Attachment 17 - RATO Performance Spec SP201308358 Rev D.pdf

SP201308358 Rev. D

See EO 16A7888-H

CAGE 98747

December 5, 2016

PERFORMANCE SPECIFICATION

FOR THE

BQM-167A ROCKET ASSISTED TAKE-OFF (RATO)

ROCKET MOTOR SUB-SYSTEM

Prepared by:

AFLCMC/EBHCA Ammunition Section

6033 Elm Lane

Hill AFB, UT 84056

SUBMITTED BY: ______________________________________

Michael Blair

Program Manager, RATO

AFLCMC/EBHCA

APPROVED FOR USE AS

PRODUCT BASELINE BY:_________________________________

Scott Burton

Chief, Ammunition Section

AFLCMC/EBHCA

DISTRIBUTION STATEMENT D: DISTRIBUTION AUTHORIZED TO THE DEPARTMENT OF DEFENSE (DOD)

AND DOD CONTRACTORS ONLY. THIS DOCUMENT CONTAINS TECHNOLOGY DEEMED CRITICAL AS OF 03

JUL 2014. OTHER REQUESTS SHALL BE REFERRED TO AFLCMC/EBHC COMPONENTS BRANCH, BUILDING

1247, 6033 ELM LANE, HILL AFB, UT 84056.

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 THE PROVISIONS OF

DOD-D-5230.25.

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS OR

RECONSTRUCTION OF THE DOCUMENT.

1.0 SCOPE

1.1 IDENTIFICATION

This specification identifies the mission, operation performance, system description and general verification requirements for a Rocket Assisted Take-off (RATO) rocket motor, Prime Item hereafter also called the RATO, used to ground-launch a BQM-167 Subscale Aerial Target drone.

2.0 APPLICABLE DOCUMENTS

The following documents, at the revision in effect at initial release of this document, shall be used as a guide, where applicable.

2.1 GOVERNMENT DOCUMENTS

DRAWINGS

TO 21-BQM167A-2-84-JG-00-1 Organizational Maintenance, Rocket Assisted Take-off

TO 21-BQM167A-4 Illustrated Parts Breakdown with Support Equipment, Air Force

Subscale Aerial Target (AFSAT) USAF Series BQM-167A

SPI F01-344-8642 Special Packing Instruction for Rocket Motor Initiator

SPI F01-522-6689 Special Packing Instruction for RATO

STANDARDS

MIL-STD-129 Marking and Identification for Shipment and Storage

MIL-STD-130 Identification Marking of US Military Property

MIL-STD-464 Electromagnetic Environmental Effects Requirements for

Systems

MIL-STD-810 Environmental Test Methods

MIL-STD-882 System Safety

MIL-STD-1168 Ammunition Lot Numbering

MIL-STD-1472 Human Engineering

MIL- STD -2073 Standard Practice for Military Packaging

DOD Instruction DOD Contractor’s Safety Manual for Ammunition and Explosives

4145.26M

HANDBOOKS

MIL-HDBK-61 Configuration Management Guidance

AIR FORCE INSTRUCTIONS

AFI 91-208 Hazards of Electromagnetic Radiation to Ordnance (HERO)

Certification and Management

2.2 NON-GOVERNMENT DOCUMENTS

1G017-105 RATO Attachment Kit with Kick Plate

CAGE 7J998

1G355-103 RATO Kick Plate Adapter

CAGE 7J998

ANSI/ASQ Z1.4 Sampling Procedures and Tables for Inspection by Attributes

ASME B1.3-2007 Screw Thread Gaging Systems for Acceptability

ASTM E1742/E1742M Standard Practice for Radiographic Examination

(Copies of specifications, standards, drawings and publications required by suppliers for specified procurement functions should be obtained from the contracting agency or as directed by the contracting officer.)

2.3 ORDER OF PRECEDENCE

In the event of conflict between the text of this document and the references cited herein, the text of this document shall take precedence.

