DS-JXNN-C08-1621_Rev_A_MK318_MOD1_Ammunition.pdf

DS/JXNN/C08/1621A

DETAIL SPECIFICATION

CARTRIDGE, CALIBER 5.56MM,

BALL, CARBINE, BARRIER

MK 318 MOD 0

09 February 2010

DISTRIBUTION STATEMENT A.

Approved for public release; distribution is unlimited.

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

COMMANDER, NAVSURFWARCENDIV CRANE, 300 HIGHWAY 361, Small Arms Ammunition and Testing BLDG. 3422, CRANE IN 47522-5001

Use the self-addressed Standardization Document Improvement Proposal (DD Form 1426) or by letter.

DETAIL SPECIFICATION

CARTRIDGE, CALIBER 5.56MM

BALL, CARBINE, BARRIER MK 318 MOD 0

Naval Surface Warfare Center

Joint Special Operations Response Department

Small Arms Weapons Division Small Arms Ammunition AND TESTING

Crane, Indiana 47522-5001 Name Signature Code Date

Prepared By: Chuck Marsh ~ JXNN ;')C7/IO

Reviewed By: Jarod Stoll fJJJ JXNN l/:J.ifl/Q

JXNN Approval Charles Buxton flt:«~_h JXNN ~/O'5//u JXN Approval Dane R. Speer flJ/J. JXN si~ ii iii

DETAIL SPECIFICATION

Revision A: The base specification was generated using the pre-production – proof of concept cartridge test results as a basis.

The purpose of Revision A is to incorporate changes to the specification based on production lot acceptance test data and to incorporate the updated drawing package. See NOR DS/JXNN/C08/1621A.

iv

DETAIL SPECIFICATION

TABLE OF CONTENTS

1.0 SCOPE

2.0 APPLICABLE DOCUMENTS

2.1 General

2.2 Government documents

2.3 Non-Government publications

2.4 Order of precedence

3.0 REQUIREMENTS

3.1 First Article

3.2 Government-loaned property

3.3 Components

3.4 Complete cartridge

3.5 Cartridge ballistic performance

3.6 Workmanship

3.7 Lot formation

3.8 Safety precautions

4.0 VERIFICATION

4.1 Responsibility for Inspection

4.2 First Article Inspection

4.3 Conformance Inspection

4.4 Non-destructive Inspection

4.5 Tests

4.6 Safety Precautions

5.0 PACKAGING

5.1 Packaging

6.0 NOTES

6.1 Intended use

6.2 Acquisition requirements

6.3 Definitions

6.4 Government-loaned property

6.5 Part or identifying number (PIN) structure

v

TABLES

I BALLISTIC FUNCTION AND SAFETY

II TEST REQUIREMENTS

III INSPECTION LEVEL

IV SAMPLE SIZE

V FUNCTION TEST AC/RE CRITERIA

VI FUNCTION AND CASUALTY TEST

APPENDICES

A PROCEDURE FOR ELECTRONIC PRESSURE AND VELOCITY TEST

B PROCEDURE FOR ACCURACY TEST

C PROCEDURE FOR FUNCTION AND CASUALTY TEST

D PROCEDURE FOR PROPELLANT HIGH TEMP. STABILITY TEST

E PROCEDURE FOR MUZZLE FLASH TEST

FIGURES

I Backlit Grid Box II Test Setup III Example Shot

DETAIL SPECIFICATION

CARTRIDGE, CALIBER 5.56MM,

BALL, CARBINE, BARRIER,

MK 318 MOD 0

1. SCOPE

1.1 Scope. This specification establishes the requirements for the 5.56mm Ball, Carbine, Barrier MK 318 MOD 0 cartridges (hereafter referred to as "test cartridge" or "cartridge"). The cartridge is intended for use in the MK 16 Special Operations Forces Combat Assault Rifle (SCAR-L) and all magazine fed 5.56mm legacy weapon systems.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements documents cited in sections 3 and 4 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DODISS) and supplement thereto, cited in the solicitation (see 6.2 b).

SPECIFICATIONS

MILITARY

MIL-I-45607.....Inspection Equipment, Acquisition, Maintenance and Disposition of

MIL-L-63460.....Lubricant, Cleaner and Preservative

MIL-P-15011.....Pallets, Material Handling, Wood Post Construction, 4-Way Entry

MIL-P-46610.....Primers, Percussion, Styphnate and Chlorate Types for Small Arms Ammunition

STANDARDS

MILITARY

MIL-STD-129.....Marking for Shipment and Storage

MIL-STD-636.....Visual Inspection Standards for Small Arms Ammunition Through Caliber .50

MIL-STD-644.....Visual Inspection Standards and Inspection Procedures for Inspection of Packaging Packing and Marking of Small Arms Ammunition

MIL-STD-1168....Ammunition Lot Numbering

DEPARTMENT OF DEFENSE (DOD)

DOD-STD-2101....Classification of Characteristics

DOD 4145.26M....Contractor's Safety Manual for Ammunition, Explosives and Related Dangerous Material

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia

PA 19111-5094.)

2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation.

