3.2 AIE 209 Diameter to notches (2 places) Level II 3.2 AIE 210 Lot number missing or incorrect Level II 3.2 Visual 211 Surface finish improper (prior to protective finish) Level II 3.2 Visual

212 Protective finish (prior to paint) improper

213 Evidence of poor workmanship Level II 3.12 Visual

Note 1: Independent verification of this characteristic is required per 4.4.3.2.3.

Note 2: Any part found without the required test stamp shall be tested to determine if the part fails the critical test. If the part fails the critical test it shall be treated as a Critical Nonconformance. If the part passes the critical test it shall be treated as a Major Nonconformance.

Sheet 25 of 43

4.3.2.10

XM1128 metal parts ballistic test.

n/a Next Higher

Critical

1 Ballistic test failure, projectile break-up or component separation in bore or in flight.

4.4.8 3.11.1 4.4.8

2 Ballistic test failure, rotating band failure.

4.4.8 3.11.2 4.4.8

3 Ballistic test failure, shearing of rotating band.

4.4.8 3.11.3 4.4.8

Major None defined

Sheet 26 of 43

4.4 Testing.

4.4.1 Mult temperature. One mult shall be checked for maximum temperature during each hour, or fraction thereof, of furnace operation. If any mult checked exceeds the applicable requirement, all mults in that heat treatment batch shall be rejected.

4.4.2 Visual examination for material defects.

4.4.2.1. Visual examination for projectile body and base closure metal defects. The entire projectile body and base closure shall be inspected visually prior to coating using a dedicated light source to assure conformance with the applicable requirements. Any projectile failing to meet the applicable requirements of 3.6.1 shall be classed defective and removed from the lot.

4.4.2.2 Visual examination for projectile cavity surface defects. The internal cavity of the projectile shall be inspected visually prior to nosing and after painting using probe lighting to assure conformance with the applicable requirements. Visual standards in accordance with 3.6.2 shall be set up for use during this inspection. Any projectile failing to meet the applicable requirements of 3.6.2 shall be classed defective and removed from the lot.

4.4.3 Mechanical properties.

4.4.3.1 Hardness. Each projectile from a heat treated lot shall be identified and subjected to a hardness test on the surface 1/2 inch forward of the rotating band. The base closure hardness test shall be conducted one inch forward of the rear face on the outside sidewall. One hardness reading shall be taken. The hardness reading obtained shall be used as the basis for selecting the tension test sample of paragraph 4.4.3.2.

4.4.3.1.1 Hardness test. The hardness test shall be conducted in accordance with ASTM

E103 and the following:

a. The surface of the component in the area designated to be hardness tested shall be prepared by machining to a sufficient depth, 0.015 inch minimum, to remove scale and get below the decarburization zone. The preparation process to be used shall require approval as part of the AIE submittal. Manual grinding shall not be used. The surface preparation requirement may be eliminated with approval from the Government (see 6.10).

b. Hardness tester periodic verification shall be performed using Brinell test standards manufactured in accordance with ASTM E10 in lieu of production samples.

c. The hardness tester shall use a standard 10mm Brinell ball. The component shall be securely supported so that no rocking or shifting of the component will occur during the test.

The tester shall apply a preload followed by application of the full load. The preload shall not exceed 10% of the major load of 3000kg. The amount of penetration of the indentor (10mm ball) during that time period when the major load is applied including the dwell time at the end of the load application shall be automatically measured. The tester shall be provided with a means to compensate for any flexing of the test item that may occur during

ECP R21A2038

NOR 1 of 8 Sheet 27 of 43 application of the major load. The hardness number will be displayed at the conclusion of the test.

d. One hardness reading shall be taken.

e. All hardness test measurements shall be automatically recorded.

4.4.3.2 Mechanical properties test. Two final heat treated components from a heat treated inspection lot shall be selected for the tension test. The components selected shall be those which have the highest and the lowest hardness reading from 4.4.3.1. From each of these components three specimens shall be tested in accordance with 4.4.3.2.1. In the event of rejection, new samples of higher or lower hardness values or both, as applicable, may be selected and tested in order to establish an acceptable hardness range. Once this range has been established all components whose hardness values fall outside the range shall be rejected (see 6.11). An acceptable hardness range is one which will provide acceptable yield and elongation results.

