180928_Draft_LITE_Plate_Perf_Spec.pdf

PRF-18001A0010

Original Design Activity:

CAGE Code 01365

Current Change Control Authority

CAGE Code 01365

PERFORMANCE SPECIFICATION

SYSTEM SPECIFICATION

FOR

BODY ARMOR, LOW INTENSITY THREAT ENVIRONMENT PLATE

This document is approved for use by all Departments and Agencies of the Department of

Defense (DOD).

Prepared by:

Program Manager Infantry Weapon Systems

Marine Corps Systems Command

2200 Lester St, Quantico, VA 22134

SUBMITTED BY: _______________________________ DATE ____________

Flora Jordan

Engineer, Individual Armor Team

Program Manager Infantry Combat Equipment

CONCURRED BY: _______________________________ DATE: ___________

Karl Solomon

Assistant Program Manager – Engineer

APRROVED FOR USE AS DATE: ___________

PRODUCT BASELINE BY: __________________________________

LtCol Christopher G Madeline

Program Manager

DISTRIBUTION STATEMENT D. Distribution authorized to Department of Defense and US DoD contractors only; Administrative or Operational use, 4 November 2016. Other requests shall be referred to the Commander, MARCORSYSCOM (Attn: PfM GCES – PM ICE) 2200 Lester Street, Quantico, VA

22134.

Comments, Suggestions, or questions on this document should be addressed to Armor Team, Program Manager Infantry Combat Equipment, 2200 Lester St, Quantico, VA 22134. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https://assist.dla.mil.

https://assist.dla.mil/

PRF-18001A0010 V1.0

UNCLASSIFIED//FOR OFFICIAL USE ONLY

i

AMSC NA FSC

THIS PAGE INTENTIONALLY LEFT BLANK

1. SCOPE

1.1 Scope. This document describes a Low Intensity Threat Environment (LITE) Plate that will improve the survivability and mobility of Marines by maximizing ballistic protection while minimizing the burdens of weight, bulk and heat stress. When placed in the Plate

Carrier Generation III (PC Gen III) the insert will provide ballistic protection from specific 5.56 mm and 7.62 mm rifle rounds, in conjunction with the use of soft armor

(mandatory source).

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this performance 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 cited in sections 3 and 4 of this specification, whether or not they are listed under Section 2, Applicable Documents.

2.2 Government Documents.

2.2.1 Specifications, standard, 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 paragraph __TBD__).

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.

2.3 Non-Government Publications. The following documents of the exact revision listed below form a part of this document to the extent specified herein.

2.4 Order of Precedence. In the event of conflict between the text of this document and the references cited herein, the text of this document takes precedence over the cited Test

Operations Procedure (TOP), and cited TOP takes precedence over MIL-STD-662F.

However, for V50 testing, MIL-STD-662F takes precedence over the cited TOP. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

AMSC NA FSC

3.1 First Article Test. First Article Testing (FAT) is a requirement for the LITE Plate.

Samples shall be subjected to FAT In Accordance With (IAW) 4.1.1.

3.2 Construction. The materials selected by the Contractor shall be capable of meeting all performance, operational, and environmental requirements specified herein. The LITE

Plate shall not contain metallic components within the hard armor composite for any reason.

3.2.1 Materials, Design & Manufacturing. Unless otherwise specified, the materials, design and manufacturing processes shall be at the discretion of the contractor provided all articles submitted to the Government meet the requirements of this specification.

3.2.2 LITE Plate Cover. The LITE Plate cover materials used shall mitigate frontal spall, increase durability, and decrease environmental deterioration of the underlying components configuration; the LITE Plate cover material shall cover the entire front and back outer surface and all side edges. The cover, including all edges, shall be free of cuts, holes, tears, abraded areas, wrinkles, bubbles, or creases. The cover shall not exhibit any areas of under adherence. There shall be no visible peeling, wrinkles, bubbles, or creases of the cover before or after any operating environment conditioning when verified in accordance with section 4.4.

3.2.2.1 Covering of Components by Spray Coating. The LITE Plate shall exhibit uniform coverage of any spray coated material. The finished LITE Plate shall exhibit no smears and or clumps on the exposed surfaces or spray coated material, nor exhibit any under covered areas on the exposed surfaces.

