SURG_Attachment_02_Phase_Two_Testing__170224.pdf

H92222-17-R-0011 Attachment 02 Phase Two

7 February 2017 Table 1: Phase Two Requirements / Verification References

Requirement Section 3 Requirements Quantity

First Article*

Conformance Inspection* Verification

Methods

Section 5 Verification Procedures

Design Verification 3.1 5.10 Major Components 3.4.1 10 Examination 5.13.1

SURG Rail Configuration 3.4.3 10 Examination 5.13.2 Suppressor Configuration 3.4.4 10 Examination/Test 5.13.3

Firing Pin 3.4.7 10 100% Examination/Test 5.13.4 Surface Finish 3.4.8 10 Examination 5.13.5

Parts Interchangeability 3.4.9 10 100% 5 Examination/Test 5.13.6 Interface & Interoperability Verification 3.5

M4A1 LRG Interface 3.5.1 10 Examination/Test 5.14.1 Weapon and Accessory Compatibility 3.5.1 10 100% Examination/Test 5.14.2

Training & Support Gear Compatibility 3.5.3 10 Examination/Test 5.14.3 Ammunition Compatibility 3.5.4 6 Examination/Test 5.14.4

Functional Performance Requirements 3.6 Reliability 3.6.1 6 1 3 Test 5.15.1

Precision, Fixture Fired 3.6.2 6 3 Test 5.15.2 Barrel Life 3.6.4 6 Test 5.15.3

Muzzle Velocity 3.6.5 3 Test 5.15.3 Suppression 3.6.6 6 1 Test 5.15.4

Ergonomics / Safety / Toxic Fumes 3.6.7 6 1 5 Examination/Test 5.15.5 Cyclic Rate 3.6.9 6 Test 5.15.7

Operational & Environmental Requirements 3.7 Altitude & Deep Water Immersion Requirements 3.7.1 1 Test 5.16.1

Drain Time 3.7.2 1 Test 5.16.2 Salt Fog 3.7.3 3 Test 5.16.3

Mud 3.7.4 3 Test 5.16.4 Freezing Rain / Ice 3.7.5 3 Test 5.16.5

Sand / Dust 3.7.6 3 Test 5.16.6

Rain 3.7.7 3 Test 5.16.7 Electromagnetic Interference & Compatibility 3.7.8 1 Examination/Test 5.16.8

Operating Temperature 3.7.9 1 Test 5.16.9 Chemical Resistance 3.7.10 1 Test 5.16.10

Drop Test / Rail Durability / Repeatability 3.7.11 1 Test 5.16.11 Support 3.8 Marking 3.8.1 10 100% VL III Examination 5.17.1

Workmanship 3.8.2 10 Examination 5.17.2 *Requirements with 100% indicated for First Article or Conformance Inspection represents that all units of the test sample will be inspected. Integers listed will be the quantity of weapons tested.

PHASE REQUIREMENTS: Phase Two (2) will be conducted with ten (10) weapons from each vendor.

5.10 Design Verification Phase Two

When specified a sample of the system shall be subjected to design verification in accordance with Table I. The specified design verifications are performed to assure that the system has the required features and performance capabilities designed into it. This assurance, when attained through the specified verification procedures, assumes that the samples tested represent the distribution of weapon systems that are producible across the full range of limits of the vendor’s current technical data, processes and materials. Any change made to the vendor’s current technical data, processes and materials, without sufficient investigation, evaluation, and government approval invalidates this important assumption. It is very costly to repeat the design verification and therefor technical data, processes, and materials shall be locked for the systems submitted and all subsequent production unless changes are approved by the Government of the baseline configuration. Conformance to the baseline configuration technical data alone does not guarantee Government acceptance of product. Phase Two testing will be done IAW Table IV.

SURG units will be confirmed by Phase One (1) measurements, photographs, and records to be unchanged from Phase One (1) to Phase Two (2).

Design Verification Test Rejection.

If any sample system fails to comply with any design verification requirement/s, the design shall be rejected. No change to the rejection decision shall be considered without a formally documented investigation into the cause and corrective/preventative actions needed to preclude reoccurrence.

5.11 First Article Inspection Phase Two.

When specified a sample of the system shall be subjected to First Article Inspection in accordance with Table I. First Article is based on the assumption that the above verified design has not been changed. Some design features are re-verified in First Article but the First Article’s primary purpose is provide confidence that the weapon systems conform to the approved verified design and that all required performance levels are still attained.

First Article Rejection.

