Attachment 2 USMA CSB-0146 dated October 2010 .pdf

USMA CSB-0146

Oct 2010

Page 1 of 12 Pages

SWORD, SCABBARD AND COVER, USMA

1. SCOPE.

1.1 Scope. This specification covers the requirements for Sword, Scabbard and Cover, USMA, for the United States Military Academy.

2. APPLICABLE DOCUMENTS.

2.1 The following documents of the issue that is in effect on the date of request for proposals form a part of this specification to the extent specified herein:

STANDARDS:

Federal

FED. TEST METHOD

STD. NO. 151

Metals; Test Methods

Military

MIL-STD-105 Sampling Procedures and

Tables for Inspection by

Attributes

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, refer to the Color Association of the United States, Inc., 315

West 39 th

Street, Studio 57, New York, NY 10018

2.3 A drawing included as part of this specification depicts in detail the components of the Sword, Scabbard and Cover, USMA. Dimensions of each component and subcomponent shall be as depicted in the drawings. All measurements are shown in millimeters. To convert to

English units, use one millimeter equal to 0.04 inches (1mm = .04 inches).

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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. The color of the brass components of the delivered production items shall be equal to the sample.

3.2 Preproduction sample approval. When required before production is commenced, the contractor shall submit to the contracting officer 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 the preproduction sample:

3.2.1.1 One two-linear 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 herein.

3.3 Materials. Where materials are not definitely specified, they shall be of the quality normally used for similar purposes in commercial practice.

3.3.1 Sword Blade. The blade shall be forged of a corrosion-resisting stainless steel

(Steel type X30Cr13 / W.1.4028 / AISI 420) and shall be carefully tempered, hardened and ground. The blade shall be tapered and have a straight, diamond-shaped cross section. The

Rockwell “C" hardness shall be from 48 to 54, measured at 3 points along the blade: 100 millimeters from the cross guard, center point of the blade, and 100 millimeters from the tip. The surface of the blade shall be carefu1ly polished to a bright finish. The blade tongue which is inserted into the Sword Hilt Assembly shall not be hardened. The weight of the blade shall be

275 grams +/- 25 grams.

3.3.1.1 Dimensions. The finished dimensions of the sword blade including hilt shall be in accordance with Technical Drawing No. 1, Sword and Scabbard, Cadet, USMA.

3.3.1.2 Blade Etch Design. The finished etch design on the blade shall be in accordance with Technical Drawing No. 1, Sword and Scabbard, Cadet, USMA.

3.3.1.3 Maker’s Mark. The manufacturer’s Maker’s Mark shall appear on the blade’s ricasso on the reverse side of the blade. The Maker’s Mark shall include the country of origin.

3.3.1.4 Acid Etch Practice. The blade design and ricasso marks shall be acid etched in accordance with commercial practice and shall have a uniform appearance and depth across each etch.

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3.3.2 Sword Hilt Assembly. The sword hilt assembly shall consist of three components, the combined weight of which shall be 420 grams +/- 15 grams:

a. Pommel

b. Grip

c. Cross Guard

3.3.2.1 Pommel. The pommel shall be made of a solid copper-zinc alloy casting containing 85% copper (material CuZn15, DIN EN 1652). The entire pommel shall be polished to a bright finish and coated with a clear lacquer of the highest commercial quality. The pommel shall be drilled and tapped in the center to receive a threaded steel pin 5 mm in diameter (M5).

The screw is to be black nickel plated. The eagle shall be cast integral with the pommel in the manner shown in Technical Drawing No. 1, Sword and Scabbard, Cadet, USMA, and with the eagle’s head facing its own right wing. The weight of the pommel without the threaded pin shall be 100 grams +/-5 grams.

