SM160M1000_E.pdf

A-10 Thunderbolt Life-Cycle Program Support (TLPS) A-10 Aircraft Structural Integrity Program (ASIP) Legacy

As-Designed Parts, Materials, and Processes List (ADPMPL)

Criteria and Control of Fracture Critical Components

Contract Number: FA8202-09-D-0002 Delivery Order: 0004

CLIN: 0054

CDRL: A140

Document Number: SM160M1000 Revision Level: E

Date: 8 November 2010

A-10 TLPS Program 1801 State Route 17C

Owego, New York 13827-3998

LM TST: Government:

Print Name: Timothy Walter Print Name:

Title: Program Manager Title:

Date: 29 September 2011 Date:

GOVERNMENT APPROVAL REQUIRED

DISTRIBUTION STATEMENT D: Distribution authorized to Department of Defense (DoD) and DoD Contractors, for administrative or operational use determined 29 June 2009. Other requests for a copy of this document shall be referred to the A-10 SPO Office, 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 Administrative 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. When it is technically infeasible to use the entire statement, an abbreviated marking may be used, and a copy of the full statement added to the “Notice To Accompany Release of Export Controlled Data” required by DoD Directive

5230.25 (reference (c)).

DESTRUCTION NOTICE: Unclassified/Limited Distribution documents shall be handled using the same standard as “For Official Use Only (FOUO)” material, and will be destroyed by any method that will prevent disclosure of contents or reconstruction of the document. When local circumstances or experience indicates that this destruction method is not sufficiently protective of unclassified limited information, local authorities may prescribe other methods, but must give due consideration to additional expense balanced against the degree of sensitivity.

77751 SM160M1000

Revision E

8 November 2010

(NGAS CAGE 26512)

ii

TABLE OF REVISIONS

Revision Date Changes Approved

Original Issue

8/28/1973.

New Document

H. Kleindienst

Revision A 3/1/1974 all Renumber pages.

i, ii Add Status of Revision pages

2.1 Add reference documents, of exact issues

3.1 Revision. Delete general definition of Class 1

part and replace with specific definition consistent with criteria for fracture critical structure given in paragraph 3.1.5 of 160P09D412.

3.2 Revision. To delete reference to major

forgings, extrusions, or machinings which are not readily repairable in the field. This change requested by A-10 SPO personnel.

3.3 New. To clarify exceptions.

5.1.1 Revision. To clarify that note is required on

assembly drawings.

5.1.1.1 Revision. To make wording consistent with

new paragraph 3.3.

5.1.2. a Revision. To denote FRC traceability specification and change requirement from mandatory to optional.

5.1.2. b Revision. Clarify equal obligation on outside sources and on in- house procedures.

5.1.2. d Revision. Clarify fact that KIC value is to be called for when it is meaningful for design and material is available for taking of valid specimens.

5.1.2,e Revision. Added items i thru vi to denote specific inspection requirements on detail part and assembly drawings in accordance with appropriate specifications and procedures. Added Table I defining hole quality inspection levels.

Added requirement that where the nature of the part is such that Class 1A applicable inspections are not warranted (e.g. fluorescent penetrant of

H. Kleindienst iii iv

TABLE OF CONTENTS

TABLE OF REVISIONS ....................................................................................... II

1.0 SCOPE

1.1 Purpose

1.2 Applicability

2.0 REFERENCE DOCUMENTS

3.0 DEFINITIONS

3.1 Class 1A

3.2 Class 1B

3.3 Exceptions

3.4 Traceability

4.0 REQUIREMENTS

4.1 Discussion

4.2 Responsibility

4.3 Fatigue and/or Fracture Critical Components

5.0 DETAIL REQUIREMENTS

5.1 Class 1A Structural Components

5.2 Class 1B Structural Components

5.3 General Requirements

6.0 NOTES

1.0 SCOPE

1.1 Purpose

This document establishes the criteria for identifying fracture and/or fatigue structural components and the detail requirement for their control.

1.2 Applicability

This document defines considerations for classifying components of the A-10 airplane weapon system. It is intended to apply controls to ensure the structural integrity of the system.

2.0 REFERENCE DOCUMENTS

2.1 The following documents form a part of this document to the extent specified herein. In the case of Military documents where a second document is shown in parentheses, that document supersedes and replaces the original. The requirements of the superseding document shall be applied in a manner that is equivalent to the requirements of the original documents. Documents under the heading of “OTHER” are applicable to post production/extended life operation of the A-10 fleet.