If any system fails to comply with any of the applicable requirements, the First Article sample shall be rejected. No change to the rejection decision shall be considered without a formally documented investigation into the cause and corrective/preventative actions needed to preclude reoccurrence.

5.12 Quality Conformance Inspection Phase Two.

When specified a sample of the system shall be subjected to quality conformance inspection in accordance with Table I. Quality conformance inspection assumes a verified design, conformance to that design and that the vendor has a sound quality control system in place. Any non-conformance indicates a flaw in those assumptions. Sampling Verification Levels (VL), when specified, pertain to sampling inspection plans in accordance with MIL-STD-1916.

Inspection Lot Formation.

Unless otherwise specified, lot formation shall be in accordance with MIL-STD-1916.

Lot Size.

The maximum lot size shall be one (1) month’s production but not to exceed 1000 systems.

Lot Identification.

Each inspection lot shall be identified with a lot number.

Conformance Inspection Rejection.

Failure to meet any of the requirements shall be cause for rejection of the lot. (See 7.2) No change to the rejection decision shall be considered without a formally documented investigation into the cause and corrective/preventative actions needed to preclude reoccurrence.

V/M/S - Visual, Manual, Standard measuring and test equipment.

When examination is specified in Attachment V, Table I V/M/S shall be used when requirement compliance can be readily determined through visual and manual examinations or simple measurement techniques utilizing Standard Measuring and Test Equipment (SMTE). SMTE is defined in “Inspection methods” of MIL-W-63150 “Weapons and Support Materiel, Standard Quality Assurance Provisions for”.

5.13 System Requirements Verification Methods

Major Components.

SURG kit will be confirmed to include all required components per section 3.4.1. to include:

Upper Receiver Group composed of upper receiver/barrel/operating system assembly and bolt/carrier assembly along with a sound suppressor (may be integral with barrel), operators manual and maintenance manual.

Rail Configuration.

SURG kit will be confirmed to meet requirements and tested for compliance with objectives for all fixed and detachable rails, rail mounting methods, locations and repeatability requirements/objectives per section 3.4.3 to include:

a. Profiling consistent with MIL-STD-1913.

b. MIL-STD-1913 rail timing and gap requirements will be evaluated. Rail mounting repeatability will be done using magnified day optic and laser sight. Both will be aligned to the same POA. Rail will be removed and reinstalled with laser sight remaining attached to rail section. POA shift between the magnified day optic and the laser sight will be documented and compared to requirements.

Suppressor Configuration.

SURG kit will be confirmed to meet requirements and tested for compliance with objectives for suppressor configuration per section 3.4.4. to include:

a. SURG suppressor will be confirmed to be rebuildable including any wear items inherent in

SURG suppressor design. Suppressor components will be inspected throughout endurance and reliability testing to identify wear components.

b. Testing to confirm the rebuildable components of the suppressor last the required 15,000 rounds or meet the 20,000 round objective will be done concurrently with the endurance and reliability testing.

c. Testing of the requirement for the suppressor not to vibrate loose will be done concurrently with endurance and reliability testing.

Firing Pin SURG kit will be confirmed to meet requirements for firing pin related thresholds per section 3.4.7.

a. Firing pin indent. The firing pin indent will be measured utilizing gage indicator in accordance with Army drawing 8440218, plug gage in accordance with Army drawing 8440219, plug gage in accordance with Army drawing 8440220, and copper compression cylinders in accordance with Army drawing 8440920 for insertion in the barrel chamber.

b. Firing pin indent. The bolt will be retracted to the open rearward position and held open. A zero indicator reading will be made on the height of the copper compression cylinder before insertion into the chamber adapter. The chamber adapter containing the copper compression cylinder will then be inserted in the barrel chamber. The bolt will be manually returned to the battery position, the trigger will be pulled to release the hammer and indent the copper compression cylinder. The chamber adapter will be removed from the barrel chamber and the depth of the indent on the copper compression cylinder determined by measuring the distance from the original zero indicator reading to the bottom of the firing pin impression.

c. Muzzle down position indent. The weapon will be held in a muzzle down position with the muzzle end supported. A zero indicator reading will be made on the height of the copper compression cylinder before insertion into the chamber adapter. The bolt will be retracted to the rearward position and held open. The chamber adapter containing the copper compression cylinder will then be inserted into the barrel chamber. The bolt will be returned to the battery position under spring action. The trigger will not be pulled. The chamber adapter will be removed from the barrel chamber and the depth of the indent in the copper compression cylinder determined by measuring the distance from the original zero indicator reading to the bottom of the firing pin impression.

d. Firing pin indent location. The firing pin indent position on pressure cylinder will be measured using approved Standard Measuring & Testing Equipment (SM&TE).

e. Firing pin protrusion. The firing pin protrusion will be tested using approved SM&TE with the firing pin in the fired position.

f. Firing pin reliability to ignite primers will be assessed during endurance testing.

g. Verify that firing pin indent requirements per MIL-DTL-71186A w/AMD3 are satisfied.