DRAWINGS

U.S. ARMY ARMAMENT RESEARCH AND DEVELOPMENT COMMAND DRAWINGS

19200-7643674...Classification of Cartridge Case Defects

19200-11820451..Case

19200-8649409...Barrel, Test, Accuracy, 5.56 MM

19200-8649410...Barrel, Test, Electronic Pressure, 5.56 MM

19200-8649417...Rifle, Test, Accuracy, 5.56 MM

19200-8649418...Fixture, Test, Accuracy, 5.56 MM

19200-10520043..Receiver, Universal, M2, Assembly, Action Time

19200-10534279..Primer No. 41

NAVAL SEA SYSTEMS COMMAND DRAWINGS

53711-7520779.......CARTON

53711-7520785.......SEPARATOR

53711-8347645.......CARTRIDGE, 5.56MM, BALL, CARBINE, BARRIER,

MK 318 MOD 0

53711-8347646.......BULLET, 5.56MM, BALL, CARBINE, BARRIER,

MK 318 MOD 0

53711-8347649.......PROPELLANT, SMP 843

12255-408JXN00001...PACK AND MARK CARTON, PAPERBOARD CARTRIDGE,

5.56MM

12255-408JXN00002...PACK AND MARK BOX, AMMO M2A1, CARTRIDGES,

5.56MM

12255-408JXN00003...PACK AND MARK BOX, WIREBOUND, CARTRIDGE,

5.56MM

PUBLICATIONS

U.S. ARMY PUBLICATIONS

SCATP-5.56MM....Small Caliber Ammunition Test Procedures For 5.56mm Cartridges

NAVAL SEA SYSTEMS COMMAND PUBLICATIONS

OP 5 Volume 1...Ammunition and Explosives Ashore Safety Regulations for Handling, Storing, Production, Renovation and Shipping

(Unless otherwise indicated, copies of the above other Government documents, drawings, and publications are available from the Commanding Officer, Naval Publications and Forms Center (Code 105), 5801 Tabor Ave., Philadelphia, PA 19120. If not available, advise contracting activity.)

2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents that are DOD adopted are those listed in the issue of the DODISS cited in the solicitation. Unless otherwise specified, the issues of documents not listed in the DODISS are the issues of the documents cited in the solicitation (see 6.2 b).

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI/ASQC-A8402.....Quality Management and Quality Assurance – Vocabulary

ANSI/ASQC Z1.4......Sampling Procedures and Tables for Inspection by Attribute

(Application for copies should be addressed to the American National Standards Institute, Headquarters, 11 West 42nd Street, 13th Floor, New York NY 10036. ANSI may also be contacted via their web site at www.ansi.org.)

2.4 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 First article. When specified in the solicitation (see 6.2.g), a sample shall be subjected to first article inspection in accordance with 4.2.

3.2 Government-loaned property. Government-loaned property (see 6.2.e and 6.4) shall be used for performing tests as specified in section 4 and appendices A and C of this specification. Government-loaned properties are MK 16 SCAR-L Carbine(s) and M4A1 Carbine(s) for Function and Casualty testing, 30 round magazines and reference cartridges for Pressure and Velocity testing.

3.3 Components. Cartridge components consist of the projectile, the cartridge case, the propellant and the primer.

3.3.1 Bullet. The bullet (projectile) for the cartridge shall be in accordance with drawing 53711-8347646.

3.3.2 Cartridge case. The cartridge case shall be in accordance with drawing 19200-11820451.

3.3.2.1 Vent hole. (C1) [A vent hole shall be present in the primer pocket of the cartridge case.]

3.3.2.2 Head Stamp. The cartridge case head stamp marking shall be in accordance with drawing 19200-11820451 with the exception of Note 7. The NATO Identification Mark referred to by Note 7 does not apply to this item.

3.3.3 Propellant. The propellant shall be SMP 843 in accordance with drawing 53711-8347649.

3.3.3.1 Presence of propellant. (C2) [Each cartridge shall contain a minimum of 13 grains of propellant.]

3.3.3.2 Charge weight. The manufacturer shall establish the charge weight to meet performance requirements.

3.3.4 Primer.

3.3.4.1 Type. The primer shall be a No. 41 primer manufactured in accordance with drawing 19200-10534279 and MIL-P-46610.

3.4 Complete cartridge.

3.4.1 Cartridge Assembly. The cartridge assembly shall be

manufactured and inspected in accordance with drawing 53711-8347645 and this specification.

3.4.2 Primer seating depth. (M101) [The primer shall be seated flush to 0.008 inch below flush of the face of the cartridge case head. The primer shall be staked or crimped in place.]

3.4.3 Case Mouth Diameter. (M102) [The case mouth diameter shall not exceed 0.251 inch after assembly and prior to application of waterproof.]

3.4.4 Cartridge overall length. (M103) [The overall length of the assembled cartridge shall not exceed 2.260 inches.] (M104) [The overall length of the assembled cartridge shall not be less than

2.190 inches.]

3.4.5 Bullet extraction. (M105) [The force required to extract the projectile from the cartridge case shall be 60 pounds minimum.]

3.5 Cartridge ballistic performance.

3.5.1 Velocity. (M106) [When conditioned at a temperature of 70° ± 5°F, the average corrected velocity shall be 3,020 feet per second (fps), ± 30 fps.] The instrumental velocity shall be measured 78 feet from the muzzle of the weapon. The standard deviation of the velocities shall be no greater than 30 fps.

3.5.2 Chamber pressure. (M107) [The average chamber pressure of the sample cartridges, conditioned at 70° ± 5°F, shall not exceed 58,700 pounds per square inch (psi). Neither the chamber pressure of an individual sample test cartridge nor the average chamber pressure plus three standard deviations of chamber pressure shall exceed 64,700 psi.]

3.5.3 Port pressure. (M108) [The mean port pressure minus three standard deviations shall not be less than 15,300 psi for sample cartridges conditioned to 70° ± 5°F.]

3.5.4 Temperature (High and Low). The pressure and velocity of sample cartridges conditioned and fired at the temperature extremes specified below shall be in accordance with 3.5.4.1, 3.5.4.2, and 3.5.4.3.

a. Conditioned at +160°+ 5°F for no less than 2 hours and fired at that temperature.

b. Conditioned at -25°+ 5°F for no less than 2 hours and fired at that temperature.

3.5.4.1 Velocity. (M109) [The average velocity of cartridges

conditioned at -25° + 5°F shall not vary by more than 225 fps from the average velocity of the cartridges conditioned at +160° + 5°F.]