3.2.3 Assembly of Components by Bonding. The LITE Plate shall exhibit no evidence of under adherence between layers or components. The finished LITE Plate shall exhibit no smears and or clumps from excess bonding agent visible on the exposed surfaces when verified in accordance with 4.4.

3.3 Production Data and Technical Data Package. The Contractor shall develop, document and maintain production data for the LITE Plate and furnish it in accordance with the contract. The production data shall be traceable with the serial number of the LITE Plate.

The serial number shall be unique to each LITE Plate. The serial number shall be traceable to the production information maintained by the contractor. Traceability information shall enable identification of equipment used, the LITE Plate manufacturing date and lot information on all materials used.

a. Production data shall include inspection data generated during manufacturing, any process data collected as part of the Contractor’s quality management system and Production Process Package (PPP). This includes, but is not limited to chemistry, weight, thickness, and dimensional measurements. If ceramics are used, grain structure analysis is required (e.g., grain size maximum, minimum, average or histogram plots or both).

AMSC NA FSC

b. Supplier lot information and traceability for all component parts shall be identified in the Technical Data Package (TDP) for the finished LITE Plate.

The TDP shall include test data from an independent test source from each subcontractor and material supplier verifying the conformance of all materials and components.

c. Operational, ownership, and environmental test data generated by the

Contractor on the LITE Plate.

d. Ballistic performance test data generated under all first article, conformance, and validation testing as described in section 4.9.

e. Ballistic test records for the LITE Plate shall be durably marked and traceable from production through to each finished lot. The LITE Plate serial number marking shall not be affected by solvents, fuels, and other liquids. Ceramic cores shall be durably marked to identify and trace component to a finished end item lot and Supplier Lot.

3.4 Workmanship. The finished product shall conform to the quality requirements established by this performance specification. The Contractor shall verify and validate that all fabrication procedures will yield quality workmanship to meet product specification and contract requirements. The contractor shall control production to minimize and where possible eliminate or avoid defects. Manufacturing practices shall be capable of consistently yielding product that conforms to all requirements in this specification and internal specifications for the product and their components. The contractor shall ensure that all materials produced and integrated into the finished LITE Plate be durable and provide consistency in appearance throughout life of the product. The LITE Plate material layers and components shall be free of contaminants such as, but not limited to:

foreign object debris, any media not associated with the TDP, loose fragments of component materials or adhesives or both, operator elements not part of component materials, cleaning residue which may result in delamination between layers. LITE Plate material interfaces shall be compatible and ensure ease of use. Workmanship shall be verified in accordance with section 4.4.

3.4.1 Areal Density. The LITE Plate shall provide uniform areal density (materials coverage) throughout the entire surface area of the LITE Plate. The only exception will be when edge materials are used to protect the plate from side impact (e.g., foam) to increase the durability. Material no thicker than 0.10 in (2.54 mm) can be used for this purpose.

Materials must extend from edge to edge to provide uniform thickness throughout the entire surface area of the LITE Plate. “Patches,” “clamps,” and other materials with partial or interrupted coverage of the LITE Plate surface area shall not be acceptable.

Materials shall not cause interference with Non Destructive Test Equipment (NDTE)

(e.g., radiographic inspection). If ceramic materials are used, the ceramic shall have uniform edges without “edge breaks” or chamfers. To reduce sharp edges, an abrasive device or other equipment may be used to clean the edges in production. Uniform areal density shall be verified in accordance with paragraph 4.4.1.

3.4.2 Dimensional Measurements. The LITE Plate shall conform to all measurements, tolerances, radius and edge chamfers cited in drawings from paragraph 2.2.2 when verified in accordance with 4.4.2.

3.5 Operating Requirements. Each LITE Plate will satisfy the following user-oriented requirements when verified in accordance with paragraph 4.5.

3.5.1 Ease of Insertion. The LITE Plate shall be able to easily slide into and out of the PC Gen

III. No obtrusive or abrasive coverings shall be applied to any of the LITE Plate surfaces.

No special training, equipment or tools will be required to insert the LITE Plate into the carrier pouch when verified in accordance with paragraph 4.5.1.