Surface Finish SURG kit will be confirmed to meet the requirements and tested for compliance with objectives for all surface finishes per section 3.4.8.

Parts Interchangeability

a. Five (5) SURG’s will be labeled 1 thru 5 and used for this test.

b. Five (5) bins shall be labeled 1 thru 5 and used for this test.

c. The first weapon will be disassembled and distributed into the five (5) bins, so that no parts with mating surfaces are in the same bin. The 5 groups of non-mating parts will be based on the supplied parts list. One (1) time use part(s) such as screws, spring pins, etc., will be placed in the same tray as their mating or associated part. Any one (1) time use part(s) rendered unserviceable by disassembly will be replaced without penalty to the interchangeability test. The components in bin 1 will then be identified as group 1. The remaining SURG’s will be field stripped and distributed in accordance with Table V:

Interchangeability Matrix so the components in bin 2 are now identified as group 2, and so on.

Table I: Interchangeability Matrix

SURG Bin 1 Bin 2 Bin 3 Bin 4 Bin 5

1 Group 1 Group 2 Group 3 Group 4 Group 5

2 Group 2 Group 3 Group 4 Group 5 Group 1

3 Group 3 Group 4 Group 5 Group 1 Group 2

4 Group 4 Group 5 Group 1 Group 2 Group 3

5 Group 5 Group 1 Group 2 Group 3 Group 4

d. From each bin and assigned M4A1 Lower Receiver Group, a new SURG equipped M4A1 will be assembled.

e. The SURG equipped M4A1 will then be subjected to headspace check, firing pin indent test, accuracy/dispersion test, and rate of fire testing.

5.14 Interface & Interoperability Verification

M4A1 Lower Receiver Group Mounting SURG kit will be confirmed to mount to the M4A1 lower receiver utilizing the current 2 pin upper receiver group attachment method per section 3.5.2 requirements.

Weapon and accessory compatibility.

SURG kit will be confirmed to meet requirements for weapon and accessory compatibility per section 3.5.2 to include:

a. The SURG samples will be checked to confirm proper M4A1 lower interface and function when installed.

b. SURG equipped M4A1 shall be tested for the following if equipped with a folding buttstock:

5.14.2.b.1 SURG equipped M4A1 will be converted to folding buttstock. Folding buttstock shall be installed per manufacturer instructions while being timed for requirement.

Folding buttstock kit shall be removed and M4A1 lower receiver group restored to standard configuration while being timed for requirement. Notes and observations on the process and the wear on the LRG will be noted.

5.14.2.b.2 SURG equipped M4A1 shall be evaluated for unimpeded firing with folding buttstock in the deployed and stowed position.

5.14.2.b.3 SURG equipped M4A1 with be evaluated to ensure SURG system can meet all required threshold with standard lower receiver assembly (M4A1).

5.14.2.b.4 Folding buttstock kit will be evaluated to ensure the system will last the lifetime of the weapon system.

5.14.2.b.5 Folding buttstock system will be evaluated with respect to unimpeded operation of all SURG and M4A1 controls or normal operations in both the deployed and stowed positions.

5.14.2.b.6 Folding buttstock will be drop tested per TOP 3-2-045 in the deployed and stowed positions for verification of threshold and objective requirements.

c. Confirm that SURG equipped M4A1 is compatible with operation of the existing MDNS weapons accessories per section 3.5.2

Training and support gear compatibility.

SURG kit will be confirmed to meet requirements for Training and support gear compatibility per section 3.5.3 to include:

a. The SURG will be configured with the associated BFA and measurements will be recorded.

b. The SURG Blank Firing Adapter will be properly configured, secured on M4A1 lower receiver group and tested for reliable function to minimum threshold requirements using M200 blank cartridges. ROF will be checked for the BFA during this testing.

c. The SURG equipped M4A1 will be configured with BFA. The assembly will be secured in a fixture and remotely fired using three rounds MK318 MOD0 / MOD1 ammunition. The SURG and M4A1 assembly will be inspected between rounds for any hazardous results.