3.5.4.2 Chamber Pressure. (M110) [The average chamber pressure of the sample cartridges conditioned at +160° + 5°F shall not exceed 67,500 psi. Neither the chamber pressure of an individual sample test cartridge nor the average chamber pressure plus three standard deviations of chamber pressure shall exceed 72,500 psi.]

3.5.4.3 Port Pressure. (M111) [The average port pressure shall not vary from the average port pressure of the sample test cartridges conditioned at 70°± 5°F by more than 2,000 psi and shall not be less than 14,600 psi.]

3.5.5 Accuracy. (M112) [The extreme spread of any individual ten-shot (10-shot) group shall not exceed 6.0 inches at 200 yards. The average extreme spread of all ten 10-shot groups shall not exceed

4.75 inches at 200 yards.]

3.5.6 Function and Casualty. The cartridges shall meet all

function and safety requirements of Table I. Misfires shall be considered separately in accordance with Table I. The cumulative total of all ballistics firing shall be used to determine compliance with the requirements of Table I.

3.5.7 Waterproof. The cartridge shall not release more than one bubble of air when subjected to a positive internal pressure of 7.5 psi for 30 seconds minimum. Bubbles originating from the projectile tip shall not be counted due to the potential for trapped air to be present in the open tip of the projectile.

3.5.8 Muzzle Flash. Prior to being released for use in production, each lot of propellant shall be subjected to the Muzzle Flash test described in Appendix E. The muzzle flash produced by the test cartridge shall not extend more than twelve (12) inches past the muzzle of the test weapon, nor shall it exceed five (5) inches in height.

3.5.9 Propellant High Temperature Stability. Prior to being

released for use in production, each lot of propellant shall be subjected to the high temperature stability test described in Appendix D. When subjected to the chamber temperature extremes, and time durations detailed in Appendix D, the average chamber pressure of five (5) cartridges shall not exceed 64,500 psi. No individual cartridge chamber pressure shall exceed 70,000 psi. The high temperature stability test results for each lot of propellant shall be included in each ammunition lot acceptance test report.

TABLE I. Ballistics Function and Safety. (1)

Characteristics (2)

Classification

Accept

Reject

1. Weapon stoppages due to the cartridge. (3) (M113) 1 2

2. Failures to extract. (3) (M114) 1 2

3. Hangfires.

(C3)

4. Misfires. (4)

a. Missing or obstructed vent hole in cartridge case. (C4) 0 1

b. Other (M115) (4) (4)

5. Bullet remaining in the bore.

(C5)

6. Primer Leak:

a. Perforation in firing pin indent.

Minor

b. Escape of gas through primer cup other than 5.a.

c. Escape of gas around primer cup. (5)

d. Loose primer.

(M116)

e. Blown primer (MK 16).

(C6)

f. Blown primer (M4A1 Carbine).(6)

(C6)

(6)

(6)

7. Cartridge case casualties: (7)

a. Longitudinal split of the:

(1) Mouth (I)

(2) Body (J)

(3) Body (K)

(M117)

(4) To Head (L)

(C7)

(5) Through Head (M)

(C8)

b. Circumferential rupture:

(1) Partial, Body (J)

(2) Partial, Body (K)

(M118)

(3) Partial, Head (L)

(C9)

(4) Complete

(C10)

8. Premature cartridge functions.

(C11)

TABLE I. Ballistics Function and Safety. (1) (Continued.)

NOTES:

(1) The occurrence of one or more critical defects attributable to the cartridge during any test, including warm and foul firings of cartridges from the test lot, shall result in rejection of the lot.

(2) For definition of characteristics, see 6.3.

(3) If weapon stoppages or failures to extract occur due to the ammunition, then the criteria for acceptance/rejection for major characteristic (M113) and (M114) shall be accept on one (1), reject on two (2) defects. If one (1) weapon stoppage or one (1) failure to extract due to the ammunition occurs, then a second Function and Casualty sample shall be tested in the same weapon at the temperature range(s) of the failure in accordance with 4.5.5.7. The occurrence of any additional weapon stoppage or failure to extract shall result in rejection of the lot and the acceptance criteria for the cumulative total of all firings is accept on one (1), reject on two (2) defect.

(4) Each cartridge that misfires shall be disassembled and examined to determine the cause of the misfire:

a. If the misfire is attributed to a defective cartridge (for other than a critical defect) due to improper assembly or missing components, then the criteria for acceptance/rejection for major characteristic (M115) shall be accept on one (1), reject on two (2). If one misfire occurs, then a second Function and Casualty sample shall be tested in accordance with Table II and Appendix C. The second function and casualty sample size shall be double the first sample size. The occurrence of any additional misfires shall result in rejection of the lot (accept on one (1), reject on two (2) defects for the cumulative total of all firings). Additionally, the occurrence of one or more critical defects during the firing of any test, including the second Function and Casualty sample, shall result in rejection of the lot.

b. The lot shall be rejected if the cartridge does not meet the critical requirements of 3.3.2.1 (presence of primer pocket vent hole) or 3.3.3.1 (presence of propellant charge).

c. If the misfire is attributed to the test weapon, then the weapon shall be repaired or replaced and another cartridge fired in place of the misfire.

(5) Gas escape around more than 50 percent of periphery of the primer cup.

(6) The M4A1 Carbine Blown Primer accept/reject criteria firing +160° + 5°F temperature condition ammunition will be accept on 4, reject on 5. One retest is allowed with the cumulative result criteria of accept on 9 reject on 10.

(7) For location of characteristics indicated by letters in parentheses, see

19200-7643674.

TABLE II. Test requirements - temperature conditioning ranges, sample sizes and paragraph references.