3.5.2 LITE Plate Color. All outer areas of the LITE Plate shall be uniformly colored the same.

The color will be agreed upon during the post-award conference prior to production (see paragraph 4.5.2).

3.5.3 Required Plate Labels and Markings. All labels and markings shall be approved by

MARCORSYSCOM prior to production. (See paragraph 4.5.3

3.5.3.1 Unique Identification and Instruction Label. As a threshold the LITE Plate shall have a combination unique identification (UID) and instruction label with the following detailed requirements:

a. The Human Readable Information (HRI) contents of the UID label shall be as follows:

1. Name of Ballistic Plate

2. Size

3. National Stock Number (NSN) / Contract Number / Lot Number / Serial

Number / Date of Manufacture / Manufacturer Commercial and Government

Entity (CAGE) code / Design Code

b. Machine Readable Information (MRI) contents of the UID label shall consist of one

ECC 200 compliant Data Matrix code containing: CAGE code of manufacturer, Lot

Number, Serial Number, Date of Manufacture, NSN, and Design Code. The tag/label shall comply with the following:

1. Data Matrix Construct: The Data Matrix shall be encoded per MIL-STD-130 using only the data identifiers (DI) and criteria shown below. The following

DI sequence shall be maintained in the order listed below:

Cage=17V followed by cage code

Lot=1T followed by lot number

Serial number=S followed by serial number

Date of production = 16D followed by production date, YYYYMMDD

National stock number=N followed by the NSN.

AMSC NA FSC

Part number = 1P followed by design code (the design code may be up to 13 alpha-numeric characters (plus only dashes “-” as special characters))

Construct Example:

[)>RS06GS17V52969GS1TE034GSS328185GS16D20080215GSN8470-01-

520-7370GS1PABC-123RSEOT

2. Data Matrix Geometry: Data Matrix codes shall be a square ECC200 matrix per ISO 16022. Individual Cell size (element size) of the code shall be between 0.020 and 0.023 inches. A quiet zone of 0.5 inches of Black label/tag material is required around the Data Matrix code.

c. The instruction label shall include the appropriate designation for each plate as to placement of the plate in relation to the body when worn. Each label shall be centered on the rear of the ballistic plate so it can be easily read when the plate is extracted from a vest pocket. The contents of the instruction label shall include the following verbiage:

1. “THIS SIDE AGAINST BODY” on the rear of the ballistic plate.

2. “Remove loose dirt from surface with a cloth or soft brush.”

3. “The LITE Plate is unserviceable if any of the following conditions are present:

a. Outer cover is damaged exposing inner materials.

b. Plate is cracked (e.g., audible rattling when shaken).

c. Cracking is felt or heard when 0.50 in (12.7 mm) perimeter of plate is firmly pinched.

d. Creaking or squeaking is heard when twisted by hand.

e. Composite is delaminating (backing materials are separating).

f. Plate has been hit by a bullet or fragment.”

d. The color of the label shall be black with white lettering/marking. All plate label and spall colors shall be approved by MARCORSYSCOM prior to production.

e. The plate label shall remain durable, legible, and affixed to the rear of the ballistic insert during field use under all environmental conditions. The label shall be of sufficient strength to withstand repeated abrasion during field use and cleaning.

f. The plates shall be delivered with unique item identifiers in accordance with the current version of DFARS clause 252.211-7003., “Item Unique Identification and

Valuation”, ANSI MH10.8.2-2013, “Data Identifier and Application Identifier

Standard” and MIL-STD-130N, “Identification and Marking of U.S. Military

Property.”

3.5.4 Health and Safety. The LITE Plate shall be non-hazardous (e.g., have no toxicological or electromagnetic radiation effects, be non-explosive, be non-carcinogenic, etc.) to the individual wearing the LITE Plate or to other Marines in the surrounding area. The

Government will verify conformance in accordance with paragraph 4.5.4.

3.5.4.1 Flammability. Demonstrate that the LITE Plate shall not drip, combust, or explode when impacted with defined threats or when subjected to elevated temperatures of 250 degrees

Fahrenheit (ºF) for ten (10) minutes (min) (-0/+1min) (see paragraph 4.5.4.1)

3.5.4.2 Personnel Hazard Inspection. Visually inspect that the LITE Plate is free of sharp edges, foreign materials, burrs, or any other conditions that may cause an injury to the user.