Results of each iteration will be photographed.

d. SURG equipped M4A1 will be confirmed to reliably function per requirements and objectives with respect to UTM 5.56mm Man Marker Rounds (MMR), UTM Battlefield Blank Rounds (BBR) and Simunition® FX® 5.56mm rounds.

e. Confirm that SURG kit comes with any non-standard supplies necessary to clean weapon.

Ammunition Compatibility.

SURG kit will be confirmed to meet requirements for Ammunition Compatibility per section

3.5.4 to include:

a. Ammunition compatibility, operating temperature and reliability will be tested simultaneously. The ammunition compatibility testing will include 1200 rounds broken into 240 Hot, 240 Cold, and 720 Ambient rounds sets similar to 3-2-045 method 4.17.2. A minimum of one (1) SURG will be used per ammunition type for at least one (1) 1200 round cycle following the firing schedule of Table VI: Reliability Firing Schedule. Ammunitions types used will be based on availability.

5.15 Functional Performance Requirements

Reliability SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Reliability per section 3.6.1 to include:

a. Testing will be performed in general accordance with TOP 3-2-045, paragraph 4.3.

b. Each SURG equipped M4A1 will be tested until they exceed allowable malfunctions per

Table I in section 3.6.1, number of maximum replacement parts exceeded or 15,000 rounds for threshold up to 20,000 rounds for objective whichever comes first.

c. For each weapon a mixture of M4A1 compatible magazines will be used per requirement in section 3.6.1.

d. Attitude Testing. Weapon will be tested IAW TOP 3-2-045 section 4.11.

e. Unrestrained firing. Weapon will be tested for malfunctions due to unrestrained firing periodically throughout endurance testing.

f. The firing schedule is shown in Table II: Reliability Firing Schedule.

g. The maintenance, inspection, and test schedule is shown in Table III: Test / Inspection /

Maintenance Intervals.

h. Design of serialized portion of the SURG suppressor will be evaluated for durability over the

SURG lifespan using a combination of live fire, simulated fire and assembly / disassembly to simulate replaceable components replacement cycle.

i. System service life assessment. Though not required, reliability testing of weapon systems beyond the defined 15,000 round (T) /20,000 round (O) life will provide assurance that potentially marginal conditions (wear-out and fatigue limits) are identified and mitigated.

Failures occurring after the service life will not be scored for acceptance/requirement purposes.

Table II: Reliability Firing Schedule

Magazine (30 rounds) Total Round Count Shot Sequence

1 30 Semi-Auto, 2 second intervals

2 60 3-5 round Auto bursts, 4-5 second intervals

3 90 Semi-Auto, 2 second intervals

4 120 Semi-Auto, 5-6 second intervals

Cool after each cycle – follow Table IV for other maintenance, inspections and tests

Note: Alternate magazine types used every other 1200 round cycle.

Table III: Test / Inspection / Maintenance Intervals

Interval Test / Inspection / Maintenance

Baseline / Start HS / Throat Erosion / Precision / Complete Sound / Flash / ROF / Firing Pin

Each 600 rounds Lubricate per OM

Each 1200 rounds HS / Throat Erosion / Complete Clean and Lubricate per OM, Muzzle Velocity / Precision

Each 2400 rounds All 1200 Round Features / Basic Sound / ROF

End of Life HS / Throat Erosion / Precision / Complete Sound / Flash / ROF / Firing Pin

Fixture Fired Precision SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Fixture Fired Precision per section 3.6.2 to include:

a. Three (3) SURG equipped M4A1 Carbines will be tested from a fixture firing 5 groups of 10 rounds each to determine system precision capabilities using MK318 MOD1 ammunition at 100 yards and 100 meters (Reference 5.15.3 for details). Three (3) SURG equipped M4A1 Carbines will be tested from a fixture firing 5 groups of 10 rounds each to determine system precision capabilities using M855A1 ammunition at 100 yards and 100 meters (Reference

5.15.3 for details). Extreme Spreads and Mean Radii will be recorded for each 10 shot group.

A minimum of ten (10) zeroing / settling shots will be fired for each fixture installation of a SURG equipped M4A1.

b. Each SURG equipped M4A1 will be tested until they fail allowable accuracy requirements or fail muzzle velocity requirements. Weapons precision will be tested at intervals to 15,000 rounds for threshold and 20,000 rounds for objective. Reference 5.15.3 Barrel Life for precision testing intervals over the course of barrel life.