3.3.2.2 Grip. The grip shall be solid cast of a nickel-copper-zinc alloy (German silver) with 58% copper, 13% nickel, 29% zinc (CuNi13Zn29). The grip shall be pressed with grooves, shall be initially plated with a minimum thickness of 10 microns of copper, and then plated with a minimum thickness of 12 microns of nickel to achieve a shiny finish. Surfaces not simulating rope are to be highly polished. Dimensions of the grip shall be in accordance with Technical

Drawing No. 1, Sword and Scabbard, Cadet, USMA. The top of the grip shall be drilled to receive the pommel’s brass set screw to position the pommel as shown on the drawing and to prevent the pommel from turning. The set screw shall be a machined brass (CuZn39Pb3 F51) metric screw 3mm in diameter (M3). The set screw shall be sized and fitted so that the top of the screw is below or at the surrounding surface. The set screw and screw hole shall be free of burrs and sharp edges after assembly. The weight of the grip shall be 155 grams +/- 5 grams.

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 oval insignia of the USMA shall appear in the center of the front side of the cross guard and shall be cast in one piece and integral with the cross guard, as shown on Technical Drawing No. 1, Sword and Scabbard, Cadet, USMA. The entire cross guard shall be polished to a bright finish and coated with a clear lacquer of the highest commercial quality. The weight of the cross guard shall be 175 grams +/-5 grams. Detail E: The quality and clarity of the lettering and decoration on the Athena Helmet crest depicted in Detail E shall be consistent with the quality and detail as shown in the drawing/photo. The actual helmet surface shall be of a consistent appearance, shiny and free from defect and imperfections. The wording of “DUTY * HONOR * COUNTRY *

U*S*M*A*” on the crest shall be readable, neat, professional and appear similar to that in the drawing Detail E. The wording “WEST POINT MD CCC II” shall be neatly poised with sufficient contrast to be readable using a 2x magnifier and easily readable using a 4x magnifier.

The appearance shall be similar to that in the drawing Detail E. A separate photo shall be

Page 4 of 12 Pages provided to display detail and quality expected for the wording and decoration referenced above in the finished product.

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.

3.3.2.5 Assembled Length. The overall length of the assembled sword shall be in accordance with Technical Drawing No. 1, Sword and Scabbard, Cadet, USMA.

3.3.3 Scabbard. The Scabbard shall consist of five components:

a. Scabbard Body

b. Mouthpiece

c. Middle Band with Hook

d. Shoe (Endpiece)

e. Liners (Pair)

3.3.3.1 Scabbard Body. The scabbard body shall be made from 1mm thick carbon steel

(DIN EN 10130:2006, Material No 1.0347 / ASTM 619), carefully polished and nickel-plated.

The dimensions shall be in accordance with Technical Drawing No. 1, Sword and Scabbard, Cadet, USMA. The weight of the scabbard body shall be 320 grams +/- 30 grams.

3.3.3.2 Mouthpiece. The mouthpiece fitting shall be made of copper-zinc alloy containing

85% copper (CuZn15, DIN EN 1652). The dimensions shall be in accordance with Technical

Drawing No. 1, Sword and Scabbard, Cadet, USMA. The mouthpiece shall be polished to a bright finish and coated with a clear lacquer of the highest commercial quality. The weight of the mouthpiece shall be 9 grams +/- 2 grams.

3.3.3.3 Middle Band with Hook. The middle band 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-soldered to the sleeve. The dimensions shall be in accordance with

Technical Drawing No. 1, Sword and Scabbard, Cadet, USMA. The middle band with hook shall be polished to a bright finish and coated with a clear lacquer of the highest commercial quality. The weight of the middle band with hook shall be 40 grams +/- 5 grams.

3.3.3.4 Shoe (Endpiece). The shoe (endpiece) shall be made of a copper-zinc alloy containing 85% copper (CuZn15, DIN EN 1652). The dimensions shall be in accordance with

Technical Drawing No. 1, Sword and Scabbard, Cadet, USMA. The entire shoe shall be polished to a bright finish and coated with a clear lacquer of the highest commercial quality. The weight of the shoe fitting shall be 54 grams +/- 5 grams.