3.0 REQUIREMENTS

3.1 PRIME ITEM DEFINITION

This RATO sub-system provides additional thrust to assist takeoff of a Subscale Aerial Target Drone aircraft (BQM-167A) during ground launch operations. This sub-system consists of a rocket motor/igniter assembly and a separate initiator/wire harness. The rocket motor forward end shall be designed to mechanically interface with a thrust adapter to translate the thrust force to the aircraft. The initiator wire harness shall be accessible to allow an electrical connection and removal at the launch site.

The rocket motor shall have a nozzle closure to protect the propellant from dust and atmospheric elements.

3.2 PHYSICAL PARAMETERS

3.2.1 Mechanical Interface. The RATO sub-system shall conform to the RATO interface configuration in the Air Force Technical Order (TO) 21-BQM167A-4 (see Figure 47.1). The RATO interface configuration is shown in Figure 1, which shows the RATO Attachment Kit drawing with Kick Plate (1G017-105). The

RATO Attachment Kit components shown in Figure 1 are defined in Table 1. The configuration shown in

Figure 1 is notional and the drawings listed in Table 1 are available upon request.

The RATO Attachment Kit requires a threaded interface at the RATO sub-system forward end that screws into the thrust adapter (RATO Kick Place Adapter 1G355-103) and conforms to the thrust adapter internal volume shown in Figure 1. The weight of the RATO is supported by a U-bracket (Aft RATO U-

Bracket Assembly 1G018-111) attached using two clamps (1G018-19) around an ablative liner (1G039-1).

The ablative liner is further attached to the RATO using two clamps (1G018-19). The basic flight configuration consists of the RATO sub-assembly assembled to the RATO Attachment Kit attached to the

BQM-167 Subscale Aerial Target Drone at the Thrust Adapter and U-bracket.

Figure 1. RATO Attachment Kit from TO 21-BQM167A-4

Table 1. RATO Attachment Kit Component Description from TO 21-BQM167A-4.

Item No.

Part Number Cage Code

Description Quantity

1 1G017-105 7J998 RATO ATTACHMENT KIT WITH KICK PLATE Ref

2 1G018-111 7J998 ASSEMBLY, U-Bracket, Aft RATO 1

3 91251A361 7J998 SCREW, 10-32 x 3.5, shcs, steel 1

4 MS21042L3 96906 NUT, 10-32, Self lock, steel 1

5 1G039-1 7J998 ABLATIVE LINERS 2

6 1G018-19 7J998 BAND CLAMP 4

7 1G019-21 7J998 FORWARD RATO INSULATOR 1

8 1G355-103 7J998 RATO KICK PLATE ADAPTER 1

9 1G355-27 7J998 RATO ADAPTER LINK 1

10 90293A114 3A054 QUICK RELEASE PIN, Fwd RATO Adapter 1

11 1G363-101 7J998 ASSEMBLY, RATO Kick Plate 1

12 91251A361 7J998 BOLT, 10-24 x 2.75, ss 1

13 91837A014 3A054 NUT, 10-24, Self lock, steel 1

14 H2128 7J998 SPRING, 0.625 OD x 4 inch 1

15 1G355-11 7J998 RELEASE PIN, Fwd RATO adapter 1

16 1G356-7 7J998 ASSEMBLY, RATO Pin Lanyard 1

17 MS51958-61 96906 SCREW, 10-34 x 3/8, pph, ss 1

18 G018-110 7J998 LRS SPINDLE ATTACHMENT KIT Ref

19 1G018-113 7J998 LRS SPINDLE ASSEMBLY 2

20 AN4-14A 88044 BOLT, 1/4-28 x 1.5, hh, steel 8

21 MS15795-809 80205 WASHER, Flat, 1/4”, ss 8

22 1G018-103 7J998 BQM-34 RAIL SPINDLE ATTACHMENT KIT Ref

23 1G018-115 7J998 ASSEMBLY, -34 Roller Support 2

24 1G018-117 7J998 ASSEMBLY, -34 Spindle Support 2

25 AN4-11A 88044 BOLT, 1/4-28 x 1.125, hh, steel 16

26 MS15795-809 80205 WASHER, Flat, 1/4”, ss 8

3.2.2 RATO Sub-system Dimensions. The overall dimensions (diameter and length) as measured from the aft end of the RATO Sub-system to the forward (FWD) end interface with the thruster adapter (1G355-

103) shall be within the dimensions shown in Figure 2.