Barrel Life SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Barrel Life per section 3.6.4 to include:

a. Precision testing will occur every 1,200 rounds fired for each SURG equipped M4A1.

Weapon will be mounted in precision fixture and a minimum of 10 settling shots will be fired for each installation of the weapon into the fixture. Weapon will be detail cleaned per manufacturer’s provided instructions prior to precision testing. For each iteration of 1200 rounds of reliability testing five (5) groups of 10 rounds each will be fired per weapon.

Average ES over the five groups may degrade up to 1.5 MOA over LAT in the first 10,000 rounds fired without failure. Average ES over the five groups may degrade up to 3.0 MOA over LAT between 10,000 and 15,000 rounds fired without failure. If weapon achieves the requirement for precision up to 15,000 rounds weapon will be tested until 20,000 rounds or failure to meet objective precision requirements. SURG unit will be considered failed if the AVG MV drops by over 200 fps from the original MV. Alternate ammunition types will be evaluated for objective requirement with respect to precision. Testing will be conducted in underground test range at 100m and results multiplied by 2.7432 to convert to 300 yards for the following round counts 0, 10,000, 15,000 and 20,000, if weapon makes it to the respective precision interval during reliability testing. Weapons will be tested at 100 yards outdoors every 1,200 rounds that underground testing is not conducted. Results at 100 yards will be converted to 300 yards to compare to the LAT plus requirements with a conversion factor of

3.0. All results will be multiplied by the respective conversion factor to convert to 300 yard results for objective and threshold evaluation.

Note: All references to MOA are true MOA unless otherwise notated.

b. Throat erosion will be measured every 1200 rounds fired for reference.

c. Headspace will be measured every 1200 rounds fired to verify requirements are meant.

d. A determination that a Sound Suppressor has had two (2) instances of strikes to baffles or end cap(s) is a determination of end of weapon life.

e. Sound Suppression will be confirmed every 2400 rounds at the shooters ear (AVG cannot exceed 140 dB). Sound pressure levels will be measured for 10 consecutive rounds of MK318 MOD0 / MOD1 fired at one (1) round every 3 seconds for each weapon in reliability testing. String of ten rounds will be done in continuum. If a ten round string is interrupted the weapon will be allowed to cool to ambient temperature and start a new ten round string.

f. Point of impact shift with respect to suppressor removal and installation for cleaning will be evaluated from fixture firing per threshold and objective requirements.

g. Muzzle velocity will be measured every 1200 rounds for comparison to threshold and objective requirements. Average muzzle velocity will be collected on the second ten round group fired for fixture fired precision using MK318 MOD1 ammunition.

Suppression SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Suppression per section 3.6.6 to include:

Flash Suppression: The average muzzle flash (suppressed weapon) of each weapon (i.e., SURG vs. MK18 MOD1 w/FMBS-c suppressor) will be measured. The purpose of the flash test is to determine the muzzle flash of a weapon system/ammunition. The test is conducted per the following steps and with supplied NSWC Crane Test Report.

a. Conduct testing in dark environment. Fire weapon from fixture or repeatable bench position within 0.25 inch in left / right and forward / rear orientations to ensure accurate measurements.

b. Setup testing equipment per supplied test report.

5.15.4.b.1 Place front edge of lens 10 feet from approximate center of the flash event downrange, at 5° left or right of bullet path.

Note: Ensure unimpeded line of sight between flash measurement equipment and muzzle of weapon.

5.15.4.b.2 Configure.

c. Fire 10 shots using MK318 MOD0 / MOD1. Fire one round every 3 seconds after the first round.

d. Allow weapon to cool thirty minutes.

e. Repeat c. and d. for three groups of ten rounds fired.

f. Collect and analyze data.

5.15.4.f.1 Flash Measurement Equipment

• 2 inch diameter lens of 150mm focal length

• Unfiltered photodiode; model SED033, International Light, Inc

• Transimpedance Amplifier; TTI Inc.

• National Instruments cDAQ set to 100 kHz sampling rate.

• 1000°C blackbody source (1inch cavity) using a variable aperture wheel.

• Five apertures ranging from 1.6mm to 12.7mm for three order of magnitude radiant intensity calibration.

g. If the average SURG muzzle flash is more than a 5% increase when compared to the average MK18 MOD1 w/FMBS-s suppressor muzzle flash, this is considered a failure.

