Attachment 14 - Performance Specification for MJU 76 Infrared Countermeasure Flare Rev B.pdf

CUI

PRF 201825310B

Original Design Activity:

CAGE Code 98747 15 April 2025

PERFORMANCE SPECIFICATION

FOR SUPERSEDING

MJU-76/B INFRARED COUNTERMEASURE FLARE PRF 201825310

27 April 2023

Revision B

Prepared for and by: AFCLMC/EBHCC

6033 ELM LANE, BLDG 1247

HAFB, UT 84056

SUBMITTED BY: DATE: 15 April 2025 Quincy Stevens Program Engineer, AFLCMC/EBHCC

APPROVED FOR USE AS

PRODUCT BASELINE BY: DATE: 15 April 2025 Steve Decker Chief Engineer, AFLCMC/EBHE

DISTRIBUTION STATEMENT D: Distribution authorized to Department of Defense and U.S. DoD contractors only, CTI, Critical Technology, and

Export Controlled, 15 April 2025. Other requests for this document must be referred to AFLCMC.EBHCC.CMFLARES@US.AF.MIL.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Section 2751 of Title 22, United

States Code) or the Export Control Reform Act of 2018 (Chapter 58 Sections 4801-4852 of Title 50, United States Code). Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25 and DoD Instruction

2040.02.

AMSC# N/A FSC 1370

Table of Contents

1. SCOPE

1.1 Scope

1.2 Definitions

2. APPLICABLE DOCUMENTS

2.1 Government Documents

2.1.1 Standards

2.1.2 Drawings

3. REQUIREMENTS

3.1 Manufacture and Inspection

3.2 Classification of Requirements

3.3 First Article Sample

3.4 Performance and Product Characteristics

3.4.1 Performance

3.4.1.1 Infrared and Thrust Output

3.4.1.2 Static Function

3.4.1.3 Aircraft Flight Function

3.4.2 Durability and Environmental

3.4.2.1 Temperature and Humidity

3.4.2.2 Vibration

3.5 Physical Characteristics and Examinations

3.5.1 Workmanship

3.5.1.1 External Dimensions

3.5.2 X-Ray

3.5.3 Seal Integrity

4. VERIFICATION

4.1 Responsibility for Inspection

4.2 Classification of Inspections

4.3 First Article Sample

4.4 Quality Conformance Inspection

4.4.1 Sampling

4.5 Tests

4.5.1 Performance

4.5.1.1 Seal Integrity Test

4.5.1.1.1 Alternate Seal Integrity Test

4.5.1.2 Infrared and thrust output function static test

4.5.1.3 Function Testing

4.5.1.3.1 Static Function Test

4.5.1.3.1.1 Case Ejection Test

4.5.1.3.1.2 Payload Ejection Test

4.5.1.3.2 Aircraft Flight Function Test

4.5.2 Durability and Environmental Tests

4.5.2.1 X-Ray Test

4.5.2.2 Temperature and Humidity Test

4.5.2.3 Vibration Test

4.5.3 Magnesium Hydroxide Test

4.5.4 Composition Burn Rate Tests

4.5.5 Retention

4.5.5.1 End Cap Test

4.5.5.2 Nose Cap Test

4.5.5.3 Igniter Wire Spring Connector Test

4.6 Flare Examinations

4.6.1 Flare Examinations

4.6.2 Packaging, Packing and Marking Examinations

5. PACKAGING

5.1 Packaging and Marking

5.2 Ammunition Data Card

5.2.1 Ammunition Data Card Content

5.3 Ammunition Lot Number

5.3.1 Ammunition Lot Number Start Date

5.3.2 Grain Creation

5.3.3 Final Assembly

5.4 Acceptance and Description Sheets

6. NOTES

6.1 Definitions

6.1.1 Flare

6.1.2 Grain Composition Batch

6.1.3 Ignition Delay Time

6.2 Conflicting Requirements

6.3 Safety Precautions

6.4 Cognizant Design Authority

6.5 Government Procuring Authority

Appendix A IR and Thrust Acceptance Testing

Addendum

ADDENDUM A ........................................................................................ (Classified Document)

Tables

TABLE I. Inspection Plans

Figures

Figure 1. Case Ejection Test Fixture

Figure 2. Calculation Method for Ignition Delay Time

Figure 3. Calculation Method for Ejection Velocity

Figure 4. MJU-76/B Velocity Ejection Test Setup

Figure 5. MJU-76/B Ejection Timestamp Determination Example

Figure 6. MJU-76/B X-Ray – Major Component Identification (0°)

Figure 7. MJU-76/B X-Ray – Major Component Identification (90°)

Figure 8. Random Vibration Envelope

Figure 9. Vibration Fixture 12255-11J00004

Figure 10. Vibration Test Setup

Figure 11. Payload Assembly

Figure 12. Attach Electric Match to Payload Assembly

Figure 13. Example IR and Thrust Test Setup

1. SCOPE

1.1 Scope. This specification establishes the requirements for the acceptance of the MJU-

76/B Flare, Countermeasure. This document is unclassified. A separate classified Addendum is provided upon approved request for classified information.

1.2 Definitions. The meanings of the terms used in this specification are listed in 6.1.

2. APPLICABLE DOCUMENTS

2.1 Government documents. The following documents of the issue in effect on date of invitation for bids or request for proposal form a part of the specification to the extent specified herein. In the event of conflict between the documents referenced herein and the contents of this specification, the contents of this specification shall be considered a superseding requirement.

Beneficial comments (recommendations, additions, deletions) and any pertinent data which may be of use in improving this document should be addressed to: AFLCMC/EBHCC, 6033

Elm Lane, Hill AFB, Utah 84056-5819, by using the Specification Change Notice (SCN) DD

Form 1696 or other document.

2.1.1 Standards

Military

MIL-STD-331 Rev D Fuzes, Ignition Safety Devices and other related components, Environmental and Performance Tests for.

