Statement_of_Work_Drawings_Range_G_HPSA_Rev2.pdf

4 April 2018

Range G High Pressure Section Adapter Statement of Work

For Test Systems Sustainment Asset Management Branch, Arnold AFB, Tennessee

1.0 Background/Introduction. The Range G facility is in need of a replacement barrel section known as the High Pressure Section Adapter (HPSA) to be fabricated by vendor per specifications via an existing drawing. Difficulty in boring extremely straight close tolerance bores over long barrels is a specialized machining operation that few manufacturers possess thus the barrels are to be fabricated by a vendor with a proven record of this capability.

2.0 Scope of Task. The contractor shall provide a 144” long HPSA barrel manufactured with nominal 14.99” outer diameters and a 3.300” bore per VG113733E sheet 1 from heat treated 4340 steel material. Specifics for the material, heat treatment, bore straightness, end threads, male and female pilots, and all other fabrication details are included on the drawing and material forging specification. The completed HPSA barrel is to be shipped to AEDC for inspection and eventual installation into the Range G Hypervelocity Launcher Facility.

3.0 Requirements.

Product Code Qty Description

VG113733E

sheet 1 1 Gun Barrel 12 feet long, 15" O.D., with one unthreaded end boss that is 20"

O.D. x 15" long. The bore is 3.300" Per Drawing VG113733 E sheet 1 & 2;

Material 4340 & Material Forging Inspection Per Spec

4.0 Period of Performance.

Delivery Date: 30 October 2018

Distribution Statement C: Distribution authorized to U.S. Government agencies and their contractors;

administrative/operational use; 26 Feb 2018. Other requests for this document shall be referred to AEDC/TSS, 1099 Schriever Ave, Arnold AFB, TN 37389. DESTRUCTION NOTICE—Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

February 23, 1999 Revised March 15 2001

TYPE C3 SPECIFICATION

FOR

MACHINED HIGH PRESSURE SECTION ADAPTER

LAUNCH TUBE FORGING

FOR THE

3.3-INCH G-RANGE LAUNCHER

FOR THE

VON KARMAN FACILITY

ARNOLD ENGINEERING DEVELOPMENT CENTER

ARNOLD AIR FORCE BASE, TENNESSEE 37389

Distribution Statement C: Distribution authorized to U.S. Government agencies and their contractors; administrative/operational use; 26 Feb 2018. Other requests for this document shall be referred to AEDC/TSS, 1099 Schriever Ave, Arnold AFB, TN 37389. DESTRUCTION NOTICE—Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

l. SCOPE

1.1 This specification establishes the requirements for the performance, manufacture, and acceptance of a machined steel forging for use as a section of a launch tube on an hypervelocity range gun.

2. APPLICABLE DOCUMENTS

2.1 Non-Government documents. The following documents form a part of this specification to the extent specified.

2.1.1 Standards.

a. ANSI/ASTM A-370-89, Standard Test Methods and Definitions for

Mechanical Testing of Steel Products.

b. ASI/ASTM A-723/A723M-88, Alloy Steel Forgings for High

Strength Pressure Component Application.

c. ANSI/ASTM E-23-88, Methods for Notched Bar Impact Testing of

Metallic Materials.

d. ANSI/ASTM E-45-87, Practice for Determining the Inclusion

Content of Steel

e. ANSI/ASTM E-112-88, Methods for Determining Average Grain Size.

2.1.2 Drawings.

a. AEDC Drawing No. VG113733, Adapter Details

3. REQUIREMENTS

3.1 Item definition. The High Pressure Section Adapter shall be a tubular steel forging, heat-treated and precision machined to the dimensions and tolerances specified on the drawing. This item, when assembled, will become part of the launch system for a hypervelocity range. It is in this assembly that the model is accelerated and directed downrange.

3.2 Characteristics.

shall be referred to AEDC/TSS, 1099 Schriever Ave, Arnold AFB, TN 37389. DESTRUCTION NOTICE—Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

3.2.1 Performance Characteristics.

3.2.1.1 Mechanical properties. The forging material shall be heat treated to meet the minimum mechanical properties shown in the following table. Test specimens shall be in accordance with Figure 7.1, machined in a direction transverse to the longitudinal axis of the forging.

3.2.2 Physical Characteristics.

3.2.2.1 Drawing The forging shall be machined in accordance with the drawing listed in 2.1.2.

3.2.2.2 Materials. Forging material shall be a vacuum-processed alloy steel which meets the mechanical provisions of paragraph 4. The chemical composition of the forging material shall be determined by the Contractor.

3.2.2.3 Grain size. The austenite grain size of the forging shall be predominantly 6 to 8 and finer, with isolated 4's not to exceed 5 percent, determination made in accordance with ANSI/ASTM E-112-88.

3.2.2.4 Microstructure. The microstructure of the forging shall be a uniform, fine-grained martensite with a maximum of 5 percent evenly distributed ferrite.

3.2.2.5 Bore Straightness The bore of the finished machined launch tube forging shall be free of any steps/ discontinuities and straight within .006 inch per foot of length.

3.3 Workmanship.The heat-treated forging shall be free of seams, segregations, cracks, flakes, dendrites, and injurious stringers that will not be removed during final machining. Machined surfaces, particularly the bore, threads, and pilots, shall be smooth and free of burrs/discontinuities.

No.

Drawing No.

Item

Yield Strength

(ksi)

Impact CVN-RT (ft-lbs.)

