G-F603_REV_E__DOC_6_approved.pdf

2017-06-19

PCO LETTER REQUEST

A-10 TLPS

Legacy VI 6/19/2017

Contract/Delivery Order Number: FA8202-15-D-0001

Program Manager: Edie Messina

Letter Number: A10-CDM-0001-E-17-0042

Date of Letter: 6/15/2017

CDRL Number: A129

Document Title:

A-10 Process Specification for Rivets-Blind, Installation of

Document/ Drawing Number: G-F603 Rev E

NOT APPROVED (See comment below)

X APPROVED

APPROVED Subject to inclusion of attached comments

OTHER (please identify below)

Notes:

Program Manager Signature and Date:

X

MESSINA.CARRI

E.E.1023771388

Digitally signed by

MESSINA.CARRIE.E.1023771388

DN: c=US, o=U.S. Government, ou=DoD, ou=PKI, ou=USAF, cn=MESSINA.CARRIE.E.1023771388 Date: 2017.06.20 09:26:45 -06'00'

77751 G-F603 Revision E

06 April 2017

Data contained on this sheet is subject to the restrictions on the title page of this document.

ii

LIST OF REVISIONS

Rev. Date Description A B C 2/1/88 This revision incorporates the following:

(a) Revised Section 2.0 and removed exact issue call out (revision levels) from documents.

(b) Added additional cherry max rivets and appropriate data to cover A-10 usage.

(c) Add improved graphics for acceptance of stem break-off.

(d) Reformatted.

(e) Updated vendor names.

REV. CHANGES REASON FOR CHANGE APPROVED

D 12/08/16

Redrew figures and tables; made minor grammatical changes.

To improve clarity. M. Kassinger

Updated Section 2.0, Applicable Documents:

• MS20605 became NASM20605.

• Added PW220T0040, which replaces QATB M-40.

Updated titles as necessary; updated callouts/references where required throughout document.

To reflect latest applicable documents.

Updated supplier information and part numbers in Sections 2.2.3, 2.2.4, and Tables II and VIII; deleted 2.2.5 (items merged into 2.2.3 due to Olympic line becoming part of Allfast); deleted

2.2.6 (#1204 fastener now manufactured by Cherry Aerospace, so was moved to 2.2.4). Former Olympic RV541 and RV571 are now Allfast AF5141R and AF5171, respectively. Added RV1303 and RV1393 as alternates to RV1203 and RV1293, respectively.

To reflect current suppliers and part numbers.

Added Para. 3.2.3.4 to cover rivet definition methodology on the Enhanced Wing Assembly.

Per Air Force direction.

iii

D (Continued)

In Para. 3.3.2.1, added the following to the end of the first sentence, and a new second sentence: “using controlled tooling or drill blocks. Gap inspection in accordance with Paragraph 4.4.1 will verify hole perpendicularity.”

To require appropriate tooling and gap inspection to ensure hole perpendicularity.

In Table I, replaced “circumferential scratches” with “circumferential grooves”; added “grooves” to list of unacceptable surface defects.

To be consistent with surface defect descriptions in PW220T0040.

In Para. 3.3.3.1, added introductory clause “Unless otherwise specified in Engineering.”

Per Air Force direction, to reflect that hole sizes for the Enhanced Wing Assembly are controlled within Engineering, not by this specification.

In Para. 4.1.1, replaced QATB M-40 with PW220T0040 as document to control inspection requirements for holes.

To reflect current applicable document.

E 04/06/17

In Para. 3.3.2.1, deleted second sentence (“Gap inspection in accordance with Paragraph 4.4.1 will verify hole perpendicularity.”) in entirety.

Comment Incorporation in compliance with AF PM Response Letter 04/03/2017.

M. Kassinger

Re-designated 3.4.2, Subtitutions, as new Section 3.5; renumbered Paras.

3.4.2.1 and 3.4.2.2 as Paras. 3.5.1 and 3.5.2, respectively.

Comment Incorporation in compliance with AF PM Response Letter 04/03/2017.