MIL-STD-810 Rev H Environmental Engineering Considerations and Laboratory Tests

MIL-STD-1168 Ammunition Lot Numbering and Ammunition Data Card

MIL-STD-1171 Energetic Material Description Sheets and Propellant Loading

Authorization Sheets

MIL-STD-1916 DOD Preferred Methods for Acceptance of Product

DOD-4145.26-M DOD Contractor’s Safety Manual for Ammunition and Explosives

2.1.2 Drawings. All applicable drawings are delineated within DL 201825310 Cage Code

98747 and applicable contract documents.

(Copies of standards, drawings, and publications required by contractors in connection with specific acquisition functions should be obtained from the contracting activity or as directed by the Contracting Activity)

3. REQUIREMENTS

3.1 Manufacture and Inspection. The flare shall be manufactured, examined, tested, and packed in accordance with (IAW) contract documents, drawing list DL 201825310, detail specification DTL 201825313, appendix A, and this specification.

3.2 Classification of Requirements. The requirements for the flare are classified herein as follows:

REQUIREMENTS PARAGRAPH

First Article Sample 3.3

Performance and Product Characteristics 3.4

Physical Characteristics and Examinations 3.5

3.3 First Article Sample. Unless otherwise specified in the contract or order, a first article sample of flares shall be prepared and tested IAW Table 1 to begin production or after any break in production greater than 45 calendar days. The flares, their components and all materials shall be of a single type, grade, class, size and composition and shall comply with all applicable provisions of this document and the contract. The sample shall be manufactured using approved production methods.

3.4 Performance and Product Characteristics. The flares shall meet the acceptance criteria for performance and product characteristics as required by the contractual documents, applicable drawings, detail specification DTL 201825313, appendix A and this specification.

Testing shall be performed in the sequence listed in Table I.

Table I. Inspection Plans

EXAMINATION AND TESTS FIRST ARTICLE

SAMPLING PLANS

INSPECTION LOT SAMPLING PLANS

Test Sequence1 Sample

Size13

Acceptance

Criteria2&3

Plan4 Sample

Size

Acceptance

Criteria2&3 V A B

Examination and Workmanship

(4.6 & 3.5) 150

Flares5 Ac 0 Re 1 X X X

(V) 120

(A) 60

(B) 60

Flares5

Ac 0 Re 1

X-ray Test (4.5.2.1)14

Sealing Test (4.5.1.1)14

Temperature and Humidity

Test (4.5.2.2)

Vibration Test (4.5.2.3)

X-ray Test (4.5.2.1)

Static Function Test

(4.5.1.3.1)( acceptance criteria, (3.4.1.2), Static Function has requirements a, b, c, & d))

Flares10

Ac 0 Re 1

Ac 0 Re 1

(a&b) Ac 0 Re 1

(c) Ac 1 Re 2

(d) Ac 1 Re 2

X X

(V) 60

Flares12

(A) 60

Flares12

Ac 0 Re 1

(a&b) Ac 0 Re 1

(c) Ac 1 Re 2

(d) Ac 1 Re 2

X-ray Test (4.5.2.1)14

Sealing Test (4.5.1.1)14

Static Function Test

(4.5.1.3.1) (acceptance criteria, (3.4.1.2), Static Function has requirements a, b, c, & d)

Flares10

Ac 0 Re 1

Ac 0 Re 1

(a&b) Ac 0 Re 1

(c) Ac 0 Re 1

(d) Ac 1 Re 2

X (B) 60

Flares12

Ac 0 Re 1

Ac 0 Re 1

(a&b) Ac 0 Re 1

(c) Ac 0 Re 1

(d) Ac 1 Re 2

IR Output and Thrust Test

(4.5.1.2) at Vendor Facility (acceptance criteria, (3.4.1.1), IR performance has requirements a, b, & c.

acceptance criteria, (3.4.1.1), thrust performance has requirements d & e)

40 IR

Test

Units

Min.6

(a,b,&c) Ac 0

Re 1

(d&e) Ac 0 Re

X X X

(V) 20

(A) 60

(B) 60

IR Test

Units

Min. 7,8,9

(a,b,&c) Ac 0

Re 1

IR Output and Thrust Test

(4.5.1.2) at Government

Facility (acceptance criteria, (3.4.1.1), IR performance has requirements a, b, & c.

acceptance criteria, (3.4.1.1), thrust performance has requirements d & e)

60 IR

Test

Units

Min.6

(a,b,&c) Ac 0

Re 1

X X

(V) 60

(A) 20

IR Test

Units

Min. 7,8

(a,b,&c) Ac 0

Re 1

Flight Test (4.5.1.3.2)

(acceptance criteria, (3.4.1.3) Aircraft

Flight Test has requirements a, b & c) 60 Flares

(a) Ac 0 Re 1

(b) Ac 0 Re 1

(c) Ac 1 Re 2

X (V) 60

Flares

(a) Ac 0 Re 1

(b) Ac 0 Re 1

(c) Ac 1 Re 2

Aging and Surveillance Units11 None None X X (V) 60

(A) 60 Reference Only

Notes: (next page)

Notes (continued):

1 Tests to be performed in order of indentured sequence within individual blocks and is not intended to indicate block sequence.

2 Ac = Acceptance number for defectives of specified requirements of Section 3.

Re = Rejection number for defectives of specified requirements of Section 3.

3 Acceptance criteria shall apply to characteristics enclosed in parentheses as a group.

4 Test plans applicable to Inspection Lots.

5 Quantity shown represents all fully assembled flares used in FAT and LAT testing, however, when tests are waived or alternate sampling plans are used this quantity shall be adjusted to only fully assembled flares. Quality assurance inspection requirements of the contract shall apply.

6 A sample of IR Test Units or Payload Assemblies (test units) representative of the first article sample shall be a minimum of 100 test units comprised of a minimum of 25 test units from each of at least four consecutive batches of composition and as close to equal quantity from each batch as possible. A test ratio of 15 to 10 Government facility to Vendor facility shall be used for acceptance.

See alternate sampling plan in note 8.

7 FOR PLAN V, IR Test Unit or Payload Assemblies, drawing 201825313, shall be randomly sampled and tested (see drawing 201825350) for lot acceptance testing after the lot population has been defined.