Temperature Ranges

Paragraph References

Tests

-25°F to

-20°F

65°F

75°F

160°F

165°F

Requirement

Verification

CARTRIDGE:

1. Bullet Extraction

3.4.5

4.5.5.2

CARTRIDGE BALLISTICS TESTS:

Cumulative Sample Size

(1)

(2)

2. Electronic Chamber Pressure, Port Pressure and Velocity(3) (4)

3.5.1 through 3.5.4.3

4.5.5.3 through 4.5.5.5

3. Accuracy

3.5.5

4.5.5.6

4. Function and Casualty

3.5.6

4.5.5.7

5. Waterproof

20(5)

3.5.7

4.5.5.8

6. Muzzle Flash

3.5.8

4.5.5.9

7. Propellant Hi Temp Stability

15(6)

3.5.9

4.5.5.10

(1) The results of all ballistics tests, including examination of misfired cartridges, fired cartridge cases and primers, shall be used to determine compliance with the requirements of Table I. The occurrence of any critical defects attributable to the cartridges (including firings of warm and foul cartridges from the test lot) shall result in rejection of the lot and no further testing shall be conducted.

(2) If the firing of a second Function and Casualty sample is required due to the occurrence of a misfire as specified by Table I, the second sample shall be a double sample and shall be fired in accordance with the Function and Casualty test procedure.

This second sample shall be tested only for misfires and critical defects in determining acceptance/rejection.

(3) Unless otherwise substantiated that the applicable chamber pressure requirements are met, chamber pressure testing shall be completed and the applicable requirements shall be met prior to conducting any other ballistics tests. Acceptable methods of substantiating that the chamber pressure requirements have been met are in-process chamber pressure checks, or propellant checks, or propellant acceptance tests. These acceptable methods do not eliminate the requirement to perform chamber pressure testing as part of the first article sample or lot acceptance testing. The contractor shall submit substantiating documentation to and receive approval from the Contracting Officer for each lot that will not be subjected to chamber pressure testing prior to other ballistic tests.

(4) For production lot acceptance and First Article acceptance, 20 samples shall be fired with the propellant positioned at the primer end of the cartridge per SCATP- 5.56mm (Heavy Bullet). Reference cartridges and all other EPVAT test samples shall be fired with the propellant at the primer end of the cartridge per SCATP-5.56mm (Heavy Bullet). Each 20 round sample shall meet the requirements of 3.5.1 through 3.5.4.3.

(5) Accept on one (1) bubble out of twenty cartridges, retest on two bubbles with a double sample containing forty (40) cartridges. Reject the lot any time there are three bubbles during either tests (20 or 40 cartridges.)

(6) For First Article and production lot acceptance, fifteen (15) rounds shall be subjected to the Propellant High Temperature Stability Test in accordance with Appendix D. The average and maximum chamber pressure of each temperature and duration shall meet the requirements of paragraph 3.5.9.

3.6 Workmanship.

3.6.1 Defects. Metallic components and the completed cartridge shall be free from folds, wrinkles, deep draw scratches, scaly metal, dents, burrs and other defects.

3.6.2 Foreign material. All components and the completed cartridge shall be free of foreign material including, but not limited to, corrosion, stains, dirt, oil, grease, smears of lacquer and metal chips.

3.6.3 MIL-STD-636. The cartridge and components shall meet the visual standards requirements of MIL-STD-636 for caliber .30 cartridges. Classification of individual visual and workmanship characteristics shall be as defined by MIL-STD-636.

3.6.4 Mixed ammunition types. For mixed ammunition types, the occurrence of a high pressure test, dummy or blank cartridge shall be classed as a critical defect. Occurrence of any other type shall be classed as a major defect.

3.7 Lot formation.

3.7.1 Cartridges. The cartridges shall be assembled into

identifiable lots. Each lot shall consist of units of product of a single type, grade, class, size and composition, manufactured under the same conditions, by the same manufacturer, and at the same time (continuous production run). Each cartridge lot shall contain no more than one lot of primers, one lot of propellant, one lot of cartridge cases and one lot of projectiles. Unless otherwise specified in the solicitation, the lot size shall be no more than 1,500,000 cartridges. Lot numbers shall be assigned in accordance with MIL-STD-1168. Each lot shall be identified as to type, caliber, model and lot number.

3.7.2 Primers. The size of any lot of primers used in the

cartridges shall be 200,000 units minimum and 1,500,000 units maximum. A primer lot shall consist of a specific product, made on consecutive work shifts, with no break in the production of that specific product.

3.8 Safety precautions.

3.8.1 Contractor. Work performed in support of this specification and solicitation, when performed by contractors, shall comply with the safety precaution requirements of DOD 4145.26M.

3.8.2 Government activity. Work performed in support of this

specification and solicitation, when performed by a Government activity, shall comply with the safety precaution requirements of NAVSEA OP 5 Volume 1.

4. VERIFICATION

4.1 Responsibility for Inspection. Unless otherwise specified herein, in the contract or purchase order, the supplier is responsible for the performance of all inspection and test requirements as specified herein. Except as otherwise specified, the supplier may utilize his own facilities or any commercial facility acceptable to the Government. The Government reserves the right to perform any of the inspections and tests set forth in this specification where such inspections and tests are deemed necessary to ensure that supplies and services conform to prescribed requirements. Unless otherwise specified herein, in the contract or in the purchase order, all test and inspection equipment (including test barrels) shall be supplied and maintained by the contractor in accordance with MIL-I-45607.

4.1.1 Quality Assurance Terms and Definitions. Reference shall be made to ANSI/ASQC-A8402 for definitions of quality assurance terms.

4.1.2 Classification of inspections. The inspection requirements specified herein are classified as follows:

a. First Article Inspection (see 4.2).

b. Conformance Inspection (see 4.3).