Added new Para. 3.5.3, permitting use of RV1303 and RV1393 when RV1203 and RV1293, respectively, are called out on Engineering documents.

Comment Incorporation in compliance with AF PM Response Letter 04/03/2017.

iv

TABLE OF CONTENTS

LIST OF REVISIONS ........................................................................................................... i LIST OF FIGURES .............................................................................................................. v

LIST OF TABLES ............................................................................................................... v

1.0 SCOPE

2.0 APPLICABLE DOCUMENTS

2.1 Government Documents

2.2 Non-Government Documents

3.0 REQUIREMENTS

3.1 Equipment

3.2 Materials

3.3 Required Procedures

3.4 Removal

3.5 Substitutions

4.0 QUALITY ASSURANCE

4.2 Acceptance Limits

4.3 Head Flushness

4.4 Gaps

5.0 PREPARATION FOR DELIVERY

6.0 NOTES

6.1 Intended Use

6.2 Approved Sources of Supply

6.3 Definitions

v

LIST OF FIGURES

Figure 1: Drawing Symbol

Figure 2A: Inspection of Collar Position

Figure 2B: Inspection of Pin Position

Figure 3: Exposed Areas of Countersink

Figure 4: Shim Configuration

Figure 5: Shim Positioning

LIST OF TABLES

Table I: Surface Defects in Fastener Holes

Table II: Hole Sizes for Non-Pull-Through Rivets

Table III: Hole Sizes for Pull-Through Rivets

Table IV: Minimum Shaved Rivet Head Diameter

Table V: Interchangeable Pull-Through Rivet Groups

Table VI: Collar and Pin (Stem) Break-Off Limits

Table VII: Allowable Gap Under Protruding-Head Rivets

Table VIII: Authorized Sources of Supply

1.0 SCOPE

1.1 This specification sets forth the requirements for the installation of blind rivets of the style specified herein in diameters from 3/32 through 1/4 inch.

1.2 This specification also covers blind, pull-through stem, and hollow rivets for use with plate nuts.

2.0 APPLICABLE DOCUMENTS

The following documents of the issue in effect on the effective date of contract shall form part of this specification. In the event of conflict between the contractual documents referenced herein and the requirements of this specification, the contractual documents referenced herein shall govern.

2.1 Government Documents

2.1.1 Federal Specifications

None

2.1.2 Military

None

2.2 Non-Government Documents

2.2.1 National Aerospace Standards

NASM20605 Rivet, Blind, Nonstructural, 100° Flush Head, Class 2 NAS1398 Rivet, Blind, Protruding Head, Locked Spindle NAS1399 Rivet, Blind, 100° Flush Head, Locked Spindle NAS1768 Rivet, Blind, Protruding Head, Mechanically Locked Spindle, Bulbed NAS1769 Rivet, Blind, 100° Flush Head, Mechanically Locked Spindle, Bulbed, Oversize NAS1738 Rivet, Blind, Protruding Head, Mechanically Locked Spindle, Bulbed

NAS1739 Rivet, Blind, 100° Flush Head, Mechanically Locked Spindle, Bulbed NAS1921 Rivet, Blind, General Purpose, Bulbed, 100° Flush Head, Mechanically Locked Spindle

2.2.2 A-10 Program Standards

SP664 Flush Fastenings—Structural (Rivets, Bolts and Screws)

PW220T0040 Post Production A-10 Inspection of Holes in Critical Structural Components

QATB M-40 Inspection of Holes in Fatigue and/or Fracture Critical Structures

2.2.3 Allfast Fastening Systems, Part of TriMas Corporation

15200 Don Julian Road, City of Industry, CA 91745; www.allfastinc.com

No. Material Description AF5171 Alloy Steel, Cadmium Plate

Flush, blind, pull-through, hollow rivet AF5141

CRES

AF5141R

RV1203

RV1303 Aluminum

100° flush shear-head Olympic lock RV1293 RV1393 Monel, Cadmium Plate

RV1293M Monel

2.2.4 Cherry Aerospace, SPS Fastener Division

1224 East Warner Avenue, Santa Ana, CA 92705; www.cherryaerospace.com

No. Material Description CR2164 Aluminum

100° flush shear-head, CherryLOCK, Nominal Shank Size CR2564 Monel, Cadmium Plate