A minimum number of samples shall be selected from each grain batch represented for Government acceptance, see table below. Every third batch will have an additional 3 samples selected for acceptance testing at Vendor facility. Additional samples, one per batch, added to meet the minimum requirement of 60 for Government acceptance for the LAT. Vendor may choose to sample minimum of

1 from every batch instead of three of every third batch for acceptance.

Grain Batch Size Minimum # of IR Test

Samples Per Batch

Under 300 grains 3

300-900 grains 6

See alternate sampling plan in note 8.

8 FOR PLAN A, IR Test Unit or Payload Assemblies, drawing 201825313, shall be randomly sampled and tested (see drawing 201825350) for lot acceptance testing after the lot population has been defined.

A minimum number of samples shall be selected from each grain batch represented for vendor acceptance, see table in note 7. Every third batch will have an additional 3 samples selected for acceptance testing at NSWC Crane. Additional samples, one per batch, added to meet the minimum requirement of 60 for Vendor acceptance for the LAT. If alternate sampling plan is utilized, and if for any reason a batch fails and is removed from the lot, the next acceptable batch in the lot must have 3 units sent for testing at NSWC Crane for acceptance and said batch noted on either the ADC or LATR.

Alternate sampling plan: The following method may be substituted to satisfy FAT or LAT requirements for IR/Thrust sampling for vendor tested samples prior to population of the lot quantity.

The alternate Batch Acceptance Sampling Method shall require random selection of IR Test Units or

Payload Assemblies from each extruded batch of composition (see Table 1 for minimum quantities).

The samples shall be tested for IR. Individual batches will be added to the lot pending the outcome of batch IR/Thrust testing as the final lot is formed. No additional IR/Thrust testing will be required for the vendor tested samples on the lot when the lot population is fully defined using this alternate sampling plan. If individual batches are not added to or removed from to the lot per this sampling plan, the applicable FATR or LATR shall include a copy of the IR/Thrust test results as well as an explanation as to why the batch was not included in or was removed from the lot. Reporting a batch in this way will not be considered a failure. While in B Plan testing, if four consecutive batches are removed or not added in this manner, three samples from the next acceptable batch shall be sent to the

Government for acceptance testing.

9 FOR PLAN B, IR Test Unit or Payload Assemblies, drawing 201825313, shall be randomly sampled and tested (see drawing 201825350) for lot acceptance testing after the lot population has been defined.

A minimum number of samples shall be selected from each grain batch represented for vendor acceptance, see table in note 7.

See alternate sampling plan in note 8.

10 Full up units sent to NSWC Crane for function testing for acceptance. All associated testing will be performed at government facility. To include X-ray test, seal test and conditioning as required.

11 Test unit quantities for Aging and Surveillance (A&S) shall be 60 units for any V Plan lot

(see 4.4.1.1) and 60 units for every A Plan Lot thereafter (see 4.4.1). Units will be shipped to

NSWC Crane. These units are for government information only and not for lot acceptance but should represent the lot and be capable of passing LAT requirements. These units are not considered to be deliverable units and are not counted towards the lot total.

12 If contractor is unable to capture the requirement of 3.4.1.2.c, the contractor is allowed to perform function testing using an alternate test method, see section 4.5.1.3.1.

13 No-test conditions must be concurred with by the Government procuring activity or designated representative.

• If during an IR test, all samples from any batch are all considered a no-test, contact the

Government procuring activity.

• A maximum of 5 no-tests are allowed per First Article or production lot for function testing and 5 no-tests are allowed for IR testing.

Approved no-test conditions are as follows;

Operator or Equipment failure.

• Match not lighting (replace match and retest same asset)

• Power loss

14 Seal test and X-ray test may be performed in reverse order as required.

15 Government testing shipping information.

Navy NSWC Crane

Bldg. 2390

300 Highway 361

Crane, In 47522-5001

Aging and Surveillance shipping information.

W53XMD

CONDITION CODE “D”

MARK FOR FG5 ACCOUNT OP6

CRANE ARMY AMMUNITION ACTIVITY

BLDG 2074 300 HWY 361

CRANE, IN 47522-5099

China Lake flight test shipping information.

NMC DET CHINA LAKE

Attn: Kathryn Mcnabb

Building 31060

1 Administration Circle

China Lake, CA 93555-6001

3.4.1 Performance.

3.4.1.1 Infrared and Thrust Output. The Payload Assembly (Dwg: 201825313) shall light and meet the static infrared intensity specified and the thrust specified in the classified Addendum to this document when tested IAW 4.5.1.2. All infrared and thrust output data shall be classified IAW the Security Classification Guide called out in the contract and DD254.

3.4.1.2 Static Function. The MJU-76/B shall exhibit the following performance characteristics over a temperature range of –65±5°F to +171±5°F when tested in accordance with paragraph 4.5.1.3.1. The ejection sequence shall be initiated and the payload assembly with igniter expelled by pressure from a CCU-145/A, BBU-35A/B, or equivalent impulse cartridge:

a. The ejection velocity of the payload with igniter assembly shall be no less than 60 ft/sec.

b. The payload with igniter assembly shall separate from the flare case and shall ignite as defined by grain ignition delay time in paragraph 6.1.3 within 150 ms after payload and igniter assembly exits case.

c. The Payload Assembly shall not experience a significant variation in visual display of the pyrotechnic combustion for a minimum of 0.5 seconds following ignition as a result of (1) the payload assembly rupturing or deflagrating; (2) the pyrotechnic grain burning through the circumference of housing; or (3) the pyrotechnic grain burning through the nose of the payload assembly.

d. During all testing, empty aluminum case shall be removable from the infrared countermeasure magazine (MJU-11/A, MJU-33/A, or equivalent) without the use of tools. If tools are needed, the extraction force required to remove the case shall be recorded and reported in the test report in pound force units.