4.2 First Article inspection. When specified in the solicitation (see 6.2 g), First Article inspection of cartridges and cartridge components shall be performed on a First Article sample (see 3.1).

The First Article inspection shall include the non-destructive inspections in 4.4 through 4.4.8 and the tests in 4.5 through

4.5.5.10 and Appendices A, B, C, D and E. The First Article quantity (sample size) of cartridges and cartridge components shall be as specified in the solicitation (see 6.2 g).

4.3 Conformance inspection. Conformance inspection of production cartridges and cartridge components shall include the non-destructive inspections in 4.4 through 4.4.8 and the tests in 4.5 through 4.5.5.10 and Appendices A, B, C, D and E.

4.4 Non-destructive inspections.

4.4.1 Inspection provisions. Unless otherwise specified herein or in the solicitation, Tables III and IV shall be used for nondestructive acceptance inspection. Inspection shall be by characteristic. Acceptance criteria shall be accept on zero defects and reject on one or more defects for all inspection levels. In Table IV, the number under each inspection level indicates sample size. An asterisk under the inspection level in Table IV indicates one hundred percent inspection. If the sample size exceeds lot size, the lot shall be one hundred percent inspected. One hundred percent inspection shall be used for all critical characteristics.

Unless otherwise specified, inspection level V shall be used for major characteristics and inspection level VII for minor characteristics. Section 3 requirements that are not annotated as critical or major shall be classified as minor. Classification of characteristics shall be defined in accordance with DOD-STD-2101.

4.4.2 Material requirements. The contractor shall maintain

certificates and test results showing compliance with all material requirements of section 3. Certifications and test results shall be included in each First Article test report and shall be available upon request for each production lot.

TABLE III. Inspection level.

Referenced AQL

Inspection Level

0.040

I

0.065

II

0.100

III

0.150

IV

0.250

V

0.400

VI

0.650

VII

1.000

VIII

1.500

IX

2.500

X

4.000

XI

6.500

XII

4.4.3 Workmanship. Cartridges and components shall be visually inspected to determine compliance with the requirements of 3.3.2.2, and 3.6.1 through 3.6.4.

4.4.4 Dimensional and weight requirement. All dimensional and weight requirements in Section 3 shall be verified by contractor gages or by Standard Measuring Instruments (SMI).

4.4.5 Vent hole and propellant presence. The contractor shall verify the presence of primer pocket vent hole (see 3.3.2.1) and the presence of a propellant charge (see 3.3.3.1) by visual inspection or by automated equipment using probes or other sensing devices.

4.4.6 Lot formation. The contractor shall maintain records on lot formation. Lot formation records shall be available upon request for review to verify that lot formation complies with 3.7.1 and

3.7.2 and that lot numbering is in accordance with MIL-STD-1168.

TABLE IV. Sample size

Inspection Levels

Lot Size

I

II

III

IV

V

VI

VII

VIII

IX

X

XI

XII

2 – 8

9 – 15

18 –25

26 – 50

51 – 90

91 – 150

151 – 280

281 – 500

501 – 1200

1201 – 3200

3201 – 10000

10001 – 35000

35001 – 150000

150001 – 500000

500000 – OVER

4.4.7 100% Examination of Cartridges. During or immediately prior to the packaging operation, 100% examination of the cartridges shall be performed to ascertain that the cartridge type conforms to the requirements of 3.6.1 through 3.6.4. All non-conforming cartridges shall be rejected.

4.4.8 Packaging, Packing and Marking Inspection. Inspection for packaging, packing and marking shall be in accordance with MIL-STD-

644. The requirements of Section 5.0 shall be met.

4.5 Tests.

4.5.1 Test conditions. Unless otherwise specified herein or in the solicitation, all testing shall be conducted with samples conditioned at 70°F ± 5°F for a minimum of two hours.

4.5.2 Test provisions. Unless otherwise specified herein or in the solicitation, each lot of components and each lot of cartridges shall be tested in accordance with the requirements stated in the specification, drawings and contract documents. Cartridges shall be randomly selected in such a manner that the sample is representative of the lot. The cartridges shall be thoroughly mixed before being divided into sample groups for each test.

4.5.3 Equipment/weapon failure. If an equipment/weapon failure occurs which prevents the obtaining of a reliable test result, then the equipment/weapon shall be replaced or repaired, the individual test cartridge result shall be disregarded and another sample cartridge shall be fired for the record. If the equipment/weapon failure prevented the obtaining of reliable results for the entire test series, then the entire test result shall be disregarded and a complete additional sample shall be fired for record. If a firing defect occurs which is not attributable to the test conditions, and which prevents obtaining a reliable result for the test, an additional cartridge shall be fired in its place. The test shall not be penalized, but the defect shall be counted in the cumulative ballistics sample for Table I.

4.5.4 Reference cartridges. Unless otherwise specified in the solicitation (6.2.e), reference cartridges shall be supplied by the Government. Government furnished reference cartridges shall be used only for calibrating test equipment, verifying test equipment calibration during testing, and determining correction factors to be applied to test results. Government furnished reference cartridges shall be used only for chamber pressure and muzzle velocity tests during First Article inspections and lot acceptance testing.

Reference cartridges furnished by the Government under this solicitation shall not be used for any other purpose. The contractor shall be responsible for furnishing secondary reference cartridges needed for in-process and in-house testing. Unused reference cartridges shall be returned to the Government upon completion of the contract.

4.5.5 Cartridge tests. Each lot of cartridges shall be subjected to the bullet extraction test in 4.5.5.2, and the ballistics tests in 4.5.5.3 through 4.5.5.10.