4.4.3.2.1 Yield strength and elongation specimens. The two components selected for testing shall have specimen taken in accordance with Figure 1 and Figure 2 and tested as follows:

a. The projectile base section tensile specimen shall be taken transversely. Failure to meet the yield strength or elongation requirements shall require a retest from the remaining portion of the base. Results of the retest specimen and the first failing specimen shall be averaged to determine compliance with Drawing 13071726 requirement. Failure of the average results to meet the drawing requirement shall be cause for rejection of the heat treated inspection lot.

b. The two projectile longitudinal specimens shall be taken 1800 from the sidewall.

Location shall be centered under the rotating band seat and in the middle of the wall thickness in that area. Failure of any specimen to comply with Drawing 13071726 requirement shall be cause for rejection of the heat treated inspection lot.

c. The two base closure specimens shall be taken 1800 from the sidewall of the closure such that the center of the gage length will be one inch from the forward face. Failure of any specimen to comply with Drawing 13071704 requirement shall be cause for rejection of the heat treated inspection lot.

4.4.3.2.2 Yield strength and elongation testing. Testing shall be conducted in accordance with ASTM E8 with the largest substandard size round specimen possible.

4.4.3.2.3 Independent verification of mechanical properties. Beginning with the first heat of material and at least once per month thereafter, two additional specimens shall be taken from each of the highest and the lowest hardness reading samples selected in 4.4.3.2 and sent to a lab for independent analysis of mechanical properties. The specimens shall be taken adjacent to the original specimens. If the independent analysis indicates that any specimen fails to meet either

ECP R21A2038

NOR 1 of 8 Sheet 28 of 43 the minimum yield strength or percent elongation, all product represented by the independent sample shall be rejected.

4.4.3.3 Plane-strain fracture toughness test. Beginning with the first heat treat lot produced and continuing until three consecutive heat treat lots have complied with the applicable minimum requirement specified, one final heat treated projectile from each heat treated lot shall be subjected to the Plane-Strain Fracture Toughness test. The projectile selected shall be of the highest hardness reading from 4.4.3.1 and may be the same as used in 4.4.3.2. Four specimens shall be tested at an independent lab. No individual fracture toughness from the side wall shall be less than the applicable requirement. No individual fracture toughness from the base shall be less than the applicable requirement. If one test is invalid, acceptance may be based on the fracture toughness of the valid sample. If any individual fracture toughness is below the minimum allowable, the heat treated lot represented shall be rejected (see 6.11). After three consecutive heat treated lots have been accepted, the test shall be conducted at least once per year. The test shall be reinstituted unless waived by USG, until three consecutive heat treatment lots have complied with the applicable requirements, if any of the following occur:

a. Any single lot fails the fracture toughness requirement.

b. Steel is procured from a different producer, or from a substantially different process.

c. Forgings are procured from a different producer.

d. Any change made in the forging process or configuration.

e. A change is made in heat treatment contractors.

f. A substantial change is made in the heat treatment process.

g. A change is made to the heat treatment metal parts configuration.

4.4.3.3.1 Plane-Strain fracture toughness samples. The two base specimens shall be taken from locations F1 and F2 on Figure 1. The test shall be conducted at a specimen temperature of -65°F. The test shall be conducted in accordance with the procedure defined in ASTM E399. The notches shall be machined across the rear face of the base specimen.

Locations F3 and F4 on Figure 1 shall be used for replacement specimens for locations F1 and F2 respectively. The two side wall specimens shall be taken from locations F5 and F6 on Figure

2. Orientation of the side wall samples shall be L-R with the notches machined across the outside diameter surface of the specimen. Locations 180 degrees from samples F5 and F6 shall be used for replacement specimens for locations F5 and F6 respectively.

4.4.3.3.2 Independent verification of Plane-Strain fracture toughness. Beginning with the three consecutive heat treat lots, and at least once per year thereafter (see 6.2) per production line for each contract, if applicable, two additional specimens shall be taken from each of the base and side wall samples selected in 4.4.3.3 and sent to a lab for independent analysis. The specimens shall be taken adjacent to the original specimens. If the independent analysis

ECP R21A2038

NOR 1 of 8 Sheet 29 of 43 indicates that any sample fails to meet Plane-Strain Fracture Toughness, all product since the last successful test represented by the independent sample shall be rejected.

F4

T

F3

F1

T

F2

F2

Approximate location of base tensile and fracture toughness specimens

(T = Tensile F = Fracture Toughness)

Recommended base fracture toughness sample size:

Thickness B= 0.375 inch Width W= 0.75 inch Span S= 3.15 inch

FIGURE 1. Projectile base mechanical properties test locations.

NOR 1 of 8 Sheet 30 of 43

F5 F5 T F6

F6 R

Approximate location of side wall tensile and fracture toughness specimens.