3.4.1.3 Aircraft Flight Function. The MJU-76/B shall exhibit the following performance characteristics when tested per Table I IAW paragraph 4.5.1.3.2.

a. The Payload Assembly shall have an ignition delay time of less than 150 ms when tested IAW paragraph 4.5.1.3.2. Visible blossoming of the plume from the nozzle end of the flare assembly (pyrotechnic grain ignition) shall immediately follow deployment of the igniter assembly (see 6.1.3).

b. The Payload Assembly shall not experience a significant variation in visual display of the pyrotechnic combustion for a minimum of 0.5 seconds following ignition as a result of (1) the payload assembly rupturing or deflagrating; (2) the pyrotechnic grain burning through the circumference of housing; or (3) the pyrotechnic grain burning through the nose of the payload assembly when tested IAW paragraph 4.5.1.3.2.

c. During all testing, empty aluminum case shall be removable from the infrared countermeasure magazine (MJU-11/A, MJU-33/A, or equivalent) without the use of tools. If tools are needed, the extraction force required to remove the case shall be recorded and reported in the test report in pound force units.

3.4.2 Durability and Environmental

3.4.2.1 Temperature and Humidity. The flare shall withstand temperature and humidity without coming apart, burning or exploding and meet the requirements paragraph 3.5.2 and 3.4.1.2 when tested IAW 4.5.2.2.

3.4.2.2 Vibration. The flare shall withstand vibration without coming apart, burning or exploding and meet the requirements paragraph 3.5.2 and 3.4.1.2 when tested IAW

4.5.2.3.

3.5 Physical Characteristics and Examinations.

3.5.1 Workmanship. External surfaces on each MJU-76/B shall be free of dirt, chips, grease, corrosion, foreign material, dents, gouges, burrs and other surface defects. Exterior surface coatings shall be continuous. The preservation, packaging, packing and marking of the MJU-76/B shall be in accordance with the drawing 201825310 and packaging drawing

201825325 when inspected IAW 4.6.1 and 4.6.2.

3.5.1.1 External Dimensions. The external dimensions of the MJU-76/B shall be

IAW 201825310.

3.5.2 X-ray. The flare shall show no evidence of missing or broken components, degraded components (e.g. ignition pellets), foreign material, improper assembly or displacement of components when tested IAW 4.5.2.1.

3.5.3 Seal Integrity. The flares shall not leak, which is evidenced by a steady stream of small air bubbles (>5 bubbles per 30 seconds), when leak tested IAW 4.5.1.1. Acceptance criteria will be provided upon Government approval of alternate seal integrity test IAW

4.5.1.1.1. Leak testing is not required on samples that have been exposed to environments per Section 3.4.2.

4. VERIFICATION

4.1 Responsibility for Inspection. Unless otherwise specified in the contract or purchase order, the contractor is responsible for the performance of all inspection requirements and testing as specified herein. Except as otherwise specified in the contract or purchase order, the contractor may use their own or any other facilities suitable for the performance of the inspection requirements specified herein, once said facility is approved by the cognizant design authority.

The government reserves the right to perform any of the inspections set forth in the specification where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

4.2 Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. First article sample (4.3).

b. Quality conformance inspection (4.4).

4.3 First Article Sample. The contractor shall produce the required number of flares, as specified in Table I, for examination, testing, evaluation. Any production of the item prior to government approval of the First Article Test Report shall be at the contractor’s risk. The First

Article Sample shall be tested by the contractor using approved testing plan and procedures, unless otherwise specified.

4.4 Quality Conformance Inspection. Any inspection lot of flares shall be homogeneous. The following conditions shall be met:

a. Units shall be manufactured at one location.

b. Any break in production that exceeds 120 hours and does not otherwise prompt a new lot number shall require notification of the government procurement activity; notification shall include reason for the stoppage and the expected duration and may request permission to continue current lot. Any break in production greater than 230 hours shall be cause for a new lot.

c. Any break in production because of any significant unplanned technical, component, tooling, machine, or facility anomaly shall be cause for a new lot. Anomalies that only require a controlled shutdown with no facility or machine repairs are not considered significant. Individual circumstances may be interpreted by cognizant design authority.

d. Any change in status of shelf life, components, materials, suppliers, or production methods shall be cause for a new lot. These changes shall be recorded on the ammo data card.

e. Inspection lot size shall be 1,680 to 10,080; not including test samples.

f. Grain composition batches shall be identified by batch numbers, preceded by the letter

“G” and containing the year (last two digits) and month (Jan = A, Feb = B, Mar = C, Apr =

D, May = E, Jun = F, Jul = G, Aug = H, Sep = J, Oct = K, Nov = L and Dec = M) of production and commencing with number B00001 and continuing in sequence until production of the flare contract is complete. The grain composition batch numbers shall be assigned after acceptance for extrusion. All grains extruded from these batches shall retain individual batch identity.

4.4.1 Sampling. Sampling, examinations, testing and acceptance of inspection lots shall be performed IAW the DOD Test Method Standard MIL-STD 1916, and as specified in the steps that follow:

a. Upon starting production or delivery of an acceptable First Article sample, as applicable, all inspection lots shall be examined, tested in sequence and accepted in conformance with Table I.

b. After an acceptable completion of a First Article or when a First Article is waived, the first inspection lot will require Plan V testing. Plan V testing will continue until an inspection lot has satisfied the Plan V testing requirements. After an acceptable Plan V test, the next inspection lot will require Plan A testing. If the Plan A fails any portion of testing, Plan V will be required for the next inspection lot. This routine is required until consecutive Plan V and Plan A have been satisfied.

c. After acceptable completion of a Plan V lot followed by a Plan A lot, sampling plan proceeds to a five, five, seven, then ten sample set of Plan B lots with one randomly selected Plan A per sample set. Plan A lots are to be selected by a DCMA representative.

Acceptable completion of all testing is needed to proceed to the next sampling set.

e.g. V, A;

B, B, B, A, B;

B, A, B, B, B;

B, B, A, B, B, B, B;

B, B, B, A, B, B, B, B, B, B

A, B, B, B, B, B, B, B, B, B

i. Upon failure of a lot for Static Function requirements (3.4.1.2 a, b, or c), the sampling plan will restart. Upon failure of a lot other than Static Function requirements (3.4.1.2 a, b, or c), a Plan A is required until a Plan A is satisfied, then the five, five, seven, then 10 sample set of Plan B lots with one randomly selected Plan A per sample set applies. Any submitted RFV or ECP for lot acceptance shall clearly delineate any request to continue or restart the sampling plan.

d. Lots are to be submitted and accepted in consecutive order.

e. Upon completion of a lot and selection of the sample, the government shall be notified.