Military

MILSTD-00453A (1)

19 December 1975 (ASTM E1742)

Inspection, Radiographic

MIL-STD-867 (USAF)

Notice 1

Temper Etch Inspection

MIL-STD-1535A Supplier Quality Assurance Program Requirements

MIL-I-6866B

(ASTM 1417-95A)

Inspection, Penetrant Method Of

MIL-I-6868E

(ASTM 1444-91)

Inspection Process, Magnetic Particle

MIL-I-8950B

(ASTM E2375 or

SAE AMS-STD-2159)

Inspection, Ultrasonic, Wrought Metals, Process For

MIL-I-25135C (3)

(AMS 2644)

Inspection Material, Penetrant

FRC /Northrop Grumman Aerospace Systems

G -J301 Etching Prior to Penetrant Inspection -Process For

Z-J901 Traceability Control of Selected Items

Z-P801 Storage, Handling, Shipping

160P09D409, Rev. A ASIP Master Plan

160P09D412, Rev. A Fracture and Fatigue Control Plan

SA160R9400, Rev. D Fatigue and Fracture Critical Parts List

CM160R5002, Rev. J Baseline Documentation Guide for Fairchild Prepared Drawings, A-10 Program

CM160M0001 Criteria And Control of Non-Structural Registered Components

QA Test Bulletin M-35 Eddy Current Inspection of Small Diameter (Fastener) Holes

QA Test Bulletin M-36 Penetrant Inspection of Fatigue and/or Fracture Critical Parts

QA Test Bulletin M-37 Magnetic Particle Inspection of Fatigue Fracture Critical Parts

QA Test Bulletin M-38 Ultrasonic Inspection of Materials for Fatigue and/or Fracture Critical Parts

QA Test Bulletin M-39 Radiographic Inspection of Fatigue and/or Fracture Critical Parts

QA Test Bulletin M-40 Inspection of Holes in Fatigue and/or Fracture Critical Parts

Other

220P09D409 Rev. C A-10 ASIP Master Plan Update

220P09D412 A-10 Fatigue and Fracture Control Plan Update

3.0 DEFINITIONS

These definitions are the criteria by which fatigue and/or fracture critical components shall be identified by Engineering. Engineering is a terminology that refers to the OEM (FRC) with respect to original production and to the cognizant Air Force program authority for all activity in the post-production era. Fatigue or fracture critical components are those which are susceptible to crack initiation and propagation mechanisms.

3.1 Class 1A

A structural component the single failure of which would result in the inunediate loss of an aircraft at the maximum expected load in the fatigue spectrum or limit load, whichever is greater, and is primarily subjected to tension loading.

3.1.1 The Class 1A components defined in 3. 1, and listed in SA160R9400 are classified as one category of Registered Components as defined in MIL-STD-1535.

3.1.2 When noted in SA160R9400, Class 1A registered components require traceability in accordance with Z-J901 (See section 5.1.2).

3.2 Class 1B

A structural component not included in Class 1A, of which a single failure would cause significant danger to operating personnel or would result in an operational penalty and is primarily subjected to tension loading. These items are listed in SA160R9400 and they do not require traceability.

3.3 Exceptions

3.3.1 General. For non-structural components see document CM160M0001.

3.3.2 Landing gear system. The landing gear system, defined as the main and nose landing gears, trunnion support fittings and drag brace support fittings, shall not be considered part of fracture controlled airframe structure (as stated in section 1.0 of 160P09D412). The main and nose gears and the drag struts shall not be classified as fatigue critical components.

These are vendor supplied parts and, for original production, the vendors’ traceability, inspection and process controls have been reviewed and found to meet or exceed the requirements of this document. New production of these parts (spares/replacement) either in existing or redesigned configuration shallconform to the original traceablilty, inspection and process control requirements that production parts were subject to.

3.4 Traceability

Traceability is the capability of retrieving all required information about an item. It includes maintenance of a complete processing history, identification of fracture toughness when required, and accessibility to supplier test reports, receiving inspection reports, QA process verification documentation, manufacturing plans, practices and operation sheets, and PAR’s.

4.0 REQUIREMENTS

4.1 Discussion

The requirements herein are implementations of the FRC Statement of Work 160P09D412 and FRC Statementof Work 160P09D409. For post-production, documents 220P09D412 and 220P09D409 apply. It is noted that OEM responsibility has transferred to Northrop Grumman Aerospace Systems.

4.2 Responsibility

All classifications were made jointly by FRC Engineering Design and Stress and shall remain in effect throughout the life cycle of the A-10 program. Post-production and sustaining phase responsibility shall belong to the A-10 SPO.

