LPF-QAR-003.pdf

This document is a Quality Assurance Requirements specification for First Article Test Plans and Reports (LPF-QAR-003) issued by the U.S. Air Force for F100 engine parts. The guideline establishes mandatory testing and documentation procedures for first article production under federal contracts. First articles must be tested in their entirety for destructive testing purposes, with remaining articles subjected only to nondestructive testing. All first articles require serialization prior to test commencement.

Testing requirements encompass dimensional conformance with finish specifications, nondestructive inspection methods (FPI, Ultrasonic, Eddy Current, X-ray, visual), material property verification (mechanical, metallurgical, chemical), and conformance to process specifications and standards. All dimensional measurements require 100% inspection with tabular formatting including drawing dimensions, tolerances, actual readings, and instrument serial numbers. Nondestructive inspections must comply with LPR-QPR-018, receive 100% coverage with no sampling permitted, and include Pratt & Whitney source approval. Material testing includes composition analysis, heat treat verification, and metallurgical microanalysis with photomicrographs for raw materials, welds, and coatings. The First Article Test Plan (FATP) requires detailed testing descriptions delivered per contract schedule, while the First Article Test Report (FATR) must include all laboratory results from contractor and sub-vendor testing. All tooling and gaging must maintain NIST-traceable calibrations, and inspection masters require current calibrations with documentation included in reports. Level II or Level III inspectors are required as applicable, with certification copies provided. Destructive testing remnants and one completed article post-nondestructive testing must be delivered with condition code marking as specified in contract requirements.