CR2564M Monel

CR2245 Aluminum Unisink head, bulbed CherryLOCK, 1/64” oversize shank CR2545 Monel

CCR264SS Alloy Steel, Cadmium Plate Flush, blind, pull-through hollow rivet

CCR264CS CRES

http://www.allfastinc.com/ http://www.cherryaerospace.com/

No. Material Description CR3222 Aluminum

100° flush-head, CRES stem CherryMAX, nominal shank size CR3522P Monel, Aluminum Coated

CR3522 Monel

CR3223 Aluminum Protruding-head, CRES stem CherryMAX, nominal shank size CR3523P Monel, Aluminum Coated

CR3523 Monel

CR3224 Aluminum 100° flush shear-head, CRES stem CherryMAX, nominal shank size CR3524P Monel, Aluminum Coated

CR3524 Monel

CR3252 Aluminum 100° flush-head, CRES stem CherryMax, 1/64” oversize shank CR3552P Monel, Aluminum Coated

CR3552 Monel

CR3253 Aluminum Protruding-head, CRES stem CherryMAX, 1/64” oversize CR3553P Monel, Aluminum Coated

CR3553 Monel

CR3255 Aluminum Unisink head, CRES stem CherryMAX, 1/64” oversize shank CR3555P Monel, Aluminum Coated

CR3555 Monel

1204 Alloy Steel, Cadmium Plate Flush, blind, pull-through, hollow rivet

3.0 REQUIREMENTS

3.1 Equipment

3.1.1 Equipment and tooling shall be suitable for and capable of performing the installation of rivets consistent with the requirements of this specification.

3.1.2 Equipment and tools for the inspection of the rivet installation must be capable of performing the specified function.

3.1.3 Select the proper installation tools for the band and size of rivet. It is recommended that the respective rivet supplier’s tooling catalog be consulted for this information. These are available for download as follows:

3.1.3.1 Allfast Fastening Systems: www.allfastinc.com

3.1.3.2 Cherry Aerospace: www.cherryaerospace.com

3.2 Materials

3.2.1 Drawing Compliance

All blind rivets shall comply with the respective part drawing listed under Section 2.0 for material and configuration.

3.2.2 Rivet Lengths

3.2.2.1 Rivet lengths shall be per drawing callout except that one longer or shorter grip length can be substituted for the drawing-specified length to compensate for thickness variations, when necessary, provided all other requirements of this specification are met. Length of the installed rivets shall be governed by actual measurement of the stack-up.

3.2.3 Codes

3.2.3.1 Each rivet called out on a drawing will be represented by a basic code tabulated on the face of the drawing. Figure 1 is an illustration of the symbols and method of specifying the coding.

3.2.3.2 Code letters and other fastener installation requirements will appear within the rivet quadrant symbol used on the drawing and will be coded as illustrated in Figure 1.

http://www.allfastinc.com/ http://www.cherryaerospace.com/

Figure 1: Drawing Symbol

3.2.3.3 Example of coded rivet symbols:

RV1203-5-2, blind rivet, 100° flush shear-head, 5/32 in. diameter,

0.125 grip, countersunk near side.

NAS1398D4-2, blind rivet, protruding-head, 1/8” diameter, 0.125 grip, head on near side.

3.2.3.4 Enhanced Wing Assembly fastener definition is not accomplished through the symbol/code system described in Paragraphs 3.2.3.1–3.2.3.3 and Figure 1. Definition is accomplished through complete fastener part number (including diameter and grip length), model orientation (manufacturer head location), and fastener attributes (e.g., hole number, countersink information, etc.).

3.3 Required Procedures

3.3.1 Fit-Up

3.3.1.1 All details shall be surface treated for corrosion protection as required by Engineering drawing or operation sheet for that stage of assembly.

3.3.1.2 Parts shall be held together during hole preparation. There shall be no evidence of dirt or chips at the interface.