Sound Suppression: A sound pressure level test shall be conducted outdoors using six (6) SURG equipped M4A1s at the beginning of testing and at end of life. Ten rounds of MK318 MOD0 / MOD1 ammunition shall be fired per weapon. The peak sound pressure levels will be measured in accordance with TOP 3-2-045, at the locations given below. Measurements will be taken with microphones and the horizontally oriented weapon at a height of 1.6 meters above ground to determine conformance to the requirement new and at end of barrel life. Additional to TOP measurements, sound will also to be measured at the shooters ear (L/R) at beginning of life, each 2400 rounds and at end of barrel or suppressor life. The four (4) positions from TOP 3-2- 045 are as follows:

• Shooters left ear position (assuming right handed shooter)

• 5 meters directly to the rear of the weapon muzzle.

• 5 meters to the left and parallel to the weapon muzzle.

• 5 meters to the left and rear at 45° from the line of fire.

Note: Shooters ear position is defined as 12 inches rear of the ejection port and 6 inches right / left of primary axis of the weapon. Reference Attachment 01 suppression section for details on shooters ear suppression measurements.

a. SURG equipped M4A1 shall fire 60 rounds in two (2) minutes at a rate of one (1) round every two (2) seconds. Immediately after firing the last round an image will be taken using AN/PVS-24 image intensifier. Two (2) minutes after the last round another image will be taken. Images will be compared to MK18 MOD1 baseline.

Ergonomics / Safety / Toxic Fumes SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Ergonomics / Safety / Toxic Fumes per section 3.6.7 to include:

a. The SURG equipped M4A1 toxic fumes emissions will be compared against the M4A1 unsuppressed. The test guidelines of TOP 3-2-045 4.15 and TOP 2-2-614 4.2 and 4.3 will be used. Fume levels will also be compared with current guidelines published by the Occupational Safety and Health Administration (OSHA) Permissible Exposure Limits (PELs), American Conference of Governmental Industrial Hygienists (ACGIH) Threshold Limit Values (TLV), and military unique criteria outlined in MIL-STD-1472G.

b. The SURG shall be tested per SS800-AG-MAN-010/P-9290 Rev. A section F.4.2 for off-gas conformance.

Heat Control / Mirage Reduction SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Heat Control / Mirage per section 3.6.8 to include:

a. The SURG equipped M4A1 will be tested using the USAF 1951 resolution chart for limit of resolution with magnified day optical sight at maximum magnification compared to the MK18 MOD1. Once baseline resolution is established, resolvability after firing at a rate of 1 round every 2 seconds for 50 rounds for threshold verification; 120 rounds for objective verification will be recorded for each weapon.

Cyclic Rate SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Cyclic Rate per section 3.6.9 to include:

a. Cyclic rate of the SURG equipped M4A1 will be checked at 2400 round intervals in testing using a minimum 10 round burst. It will be checked at ambient and temperature extremes as well as with alternate ammunition types. SURG kit can include replacement buffer and buffer spring to replace like parts in M4A1 lower receiver group. Parts will be installed per manufacturer provided instructions prior to testing.

5.16 Operational & Environmental Requirements

Altitude and Deep Water Immersion SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Altitude and Deep Water Immersion per section 3.7.1.

Any SURG components which could be affected by changes in atmospheric pressure will be exposed to altitudes up to 30,000 feet [9144 meters] above sea level (4.3 psi) and down to 66 feet [20.1 meters] deep in salt or fresh water (44.1 psi) for 8 hours (T).

Drain Time

Drain Time per section 3.7.2.

The SURG equipped M4A1 will be fully immersed in water and then quickly removed with the muzzle parallel to the ground and timed for how long it takes for water to stop flowing (down to drips). The SURG equipped M4A1 will also be tested in the same manner with a shot being fired immediately after 3 seconds of drain time. The suppressor will be inspected for any baffle strikes after firing. Drain time will be filmed with time stamp ensuring the same level of flow is recorded as “drained”.

Salt Fog SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Salt Fog per section 3.7.3.

One (1) rifle with empty magazine inserted into SURG equipped M4A1, debris mitigation / dust cover closed will be exposed to salt fog in accordance with TOP-3-2-045 4.5.7 Salt Fog along with 8 loaded M4A1 compatible magazines. The exposure shall be alternating 24-hour periods of salt fog exposure and 24-hour drying conditions for a minimum of four (4) 24-hour periods (two (2) wet and two (2) dry) in accordance with the TOP. After 48 hours the weapon shall fire 240 rounds without any maintenance using the reliability firing cycle. Minimal necessary maintenance will be performed to restore operation if the weapon ceases to function. There shall be no evidence of any corrosion that prevents functioning. Inspect and record data per TOP.