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3.3.3.5 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 inside length of the scabbard body. See Technical Drawing No. 1, Sword and Scabbard, Cadet, USMA. Both liners shall have a foam (ISO 845, 22 kg/m ) reinforcement positioned in the center of the scabbard to give better hold to the sword when inserted into the scabbard. The foam shall be 10 millimeters thick and 180 millimeters +/- 15 millimeters long. The weight of one liner with foam shall be 8 grams +/- 1 gram. The liners shall be placed/installed in the scabbard body in such a way that they will not dislodge and be pushed down into the body to prevent the blade from being fully inserted into the scabbard.

3.3.3.6 Fittings. The fittings shall be secured to the scabbard body with machined brass

(CuZn39Pb3 F51, ASTM (UNS) C38500) metric screws 3mm in diameter (M3). All screws shall be sized and fitted so that the top of the screw is below or at the surrounding surface. All screws and screw holes shall be free of burrs and sharp edges after assembly.

3.3.3.7 Plating. All plating on the scabbard tube shall have a minimum thickness of 10 microns thickness, measured at 3 points: 100 millimeters from the top, at the center, and 100 millimeters from tip.

3.3.3.8 Lacquer. All brass components shall be lacquered with a clear lacquer complying with US safety standard ASTM F963-07.

3.3.3.9 Finish. The finished scabbard shall be clean, smooth and free from pits, dents and other imperfections that may affect the appearance. The scabbard body shall be polished to a bright mirror finish. The mouthpiece, middle band with hook, and shoe shall be polished to a bright finish and coated with a clear lacquer of the highest commercial quality.

3.3.3.10 Weight. The weight of the complete scabbard shall be 430 grams +/- 30 grams.

3.3.3.11 Performance. The completed scabbard with its liners shall provide sufficient friction to keep the sword in the scabbard when the scabbard and sword are turned upside with the mouth toward the ground. The scabbard and its liners shall also provide smooth and uniform ease of movement when the sword is drawn from and returned to its scabbard. The liners shall be covered against failure in the warranty for the period of three years from the date of receipt.

3.3.4 Leather cushion. Each sword shall have a washer cushion made of black Russian leather that is at least 1.5 millimeter 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.

3.3.5 Cover. Each sword and scabbard shall be provided with a blue, Pantone blue color

286, cotton, flannelette cover to fit the assembled sword and scabbard. The cover shall have a drawstring.

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3.3.5.1 Flannelette. The flannelette cover shall be vat-dyed, blue in color. The fabric shall be free of any imperfections that may affect the appearance or serviceability of the cover.

The fabric shall have the following characteristics:

a. Content: 80% polyester, 20% cotton

b. Weight: 93 grams/m

c. Texture: At least 45 yarns in the warp and 45 yarns in the filling.

d. Pantone blue color 286

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

Specification USMA CSB-0146, March 2010

Contract number and date

Contractor s name and address

U.S. Military 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 and as defined in Technical

Drawing No. 1, Sword and Scabbard, Cadet, USMA. Components shall be free from split, puncture, malformation or fracture.

3.5.2 Soldering. Soldering shall be complete, sound, uniform and free from burn-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 the drawings and in accordance with commercial practice. Embossing, including letters, shall be raised

(solid). All artwork shall be as depicted in the drawings. All etching, embossing, and art work shall be identical on like parts. The height of the initials “U.S.M.A.” is specified in Technical

Drawing No. 1, Sword and Scabbard, Cadet, USMA. The space within the design on the back side of the blade will be blank (unetched) and shall match the highly polished appearance of the rest of the blade. 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.

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3.5.5 Different Sword Lengths. Upon request, the contractor shall provide swords of a different length from the standard “30-inch” blade length. If so requested, the length of the blade and the length of the scabbard body on Technical Drawing No. 1, Sword and Scabbard, Cadet, USMA, shall be modified by 25.4 mm per inch added or subtracted from the standard length.