NOTES:

1. Although inspection lots may be tested and accepted IAW Plan B tests, all inspection lots must be capable of passing all Plan A tests.

2. The Government reserves the right to perform any or all tests on any inspection lot if deemed necessary to assure delivery of acceptable supplies.

4.5 Tests. Random samples of flares and payload assemblies shall be selected and tested as specified in 4.3 or 4.4, as applicable.

4.5.1 Performance.

4.5.1.1 Seal Integrity Test. To ensure that the flares maintain performance characteristics in an operational environment, gross leak testing must be performed IAW MIL-STD-331

Rev D Sections C8.5.2.1 and C8.7.5, Bubble Method, except as noted below.

NOTE: The completed flare unit is referred to as a “fuze” within MIL-STD-331 Rev D.

a. Suitable leak test liquid shall be water at a temperature between 60°F-80°F. Any other test liquid may be used once approved by the Cognizant Design Authority.

b. A wetting agent may be used.

c. Occluded air on the surface of the unit or a small amount of air trapped between the end cap seal and the end of the case of the unit shall not be considered defective units.

CAUTION

The water tank should be equipped so that the flare must be raised above the water level while still under vacuum before releasing the vacuum and removing the flare.

4.5.1.1.1 Alternate Seal Integrity Test. Any alternate proposed leak tests shall require approval prior to use by the government procurement activity.

4.5.1.2 Infrared and thrust output function static test.

a. The MJU-76/B Payload Assembly shall be tested in a qualified radiometric test facility

IAW Appendix A. The payload assemblies are functioned at ambient temperature conditions. The payload assemblies are functioned one at a time in order to collect the data necessary to evaluate the flares.

b. The relative unclassified test data for radiometric intensity and thrust versus time shall be provided electronically to the government procurement activity. Defectives are units failing to meet the IR and thrust requirements of 3.4.1.1., still to be reported on applicable test report CDRL.

c. Classified raw data files to include the IR excel calibration file(s) generated shall be provided to the Government procuring activity per Government direction within 45 days of completion of lot acceptance testing.

4.5.1.3 Function Testing.

4.5.1.3.1 Static Function Test. The MJU-76/B shall be functioned using a CCU-

145/A or BBU-35A/B, or equivalent impulse cartridge. 4.5.1.3.1.1. or 4.5.1.3.1.2 satisfy the function testing requirement.

4.5.1.3.1.1. Case Ejection Test. The MJU-76/B shall be functioned using Case

Ejection Test Fixture DEV23122, Figure 1. A tether has been found beneficial to retain the ejected Case and Cap Assembly during functioning. When loading the

Case Ejection Test Fixture, excessive force should not be required.

a. The fixture (DEV23122) shall be securely mounted to a rigid object at an angle 45

± 5 degrees from horizontal. The rigid object, recommended to be the ground or a concrete pad, must generate minimal oscillation to prevent ringing within the thrust data collection. Figure 3 shows how the witness board (with witness lines in 1.0 ft segments) shall be mounted.

T0 (Time 0) is the first segment and shall be located 10.5-11.5 inches from the end of the Case Ejection Test Fixture. T0 is recorded when the Cap Enclosure of the

Cap Assembly reaches the leading edge of this first line on the witness board. T0 is used to determine the ejection velocity.

T1 (Time 1) (which is optional) is recorded when the Cap Enclosure of the Cap

Assembly reaches the leading edge of this second line on the witness board.

T2 (Time 2) is recorded when the Cap Enclosure of the Cap Assembly reaches the leading edge of the third line on the witness board.

See Figure 3 for example of T0 and T2 determinations.

b. Ignition delay time (para 6.1.3.1) is determined by calculating the difference between T0T and T1T, shown in Figure 2. The load cell shall be rated for 2,000 pounds. The thrust force shall be recorded using a data acquisition system set at

3,000 samples per second minimum.

T0T (Thrust Time 0) is the highest thrust peak within 50 milliseconds.

T1T (Thrust Time 1) is the highest thrust peak after 50 milliseconds.

If the ignition delay is unable to be obtained via above method, visual ignition delay time may be used IAW 6.1.3.1

c. Ejection Velocity is determined by dividing the distance traveled (2ft) by the difference between T2 (Time 2) and T0 (Time 0). Ejection Velocity = 2ft/(T2 - T0)

= ft/s

If T2 cannot be recorded due to early ignitions and possible whiting out of the high-speed video, T1 can be used and the velocity can be determined over 1ft.

d. The flare sample shall be divided up with 2/3 at -65±5°F, and 1/3 at 171±5°F for

FAT or LAT. The flares shall be temperature conditioned (–65±5°F and/or 171±5°F) with impulse cartridges and the cap assemblies for a minimum of 4 hours prior to function. Each group of flares shall be tested within 10 minutes of removal from the conditioning chamber.

NOTE: An impulse cartridge can be installed inside the flare and conditioned for a minimum of 4 hours outside the fixture, as long as the impulse cartridge/flare assembly can be installed into the fixture and tested within 10 minutes of removing the impulse cartridge/flare assembly from the conditioning chamber.

The impulse cartridge should not be handled during the installation of the impulse cartridge/flare assembly into the fixture. The flare may be conditioned with the test cap.

e. There shall be 1 High Speed camera utilized to capture the test. The camera shall be recorded at 3000 frames/sec minimum for 0.5 second minimum. Camera frame should be located in such a way as to not have a complete ‘white out’ during function. Entire burn should be captured. A secondary camera at a lower frame rate to capture full burn duration may be used.

f. Defectives are payload assemblies or grain/housing sub-assemblies failing to meet the requirements of. Paragraph 3.4.1.2

Figure 1. Case Ejection Test Fixture

Figure 2. Calculation Method for Ignition Delay Time

Figure 3. Calculation Method for Ejection Velocity

4.5.1.3.1.2 Payload Ejection Test. The MJU-76/B shall be functioned using an

ALE-40, -45, -47 or equivalent Dispenser and a Magazine (MJU-11/A or MJU-33/A or equivalent).

a. The magazine shall be mounted to a test platform so that the firing orientation is upward at an angle 50 ± 10 degrees from horizontal. Figure 4 shows how the witness board (with witness lines in 1.0 ft segments) shall be mounted with respect to the magazine during static function.

