Attachment 1 SOW.docx

FA7000-11-T-0006

Attachment 1

USAFA CU 945-05

20 October 2010

SWORD, SCABBARD AND COVER, CADET’S

1. SCOPE.

1.1 Scope. This specification covers the requirements for Sword, Scabbard and Cover, Cadet's, for the U. S. Air Force Academy.

1.2 Classification. The Sword and Scabbard shall be of one type and five classes:

SCHEDULE OF SWORD LENGTHS

2. APPLICABLE DOCUMENTS.

2.1 The following documents of the issue in effect on the date of invitation for bids, form a part of this specification to the extent specified herein:

STANDARDS:

Federal

(Copies of specifications, standards, drawings and publications required by contractors in connection with a specific procurement function may be obtained from the procuring activity or as directed by the contracting officer.)

2.2 Other Publications.

2.2.1 American Society for Testing Materials, Methods for Chemical Analysis of Metals. Application for copies of A.S.T.M. Standards should be addressed to the American Society for Testing Materials, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA, 19428-2959.

2.2.2 For textile colors, The Color Association of the United States, Inc., 315 West 39th St., Studio 507, New York, NY 10018.

3. REQUIREMENTS.

3.1. Sample. Samples are furnished as a guide only. Variations from this specification may appear in the sample, in which case this specification shall govern. Except for such variations, the design, appearance, quality and workmanship in all respects not covered by this specification shall be equal to the sample (See 6.2).

3.2 Preproduction sample approval. When required (See 6.2) before production is commenced, the contractor shall submit to the contracting officer for approval, a finished Sword, Scabbard and Cover conforming to the requirements for design, construction and workmanship of this specification.

3.2.1 The following shall be submitted along with preproduction sample:

3.2.1.1 One two-yard sample of basic fabric for Cover (full width).

3.2.1.2 Test results covering the physical characteristics of each metal and plating as specified in this specification.

3.3 Materials.

3.3.1 Sword Blade. The blade shall be made of a corrosion resisting, stainless steel containing not less than 13.0% chromium and 0.4% carbon, and shall be carefully tempered, hardened and ground. The blade shall be tapered and have a straight diamond shape. The Rockwell "C" hardness shall be from 48 to 54, measured in 3 points: 4 inches from the cross guard, center and 4 inches from the tip. The surface of the blade shall be carefully polished to a bright finish. The blade tongue which holds the guard shall not be hardened. The weight of the blade shall be 275 gr + 25 gr.

3.3.1.1 Dimensions. The finished dimensions of Sword blade and hilt shall be in accordance with this specification. The tip of all classes of swords shall be graduated the same from the tip upwards for 290 millimeters.

3.3.1.2 Length. The finished blade length and overall length shall be in accordance with Table I.

TABLE I

SWORD MEASUREMENTS

(All Measurements Shown are Expressed in Millimeters)

NOTE: The inside dimension of Scabbard shall be 4 millimeters longer than the blade length.

3.3.1.3 Design. The finished design on blade shall be in accordance with Figure 1. The design shall appear on front side of blade only.

3.3.2 Sword Hilt Assembly. The Sword Hilt assembly shall consist of three components:

a. Pommel

b. Grip

c. Cross Guard

3.3.2.1 Pommel. The pommel shall be made from a copper-zinc alloy casting containing not less than 85.0% copper (material CuZn15, DIN EN 1652). The weight of the pommel shall be 97 gr + 5 gr. The entire pommel shall be silver plated and polished with the designs being oxidized and satin brush highlighted. The pommel shall be drilled and tapped in center back for 2.5 millimeter diameter, silver plated, set screw (CuAn39Pb3 F51, ASTM(UNS) C38500), oval head slot type. The pommel shall be shaped to resemble a world map in raised relief. See Figure 2.

3.3.2.2 Grip. The grip shall be solid cast of a nickel-copper-zinc alloy (German silver) with 58% copper, 13.0% nickel, 29% zinc (Cu58%, Ni13%, Zn29%). The entire grip shall be silver plated and polished with grooves being oxidized and satin brush highlighted. The grip shall be pressed with grooves. The back of the grip at top shall be drilled to receive the brass set screw of the pommel (CuZn39Pb3 F51, ASTM (UNS) C38500), to prevent pommel from turning. The weight of the grip shall be 39 gr + 5 gr. See Figure 3.

3.3.2.3 Cross Guard. The cross guard shall be made from a solid copper-zinc alloy casting containing 85% copper (CuZn15, DIN EN 1652). The entire cross guard shall be silver plated and polished with the designs being oxidized and satin brush highlighted. The weight of the cross guard shall be 107 gr + 5gr. See Figure 3.

3.3.2.4 Assembly. All component parts shall be accurately machined for size and fit to assure a solid and proper assembly. The finished mounting shall be clean, smooth and free from dents and other markings that may affect the appearance.