Figure 2. RATO Motor Assembly Overall Dimensional Requirements.

3.2.3 RATO Forward End Thread Requirements. The RATO sub-system forward end shall have 7-1/2 inch screw threads with 12 threads per inch and 1.005 inches length including undercut as shown in

Figure 2 that interface with the thrust adapter (RATO Kick Plate Adapter 1G355-103) as specified by:

Unified Screw Threads, Standard Series, 7.5-12UNS-2AG

After Plating

Major Diameter 7.4978 - 7.4864

Pitch Diameter 7.4437 - 7.4365

Minor Diameter 7.4076 Max

Before Plating

Major Diameter 7.4962 - 7.4854 SPL

Pitch Diameter 7.4405 - 7.4345 SPL

Minor Diameter 7.4066 Max

3.2.4 Overall Weight. The total weight of the RATO shall be less than or equal to 144 lbs.

8.7 Max

Zone 1

Aft End

47.1 Min

Zone 2 Zone 3

50.54 Max

50.39 Min

FWD

End

Thread Zone (see Paragraph 3.2.3 for details)

8.015 Max

7.995 Min

Diameter 8.015 Max Diameter

8.268 Max

Diameter

1.005

3.2.5 Structural Design. Structural design analyses and tests shall be performed to verify positive margins of safety for all RATO components. The RATO component designs shall address all critical loads and environments in the appropriate configurations, including pressure, thrust, vibration and thermal loads that occur from manufacturing, storage, transportation and handling, assembly, test, and flight.

Component designs shall include appropriate factors of safety and design factors based on industry standards. Tests shall include appropriate test factors based on industry standards.

3.3 PERFORMANCE

The performance of this sub-system shall be reliable and uniform throughout the storage environment and operation envelopes specified herein.

3.3.1 Average Thrust. The RATO shall provide a nominal thrust of 8,900 lbf at +65o F at sea level.

Maximum Thrust shall be no more than 12,000 lbf.

3.3.2 Action Time. The RATO shall provide nominal thrust for approximately 2.4 seconds at +65o F at sea level. Average Thrust x Action Time shall fall within the limits specified by section by 3.3.3. Burn Time is defined as initial 10% maximum pressure until web burn-out tangency point. Action Time is defined as initial 10% of maximum pressure until final pressure drops down to 10% of maximum pressure.

3.3.3 Total Impulse. The RATO shall provide the following total impulse for the following temperatures*:

-40° F +65° F +140° F

Minimum Impulse, lbf-sec 20,680 21,010 21,210

Maximum Impulse, lbf-sec 21,520 21,870 22,070

*(+/- 5° F for each temperature)

3.3.4 Ignition Delay. The RATO ignition delay (T=0 to 90% full thrust) shall be 0.25 seconds maximum.

3.3.5 Operational Envelope and Environment. The RATO shall perform satisfactorily within the following conditions.

3.3.5.1. Operational Temperature: -40° F to 140° F

3.3.5.2. Operational Altitude: Sea Level to 10,000 feet

3.3.5.3. Operational Humidity: 5% to 100%

3.3.6 Acceleration Force. The RATO shall be designed to withstand the following acceleration forces.

3.3.6.1 Perpendicular to the axis: 12g acceleration

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3.3.6.2 Parallel to the axis: 30g acceleration

3.3.7 Initiator. A stand-alone initiator assembly shall be provided that can be shipped separately and easily inserted into the RATO while it is mounted on the drone. The initiator shall produce proper ignition of the igniter and main propellant with less than or equal to 10 amperes of current applied to the leads of the initiator. The initiator shall provide a “no fire” condition when one (1.0) ampere of current is applied for five (5) minutes.