4.5.5.1 Appendices A,B,C, D and E. Appendices A,B,C,D, and E

provide more detail to the ballistics test requirements. The following document shall be used as stated in these appendices:

Small Caliber Ammunition Test Procedures (SCATP)-5.56mm (Heavy Bullet) Cartridges.

4.5.5.2 Bullet extraction. The cartridge shall be secured in the test machine so that the extraction force is collinear with the cartridge central axis. The cartridge case shall be held in such a manner that the projectile is not pinched. The extraction force shall be applied by using a test machine crosshead travel rate (pulling rate) of 0.20 to 0.30 inches per minute. Each sample shall be tested to failure and the maximum load occurring during projectile separation from the cartridge case shall be recorded. If the projectile pulling collet or jaws slip off the projectile, and the force met the extraction force requirement of 3.4.5, then it shall be considered a valid test. If the force did not meet the requirement of 3.4.5, then it shall be considered a retest. The lot shall be rejected if two or more cartridges fail to meet the requirements of 3.4.5.

4.5.5.3 Velocity. The velocity test shall be conducted in

accordance with Appendix A. The lot shall be rejected if the average velocity (corrected) of the projectiles does not meet the requirements of 3.5.1 or if the standard deviation of the velocities does not meet the requirements of 3.5.1 when temperature conditioned at 70°F. The lot shall also be rejected if one or more of the samples conditioned at -25°F or +165°F fail to meet the requirements of 3.5.4.1.

4.5.5.4 Chamber pressure. The test shall be performed in

accordance with Appendix A. Unless otherwise specified in the solicitation, the contractor shall provide the test barrel for pressure testing. The lot shall be rejected if the average peak chamber pressure (corrected) of any test sample at the 70°F temperature range fails the requirements of 3.5.2 or if one or more cartridges fail the individual sample requirements (corrected) of

3.5.2. The lot shall also be rejected if one or more of the samples temperature conditioned at -25°F or +165°F fails to meet the requirements of 3.5.4.2.

4.5.5.5 Port Pressure. The test shall be performed in accordance with Appendix A. Unless otherwise specified in the solicitation, the contractor shall provide the test barrel for pressure testing.

The lot shall be rejected if the average peak port pressure of any test sample (corrected) at the 70°F temperature range fails the requirements of 3.5.3 or if one or more cartridges fail the individual sample requirements (corrected) of 3.5.3. The lot shall also be rejected if one or more of the samples conditioned at -25°F or +165°F fail to meet the requirements of 3.5.4.3.

4.5.5.6 Accuracy. The accuracy test shall be conducted in

accordance with Appendix B. The requirements of 3.5.5 shall be met.

The lot shall be rejected if the average extreme spread of all 10-shot groups exceeds the specified requirement or if two or more 10-shot groups exceed the individual group requirement.

4.5.5.7 Function and Casualty. The Function and Csualty test shall be conducted in accordance with Appendix C. The misfire requirement of 3.5.6 shall be met. The desired acceptance/ rejection shall be as shown in Table V below.

4.5.5.8 Waterproof. A total of 20 rounds shall be subjected to the waterproof test in accordance with SCATP-5.56mm (Heavy Bullet). The requirement of 3.5.7 shall be met.

4.5.5.9 Muzzle Flash. The Muzzle Flash test shall be conducted in accordance with Appendix E. The muzzle flash of five (5) individual shots shall meet the requirements of 3.5.8. The Muzzle Flash test results or the propellant manufacturer certificate of compliance shall be included in each lot acceptance test report.

4.5.5.10 Propellant High Temperature Stability. The Propellant High Temperature Stability Test shall be conducted in accordance with Appendix D. The requirement of paragraph 3.5.9 shall be met.

The propellant high temperature stability test results or the propellant manufacturer certificate of compliance shall be included in each lot acceptance test report.

TABLE V. Function test AC/RE criteria

Number of Stoppages

Type of Stoppage

Accept (AC)

Reject (RE)

Failure to extract

Failure to chamber

Failure to lock slide back (last round)

All other stoppages

4.6 Safety Precautions. Compliance with the safety precautions of

3.8.1 (contractor) or 3.8.2 (government activity) shall be verified as part of the safety survey conducted during solicitation pre-award.

5. PACKAGING

5.1 Packaging. For acquisition purposes, packaging requirements shall be as specified in the solicitation (see 6.2.c.). When actual packaging of material is to be performed by DOD personnel, DOD personnel need to contact the responsible packaging activity to ascertain requisite packaging requirements. Packaging requirements are maintained by the Inventory Control Point's packaging activity within the Military Department or Defense Agency, or within the Military Department's System Command. Packaging data retrieval is available from the managing Military Department’s or Defense Agency's automated packaging files, CD-ROM products, or by contracting the responsible packaging activity.

6. NOTES

(This section contains information of a general or explanatory nature that may be helpful, but is not mandatory.)

6.1 Intended use. The caliber 5.56mm cartridges covered by this specification are for use in the MK 16 SCAR-L Carbine, and the M16 family of weapons chambered for caliber 5.56mm cartridges. These cartridges are intended for use in magazine fed weapon systems only.

6.2 Acquisition requirements. Acquisition documents include the solicitation, quotation, contract and/or purchase order and are herein referred to as "solicitation". Acquisition documents must specify the following:

a. Title, number and date of the specification.

b. The issue of DODISS to be cited in the solicitation and, if required, the specific issue of individual documents referenced (see 2.2 through 2.3).

c. Packaging, packing, palletizing, marking and labeling requirements: See 5. Solicitation must specify that packaging, packing, palletizing, marking and labeling shall be in accordance with MIL-P-15011, MIL-STD-644, drawings 19-48-4116, 19-48-4116/5A (53711-7520780, 53711-7520781, and 53711-7520782.

d. Item designators (Department of Defense Identification

Code/Naval Ammunition Logistic Code (DODIC/NALC) Index, Navy Item Identification Number, National Stock Number (NSN), and nomenclature).

e. Government-loaned property:

(1) Identification of Government-owned property to be loaned to the contractor for use under this specification only, to include quantities and test weapon serial numbers.