3.3.3 Scabbard. The Scabbard shall consist of four components:

a. Scabbard Body

b. Top Fitting

c. Shoe

d. Liner

3.3.3.1 Scabbard Body. The scabbard body shall be made from 1mm thick carbon steel (Material) No. 1.0338/ASTM 620-84, carefully polished and nickel-plated. The weight of the scabbard body shall be 290gr + 30 gr. The plating shall be minimum 15 microns thick. See Figure 3 & 4.

3.3.3.2 Top Fitting. The top fitting shall consist of a sleeve fitting with a hook, each made of copper-zinc alloy containing 85% copper (CuZn15, DIN EN 1652). The hook shall be silver-solder soldered to the sleeve. The entire top fitting shall be silver plated and polished with the designs and grooves being oxidized and satin brush highlighted. Dimensions shall be in accordance with the technical drawing. The weight of the top fitting shall be 75 gr + 5 gr. See Figure 4.

3.3.3.3 Shoe. The shoe shall be made from a copper-zinc alloy containing 85% copper (CuZn15, DIN EN 1652). The weight of the shoe fitting shall be 70 gr + 5 gr. The entire shoe shall be silver plated and polished with the designs and grooves being oxidized and satin brush highlighted. See Figure 4.

3.3.3.4 Liners. The conical-shaped liners inside the scabbard body shall be made from 1 mm thick brown cellulose-sheet, according to EN 60641-(1-2-3). The liners shall extend the total length of the scabbard body. The liner shall fit the inside dimensions of the scabbard body without being loose.

3.3.3.4.1 Both liners shall have a foam (ISO 845, 22 kg/m3 ) reinforcement in the center to give better hold to the sword when entered into the scabbard. The foam shall be 0.4 inches thick and 7 inches + .5 inches long. The weight of one liner with foam shall be 9 gr + 1 gr.

3.3.3.5 Fittings. The fittings shall be secured to the scabbard body with brass (CuZn39Pb3 F51, ASTM (UNS) C38500) machine screws, silver plated and counter sunk. All brass components shall be lacquered with a clear lacquer complying with US safety standard ASTM F963-07. See Figure 4.

3.3.3.6 The finished scabbard shall be clean, smooth and free from pits, dents and any other imperfection that may affect the appearance. See Figure 5.

3.3.4 Plating. All plating shall be a minimum of 0.001 inch in thickness.

3.3.5 Leather Cushion. Each sword shall have a washer cushion made of black leather at least 1.5 mm thick. The washer shall act as a cushion between the base of the cross piece and the mouthpiece of the scabbard. The vegetable-tanned leather cushion shall be acid-free and waterproof. The washer shall act as a cushion between the base of the cross guard and the top fitting of the scabbard. See Figure 6.

3.3.5.1 Each sword shall have a 1/16 inch thick, leather washer at the base of the cross guard. The washer shall act as a cushion between the base of the cross guard and the top fitting of the scabbard. See Figure 6.

3.3.6 Cover. Each sword and scabbard shall be provided with a dark blue, cotton, flannelette, cover to fit the assembled sword and scabbard. The cover shall have a drawstring. See Figure 7.

3.3.6.1 The flannelette cover shall be vat dyed a dark blue and have the following features:

3.4 Marking. Each Sword and Scabbard shall have a tag attached to the hilt showing the following information:

Class number of sword Specification title, number and date Contract number and date Contractor's name and address U. S. Air Force Academy

3.5 Workmanship. The quality of manufacture shall be controlled to guarantee conformity with the standard of workmanship established in this specification. The finished sword, scabbard and cover shall be clean and free from any defects that may affect appearance or serviceability.

3.5.1 Construction. The construction of components and assemblies of the items covered herein shall conform to the requirements of this specification as defined in the attached drawings. Components shall be free from split, puncture, malformation or fracture.

3.5.2 Soldering. Soldering shall be complete, sound, uniform and free from urn through area, pits, slag inclusion, porosity, cracks, fracture, flash and excess flux deposits.

3.5.3 Etching, embossing and art work. Acid etching shall be as shown on drawings and in accordance with commercial practice. Embossing, including letters, shall be raised (solid). All artwork shall be as depicted in drawings. All etching, embossing, and art work shall be identical on like parts. The height of the bold letters of the inscription “U.S. Air Force Academy” is 6mm. The etching shall be not only superficial but tactile.

3.5.4 Removal of burrs, sharp edges and flash lines. All burrs, sharp edges, and flash lines shall be removed prior to plating and polishing.

4. QUALITY ASSURANCE PROVISIONS.

4.1 Supplier's Responsibility. The supplier is responsible for the performance of all inspection requirements as specified herein. Except as otherwise specified, the supplier may utilize his own or any other inspection facilities and services acceptable to the Government. Inspection records of the examination and tests shall be kept complete and made available to the Government as specified in the contract or order. The Government reserves the right to perform any of the inspections set forth in the specification where such inspections are deemed necessary to assure that supplies and services conform to prescribed requirements.