3.3.7.1 Electrical Interface. If a forward initiator is used, the initiator circuit shall consist of two insulated lead wires extending two (2) inches from the rocket center, with bare ½-inch lead wire ends. If ignition is from the nozzle end, then wires must be routed to the forward end and secured to prevent routine handling from loosening or damaging them. Verification shall be accomplished by successful motor ignition per section 3.3.4.

3.3.8 Grounding. A grounding connection shall be provided through the unit and its attachment fittings, with no more than two (2) ohms resistance end to end.

3.3.9 Reliability. The RATO sub-system shall provide a functional reliability of not less than 95%.

3.3.9.1 Shelf Life. The rocket motor/igniter and initiator shall meet all requirements specified herein after being stored for 120 months in temperatures ranging from -65° F to 160° F, with humidity ranging from 5% to 100% and altitude between Sea Level and 10,000 feet in accordance with (IAW) DoD 4145.26M Safety manual.

3.3.9.2 Service Life. The service life shall be not less than 120 months after all components are assembled for the first time. The rocket motor/igniter and initiator may be assembled and disassembled multiple times during this time period.

3.3.10 Maintainability. The RATO sub-system shall require no maintenance.

3.3.11 Human factors engineering. The RATO sub-system shall meet the human factors engineering requirements of MIL-STD-1472. Consideration shall be given, but not limited to, the installation of the igniter into the RATO motor, and installation of the RATO sub-system onto the BQM-167 drone. The

RATO sub-system shall include human engineering design principles and practices to achieve mission success through the integration of the human into the system in order to obtain an effective, simple, efficient, reliable, and safe system during operation, training and maintenance. Emphasis shall be placed on the tasks of assembly, installation, and preflight inspection. All tasks must be able to be performed in a bright glare environment and in total darkness using a hand-held flashlight.

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3.4 Safety

3.4.1 Design Safety. The RATO design and product baseline shall comply with this specification and receive safety certification from the Non-Nuclear Munitions Safety Board (NNMSB). Once the RATO design is established, the design baseline shall be submitted to the Government for concurrence.

Once the design is accepted all changes (Engineering Change Proposals (ECPs) and Request for Variance

(RFVs)) to the RATO require Government concurrence of classification. Class I ECPs and critical or major variances must be prepared in accordance with the guidance of MIL-HDBK-61 and submitted to the

Government for approval.

3.4.2 Hazards of Electromagnetic Radiation to Ordnance (HERO). The RATO system shall be protected from induced or unintended firing stimuli that exceed the safety or reliability defined in MIL-STD-464 when exposed to the specified HERO environments.

4.0 QUALIFICATION TEST REQUIREMENTS

4.1 GENERAL REQUIREMENTS

4.1.1 First Article Acceptance Test (FAAT) sample. Unless otherwise specified, the contractor shall submit a FAAT sample to the government for evaluation prior to the initiation of regular production.

The FAAT is required for a production facility that has not been previously qualified to manufacture the

RATO. The sample shall consist of sixteen (16) RATO Sub-systems, eight (8) for static fire and eight (8) for flight testing, produced using the same materials, methods, equipment and processes used in regular production. The sample shall be evaluated IAW the provisions of 4.2 and 4.3 to demonstrate the adequacy and stability of the contractor’s processes and procedures. Unless otherwise directed by the contracting officer, regular production is under no circumstances authorized to commence or resume until the FAAT sample is approved or accepted.

4.1.2 Delta First Article Acceptance Test (Delta FAAT) sample. Unless otherwise specified, the contractor shall submit a Delta FAAT sample to the government for evaluation prior to resuming regular production. The Delta FAAT is required for a previously qualified production facility that has had a break in production of 180 days or more. The sample shall consist of eight (8) RATO Sub-systems for static fire testing, produced using the same materials, methods, equipment and processes used in regular production. The sample shall be evaluated IAW the provisions of 4.2 with the exception of 4.2.8 (Flight

Test) to demonstrate the adequacy and stability of the contractor’s processes and procedures. The

Government reserves the right to require additional samples whenever regular production is interrupted for 180 days or more, or when process changes have been made. Unless otherwise directed by the contracting officer, regular production is under no circumstances authorized to commence or resume until the Delta FAAT sample is approved or accepted.