Mud SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Mud per section 3.7.4. to include wet mud and then upon passing wet mud testing dry mud testing. A total of three (3) SURG equipped M4A1s with three (3) fully loaded magazines will be used for this test.

Wet Mud:

a. Wet mud. (120 rounds total) The wet mud test shall be conducted in accordance with TOP-

3-2-045, paragraph 4.5.5. The muzzle will be taped over during this testing. A full 30 round magazine of MK318 MOD0 / MOD1 will be inserted and a round will be chambered and the safety engaged before SURG equipped M4A1 mud exposure.

b. After immersion, the test items will then be wiped off by hand to remove excess mud and each weapon will then fire the loaded round and inserted magazine worth of ammunition. 60 additional MK318 MOD0 / MOD1 rounds will be fired along with 30 M855 rounds.

c. At the completion of firing, each weapon will undergo a visual / manual function check.

Dry Mud:

d. Dry mud. (120 rounds total) The dry mud test shall be conducted in accordance with TOP-3-

2-045, paragraph 4.5.5. The muzzle will be taped over during this testing. A full 30 round magazine of MK318 MOD0 / MOD1 will be inserted and a round will be chambered and the safety engaged before SURG equipped M4A1 mud exposure.

e. After immersion, the weapon shall then be left to dry at 70 ± 5 °F for at least 4 hours prior to a firing attempt (no removal of any mud).

f. Each weapon shall then fully fire the loaded round and inserted magazine. 60 additional MK318 MOD0 / MOD1 rounds will be fired along with 30 M855 rounds.

h. At the completion of firing, each weapon shall undergo a visual/manual safety function check.

Freezing Rain/Ice SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Freezing Rain/Ice per section 3.7.5.

A total of three (3) SURG equipped M4A1s will be used for this test. The 30-round magazine will be loaded to its capacity with MK318 MOD0 / MOD1 ammunition. Each rifle and loaded magazines will be conditioned in a temperature chamber at 0°F ±3°F [-18°C] for 8 hours. The temperature of the chamber will then be raised to 20°F ±3°F [-7°C]. A light spray of water will be applied to the system until 0.126 to 0.252 inches (3 to 6 millimeters) of ice has accumulated.

Without removing the ice, each system must demonstrate conformance to the requirement individually after the firing of 120 rounds of MK318 MOD0 / MOD1 ammunition.

Sand / Dust SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Sand / Dust per section 3.7.6.

A total of three (3) SURG equipped M4A1s with four (4) fully loaded magazines will be used for this test. Each rifle and loaded magazines will be subjected to testing in accordance with TOP 3- 2-045, Sand and Dust section 4.5.4 “Static test procedure for dust exposure”. SURG must demonstrate conformance to the requirement individually after the firing of 120 rounds of MK318 MOD0 / MOD1 ammunition. All loaded magazines will be exposed to sand / dust during testing.

Rain SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Rain per section 3.7.7.

A total of three (3) SURG equipped M4A1s and four (4) fully loaded magazines will be used for this test. The 30-round magazines will be loaded to capacity with MK318 MOD0 / MOD1 ammunition. Each rifle and loaded magazines will be subjected to testing in accordance with TOP 3-2-045, “Water Spray (rain) Test”. Each system must demonstrate conformance to the requirement individually after the firing of 120 rounds of MK318 MOD0 / MOD1 ammunition.

All loaded magazines will be exposed to rain during testing.

Electromagnetic Interference and Compatibility SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Electromagnetic Interference and Compatibility per section 3.7.8.

The SURG shall be tested IAW MIL-STD-461F, MIL-STD-464C, TOP 1-2-511 when applicable for interference with or affected by electromagnetic emissions from battlefield electrical device operations in the immediate vicinity (up to 3 meters). The SURG shall be tested IAW MIL-

STD-461F, MIL-STD-464C, TOP 1-2-511 when applicable for full functionality during and after exposure to Electromagnetic energy/pulses.

