M16 Thruster - RFV 8596419 .pdf

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OMB NO. 0704-0188

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DD FORM 1694, (Continuation Page) (REV 4/2015)

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DD FORM 1694 CONTINUATION PAGE INSTRUCTIONS

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REQUEST FOR VARIANCE (RFV)

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INSTRUCTIONS FOR PREPARATION OF REQUEST FOR VARIANCE UTILIZING DD FORM 1694

Instructions associated with Request for Variance Continuation Page. Use of the Continuation Page should be limited to instances when there is inadequate space provided on the parent Request for Variance, DD Form 1694. If the format or space provided in the Continuation Page is insufficient, the submitter may instead attach the necessary information to the RFV form.

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9.0.0.2.20120627.2.874785

C. Distribution authorized to U.S. Government agencies and their contractors (Administrative or Operational Use) 29 Apr 2020.

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rfvNumber: FY20-V030 procuringActNo: N00174

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12. DESCRIPTION OF VARIANCE:

Note 2. WIRE, COPPER, TYPE S, UNCOATED, A-A-59551. INITIAL WIRE SIZE AND TEMPER OPTIONAL. WIRE SHALL BE PROCESSED BY DRAWING, ANNEALING, AND/OR MACHINING TO MEET FINAL SIZE AND SHEAR STRENGTH. THE MINIMUM ELONGATION OF THE WIRE SHALL BE 1% IN 10 INCHES.

13. NEED FOR VARIANCE:

The current Note 2 implies that the wire must remain in the annealed temper and be certified to ASTM B3 (ASTM B3 is required by A-A-59551 for the annealed temper). ASTM B3 requires the minimum elongation for .0403 diameter wire to be 25 % minimum. Vendors has not been able to achieve the required shear value while maintaining 25 % elongation. Testing indicates that to just get into the minimum range of the shear requirement requires elongation to be decreased to around 8%.

To achieve the shear value, the wire often requires special processing. For example to increase its shear value, the wire can be drawn down from a larger size to a smaller size through a die to work harden the wire and increase its shear strength (also decreases elongation). For example to decrease its shear value, the wire can be annealed by thermal treatment (also increases elongation). The making of a shear pin for CAD/PAD devices often requires a unique process.

Specifications such as A-A-59551, ASTM B1/B2/B3 only define a few tempers for the wire (annealed/soft, medium-hard, hard) which is not adequate enough freedom for a manufacturer to create a shear pin to a very specific shear range. The larger industry mostly cares about elongation to make sure wires are "bendy" enough to not break and tensile strength.

The most important property of the material is the shear value which ultimately is correlated with the safety factor on the initiation of the M16 Thruster. Elongation is not important for the shear pin. In the M16 Thruster the shear pin is only held in single shear and experiences no tensile or stretching/strain effects.

ASTM B1 (hard temper) and ASTM B2 (medium-hard temper) allow elongation values down to 1% for the .0403 wire size. Several other copper CAD/PAD shear pins have used the medium-hard temper with no issue.

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DD FORM 1694, APR 2017

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REQUEST FOR VARIANCE

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PLEASE DO NOT RETURN YOUR COMPLETED FORM TO THIS ADDRESS. RETURN COMPLETED FORM TO THE ACQUIRER ISSUING CONTRACTING OFFICER FOR THE CONTRACT/PROCURING ACTIVITY NUMBER LISTED IN BLOCK 22 OF THIS FORM.

5. VARIANCE PRE OR POST-PRODUCTION:

6. BASELINE AFFECTED:

7. SYSTEM INFORMATION

10.a. OTHER EXTERNAL SYSTEM AFFECTED?:

11. IDENTIFICATION OF VARIANCE

11.a. VARIANCE CLASSIFICATION:

16. RECURRENCE

16.a. RECURRING VARIANCE?:

21. CONTRACT INFORMATION

22. CONTRACTING OFFICER

23. ORIGINATING ACTIVITY

BELOW TO BE COMPLETED BY THE APPROVING ACTIVITY

25.a. RECOMMENDATION:

26.a. DISPOSITION: (Configuration Approval Authority)

27. LIST OF ATTACHMENTS

9.0.0.2.20120627.2.874785 C. Distribution authorized to U.S. Government agencies and their contractors (Administrative or Operational Use) 29 Apr 2020. Other requests for this document shall be referred to NSWC Indian Head EOD Technology Division, Code E26.

List Of Attachments (1) FY20-V030 Attachment.pdf

CAD/PAD Division 4393 Benson Rd, Bldg 1557 Indian Head, MD 20640