T0 (Time 0) is the first segment and shall be located 7.25-8.25 inches from the end of the dispenser magazine. T0 is recorded when the nose of the payload assembly reaches the leading edge of this first line on the witness board. T0 is used to determine the ignition delay time (see para 6.1.3.2) and to determine the ejection velocity.

T1 (Time 1) (which is optional) is recorded when the nose of the payload assembly reaches the leading edge of this second line on the witness board.

T2 (Time 2) is recorded when the nose of the payload assembly reaches the leading edge of the third line on the witness board.

T3 (Time 3) is recorded when the grain ignites.

See Figure 5 for example of T0, T2, and T3 determinations.

b. Ignition delay time (para 6.1.3.2) is determined by calculating the difference between T3 (Time 3) and T0 (Time 0) and shall be reported in milliseconds (ms).

c. Ejection Velocity is determined by dividing the distance traveled (2ft) by the difference between T2 (Time 2) and T0 (Time 0). Ejection Velocity = 2ft/(T2 - T0)

= ft/s

If T2 cannot be recorded due to early ignitions and possible whiting out of the high-speed video, T1 can be used and the velocity can be determined over 1ft.

d. The flare sample shall be divided up with 2/3 at -65±5°F, and 1/3 at 171±5°F for

FAT or LAT. The flares shall be temperature conditioned (–65±5°F and/or 171±5°F) with impulse cartridges in the magazine for a minimum of 4 hours prior to function.

Each group of flares or magazine shall be tested within 10 minutes of removal from the conditioning chamber.

NOTE: An impulse cartridge can be installed inside the flare and conditioned for a minimum of 4 hours outside the magazine, as long as the impulse cartridge/flare assembly can be installed into the magazine and tested within 10 minutes of removing the impulse cartridge/flare assembly from the conditioning chamber.

The impulse cartridge should not be handled during the installation of the impulse cartridge/flare assembly into the magazine.

e. The payload assembly or Payload Sub-Assembly (igniter released) shall be allowed to travel in an uninhibited flight path as required to collect the necessary performance data.

f. There shall be 3 High Speed cameras utilized to capture the test displaying the following approximate distances: 0 to 4ft, 0 to 12ft, 0 to 50ft. Cameras capturing 0 to

4ft and 0 to 12ft shall be recorded at 3000 frames/sec minimum. The Cameras capturing 0 to 50ft shall be recorded at 1000 frames/sec minimum.

g. There shall be 3 Standard Video rated at a minimum frame rate of 30 frames/sec utilized to document the test.

• Camera #1 shall be located approximately 15 to 20 yards behind the dispenser capturing the functioning and flight of the payload assembly for the first 30 to 50 feet.

• Camera #2 shall capture the function and flight of the payload assembly or grain/housing sub-assembly for approximately the first 100 feet. The camera should face the witness board.

• Camera #3 shall be located far enough away to capture greater than 0.5 second of the flight of the payload assembly or Payload Sub-Assembly in an effort to document and verify the requirements in paragraph 3.4.1.2

• Camera set up to be approved by cognizant design authority.

h. Defectives are payload assemblies or grain/housing sub-assemblies failing to meet the requirements of. Paragraph 3.4.1.2

Figure 4. MJU-76/B Ejection Velocity Test Setup

Figure 5. MJU-76/B Ejection Timestamp Determination Example

4.5.1.3.2 Aircraft Flight Function Test. The MJU-76/B shall be tested by the

Government from an aircraft using a CCU-145/B, BBU-35A/B, or equivalent

Impulse Cartridge. The payload assembly with igniter shall be dispensed from an aircraft at 450 ± 50 knots indicated air speed (KIAS) and 5,000-10,000 ± 1000 ft altitude above sea level (MSL). Photographically record the payload assembly ejection from the flare canister to record ignition delay and the trajectory of the grain/housing sub-assembly. Record the trajectory of the Payload Sub-Assembly for a minimum 0.5 second. A minimum frame rate of 200 frames per second shall be used. Defectives are grain/housing sub-assemblies failing to meet the requirements of 3.4.1.3 a, b & c. Failure of the impulse cartridge or dispenser system shall not constitute a defective payload assembly. The flight test results must be reported to

T Timestamp

T Timestamp

T Timestamp

Leading edge of 1st line

Grain ignition, full stable plume

Leading edge of 3rd line the Government Procuring Activity within 60 days after receipt of samples if flight test data is to be used for acceptance or rejection of the representative lot.

4.5.2 Durability and Environmental Tests.

4.5.2.1 X-ray Test. Each MJU-76/B shall be subjected to 0 and 90 degree x-ray examination in accordance with ASTM E1742 or other Government approved procedure(s). The 0 and 90 degree x-ray shall be used as a means of acceptance.

Flares failing to meet the requirements of 3.5.2 are considered defectives. Refer to

Figures 6 & 7 inspection for detail.

Figure 6. MJU-76/B X-Ray – Major Component Identification (0°)

Figure 7. MJU-76/B X-Ray – Major Component Identification (90°)

4.5.2.2 Temperature and Humidity Test. The flares shall be subjected to one 14 day temperature and humidity cycle as prescribed in Test C1 of MIL-STD-331 Rev D. The flares shall be tested bare on the shelf. Flares failing to meet the requirements of 3.4.2.1 are considered defective.

4.5.2.3 Vibration Test. The MJU-76/B shall be subjected to a total of 9 hours (three axes (vertical, first transverse, and second transverse), and three temperatures) of random vibration in accordance with the requirements described in MIL-STD-810 Rev. H, Test

514.8, Category 12 (Jet Aircraft) and Category 13 (Propeller Aircraft), Procedure I without isolators. The test levels are shown in Figure 8. The flares shall be loaded into a

MJU-11A magazine or equivalent and secured to the vibration fixture depicted in Figure

9 and 10. The average of two accelerometers, as shown in Figure 10, shall be used to control the vibration table inputs in accordance with the vibration spectra shown.