(2) Method by which contractor shall receive, account for during use, and return Government-loaned property to the Government upon termination or completion of the solicitation.

(3) All unexpended reference cartridges shall be returned to the Government with the test weapons. Record of test rifles used and the number of cartridges expended in each weapon used shall be included as data in the test report(s).

f. Data Item Descriptions (DIDs) that are to be substituted for canceled and superseded DIDs, with reference to the appropriate Contract Data Requirements List (CDRL) (DD Form 1423).

g. First Article: The solicitation must specify if First

Article inspection is required. If First Article inspection is required, the solicitation must specify the quantity (sample size) of cartridges and the component name and quantity of each cartridge component to be subjected to First Article inspection. The solicitation must also include clauses that require the following: First Article sample shall be representative of the manufacturing methods and processes to be used for quantity production. First Article sample shall be tested and the First Article report submitted prior to the beginning of production. Further production of cartridges prior to acceptance of First Article sample and written approval by the contracting officer shall be at the risk of the contractor.

Additionally, any change in a component type or manufacturer after approval of the First Article sample shall require an additional First Article sample to be submitted and accepted prior to further production (including certification of propellant reactivity stability). The Government may require sample cartridges delivered to the Government and may subject sample cartridges to any or all of the inspections and tests specified in this specification, the applicable documents referenced herein or in the solicitation. The increased quantity shall be for informational purposes and will not effect the accept/reject criteria. Rejection criteria: if any cartridge in the First Article sample fails to comply with any of the applicable requirements, the first article sample shall be rejected.

6.3 Definitions.

a. Misfire: Failure of a cartridge to fire after the initiating impulse has been applied to the primer, normally due to:

(1) Primer fails to fire when struck by firing pin.

(2) Propellant does not ignite when primer fires.

b. Hangfire: Any perceptible delay in the functioning of a cartridge after the initiating impulse has been applied to the primer.

c. Blown primer: A blown primer is a primer which, when the cartridge is fired, is separated completely from the head of the cartridge case. The head of the case and the primer pocket may be enlarged and deformed.

d. Longitudinal split: A longitudinal separation of the metal in the cartridge case wall produced by firing.

e. Circumferential rupture: A circumferential separation of the cartridge case wall produced by firing. A partial rupture is one that extends less than 360 degrees around the case. A complete rupture is one that extends entirely around the case, separating the case into two parts.

f. Premature cartridge function: A premature function of the cartridge prior to intentional initiation of the firing mechanism of the weapon. Such failures usually occur during cycling of the weapon mechanism and prior to complete locking of the weapon's bolt.

g. Loose primer: Independent movement of primer in the cartridge case primer pocket or the primer falls out of the cartridge case primer pocket.

6.4 Government-loaned property: Government-loaned property is defined as property "that the Government loans to the contractor for testing or any other purpose and which does not lose its identity by becoming part of the commodity" (5.3.3.13 of MIL-STD-961D). The contracting officer should arrange to loan the property listed in

3.2 to the contractor awarded the contract or purchase order (see 6.2.e.).

6.5 Part or identifying number (PIN) structure. See 6.2.d.

APPENDIX A

PROCEDURE FOR ELECTRONIC PRESSURE AND VELOCITY TEST

A.1 SCOPE

A.1.1 Scope. The electronic pressure and velocity test shall be performed to determine the chamber pressure level, port pressure level, velocity level and the uniformity of the cartridges. This test shall be performed prior to the conduct of other ballistic tests.

A.2 EQUIPMENT

A.2.1 Mount. A pier or mount of solid construction shall be utilized to mount the universal receiver and barrel assembly.

A.2.2 Barrel. The test barrel shall be 20.000 ± 0.010 inches in length and shall be in accordance with the requirements of SCATP- 5.56mm (Heavy Bullet) Cartridges and drawing 19200-8649410. The barrel and universal receiver assembly shall be headspaced in accordance with the requirements of SCATP-5.56mm (Heavy Bullet) Cartridges. The barrel assembly shall be acceptable provided the values obtained with the reference cartridges during the test are as described: the peak average chamber pressure is within plus or minus 3,500 psi of the assessed value of the reference lot, the peak port pressure is within plus or minus 2,000 psi of the assessed value of the reference lot and the average velocity is within plus or minus 35 fps of the assessed value of the reference lot.

A.2.3 Transducer. A piezoelectric transducer shall be used in accordance with the requirements of SCATP–5.56MM (Heavy Bullet) for EPVAT testing. The transducer shall be calibrated in accordance with SCATP–5.56MM (Heavy Bullet). If Kistler type transducers are used, calibration is not required.

A.2.4 Measuring equipment. Equipment shall be in accordance with the requirements of SCATP–5.56MM (Heavy Bullet) for EPVAT testing, less the equipment required to measure action time.

A.3 USE OF REFERENCE CARTRIDGES

A.3.1 Reference cartridges shall be used to establish range and equipment corrections prior to firing an ammunition lot for acceptance. A minimum of twenty (20) reference cartridges shall be fired for each test sample of forty (40) cartridges. If several electronic pressure and velocity tests are grouped such that they may be fired in a common test barrel and within a period of time of 4 hours maximum, then a single twenty (20) cartridge reference firing may be performed. Reference cartridges shall be temperature conditioned at 65°F to 75°F only.

APPENDIX A (cont.)