3.3.1.3 Burrs that could prevent seating of the fastener head shall be removed.

3.3.1.4 For sealing applications, compounds shall be applied to faying surfaces before riveting in locations specified on Engineering drawings.

3.3.2 Holes

3.3.2.1 Fastener holes shall be drilled perpendicular within 2° to the surface against which the installed fastener head will bear using controlled tooling or drill blocks. All (100%) structural holes prepared for the installation of fasteners in accordance with this specification shall, unless otherwise noted on the drawing, have a surface roughness of 125 RHR or smoother.

See Table I for acceptance limits.

Table I: Surface Defects in Fastener Holes

Acceptable Not Acceptable

1. Circumferential grooves that are a minimum of 1/16” or 10% of the part thickness from the surface of the part, whichever is smaller.

1. Grooves, scratches, nicks, or cuts intersecting a part surface or exceeding limits specified as acceptable.

2. Spiral scratches that are a minimum of 1/16” or 25% of the part thickness from the surface of the part, whichever is smaller.

3. Longitudinal scratches not more than 50% of the length of the hole in any one part that neither start nor end within 1/16” or 25% of the part thickness from the surface of the part, whichever is smaller.

4. Any visible defect that does not exceed the specified surface roughness.

3.3.3 Hole Sizes

3.3.3.1 Unless otherwise specified in Engineering, hole sizes for flush- and protruding-head rivets, except flush blind pull-through hollow rivets shall conform to Table II requirements.

Table II: Hole Sizes for Non-Pull-Through Rivets

Rivets

NAS1921

NAS1398 & NAS1399

CR2164 & CR2564

CR3222 & CR3522

CR3223 & CR3523

CR3224 & CR3524

CR2245 & CR2545

RV1203 & RV1293

RV1303 & RV1393

NAS1768 & NAS1769

NAS1738 & NAS1739

CR2245 & CR2545

CR3252 & CR3253

CR3552 & CR3553

CR3255 & CR3555

Nominal Rivet Diameter, in. Hole Size, Nominal, in. Hole Size, Oversize, in.

1/8 0.129 / 0.132 0.143 / 0.146

5/32 0.160 / 0.164 0.176 / 0.180

3/16 0.192 / 0.196 0.205 / 0.209

1/4 0.256 / 0.261 0.271 / 0.275

3.3.3.2 Hole sizes for hollow, pull-through rivets shall conform to Table III requirements.

Table III: Hole Sizes for Pull-Through Rivets

Nominal Rivet Diameter, in. Hole Size, in.

3/32 0.097 / 0.101

1/8 0.129 / 0.132

3.3.4 Rivet Heads

3.3.4.1 Flush-head rivets shall be installed in accordance with SP664 or as required to meet the flushness requirements of the drawing.

3.3.4.2 Where the fastener fillet radius between the head and the shank interferes with the proper installation of the fastener, Manufacturing may use a radius or chamfer on the edge of the hole. This relief shall not exceed the nominal fastener radius.

3.3.5 Angularity

3.3.5.1 Blind side taper shall be limited to 7° maximum.

3.3.6 Care and Cleanliness

3.3.6.1 These fasteners are factory lubricated; therefore, neither degreasing nor lubrication is permitted.

3.3.6.2 These fasteners shall be kept in their original container at all times prior to the actual installation. Loose parts shall not be stored in open bins.

3.3.6.3 Plain, countersunk or dimpled holes requiring sealing of the installed fastener shall be pre-cleaned in accordance with the sealing document specified on the drawing.

3.3.7 CherryMAX Rivet Installation Caution Note

During rivet installation, every effort should be made to hold the riveter and pulling head in line with the rivet axis as accurately as possible, apply a steady, firm pressure against the rivet head, and then pull the trigger of the rivet gun. This will minimize the potential for head gapping and sheet gapping.

3.3.8 Temporary Coatings

3.3.8.1 Remove all temporary coatings from mating and faying surfaces prior to assembly.

3.3.8.2 Flush-head fasteners can be installed through temporary protective coating, if rivet flushness requirements are met.