Elongation 2

in. gage (%)

Reduction of area (%)

VG113733

Adapter Detail shall be referred to AEDC/TSS, 1099 Schriever Ave, Arnold AFB, TN 37389. DESTRUCTION NOTICE—Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

4 QUALITY ASSURANCE PROVISIONS.

4.1 Responsibility for inspection. The Contractor is responsible for the performance of all tests and inspections to ensure compliance with requirements. The Contractor shall document and provide the Contracting Officer with all inspection and test data prior to shipment of the contract items. The Government will perform the following Procurement Quality Assurance inspection at AEDC.

a. Inspection of all dimensions noted I on the drawings.

4.2 Tests and verifications.

4.2.1 Mechanical properties.

4.2.1.1 Contractor test wafers. Test specimens shall be removed from both ends of the tube forging in accordance with attached Figure 7.1. All test wafers except macro-structure and grain size wafers specified in 4.2.1.2, shall remain a part of each forging until final heat-treating has been completed.

4.2.1.2 Government test wafers. After forging, but before heat treatment, the Contractor shall send a sample wafer of both ends of each forging (see Figure 7.1) to the Contracting Officer for examination of macrostructure, determination of grain size, and inclusion examination. Immediately after heat treatment, the Contractor shall send an additional wafer from both ends of each forging to the Contracting Officer (see Figure 7.1) for confirmation of mechanical properties and microstructure. Drawing numbers shall be affixed to the wafer(s) they represent.

4.2.1.3 Test procedure. The test specimens noted above shall be tested in accordance with ANSI/STM A-370-89 and ANSI/ASTM E-23-

88. The Contractor shall determine the transverse mechanical properties at room temperature including hardness, ultimate tensile strength, yield strength at 0.2% offset, impact strength (Charpy v-notch), percent elongation, and percent reduction of area. The Contractor shall also determine the percent shear of the impact specimens in accordance with the procedures specified in

ANSI/ASTM A-370-89.

4.2.2 Magnetic particle inspection. After final machining, each forging shall be inspected both longitudinally and circumferentially in accordance with

ANSI/ASTM A-723/A723M-88.

shall be referred to AEDC/TSS, 1099 Schriever Ave, Arnold AFB, TN 37389. DESTRUCTION NOTICE—Destroy by any method that will prevent disclosure of contents or reconstruction of the

a. Type of current to be used is a.c. (alternating current).

b. Application of particles shall be either wet or dry.

c. De-magnetization is not required.

4.2.3 Ultrasonic inspection. After heat treatment, inspect each forging in accordance with ASTM A-723/A723M-88. Calibration criteria are as follows:

4.2.3.1 Straight beam (longitudinal) #8 DAC (distance-amplitude correctional).

a. Record any indication exceeding 50% of the reference level.

b. Record any indication exceeding the resultant back reflection.

c. Reject any indication equal to or larger than the reference level.

d. Reject any indication that is accompanied by a complete loss of back reflection.

e. The test-metal distance to the flat bottom calibration holes shall be equal to approximately 25% and 75% of the anticipated scanning distance. The calibration block shall be fabricated from material that is ultrasonically similar to that being tested.

4.2.3.2 Angle beam (shear).

a. 60-degree V notch x 1.0-inch long and 3% radial wall thickness deep or .25 inch, whichever is smaller.

b. Record indications equal to or exceeding 50% of the reference level.

c. Reject indications that exceed the reference level

4.2.4 Inclusion content. The inclusion content of each forging shall be determined in accordance with ANSI/ASTM E-45-95. The procedure used shall be Method A - Microscopic Method for Use on Vacuum Processed or Other Special Quality Steel. The maximum fields shall be as follows:

shall be referred to AEDC/TSS, 1099 Schriever Ave, Arnold AFB, TN 37389. DESTRUCTION NOTICE—Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

MICRO TYPE THIN THICK

A 2-1/2 2 B 2-1/2 2 C 2-1/2 2 D 2-1/2 2

Specimens for inclusion content shall be taken at the inside diameter of the forgings and specimens for ferrite content at mid-wall.

4.3. Qualty conformance inspections. Quality conformance inspections for each forging shall consist of the following:

4.3.1 Dimensional inspection. The finished machined forging shall be dimensionally inspected to ensure compliance with 3.2.2.5 and the contract drawing specified in 2.1.1. Bore diameter for a distance of six inches from each end of the launch tube shall be recorded. All "as-built" dimensions shall be recorded by the Contractor.

4.3.2 Bore straightness. Bore straightness specified in 3.2.2.5 shall be determined optically. The measured centerline of the bore shall not deviate by more than .006 inch from an optically straight centerline established between any two points along the length of the bore at least two feet apart.

Total deviation from the optical centerline at any point is the vector sum of the horizontal and vertical deviation measurements at that point.

Measurements are to be recorded at six-inch intervals.

4.3.3 In the event a non-conformance to the specification should a rise and the contract items cannot be reworked back to specification, contact the Contracting Officer or his designated representative immediately.

5. PREPARATION FOR DELIVERY

5.1 The Contractor shall provide all preservation, packaging, and packing to ensure safe delivery of the finished machined forging to AEDC. Finished surfaces shall be adequately protected to prevent marring, scratching, rust and contamination.

6. NOTES

Not applicable.

7. APPENDIX

7.1 Specimen locations.

shall be referred to AEDC/TSS, 1099 Schriever Ave, Arnold AFB, TN 37389. DESTRUCTION NOTICE—Destroy by any method that will prevent disclosure of contents or reconstruction of the

Fig. 7.1