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4.1.3 Safety Precautions. Minimum explosive safety precautions for use by the contractor shall be IAW

DOD Instruction 4145.26M. System safety shall be IAW DOD Instruction MIL-STD-882.

4.2 PERFORMANCE TESTS

The rocket motor First Article Acceptance Test (FAAT) shall be qualified IAW the Table 2 test matrix and the following test and inspection procedures.

Table 2. RATO FAAT Test Matrix.

Section Test Test

Temp (F)

Motor*

1 2 3 4 5 6 7 8

4.2.1 X-ray inspection — A A A A

4.2.2 Continuity — B B B B

4.2.3 High temp. storage 160 C C C C

4.2.1 X-ray inspection — D D D D

4.2.4 Thermal cycling 65 to 160 E E E E

4.2.1 X-ray inspection — F F F F

4.2.5 Vibration

65 G G

160 G G

4.2.1 X-ray inspection — H H H H

4.2.6 2-foot drop 40 I

140 I

4.2.1 X-ray inspection — A A A A J J I I

4.2.2 Continuity Static Fire Temp B B B B K K J J

4.2.7 Static firing

40 C C L K

140 C C L K

* Motor test sequence is designated by ascending letters (A, B, C, etc.)

4.2.1 X-Ray Inspection. X-ray inspection shall be accomplished IAW ASTM E1742/E1742M, Annex A3, standard practice for radiographic examination of loaded rocket motors, including case, propellant and grain acceptance criteria.

4.2.2 Continuity. Electrical continuity shall be measured within +/- 0.01 ohms end-to-end from the rocket motor forward end to the nozzle IAW section 3.3.8.

4.2.3 High Temperature Storage. The rocket motors shall be stored at a high-temperature of +160o +/- 5o

F for 45 days prior to continuing the following tests.

4.2.4 Thermal Cycling. The rocket motors shall be cycled between +160o F and -65o F for a total of seven

(7) cycles IAW MIL-STD-810G w/Change 1 Method 501.6 as illustrated in Figure 3 below. The temperature tolerances shall be 160 to 165o F for the upper value, and -65 to -70o F for the lower value.

The first cycle shall ramp up from room ambient (~70o F) to +160 over 12 hours minimum, stabilize for 8 hours minimum, ramp down to -65 over 24 hours, stabilize again for 8 hours, then ramp up to +160. The procedure shall be repeated for six (6) more cycles, with the final ramp-up ending at ambient temperature.

Figure 3. RATO Thermal Cycling Profile.

4.2.5 Vibration. The rocket motors shall be subjected to a vibration environment IAW Category 4 secured cargo of MIL-STD-810G w/change 1 Method 514.7. Test levels shall be IAW common carrier

Figure 514.7C-2. The test duration shall be three (3) hours for each of three orthogonal axes to simulate

3,000 miles of land transportation. Prior to the test, alternate rocket motors shall be thermally conditioned for 12 hours to either -65o +/- 5o F or +160o +/- 5o F.

4.2.6 Two-Foot Drop. Alternate rocket motors shall be thermally conditioned for 12 hours to either -40o

+/- 5o F or +140o +/- 5o F and then dropped from a height of two (2) feet, measured from the lowest point on the motor to the impact surface. Each motor shall be dropped vertically on its nozzle end, vertically on its forward end and horizontally. The impact surface shall be a steel plate, not less than one (1) inch thick, on a concrete floor. A mechanical guard to protect the initiator from impact, or substitution of a suitable plug for the initiator is acceptable for this test.

4.2.7 Static Firing. Prior to the test, alternate rocket motors shall be thermally conditioned for 12 hours to either -40o +/- 5o F or +140o +/- 5o F. The RATO shall be securely mounted on an anchored test stand, Cycle 1 Cycle 2 Cycle 3 Cycle 4 Cycle 5 Cycle 6 Cycle 7

12 Hours Min

24 Hours 8 Hours Min instrumented to verify performance and test fired IAW requirements stated in sections 3.3.1 through

3.3.4.