3.3.8.3 Temporary protective coating remaining after countersinking may remain under manufactured head of countersunk fasteners providing head gapping allowances are met.

3.3.9 Shaving

3.3.9.1 When the drawing specifies rivet head shaving, they shall be shaved 0.005” maximum in height. Table IV specifies the minimum allowable shaved head diameter.

Table IV: Minimum Shaved Rivet Head Diameter

Rivet Diameter, in. Minimum Shaved 100° Head Diameter, in.

1/8 0.213

5/32 0.274

3/16 0.341

1/4 0.464

3.3.9.2 Where shaving in fluid tanks is required by drawing, after shaving there shall be no loose or hanging burrs, nor feather edges that will loosen, break off and contaminate the fluid.

3.3.10 Where the stem has broken off above flush or the collar is above flush, they may be shaved within the dimensional limits of Table VI columns “A” or/and “B” to meet the flushness requirement. However, for this case, the rivet head shall not be shaved. Reference Figure 2A.

3.3.10.1 Rivets that will come in contact with bladders shall have the stem and locking collar shaved 0.010” maximum when they are above the rivet head surface. This applies to flush or protruding-head rivets. No sharp edges are permitted.

3.3.10.2 The sheet surface shall not be damaged by the shaving cutters or tool.

3.3.10.3 Reduced (shear) head rivets (NAS1097 head size) shall not be shaved.

3.4 Removal

3.4.1 Using a drill bit just larger than the stem size of the rivet, drill down to the base of the locking collar. When the correct size drill is used, the remnants of the collar will climb up the drill bit. At this point, with the drill stopped, break off the rivet head with the drill bit. Push in the rivet body.

3.4.1.1 If the hole size is still within acceptable limits, install a new rivet. Should the hole be oversize, proceed in accordance with standard procedures for defects.

3.5 Substitutions

3.5.1 The “A”-code rivets (full serrations) and no-code rivets (partial serrations) are physically and functionally interchangeable except for installation tools required. All blind fasteners installed by automatic rivet installation equipment shall be “A”-code only.

3.5.2 All flush blind pull-through rivets of the same material as listed in Table V are physically and functionally interchangeable.

Table V: Interchangeable Pull-Through Rivet Groups

Material

Alloy Steel Cadmium Plate CRES

Interchangeable Group

CCR264SS CCR264CS

AF5171 AF5141

1204 –

NASM20605S NASM20605R

3.5.3 When RV1203 or RV1293 fasteners are called out on Engineering documents, RV1303 or RV1393 fasteners, respectively, may be used.

4.0 QUALITY ASSURANCE

4.1 Responsibility for inspection, unless otherwise specified in the contract of purchase order, is the supplier’s. The supplier is responsible for performing all required inspections and satisfying all quality assurance provisions and requirements specified herein.

4.1.1 Where either QATB M-40 or PW220T0040 is referenced on a drawing or applicable to designated hole(s), the inspection requirements of PW220T0040 shall supersede the requirements of this document.

4.1.2 Integrity

4.1.2.1 The stem, locked in place by the collar, shall be capable of withstanding an axial force of 50 ± 5 lbs. without being pushed out. When applicable, push-out will be performed after shaving.

4.1.2.2 There shall be no evidence that the rivet can rotate in the hole or that looseness of the stem, locking collar or rivet body exists when examined by finger pressure or fingernail prying.

4.2 Acceptance Limits

4.2.1 Pin and Collar Positions

4.2.1.1 The swaged locking collar shall be within the limits shown in column “A” of Table VI.

Reference Figure 2A.

4.2.1.2 The pin shall break off within the limits shown in columns “B” and “C” of Table VI.

Reference Figure 2B.

Table VI: Collar and Pin (Stem) Break-Off Limits

Rivet

“A” Maximum Distance of Locking Collar Above or Below Rivet Head, in.

“B” Maximum Distance of Top of Land on Pin Above Rivet

Head, in.

“C” Maximum Distance of Top of Land on Pin Below Rivet

Head, in.

Nom.

Dia., in.