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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, 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 MIL-STD-105. 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 I. Defects with an asterisk (*) in the 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.

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

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4.5 Defects.

TABLE I CLASSIFICATION

DEFECT MAJOR MINOR A MINOR B

Blade

Bent or distorted and not fitting the scabbard correctly.

X

Edge nicked affecting appearance. X

Weight not within tolerance. X

Edge not uniform in thickness on both sides of blade.

X

Blade lengths which are more than 15 mm longer or shorter than as specified.

X

Not polished to a bright finish. X

Blemishes. X

Design on Blade

Design not clear. X

Design with blemishes. X

Design not imposed properly. X

Maker’s mark not uniform in depth or appearance. X

Leather Cushion

Omitted. X

Not the proper material, size or thickness. X

Sword Hilt Assembly

Grip and cross guard not assembled properly. X

Weight not within tolerance. X

Grip and cross guard loose. X

Pommel

Threaded pin incorrect size or design. X

Weight not within tolerance. X

Incorrect shape and clearness of design. X

Eagle’s head not facing properly. X

Not polished to bright finish. X

Not properly lacquered. X

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Grip

Weight not within tolerance. X

Incorrect shape and clearness of cut in grooves. X

Set screw not set to proper depth. X

Not properly polished. X

Cross Guard

USMA design not cast integral to cross guard X

Incorrect shape. X

Weight not within tolerance. X

Design not clear. X

Not polished to bright finish. X

Not properly lacquered. X

Scabbard

Incorrect shape and clearness of design. X

Weight not within tolerance. X

Too tight to insert sword properly or withdraw properly.

X

Dents. X

Blemishes. X

The scabbard has incorrect liner. X

Liner is missing foam backing(s) and/or sword slides out of scabbard when scabbard is turned upside down.

X

Mouthpiece Fitting

Weight not within tolerance. X

Not highly polished or properly lacquered. X

Screw not correct size or set to proper depth. X

Middle Band with Hook Fitting

Silver-soldered joint not uniform in appearance. X

Weight not within tolerance. X

Not highly polished or properly lacquered. X

Screw not correct size or set to proper depth. X

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Shoe Fitting

Screw not correct size. X

Weight not within tolerance. X

Not highly polished or properly lacquered. X

Screw not set to proper depth. X

General

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

X

Burrs remaining on screws or screw holes. X

Flannelette Cover

Any seam or stitch type operation omitted. X

Seam allowance not maintained, improper seams or stitching resulting in badly twisted, pleated or bulging seams on outside of cover.

X

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

X

Multiple skipped stitches, loose or tight stitch tension resulting in an unsatisfactory seam.

X

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

On outside, any raw edge. X

Component and Assembly

Any component part omitted. X

Any defects of component or assembly, definitely affecting serviceability, including manual of arms.

X

Any defect of component or assembly affecting appearance or limiting serviceability (Unless otherwise classified herein).

4.6 Warranty – Repair/Replacement Provisions. The contractor shall warrant the Sword, Sword Components, Scabbard and Scabbard Components against more than a two percent

(2%) breakage over a three (3) year time period. This period will be based on the year stamped on the sword as required herein and using the delivery month of the year provided as the year start month. In the event of breakage or component failure the government shall collect the broken swords and scabbards. If more than two percent of the provided items from any single year fail the customer shall contact the contractor for return for replacement

Page 12 of 12 Pages or repair instructions. This warranty will include, but is not limited to, breakage or failure of the set screws, hilt assemblies, mouth piece and sleeves (scabbard-liners).

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, swords shall be packed in a manner which will insure acceptable and safe delivery at destination. As far as practicable, supplies of one type and class 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.

C. 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.

CUSTODIAN PREPARING ACTIVITY

U S Military Academy Corps Support Branch (MATR-S)

West Point, NY 10996 USMA

West Point, NY 10996

REVIEWING ACTIVITY:

DCSLOG (MALO)

USMA

West Point, NY 10996