Fracture toughness specimens may be taken 90 degrees from tensile specimens.

(T = Tensile F = Fracture Toughness R = Stress relief)

Recommended side wall fracture toughness sample size:

Thickness B= 0.26 inch Width W= 0.52 inch Span S= 2.15 inch

FIGURE 2. Projectile rear mechanical properties test locations.

Sheet 31 of 43

CUI

4.4.4 Welded rotating band.

4.4.4.1 Rotating band welder qualification sampling. The first five banded bodies, after the welded overlay band has been applied, for each welding machine in operation, shall be subjected to the test outlined below. Reduced sampling of one in twenty banded bodies may be implemented after five consecutive banded bodies per each welding machine in operation have been found acceptable. A welding machine shall be considered qualified after five consecutive samples of one in twenty banded bodies per each welding machine in operation have been found acceptable. These bodies shall have the band removed by machining and chemically etching without damaging the band seat. These bodies will be subjected to tests in accordance with 4.4.4.3.

4.4.4.2 Rotating band welder post qualification sampling. Sampling of one in each half shift (not to exceed five hours) of production, or fraction thereof, per welding machine in operation shall be implemented after a welding machine has been qualified. Each sample shall have a band chemical analysis taken in accordance with 4.4.4.3.1. One sample for each welding machine in operation shall have the band chemically removed and examined in accordance with

4.4.4.3.2. The body having the highest acceptable iron content rotating band during each shift of post qualification sampling, when tested per 4.4.4.3.1, shall be tested in accordance with

4.4.4.3.3. Failure of the body to comply with the specified requirements will require rejection of all bodies having bands welded by the same welder during the same sampling period. Failure of any body will also require that the body exhibiting the highest iron content from each welder will be similarly tested. Failure of any body will result in rejection of the quantity from each discrete welder represented by the sample. A failure on any welding machine will mandate the return to the original welder qualification sampling of 4.4.4.1. However, post qualification sampling may be implemented after the first five banded bodies have been found acceptable.

4.4.4.3 Destructive testing. Any banded body to be tested shall have the band removed by machining and chemical etching without causing damage to the band seat. These bodies will be subjected to the following tests:

4.4.4.3.1 Band chemical analysis. Sample chips shall be obtained from each band from the last 1.02 mm (.04 inch) removed when machining to the finished diameter. All chips shall be collected and identified with the body from which the chips were machined. A minimum 5 gram (.176 ounce) sample from each complete specimen thus obtained from each band shall be analyzed by any method that has been approved by the technical agency. The sample may not be cleaned with a magnet. Failure to comply with the requirements of the drawing shall be cause for rejection of the production represented by the sample.

4.4.4.3.2 Visual examination for minimum melt requirements. Failure to comply with the requirements of the drawing shall be cause for rejection of the production represented by the sample. (See 3.7.3)

ECP R21A2038

NOR 1 of 8 Sheet 32 of 43

4.4.4.3.3 Visual examination for bandseat subsurface defects. Turn down the band seat to the largest diameter specified in 3.7.4 and inspect in accordance with 4.4.5.4. Any defect indication per 3.7.4 other than at the starting weld pass is considered to be a reject. If indications are present at the starting weld pass turn down the band seat to the smallest diameter specified in

3.7.4 and again inspect in accordance with 4.4.5.4. Any defect per 3.7.4 is considered to be a reject. The starting weld pass area is defined as 19 mm (3/4 inch) maximum on each side of the start-stop weld center line. Should any sample for any of the above tests fail to comply with minimum acceptance requirements, the quantity of bodies represented by that sample shall be rejected.

4.4.4.3.4 Rotating band stress relief verification. A sample from the two highest iron content first article chemical analysis samples shall be used to verify stress relief of the heat affected zone (if applicable). The stress relief shall also be verified each time a coil is replaced or a process change is made. The heat affected zone specimen shall be taken from location R on Figure 2. Rockwell hardness measurements shall be taken starting 1/16 inch from the band seat center and in 1/16 inch increments moving toward the interior of the projectile to a depth of one half inch below the band seat. Testing shall be in accordance with ASTM E18. Failure to meet the requirement of 3.7.5 shall be cause for rejection.

4.4.4.3.4.1 Induction stress relief. If induction is employed for stress relieving, as part of

First Article Testing and at least once per year per production line for each contract, if applicable, validation that the stress relief process does not contribute to hydrogen embrittlement issues shall be conducted to satisfy the requirements in TT-C-490 and MIL-STD-171.