Operating Temperature SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Operating Temperature per section 3.7.9. to include:

a. Cold function. A total of three (3) SURG equipped M4A1s with fully loaded magazines shall be shall be used for this test. Each system shall be lubricated using cold weather lubricant for small arms weapons in accordance with MIL-PRF-14107. The system, including the ammunition, will be conditioned in a cold temperature chamber at -60°F +/- 5°F [-51°C] for no less than 4 hours, and shall be fired within 1 minute of being removed from chamber. The system will be subjected to a low temperature test in accordance with TOP 3-2-045 “Low Temperature Test” 4.5.1 b for a total of 240 rounds. Automatic rate of fire will be checked for each ammunition type. Ammunition types used: MK318 MOD0 / MOD1, M855A1 and alternate ammunition as available.

b. Hot function. A total of three (3) SURG equipped M4A1s with fully loaded magazines will be used for this test. Each weapon shall be lubricated using lubricant for small arms weapons, in accordance with MIL-PRF-63460. The system, including the ammunition, will be conditioned in a hot chamber at +160°F +/- 5°F [71°C] for no less than six (6) hours, and will be fired within 1 minute of being removed from the temperature chamber. The system will be subjected to a high temperature test in accordance with TOP 3-2-045 “High Temperature Test” 4.5.1 for a total of 240 rounds. Automatic rate of fire will be checked for each ammunition type. Ammunition types used: MK318 MOD0 / MOD1, M855A1 and alternate ammunition as available.

Chemical Resistance SURG kit will be confirmed to meet requirements and tested for compliance with objectives for Chemical Resistance per section 3.7.10.

a. Chemical resistance. All non-metallic components of the SURG will be tested in accordance with TOP 3-2-045 and TOP 3-2-609. The chemicals chosen are in Table XI: Conditioning Chemicals.

Table IV: Conditioning Chemicals

Compound Name Details

1 Cleaning compound, solvent MIL-L-372B Bore cleaner

2 Dry cleaning solvent P-D-680, type I or equivalent (naphtha solvent)

3 Engine oil MIL-L-2104

4 Lubricant, semi-fluid, automatic weapon MIL-L-46000B (LSA)

5 Lubricating oil, general purpose VV-L-800 (PL-S)

6 Lubricant, cleaner, and preservative MIL-L-63460A (CLP)

7 Gasoline, commercial, or combat ASTM D 910

8 Turbine fuel (JP-8) MIL-T-83133

9 Fuel oil diesel (DL-2) ASTM D 975 Grade Low Sulfur No. 2

10 Insect repellent 0-I-503E

11 Dexron VI Transmission fluid

12 Antifreeze, ethylene glycols MIL-A-46153

13 Carbon-removing compound P-C-111B, type II

14 Water Water (distilled)

15 Simulated sea water or 5% Sodium chloride ASTM D1141

16 Decontaminating agent DS2 MIL-D-50030

17 Decontaminating STB MIL-D-12468

18 Lubricating oil, weapons MIL-L-14107 (LAW)

19 Hydraulic fluid, petroleum base MIL-H-5606

20 Hydraulic fluid, fire-resistant MIL-H-46170

b. SURG kit will be verified to not have adverse effects due to cleaning in common authorized armory cleaning tanks.

Drop Test / Rail Durability / Repeatability

Drop Test / Rail Durability / Repeatability per section 3.7.11. to include:

a. A SURG equipped M4A1 will be conditioned at ambient (70°F ± 5°F) for 2 hours. The system will then be subjected to a 5 foot drop test consisting of 3 drops muzzle down plus 4 more drops in the various orientations per TOP 3-2-045 and ITOP 4-2-602 onto plywood backed by concrete. The SURG equipped M4A1 will have a primed cartridge case in its chamber and an empty 30-round magazine installed. The bolt will be closed and the safety selector placed in the safe position. After each subsequent drop the condition of the weapon including the primed cartridge and any specific SURG safety feature degradations will be recorded and photographed. Any failures suspected to be attributed to the LRG should be noted as such and investigated via high speed footage for confirmation of LRG attributable malfunctions.

b. Rail durability and repeatability will be measured per TOP 3-2-045 rough handling test. A magnified day optic and rail mounted visible laser(s) will be installed on SURG equipped M4A1. Optic and laser(s) will be mounted pre-test and aligned to the same POA. Post testing optic and laser(s) POA shift between the day optic and laser will be recorded.

c. Forend mounted accessory rails are to be evaluated per the threshold requirements with respect to removal and installation and POA shift.

5.17 Support.

Marking.

Verify that SURG kit markings are in accordance with requirements in section 3.8.1.

Workmanship Verify that SURG kit workmanship features are in accordance with requirements in section 3.8.2.

c. Confirm that SURG equipped M4A1 is compatible with operation of the existing MDNS weapons accessories per section 3.5.2