Vibration time at each axis shall be one hour at ambient, one hour at +171°F±10°F, and one hour at -65°F±10°F. Preconditioning at each temperature shall be a minimum of two hours. Flares failing to meet the requirements of 3.4.2.2 are considered defective.

FIGURE 8. Random Vibration Envelope

Figure 9. Vibration Fixture 12255-11J00004

FIGURE 10. Vibration Test Setup

4.5.3 Magnesium Hydroxide Test. Each blend of ignition composition (dwg 201825344) shall be tested IAW DTL 201825313 4.2.3. Percent by weight shall be reported in each associated

FAT/LAT report. Results are valid for no more than 30 days prior to Flare Assembly (DTL

201825313 3.3.6); furthermore, results are only valid if blend is stored within a sealed desiccated container when not in use. Any blends of ignition composition which, once tested, exceed 2.5% by weight of Mg(OH)2 (Magnesium Hydroxide) are deemed unacceptable.

4.5.4 Composition Burn Rate Tests. The loose grain and ignition comps shall be tested per batch

IAW DTL 201825313 4.2.1 and 4.2.2. Burn rate test results shall be reported in each FAT/LAT report.

4.5.5 Retention.

4.5.5.1 End Cap Test. The End Cap shall have a retention value of 150-300 lbs when tested IAW DTL 201825313. End Cap Test results shall be reported in each FAT/LAT report.

4.5.5.2 Nose Cap Test. The Nose Cap shall have a retention value of 600 lbs minimum when tested IAW DTL 201825313. Nose Cap Test results shall be reported in each

FAT/LAT report.

4.5.5.3 Igniter Wire Spring Connector Test. The wire springs shall have a retention range of 18-50 lbf when tested IAW DTL 201825313. Retention forces for lots of springs used shall be reported in each FAT/LAT report.

4.6 Flare Examinations.

4.6.1 Flare Examinations. Examinations shall be made to ascertain that the flares meet the requirements of drawing 201825310, DTL 201825313, appendix A and this specification. Only flares containing no defects shall be used for further testing or returned to the lot.

4.6.2 Packaging, Packing, and Marking Examinations. The packaging, packing, and markings shall conform to Section 5 of this specification.

5. PACKAGING

5.1 Packing and Marking. The preservation, packing and marking shall be IAW 201825325 and applicable contract documents. Palletization using wood (19-48-4116-20PA1002) or steel

(8601635) pallets shall be per contract documents instructions.

5.2 Ammunition Data Card. Data cards shall be prepared in accordance with MIL-STD-1168 and the WARP User Manual.

5.2.1 Ammunition Data Card Content. Energetic mixtures including energetic materials (pyrotechnics, propellants, explosives) and their constituents shall be entered using the actual manufacturing activity’s part number, lot number, and manufacturing date.

Components, sub-components, and materials of end items shall also be entered using the actual manufacturing activity’s part number, lot number, and manufacturing date. The ADC data and information entered into WARP for all materials and components shall stand alone for traceability to the actual manufacturing activity’s information (manufacturing part number, manufacturing date, manufacturing activity’s lot number, etc.).

5.3 Ammunition Lot Number. Ammunition lot number shall be in accordance with MIL-

STD-1168.

5.3.1 Ammunition Lot Number Start Date. Start of manufacturing with respect to MIL-

STD-1168 section 4.1.2 shall be defined as assembly of the first grain into a case (drawing

201825310) commonly referred to as “final assembly” or “flare assembly”.

5.3.2 Grain Creation. Grains shall be extruded no more than 14 days after completion of the blending of Grain Chemical Composition drawing 201825346.

5.3.3 Final Assembly. Final assembly of grains into aluminum body tubes per drawing

201825313 and payload assembly into case per dwg 201825310 shall occur no more than 90 calendar days after extrusion of a blend batch is complete.

5.4 Acceptance and Description Sheets. Documentation for each lot submitted shall include

Acceptance and Description Sheets IAW DI-MGMT-81978 (MIL-STD-1171) for propellants explosives and/or chemical materials used in the end item or components.

6. NOTES

6.1 Definitions.

6.1.1 Flare. The MJU-76/B is an expendable infrared (IR) countermeasure for aircraft applications. The payload assembly, when launched from an aircraft, will attain a trajectory similar to the aircraft’s and will provide an IR output to improve the aircraft’s capability to counter or decoy IR threats.

The MJU-76/B has approximately a 1” x 1” square cross section and is approximately 8” long. It is ejected from an infrared countermeasure magazine (MJU-11/A, MJU-33/A or equivalent) housed within an infrared countermeasure dispenser (ALE-40, -45, or -47 or equivalent). The dispenser transmits a firing pulse into the pyrotechnic squib (impulse cartridge; CCU-145, BBU-35 or equivalent) installed in the base end of the flare case. The impulse cartridge ejects the payload assembly from the flare case. The impulse cartridge lights a pyrotechnic pellet within the igniter assembly. Once the aft end of the flare clears the case, the flame from the igniter pellet is exposed to the main pyrotechnic grain of the payload assembly. The main flare grain ignites. Ignition of the main pyrotechnic grain displaces the igniter assembly and provides thrust and infrared energy (intensity).

6.1.2 Grain Composition Batch. The term “grain composition batch” is defined to be an accumulation of grains made under one of the following two conditions: 6.1.2.1 and

6.1.2.2.

6.1.2.1 One condition of a batch is defined by a single blend (Dwg 201825346) of raw materials.

6.1.2.1.1 Batch size between 100 and 900 grains.

6.1.2.1.2 Grains created on a single extruder.

6.1.2.1.2.1 Grains shall be extruded under the same process control parameters or set points.

6.1.2.1.2.2 Grains extruded during a single uninterrupted shift, when operators don’t have any extrusion parameter adjustments.

6.1.2.1.2.2.1 Mixing, blending, granulation, and extrusion of grains shall be overseen by the same operator/team with a single 12-hour maximum shift for each respective processing step.