Demonstrate that the LITE Plate will not cause injury to the user or surrounding troops when ballistically tested (see paragraph 3.8). Any component of the LITE Plate that can cause personnel injury will not be acceptable (see paragraph 4.6.7.2).

Chemicals recognized by the Environmental Protection Agency (EPA) as human carcinogens shall not be used in applications that may affect the end user.

Hazardous materials that can be exposed to personnel or the environment during any operational (to include fabrication, transportation, setup and teardown) or maintenance procedures, or exposed as a result of damage to the equipment, or requiring special disposal procedures, shall be eliminated to be consistent with operational requirements.

Environmentally acceptable substitutes shall be used without degrading operational function and increasing cost. Hazardous material exposure to personnel shall be controlled to levels below the Occupational Safety and Health Administration (OSHA)

Permissible Exposure Limits. The LITE Plate shall not present any uncontrolled health hazard throughout the life-cycle of the item. The LITE Plate design shall not use materials that cause skin irritation or allergies. (see paragraph 4.5.4.2)

3.5.5. Magnetic Influence. There shall be no magnetic influence on a compass at any distance from the LITE Plate (see paragraph 4.5.5).

3.6 Operating Environment Requirements. Unless otherwise stated, ballistic validation testing will be performed with threat “2” as specified in paragraph 3.7.4. Ballistic performance will not be degraded from exposure to the environmental conditions when conditioned as specified in paragraph 4.6 and then ballistically tested in accordance with paragraph 4.7 and Appendix A.

3.6.1 Weatherometer Resistance. The finished LITE Plate after being subjected to the weatherometer resistance testing shall exhibit no evidence of cracking, blistering, color change, separation of edging (if used) or ballistic degradation when conditioned in accordance with paragraph 4.6.1.

3.6.2 Temperature Extreme. The LITE Plate shall provide structural and ballistic protection when exposed to temperatures ranging from -60 ºF to +160 ºF when conditioned in accordance with paragraph 4.6.2.

3.6.3 Fluid Resistance. The LITE Plate shall maintain structural and ballistic integrity after exposure to common battlefield contaminants or environmental conditions as detailed in paragraph 4.6.3.

AMSC NA FSC

3.6.4 Altitude. The LITE Plate shall meet all performance requirements from sea level to

15,000 feet (ft.) altitude. No structural, visible, operational degradation, or safety hazard shall occur when the LITE Plate is exposed to a pressure change equivalent to a change in altitude from 40,000 ft. to 15,000 ft. (12192 meters (m) to 4572 m) at a rate of 1500 ft./min - 2000 ft./min (457.2 m/min - 609.6 m/min) (see paragraph 4.6.4).

3.6.5 Temperature Shock. The LITE Plate shall meet all performance requirements after exposure to temperature changes between the high and low operating temperature extremes; temperature shock should occur within a five minute period when conditioned in accordance with paragraph 4.6.5.

3.6.6 Vibration. The LITE Plate shall not experience any structural, visible, or operational degradation when subjected to vibration. Vibration testing shall be conducted in accordance with 4.6.6.

3.7 Performance Requirements. The LITE plate shall meet the following performance requirements when verified in accordance with 4.7.

3.7.1 Areal Density. The finished LITE Plate shall have a threshold areal density of 4.55 pounds per square foot (T) and an objective areal density of 3.83 pounds per square foot

(O). These threshold and objective areal densities coordinate with the threshold and objective weights found in Table 1. Areal density shall be verified in accordance with paragraph 4.7.1).

Table 1.