A.3.2 After the required number of reference cartridges has been fired, the actual average chamber pressure, the actual average port pressure and the actual average velocity of the reference cartridges shall be compared with the assessed value. If the assessed value is higher than the actual average chamber/port pressure of the reference cartridges, the difference is a plus correction and shall be added to the average chamber pressure of the test cartridges. If the assessed value is lower than the actual average chamber/port pressure of the reference cartridges, the difference is a minus correction and shall be subtracted from the average chamber pressure of the test cartridges. If the assessed value and the actual average chamber/port pressure of the reference cartridges are identical, then no correction is applied. If the assessed value is higher than the actual average velocity of the reference cartridges, the difference is a plus correction and shall be added to the average velocity of the test cartridges. If the assessed value is lower than the actual average velocity of the reference cartridges, the difference is a minus correction and shall be subtracted from the average velocity of the test cartridges. If the assessed value and the actual average velocity of the reference cartridges are identical, then no correction is applied.

A.4 ELECTRONIC PRESSURE AND VELOCITY TEST PROCEDURE

A.4.1 Cartridge conditioning. The required number of test cartridges shall be placed in a vertical position, primer-end down, in recessed holding blocks. The cartridges shall be permitted to come to a temperature of 60°F to 80°F prior to being placed in the controlled temperature room or container. The recessed holding blocks containing the cartridges shall be placed in a controlled temperature room or container in such a manner that all the cartridges are subjected to a uniform temperature for a minimum of two hours, prior to firing. The container or room shall be maintained at the temperature range for each test specified in Table II. Reference cartridges shall be temperature conditioned at 70°± 5°F only for each temperature range of firing.

A.4.2 Barrel preparation The chamber and bore of the test barrel shall be thoroughly cleaned and wiped dry prior to firing, and shall be cleaned after firing each group of rounds for record.

A.4.3 Firing.

A.4.3.1 Two (2) warming (fouling) shots shall be fired after each cleaning of the test barrel. During warm and foul, chamber pressure shall be measured using transducer in accordance with paragraphs A.4.3.3 through A.4.3.6 below, but the readings shall not be included in the record of the sample.

APPENDIX A (CONT)

A.4.3.2 The cartridges shall be placed in an insulated box (five cartridges at a time) and the box placed at a point convenient to the technician. The cartridges are then removed singly from the insulated box immediately before firing. If an insulated box is not available, then the cartridges shall be removed singly from the controlled temperature room or container immediately before firing.

A.4.3.3 The cartridge shall be chambered very carefully.

A.4.3.4 The breech-block shall be closed gently.

A.4.3.5 The trip lever to which the lanyard is attached shall be carefully engaged to the hammer. If the technician encounters any difficulty closing the breech-block or engaging the trip lever, the test shall be discontinued until such difficulty is corrected. If any delay should occur after the cartridge is placed in the chamber, and the duration of the delay is approximately 1 minute or longer, that cartridge shall be extracted and another inserted in its place.

A.4.3.6 The cartridge shall be fired. The breech-block shall be lowered and the cartridge case extracted.

A.4.3.7 The procedure prescribed in A.4.3.3 through A.4.3.6 is repeated until the required number of cartridges has been fired.

A.4.3.8 The average chamber and port pressures of the reference cartridges shall be compared to their respective assessed values for the reference lot to assure that the test barrel meets the requirements of A.2.2. The average velocity of the reference cartridges shall be compared to the assessed value for the reference lot to assure that the test barrel meets the requirements of A.2.2.

A.4.3.9 The chamber and port pressure correction shall be obtained as prescribed in A.3.2. The velocity correction shall then be obtained as prescribed in A.3.2.

A.4.3.10 The chamber pressure correction obtained with the reference cartridges shall be applied to the average chamber pressure and to the maximum individual chamber pressure obtained with the test cartridges as prescribed in A.3.2. The port pressure correction obtained with the reference cartridges shall be applied to the average port pressure as prescribed in A.3.2. The velocity correction obtained with the reference cartridges shall be applied to the average velocity obtained with the test cartridges as prescribed in A.3.2.

A.4.3.11 The maximum individual peak pressure and the time of flight over the screens and/or the velocity shall be recorded.

APPENDIX A (CONT)

A.4.3.12 The test cartridges shall then be fired in accordance with A.4.3.1 through A.4.3.7 above.

A.4.3.13 Continuous air cooling should be used on the barrel throughout the test. If air cooling is not available, firing should be regulated so that one cartridge is fired every 15 seconds. The barrel shall be allowed to cool to ambient temperature between each series of tests, or after a maximum of sixty (60) cartridges have been fired. At no time shall the exposed metal surface of the test barrel become too hot to grasp with the bare hands (approximately 140°F). After the barrel has cooled to ambient temperature, warming (fouling) shots shall be fired in accordance with A.4.3.1 prior to continuation of the test.

A.5 EXAMINATIONS

A.5.1 Examinations. All fired cartridge cases and primers shall be visually examined to determine compliance with the applicable requirements of Table I. In the event that fired case or primer defects are encountered, or if a misfire(s) occurs, then the test weapon shall be examined to determine if the defect(s) is attributable to the weapon. If the weapon is at fault, then the test shall be disregarded and the weapon shall be repaired or replaced prior to performing a retest. If the defect cannot be attributed to the weapon, then the defect shall be attributed to the cartridges. Misfired cartridges shall be disassembled to determine the cause of the misfire.

APPENDIX B

PROCEDURE FOR ACCURACY TEST

B.1 SCOPE

B.1.1 Scope. The accuracy test shall be performed to determine the uniformity and dispersion of the bullets at a specified distance from the test weapon.

B.2 EQUIPMENT

B.2.1 Range. The firing range shall be arranged such that a horizontal distance of 200 to 201 yards is maintained from the muzzle of the test weapon to the face of the test targets.

B.2.2 Weapon mount. The accuracy test weapon shall be supported during testing by mounting in the accuracy test fixture as described…