4.2.8 Flight Test. Eight RATO motors shall be individually mounted to a BQM-167A Subscale Aerial Target at the launch site for flight testing. Final qualification and design/manufacturing acceptance shall be determined based on successful launch and flight of the eight aerial targets without modification to the

BQM-167A Subscale Aerial Target, hanger assembly and launch rails.

4.2.9 Maintainability. The RATO sub-system shall require no maintenance.

4.2.10 Human factors engineering. Verification of the human factors requirements of 3.3.11 shall be conducted during flight test and supporting logistics suitability evaluations. Reported and observed problems shall be analyzed to determine human engineering deficiencies.

4.3 Safety

4.3.1 Design safety. The following information must be provided to the Government for NNMSB certification:

A copy of all drawings to include packaging/container configuration data

Details of all propellant/explosive compositions (materials and % by weight) for motor, igniter, etc.

Details of all testing accomplished

A detailed narrative on the functional sequence

Copies of any hazard/safety analysis accomplished on the system

4.3.2 HERO. The contractor shall comply with AFI 91-208, Hazards of Electromagnetic Radiation to

Ordnance (HERO) Certification and Management and shall submit HERO test plans, test reports

(including data), and recommended HERO classifications as defined by MIL-STD-464 to the Government to obtain a final Air Force HERO classification.

5.0 QUALITY ASSURANCE PROVISIONS

5.1 GENERAL

The following sub-paragraphs outline the quality assurance provisions required to be implemented and carried out during production of the RATO Sub-systems.

5.1.1 Responsibility for Inspection. Unless otherwise specified in this specification or in the contract or purchase order, the supplier is responsible for the performance of all testing, inspection and/or other verification requirements specified herein. Unless otherwise specified, the supplier may utilize his own facilities or any commercial laboratory acceptable to the Government contracting agency. The contracting agency reserves the right on the part of the Government to witness or to separately perform any of the tests or inspections or otherwise accomplish any or all tests and inspections set forth in this specification where such are deemed necessary to ensure supplies and services conform to the prescribed requirements.

5.1.1.1 Submission of product. When the completed product is submitted to the Government for acceptance, the contractor, upon request, shall supply, in written or printed form, the information required in the list below, accompanied by a certificate which attests that the information provided is correct and applicable to the product being submitted:

a. A statement that the lot complies with all of the quality assurance provisions specified within this specification.

b. Number of units of product inspected.

c. Results obtained, by defect code and/or by section 5. paragraph number, for all inspections and tests performed, IAW the verifications required by this specification.

d. Certificates of conformance on all material purchased by the contractor when such material is controlled by Government or commercial specifications referenced in the contractual documents.

e. Number of items in the lot.

f. Date submitted.

g. Actual data sheets and recordings of the associated, successful, acceptance tests and inspections.

5.1.2 Special Tests and Examinations RATO sub-systems selected for FAAT shall be from among those manufactured to the production drawings and procedures, using only production parts and processes.

Except as otherwise permitted by the Government, materials and parts shall be procured from the sources used during production.

5.1.2.1 Contractor FAAT Program. When a FAAT lot is included in the contract, the contractor shall conduct the FAAT prescribed herein on the submitted FAAT sample of nine (9) RATO Sub-Systems tested IAW 4.2. In the event of lot rejection, the Government reserves the right to require the contractor to take corrective action, to resubmit a new lot or portion thereof, and to specify which tests are to be re-accomplished and how many test items are to be expended during each test. The

Government reserves the right to require additional FAAT samples whenever regular production is interrupted for 180 days or more, or when process changes have been made.

5.2 QUALITY CONFORMANCE INSPECTION

5.2.1 Lot Formation. The term "lot" as used throughout this specification refers to an inspection lot, which is defined as a homogeneous collection of units of production from which a representative sample is drawn and inspected to determine conformance of the lot with applicable requirements.

