First Article Test Plan.pdf

LPF-QAR-003 is a U.S. Air Force quality assurance requirements document establishing guidelines for the preparation of first article test plans and reports for F100 engine parts under federal contracts.

The document mandates comprehensive testing and documentation for first articles, with quantity determined by contract specifications. One article must undergo complete destructive testing including all procedures, while remaining articles are tested only on nondestructive portions. Testing requirements encompass dimensional conformance with finish specifications, nondestructive inspections (FPI, ultrasonic, eddy current, X-ray, and visual), material property verification (mechanical, metallurgical, and chemical), and compliance with all referenced processes, specifications, and standards. All first articles must be serialized with serial numbers identified before testing commencement. Dimensional inspection requires 100% measurement of all dimensions listed on assembly and detail drawings with tabular documentation including drawing dimension, tolerance, actual reading, instrument/gage/tooling serial number, and gage calibrations traceable to NIST per ISO 10012-1. Nondestructive inspections must receive 100% coverage per QAD specifications with results presented in tables showing features inspected, acceptance/rejection criteria, results, and gage/master serial numbers. Sources must be Pratt & Whitney approved per OC-ALC/LPFR letter. Visual inspections shall reference specific Pratt & Whitney Visual Inspection Standards with results documented in tables. Material properties testing includes mechanical, metallurgical, and chemical analysis with composition, heat treat condition verification and metallurgical microanalysis for raw materials, welds, brazings, and coatings. First Article Test Plans (FATP) and First Article Test Reports (FATR) must be delivered to the Contracting Officer per contract schedule or Form DD1423 with detailed, specific testing instructions and all complete laboratory test results. Disposition requirements specify that destructive testing remnants and one nondestroyed article marked "UNSERVICEABLE - Condition Code R" be delivered with the FATR. All first and production articles must be newly manufactured from materials meeting drawing metallurgical requirements with no previously manufactured items delivered without approval, and subcontractor sources previously identified must be the sole sources used unless OEM-approved alternatives are substantiated and authorized by OC-ALC/LPFR. Engineering Instructions take precedence over all other technical instructions.