4.2 Inspection for Purposes other than Acceptance.

4.2.1 Preproduction Sample. When required (See 6.2), the preproduction sample shall be inspected for compliance to design, construction, workmanship and appearance.

4.3 Inspection for Acceptance. Unless otherwise indicated hereinafter, inspection shall be in accordance with ANSI Z1.4. Inspection level will be Level III. Acceptable quality levels will be 2.5 DHU for majors, 15.0 DHU for majors and minor A's combined, and 40.0 DHU for totals for defects listed in Table II. Defects with an asterisk (*) in classification column will be classified as a major defect when affecting appearance or serviceability seriously; as a minor A defect when affecting appearance or serviceability but not seriously.

4 3 1 Sampling for Testing. The sample unit for testing of each component shall be the quantity necessary to perform all required tests one time each.

4.3.2 Examination of the End Item. The contractor shall inspect the finished swords for compliance with this specification prior to submitting them to the United States Government for final inspection and acceptance.

4.3.3 Final Inspection. The passing as satisfactory of the preproduction sample or any detail of construction or material shall not be construed as relieving the contractor of responsibility for faulty workmanship or material which may be discovered at any time prior to final acceptance.

4.3.3.1 The point of final inspection and acceptance of the finished articles shall be as specified in the contract or order. (See 6.2)

4.4 Tests. All tests shall be conducted in accordance with the test methods specified herein.

TABLE II CLASSIFICATION

Blade

Edge not uniform in thickness on both sides of blade

X

Blade lengths which are 3/4 inch or shorter than as specified

X

Not polished to bright finish

X

Blemishes

X

Design on blade

Design with blemishes.

X

Design not imposed properly.

X

Leather cushion

Not the proper size.

X

Lacquer

Top fitting and shoe lacquer omitted.

X

Not properly lacquered.

X

Sword Hilt Assembly

Grip and cross guard loose.

X

Pommel

Incorrect shape and clearness of design.

X

Not properly finished.

X

Grip

Incorrect shape and clearness of cut in grooves.

X

Not properly polished.

X

Cross Guard

Clearness of design.

X

Not properly plated exposing copper.

X

Scabbard

Dents.

X

Blemishes.

X

Design not properly imposed.

X

Top Fitting

4.5 Defects. (cont)

TABLE II CLASSIFICATION

Screw or screws not silver plated.

X

Shoe Fitting

Screw or screws not silver plated.

X

The scabbard has incorrect liner.

X

General

Finish not clear, containing scars and blemishes and not properly polished.

X

Flannelette cover

Thread breaks or ends of joining seams (when not caught in other seams) not securely backstitched.

X

Open Seams.

On outside, any open seam.

NOTE: One or more broken or 2 or more continuous skipped or run off stitches constitute an open seam.

X

Raw Edges.

On outside - any raw edge.

X

Component and Assembly.

5. PREPARATION FOR DELIVERY.

5.1 Packaging. Each sword and scabbard shall be put into a flannelette cover and then packaged by inserting each one snugly in a spiral or convolute wound tube.

5.2 Packing. Unless otherwise specified in procurement documents (See 6.2), swords shall be packed in a manner which will insure acceptance and safe delivery at destination. As far as practicable, supplies of one type and class only shall be packed in containers which (together with packaging, wrapping and inner packing) conform to carrier rules and regulations as applicable to the mode of transportation selected.

5.3 Marking. Interior boxes and shipping containers shall be marked with the name of the commodity, type and quantity contained therein, as defined in the contract or order under which the shipment is made, the name of the contractor and the contract or order number. Shipping containers packed with swords of assorted classes shall be marked to show the quantity of each class packed therein.

6. NOTES.

6.1 Intended Use. The sword covered by this specification is intended for use by Cadet Officers of the United States Air Force Academy.

6 2 Ordering Data. Procurement documents should specify the following:

a. Title, number and date of this specification.

b. Sword, Class Number. (See 1.2 and 3.3.1.2).

c. Availability of sample (See 3.1).

d. Requirements for preproduction sample (See 3.2.).

e. Point of final inspection and acceptance (See 4.3.3.1).

f. Packaging, packing and marking requirements if different from those specified herein (See 5.1, 5.2, and 5.3).

6.3 Design Data. The design of the Sword, Scabbard and Cover is shown in Figures 1 through 7.

6.4 Patent Notice. When Government drawings, specifications and other data are used for any purpose other than in connection with a definitely related Government procurement operation, the United States Government thereby incurs no responsibility nor any obligation whatsoever; and the fact that the Government may have formulated, furnished, or in any way supplied the said drawings, specifications or other data is not to be regarded by implication or otherwise as in any manner licensing the holder or any other person or corporation or conveying any rights or permission to manufacture, use or sell any patented invention that may in any way be related thereto.

USAF Academy CO 80840

REVIEWING ACTIVITY:

10th Logistics Readiness Squadron (10 LRS) USAF Academy CO 80840