Dash No. 1/ 2/ 1/ 2/ 1/ 2/

1/8 4 0.012

Flush 3/

0.016

0.010

0.008 0.015

5/32 5 0.015 0.020 0.010 0.020

3/16 6 0.018 0.024 0.012

1/4 8 0.021 0.028 0.015 0.014 0.025

1/ For non-CherryMAX rivets.

2/ For CherryMAX rivets.

3/ 0.020 flash permitted; see Detail A of Figure 2A.

Figure 2A: Inspection of Collar Position

Figure 2B: Inspection of Pin Position

4.3 Head Flushness

4.3.1 Head flushness shall be in accordance with the drawing requirements or SP664 if unspecified.

4.3.2 Manufacturer’s tolerances on the heads of flush-head fasteners may result in partially exposed countersinks. See Figure 3. Exposed areas around the fastener head are acceptable if the fastener tolerance, hole tolerance, and flushness requirements are met.

Figure 3: Exposed Areas of Countersink

4.3.3 The rivet tail protrusion for 3/32” diameter pull-through hollow rivets used in nut plates shall be within 0.062”–0.250” beyond the nut plate after installation.

4.4 Gaps

4.4.1 Gaps shall be evaluated in accordance with the following:

4.4.1.1 There shall be no measurable gap under the formed tail of the installed rivet. Check when tails are accessible.

4.4.1.2 The manufactured heads of all universal-head fasteners shall seat such that a shim (Table VII) does not contact the fastener shank when inspected as shown in Figures 5(a) and 5(b). Contact with the shank is indicated when the shim does not wedge and will slide freely under the head as shown in Figure 5(b).

Table VII: Allowable Gap Under Protruding-Head Rivets

Rivet Diameter, in. Minimum Gap, in.

1/8 0.003

5/32 0.004

3/16 0.005

1/4

4.4.2 The manufactured heads of all flush-head fasteners shall seat such that:

4.4.2.1 A 0.002-inch-thick shim, of the configuration shown in Figure 4, cannot be inserted between the fastener head and the countersink for more than 40% of the circumference of the head.

Figure 4: Shim Configuration

4.4.2.2 A 0.002-inch-thick shim does not contact the fastener shank when inspected as shown in Figures 5(c) and 5(d).

Figure 5: Shim Positioning

5.0 PREPARATION FOR DELIVERY

Not Applicable

6.0 NOTES

6.1 Intended Use

6.1.1 This specification is for installation and inspection of specified blind rivets.

6.2 Approved Sources of Supply

6.2.1 The following companies, their licensees and authorized suppliers are the only authorized sources of supply: See Table VIII.

Table VIII: Authorized Sources of Supply

Fastener Source CAGE Code

NAS1398/1399

A-Code and Non-A-Code

Allfast Fastening Systems, Part of TriMas Corporation 53551

Cherry Aerospace, SPS Fastener Division 11815

NAS1738/1739

Cherry Aerospace, SPS Fastener Division 11815

Allfast Fastening Systems, Part of TriMas Corporation 53551

NAS1768/1769 Allfast Fastening Systems, Part of TriMas Corporation 53551

NAS1921 Cherry Aerospace, SPS Fastener Division 11815

CCR264CS, CCR264SS Cherry Aerospace, SPS Fastener Division 11815

1204 Cherry Aerospace, SPS Fastener Division 11815

AF5141, AF5141R, AF5171 Allfast Fastening Systems, Part of TriMas Corporation 53551

RV1203, RV1293, RV1303,

RV1393

Allfast Fastening Systems, Part of TriMas Corporation 53551

CR2164 and CR2564, CR2245 and CR2545, CR3222 and CR3522, CR3223 and CR3523, CR3224 and CR3524, CR3252 and CR3552, CR3253 and CR3553, CR3255 and CR3555

Cherry Aerospace, SPS Fastener Division 11815

6.3 Definitions

6.3.1 Blind rivets, for the purpose of this specification, are defined as a two- or three-piece part having a predetermined grip length, a stem locking ring, and are self-installing with special tools from one side.