4.3 Fatigue and/or Fracture Critical Components

Components listed in SA160R9400 shall be separately detailed on Engineering drawings.

Changes or additions to components listed in SA160R9400 shall be accomplished by contract authorization to the OEM or by Air Force generated Engineering Change Orders against that document.

5.0 DETAIL REQUIREMENTS

The following information shall appear on a drawing or be included in documentation which is referenced on the drawing. This document is part of the documentation of the drawing and shall be entered on the Engineering drawing in accordance with the FRC Engineering Manual or consistant with format of existing original production drawings. These requirements also apply to new design and major modifications.

5.1 Class 1A Structural Components

5.1.1 Drawing Notes.

5.1.1.1 For all items in SA160R9400, add as Note #1 on the drawing detailing that part:

“1. This is a fatigue and fracture critical part, Class 1A, lAW SM160M1000. “

5.1.1.2 Where SA160R9400 indicates part is traceable, add the following sentence to Note #1 shown in 5.1. 1. 1:

“Control traceable items lAW Z-J901, Code (S, L or T).”

(NOTE: State the code required for the applicable part.)

5.1.1.3 For the next higher assembly, and all subsequent next higher assemblies installations containing that traceable item, add as Note #1 applicable to the next higher assembly/installation, the following:

“1. This assembly/installation contains a traceable part IAW Z-J901”

5.1.2 Process Control. The critical methods and processes shall be specified. Manufacturing practices , plans, and operation sheets of FRC and Suppliers shall be approved by FRC Engineering and FRC Quality Assurance. These requirements shall now apply to authorized suppliers of affected parts/assemblies/installations associated with new production, modification, spares, replacements, etc. in the post-production era. These suppliers shall be responsible to approve manufacturing practices, plans, and operation sheets. Approval shall be given prior to production. The documentation submitted for approval shall include:

1. The methods and type of critical processing to be used (subject to limitations imposed because of proprietary information). Applicable specification data are to be included.

2. The location within the processing cycle where inspections will take place.

3. The attributes of the products which will be inspected at each inspection point.

4. The materials and methods of preservation and packaging to be used to protect the product (reference section 5.1.2.3).

Revision or variation to any of the above listed controls is prohibited prior to FRC or other contract responsible cognizant supplier Engineering and Quality Assurance acceptance.

Engineering drawings identify the applicable product specification. Document CM160R5002 lists the specification issue to be complied with. Where documents do not indicate specification issue definition, FRC Configuration Management shall be consulted for direction. For post-production, the cognizant Air Force authority shall be consulted.

5.1.2.1 PAR’s. Problem Action Reports on nonconforming material or components shall be submitted to the cognizant supplier Chief of Stress, or his designated representatives, for disposition.

5.1.2.2 KIc, Plane Strain Fracture Toughness. Where a valid KIc is a meaningful value in determining the life of the part, KIc test(s) will be specified on the drawing and value(s) shall be expeditiously determined and reported by the supplier/processor. Unless otherwise noted, delivery of a part and/or subsequent processing shall not be delayed pending receipt of KIc data at FRC or other supplier. FRC or other contract responsible cognizant supplier Quality Assurance shall upon receipt of reported values immediately inform FRC/responsible supplier Engineering who shall initiate corrective action as necessary where a reported value fail to meet the value used for design.

5.1.2.3 Inspection. Special inspection procedures and/or notes shall be included on the detail part drawing and assembly drawings. Applicable drawings shall include the inspections i), ii), and vi). Magnetic particle inspection (i) is required for machined or formed steel parts.

Fluorescent penetrant inspection (ii) is required for machined or formed parts. It may be used for precipitation hardened steels. All finished holes shall be inspected to the requirements of paragraph (vi). Inspection (v) is required for steel surfaces of 180 ksi and over at the time of machining. Inspections (iii) and (iv) are optional as Quality Assurance tests for stock forms (extrusions, forgings, plate, castings) and for welds.

