First_Article_Test_Plans.pdf

This document is a U.S. Air Force quality assurance requirements specification (LPF-QAR-003) for first article test plans and reports pertaining to F100 engine parts.

The document establishes mandatory guidelines for contractors preparing first article test plans (FATP) and first article test reports (FATR) for F100 engine components. First articles must be serialized and subjected to 100% dimensional inspection of all assembly and detail drawing dimensions with no sampling allowed. All dimensions must be recorded in tabular format showing the feature measured, dimension, tolerance, actual reading, and instrument used. Tooling and gaging equipment require NIST-traceable calibrations per ISO 10012-1. Testing requirements include dimensional conformance with finish specifications, non-destructive inspections (FPI, ultrasonic, eddy current, X-ray, and visual), material properties testing including mechanical and metallurgical analysis, and compliance with drawing specifications and standards. For non-destructive inspections, 100% of inspections identified on quality assurance documents must be completed with no sampling permitted. Contractors must employ Level II or Level III certified inspectors as applicable, and inspection results must be presented in detailed tables documenting acceptance/rejection criteria and gage serial numbers. Contractors must deliver the FATP to the contracting officer per contract schedule or Form DD1423, followed by delivery of the completed FATR with all laboratory test results. First articles and production articles must be newly manufactured under the current contract using approved subcontractors and material suppliers. Any changes to previously identified sources require OC-ALC/LPFR approval, and Engineering Instructions take precedence over all other technical instructions.