Size Threshold

Weight [lbs]

Objective

Weight [lbs]

Extra-Small

(XS)

2.38 2.0

Extra-Small

Short (XS-S)

2.23 1.87

Small Short (S-

S)

2.64 2.22

Small (SM) 2.93 2.46

Small Long (S-

L)

3.00 2.52

Medium (MD) 3.40 2.86

Large (LG) 3.95 3.32

Extra-Large

(XL)

4.52 3.8

Side Plate (6 x 6) 1.14 0.96

Side Plate (6 x 8) 1.52 1.28

3.7.2 Thickness. The LITE Plate in finished form shall have uniform threshold thickness of

1.00 in (T) throughout and an objective thickness of 0.75 in (O) throughout. The

AMSC NA FSC

tolerance of the thickness shall not exceed 1/8 inch between any two measurements when verified in accordance with paragraph 4.7.2

3.7.3 Durability. The LITE Plate when inserted into a shootpack shall withstand two free fall drops on to the strike face at a height of 48.0 in ± 0.5 in (1,219.2 mm ± 12.7 mm) onto a

2.0 in thick plywood surface backed by concrete without any detrimental effects to ballistic performance, major surface characteristics, or physical properties. (see paragraph

4.7.3).

3.7.4 Required V50 Ballistic Protection Limit. The LITE Plate shall be capable of providing the minimum (threshold) V50 ballistic protection limits listed in Table 2 at 0 degree obliquity in ambient environmental condition (see paragraph 4.7.4) when tested in accordance with section 4.7.4, 4.7.5, and Appendix A.

Table 2.

Threat Standoff [m] V50 Required Minimum

Velocity [ft./s] Obliquity

2 150 2450 0 Degree

3 0 3250 0 Degree

3.7.5 Required V0 Resistance to Penetration (RTP) Ballistic Performance. At a minimum

(threshold), the ballistic plates shall defeat the specified projectiles at the specified velocities and obliquities without exceeding the maximum back face deformation listed in Table 3, in all environmental conditions listed in paragraph 4.6 when tested in accordance with section 4.7.4, 4.7.6, and the FAT protocol in Appendix A.

Table 3.

Threat Standoff

[m]

V0 Required

Velocity and

Tolerance [ft./s]

Shots Obliquity Max BFD

1 0 2750 + 50 2 1st @ 0 degree, 2nd @ 30 degree <58mm

2 150 2450 + 50 2 1st @ 0 degree, 2nd @ 30 degree <58mm

3 0 3250 + 50 2 1st @ 0 degree, 2nd @ 30 degree <58mm

4 0 2350 + 50 2 1st @ 0 degree, 2nd @ 30 degree <58mm

3.7.5.1 Probability of No Complete Penetration Analysis. For each valid test shot, the result is determined to have experienced either a system complete penetration or a system partial penetration. The numbers of complete and partial penetrations are the basis for calculating the 90 percent (%) Lower Confidence Level (LCL) for Probability of no

AMSC NA FSC

complete Penetration P(nP) via the Clopper-Pearson method, with the numerical result truncated by applying the “floor function” to two-decimal place precision. The LCL for

P(nP) is calculated for the first and second shots by combining shot locations, plate sizes, and environmental conditions. The LCL must meet or exceed the requirement specified in the respective FAT or LAT table. For example, if the 90% LCL for the P(nP) associated with a set of second shot data from FAT were calculated to be 0.699987, the reported result would be 0.69 and the outcome would be considered to be non-compliant with the prescribed criterion of 0.70. For all instances of statistical testing, a full data set is required to make the calculations to accept or reject the FAT or LAT. In cases where the second shot was determined unfair after a fair first shot, the first shot only shall be used in the analysis for both penetration and BFD. A subsequent plate shall be used to gather data on the second shot in order to fulfill the sample size required in the analysis matrix. Both shots on the subsequent plate shall be counted for record (assuming both fair hits) and included in the analysis.

3.7.6 Back Face Deformation. The LITE Plate back face deformation shall not exceed 58 mm when measured in accordance with paragraph 4.7.6.3.