Unless otherwise specified, a lot shall be made up of a homogeneous collection of complete RATO Sub-systems. The sample selected shall represent only that quantity of units from which the sample was drawn and shall not be construed to represent any prior or subsequent quantities presented for inspection. Homogeneity shall be considered to exist provided the lot has been produced by one manufacturer, in one unchanged process, in accordance with the same drawing, specification, or revision thereof. Changes to either process specifications or to drawings which do not affect safety, performance, interchangeability, or storage, as determined by the Government, shall not be deemed to alter the homogeneity of the lot. Lots shall be numbered IAW MIL-STD-1168.

5.2.1.1 Lot size. Unless otherwise specified in the contract, the inspection lot size of end items deliverable under the contract shall not be less than the smallest weekly production quantity scheduled during the contract period, nor more than the largest quantity scheduled for delivery during any month of the contract period.

5.2.1.2 Lot sampling for lot acceptance testing (LAT). From each production lot (as defined in 5.2.1) of

RATO sub-systems submitted for acceptance, each item of which has passed quality conformance examinations and the tests of 5.2.2, a sample shall be selected IAW ANSI/ASQ Z 1.4-2008, special inspection level S-3, acceptable quality level (AQL) 1.5, single sampling plan. System functional tests for lot acceptance shall be considered destructive.

5.2.1.3 Lot acceptance testing. Unless otherwise specified in the contract, testing of all sample RATO sub-systems from production lots shall be as specified in the following paragraphs.

5.2.2 Lot Acceptance Test. A Lot Acceptance Test shall be conducted with 100% inspection IAW sections

4.2.1 and 4.2.2. A static test firing of one (1) asset per lot shall be at ambient temperature conducted

IAW section 4.2.7.

5.3 MANUFACTURING QUALITY

5.3.1 Marking. RATO sub-systems shall be marked for identification IAW MIL-STD-129 and MIL-STD-130.

The identification data applied to each rocket motor via stencil or decal shall be as follows:

IUID Label

1. "NSN: “ XXXX-XX-XXX-XXXX

2. "RATO ROCKET MOTOR"

3. Manufacturer's Part Number

4. Manufacturer's Propellant Lot Number

5. Serial Number

5. Date of Manufacture

6. "HAZARD CLASSIFICATION: EXPLOSIVE” hazard class (e.g. 1.3C)

7. "Manufactured by:" name & address

8. "CAGE CODE:" cage code

9. Two-dimensional bar code

5.3.2 Unit Packaging. The rocket motor/igniter assembly and the initiator shall be packaged separately per MIL-STD-2073.

5.3.3 Workmanship. The workmanship displayed in the RATO sub-system fabrication and assembly shall ensure the ability of the rocket motor to meet performance requirements under all expected environmental conditions. The dimensions, finishes, tolerances and quality specified herein, and on applicable drawings, specifications and inspection manuals shall be maintained. All components and assemblies shall be free from burrs, contamination, sharp edges, corrosion, cracks, dents, chipped paint, excessive wear and foreign material.

5.3.4 Interchangeability. Design of components shall ensure interchangeability of parts and assemblies wherever possible. Quality control of components shall be exercised to ensure such interchangeability.

5.3.5 Finishes and Protective Coatings. Protective treatments, coatings and paint finishes shall be used on non-working surfaces that are not corrosion resistant or otherwise suitably protected. Nonetheless, electrical continuity shall be maintained end-to-end IAW section 4.2.2.

5.3.6 Shipping, Handling, and Storage. The complete rocket motor including propellant charge shall withstand environmental conditions that occur during shipping, handling and storage prior to firing as specified in section 4.2 and 4.3. There shall be no degradation that would reduce the reliability or consistency of performance as specified in sections 3.3.1 through 3.3.4.

6.0 PREPARATION FOR DELIVERY

6.1 Preparation and Packaging. The rocket motor/igniter assembly and the initiator shall be packaged and shipped separately IAW MIL-STD-2073. The rocket motor shall be packaged IAW SPI F01-522-6689.

The initiator shall be packaged IAW SPI F01-344-8642. Use of alternate packaging drawings is allowed with concurrence of the procuring activity.

6.2 Marking for Shipment. RATO Sub-Systems shall be marked for shipment IAW MIL-STD-129.