6.1.2.1.2.2.2 Routine scheduled break periods less than 2 hours (e.g. smoking, 10-

20 minute, lunch, administrative meeting) are not to be considered an interruption.

6.1.2.1.2.2.3 Routine interruptions such as a thunderstorm are not cause for a new batch as long as other parameters are met.

6.1.2.2 The second condition of a batch is defined where multiple blends (Dwg

201825346) are mixed or blend size is of insufficient size to be a viable batch under condition one. These multiple blends shall maintain the same nominal formulation.

6.1.2.2.1 Maximum batch size is 900 grains.

6.1.2.2.2 Any intentional ingredient variation shall constitute a new batch, including intentional variation of fine and course magnesium.

6.1.2.2.3 Any unintentional ingredient variation (e.g. inherent weight measurement error) between mixes or blends shall be less than 0.25% by weight per ingredient.

6.1.2.2.4 Individual chemical constituents (e.g. Mg, PTFE, co-polymer) shall be from the same manufacturer lot. Processing ingredients (e.g. acetone, ISO-hexane, etc) do not require lot traceability.

6.1.2.2.5 Mixes or blends of grain composition (Dwg 201825346) shall be processed under the same control parameters or set points. For example parameters such as mixing/blending times, solvent content, vacuum time, drying time, RPM, and/or pre-heat time and temperature shall be maintained within a grain composition batch.

6.1.2.2.6 Grains created on a single extruder.

6.1.2.2.6.1 Grains shall be extruded under the same process control parameters or set points.

6.1.2.2.6.2 Grains extruded during a single uninterrupted shift, when operators don’t have any extrusion parameter adjustments.

6.1.2.2.6.2.1 Mixing, blending, granulation, and extrusion of grains shall be overseen by the same operator/team with a single 12-hour maximum shift for each respective processing step.

6.1.2.2.6.2.2 Routine scheduled break periods less than 2 hours (e.g. smoking, 10-

20 minute, lunch, administrative meeting) are not to be considered an interruption.

6.1.2.2.6.2.3 Routine interruptions such as a thunderstorm are not cause for a new batch as long as other parameters are met.

6.1.2.3 Further interpretations/definitions can be approved by government cognizant design authority.

6.1.3 Ignition Delay Time. The term “Ignition Delay Time” shall be defined as one of the following.

6.1.3.1. The time from when the case is ejected from the case ejection fixture to the indication of onset of intensity. Intensity output from the main grain of the Payload

Assembly does not begin until the Igniter Assembly is jettisoned from the Payload Assembly with Igniter Assembly. First indication of intensity output from the main grain is defined by visible blossoming of the plume in the video (reference Figures 2, 3 and 5). Formation of a thrust plume at the nozzle end of the flare shall immediately follow the first indication of intensity.

6.1.3.2. The time from when the Payload Assembly with Igniter Assembly exits the case to the indication of onset of intensity. Intensity output from the main grain of the Payload

Assembly does not begin until the Igniter Assembly is jettisoned from the Payload Assembly with Igniter Assembly. First indication of intensity output from the main grain is defined by visible blossoming of the plume in the video (reference Figure 4 and Figure 5). Formation of a thrust plume at the nozzle end of the flare shall immediately follow the first indication of intensity.

6.2 Conflicting Requirements. Refer in writing to the cognizant design authority for clarification of any conflicting requirements arising between this specification and any other specifications, publication, or drawing listed herein.

6.3 Safety Precautions. The safety precautions specified in DOD 4145.26M should be observed during loading, assembly, testing and handling operations. The use of this manual shall not be construed as to relieve the contractor or manufacturer of responsibility for the safety of their operations.

6.4 Cognizant Design Authority. The term “Cognizant Design Authority” is defined as the

Government Program Office that has current design responsibility as noted by the current CAGE

CODE of the Technical Data Package. Any communication to the Cognizant Design Authority should be transmitted through the contract PCO.

6.5 Government Procuring Activity. The term “Government Procuring Activity” is defined as the Government Program Office that is running the contract. Any communication to the

Government Procuring Activity should be transmitted through the contract PCO.

APPENDIX A

INSTRUCTIONS FOR THE IR OUTPUT AND THRUST ACCEPTANCE TESTING OF

THE MJU-76/B INFRARED COUNTERMEASURE FLARE

A1. INTRODUCTION

This appendix is provided to describe the facility, test setup, function procedures, and data acquisition process to be used to conduct infrared output and thrust lot acceptance tests of the MJU-76/B payload assembly, see Figure 11. Contractors are REQUIRED to correlate their Data Acquisition System with the government facility at Crane Division, Naval

Surface Warfare Center, Crane, Indiana. Using a different fixture design and/or test equipment setup for performing any testing must be pre-approved by Cognizant Design

Authority.

A2. FACILITY

The facility and equipment described herein as a reference are located at the Crane

Division, Naval Surface Warfare Center in Building 366. Exhaust fans are used to evacuate smoke after the function of each flare.

A3. TEST SETUP

The payload assembly shall be mounted onto the Static IR/Thrust Test Assembly (Dwg:

DEV22065) in a position that places its longitudinal axis perpendicular to the IR detector and in-line with the thrust load cell as shown in Figure 12. The thrust test assembly shall be calibrated within 48 hours of the test. The thrust measurement equipment and parameters listed in OES 4000 shall be utilized for the test. Deviations from the equipment or parameters listed in OES 4000 shall require approval by the Cognizant

Design Authority and documented in the test report.

Two IR Detectors will be set perpendicular to the test sample at a distance of 35.0 ± 0.5 meters of a known distance to nearest cm (inputted into software upon calibration) and equipped with appropriate band-pass filters as specified in the classified addendum. The radiometers shall be calibrated with a 1000C blackbody prior to performing lot acceptance testing (OES-4000). The approved calibration process shall be performed within 48 hours prior to testing being performed. Any alteration of the test equipment outside of the initial set up process (ie. equipment is moved) requires re-calibration before testing resumes. For questions regarding when calibration is required, contact cognizant design authority. See Figure 13, for typical detector setup relative to the test assembly.

A4. FUNCTION PROCEDURE AND DATA ACQUISITION

The payload assembly…