Where material forms (sheet material, thin gauge net section extrusions) are used which are normally accepted for primary structure use without NDI because their nature and processing would not develop surface flaws, inspection categories (i) and (ii) may be excluded.

i) Magnetic particle inspection methods in accordance with QA Test Bulletin M-37.

ii) Fluorescent penetrant inspection methods, in accordance with QA Test Bulletin M-

36. It is necessary to pre-etch aluminum alloys, in accordance with FRC Specification G-J301, or in accordance with a method approvcd by FRC and/or the Air Force. Areas excepted from etching are threads (internal or external), precision finished or reamed holes, and chemically milled surfaces.

iii) Ultrasonic inspection in accordance with QA Test Bulletin M-38 to levels specified on drawings or specifications. The use of ultrasonic methods with bonded construction shall be in accordance with the contractor’s requirements.

iv) Radiographic inspection shall be in accordance with QA Test Bulletin M-39, interpreting MIL-STD-453.

v) Temper etch inspection, when specified on drawings/specifications, shall be in accordance with MIL-STD-867.

vi) Hole quality inspections shall be performed in accordance with the criteria and practice in QA Test Bulletin M-40. The symbols and inspection levels for applications in fatigue and fracture critical regions of Class 1A parts are given in Table I.

All holes through fatigue and fracture critical regions shall be inspected to at least level A2. A note (or notes with appropriate zoning if more than one quality inspection level is applicable) shall be included on the drawing.

Where the drawing is not zoned this note shall read:

“Inspect all holes in Class 1A parts to quality level x (use appropriate symbol) in accordance with QATB M-40.”

Where the drawing is zoned the notes shall refer to a zone and read:

“Inspect all holes to quality level x in accordance with QATB M-40.”

Quality Level

Application

Inspection Requirement

A1 SPECIAL FATIGUE AND FRACTURE CRITICAL HOLES

Design requires less than standard† initial flaw or importance of attachment warrants highest quality.

Special inspection* plus visual inspection of each hole in accordance with QATB M-40

A2 FATIGUE AND FRACTURE CRITICAL HOLES

Design satisfied with standard or larger flaw.

Visual inspection of each hole or process control in accordance with

QATB M-40

B ALL OTHER HOLES IN CLASS 1A PARTS

Structural areas where design is not predicted by fatigue or fracture.

Sample visual in accordance with

QATB M-40

* Special Inspection refers to eddy current, fluorescent penetrant, magnetic particle, or magnified visual, as appropriate.

†Standard initial flaw refers to initial flaw assumptions specified in 160P09D412, 220P09D412 paragraph 3.1.5.4.1.

TABLE I: Hole Inspection Levels

5.2 Class 1B Structural Components

5.2.1 Drawing Note. The first numbered Note on a drawing shall read:

“1. This is a fatigue critical part, Class 1B, IAW SM160M1000.”

5.2.2 Additional requirements for a fatigue critical part Class 1B:

a. Inspection. Inspection requirements shall be specified on the engineering drawing and shall be as follows:

1. For Aluminum Parts add the following as a NOTE:

“Fluorescent penetrant inspect lAW MIL-I-6866, Type I, Method A or B and MIL-I-25135 Sensitivity Group VI”.

When shot peening of the machined part is required add “prior to shot peening” to the above note.

2. For Steel Parts, add the following as a NOTE:

“Magnetic Particle inspect finish machined part lAW MIL–I-6868”.

When steel parts are heat treated to 180 ksi and above, and these parts are shot peened, two inspections are required. For these parts add “last operation prior to shot peening and first operation after plating” to the above note.

3. For Raw Material, Aluminum and Steel, where forgings, bar and/or extrusions are of adequate section thickness (determined by Engineering Materials) that requires ultrasonic inspection, add the following on the detail drawing, as a NOTE:

“ Ultrasonic inspect IAW MIL-I-8950, Cl. A”

b. Process Control. Process procedures shall be specified. Manufacturing practices, plans, and operation sheets of FRC and supplier shall be approved by FRC Engineering and FRC Quality Assurance. Approval shall be given prior to production.

While Engineering drawings do not list the exact issue of applicable specification, the issues listed in report CM160R5002 shall be observed. Where such definition is not present FRC Configuration Management shall be queried for direction. The records should indicate the material, process, and/or inspection specification or standard to which the item is being made. These requirements shall apply to suppliers of affected parts/assemblies/installations associated with new production, modifications, replacements, etc. in the post-production era.

c. PAR’s. Problem Action Reports on nonconforming material shall be submitted to the cognizant supplier Chief of Stress, or his designated representatives, for disposition.

5.3 General Requirements

5.3.1 Storage. Control shall be maintained to identify and/or segregate applicable materials so they are used for the fatigue and/or fracture critical parts intended and to prevent non-traceability controlled materials from entering the inventory of traceable items.

5.3.2 Storage, Shipping, and Handling. The requirements of Z-P801 for registered components shall be observed for Class 1A and 1B parts.

6.0 NOTES

6.1 The safe crack growth classificalions of 160P09D412 and 220P09D412 are subclasses of fracture critical parts classified as 1A under this document, SM160M1000.