3.7.6.1 Back Face Deformation Analysis. . For BFD, the metric of merit is a one-sided Upper

Tolerance Limit (UTL) based on the assumption of normally distributed BFD data; the

UTL to be calculated is specified in Appendix A for FAT. The BFD UTLs are calculated for the first and second shots by combining shot locations, plate sizes, and environmental conditions. Validated one-decimal place BFD measurements, for tested hard armor inserts that did not experience complete penetrations, are the basis for any UTL calculation. The UTL is defined as Yu = Ῡ + ks, where Ῡ is the mean of all valid BFD measurements, k is a look-up constant (varying with the sample size, UTL percentage, and confidence percentage), and s is the sample standard deviation. The UTL is reported to one decimal place precision after adjusting upwards via the “ceiling function” ensuring that a conservative UTL is reported. For example, calculated results of 38.1349 mm and

38.1999 mm are each reported as 38.2 mm. Compliance with the BFD requirement is achieved only if the associated UTL is less than or equal to 58.0 mm. When calculating the sample average (mean) and standard deviation in order to compute the UTL, calculate both the mean and standard deviation to six significant digits. This is to avoid the rounding of these intermediate quantities affecting the reported UTL. The final result (the

UTL) is then reported to one decimal place as specified above.

3.7.7 Shatter Gap. The LITE Plate shall be tested to ensure the plate does not exhibit shatter gap phenomena. Shatter gap testing shall be performed in accordance with Table 4 below. (see paragraph 4.7.7 and Appendix A).

Table 4.

Threat Shatter Gap Required

Velocity Range [ft./s]

Shots Obliquity

2 1800-1900 1 0 degree

2 1901-2000 1 0 degree

AMSC NA FSC

2 2001-2100 1 0 degree

2 2101-2200 1 0 degree

3.7.8 Spall, Debris, and Residual Penetrator. The LITE Plate will be designed to mitigate injury to the wearer or surrounding individuals from frontal spall, penetrator, or armor debris ejecta when tested against the required threats (see paragraph 4.7.6 and Appendix A).

4. VERIFICATION

4.1 Classification of Testing. The testing requirements specified herein are categorized as

First Article Testing (FAT) and Lot Acceptance Testing (LAT). Unless otherwise specified in the contract or purchase order, the LITE Plate Contractor is responsible for meeting all FAT and LAT requirements herein.

4.1.1 First Article Testing (FAT). LITE plates shall examined for compliance with the requirements specified in Section 3. FAT includes the verifications listed in 4.5, 4.6, 4.7, and 4.8, and 4.9 (see Table 5). Table 5 delineates requirements and the associated verification methods. FAT may be conducted in any order deemed necessary to meet the

Government’s schedule or to highlight operational areas where the LITE Plate is not performing at its best. The following items shall be submitted for FAT:

156 Finished Torso Plates: 6 XS-S, 19 XS, 19 SM-S, 21 SM, 6 SM-L, 40 MD, 24 LG, 21 XL

8 Torso Dry Lay Ups: 1 XS-S, 1 XS, 1 SM-S, 1 SM, 1 SM-L, 1 MD, 1

LG, 1 XLG

72 Finished Side Plates: 36 6x6, 36 6x8

2 Side Plate Dry Lay Ups: 1 6x6, 1 6x8

4.1.1.1 Ballistic FAT. All requirements defined in section 3.8 shall be met. The ballistic portion of FAT shall be conducted in accordance with section 4.9 and Appendix A and shall be evaluated in accordance with the acceptance and rejection criteria outlined in Appendix

A.

4.1.1.2 Non-Ballistic FAT. All requirement defined in sections 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, and 3.9 shall be met. One or more Major/Minor/Critical defect constitutes a FAT rejection.

Major, minor, and critical defects are defined in Table 6 in section 4.4.

4.1.2 Lot Acceptance Testing (LAT). LAT shall only be performed on valid approved FAT designs and production representative end items. All requirements and verification as designated in Table 5 “Requirements and Verifications” for LAT shall be met in accordance with the specified section 3 when validated in the corresponding section 4.

An Acceptable Quality Level (AQL) of 0.10 shall be used for critical defects IAW

ANSI/ASQ Z1.4, General Inspection Level II. An AQL of 4.0 shall be used for minor defects IAW ANSI/ASQ Z1.4, General Inspection Level II. LAT shall be conducted in accordance with the protocol as specified in Appendix B. The Sampling inspection, as part of manufacturing operations, is an acceptable practice to ascertain conformance to

AMSC NA FSC

requirements; however, this does not authorize submission of known defective material, either indicated or actual, nor does it commit the Government to accept defective material.

4.2 Requirements and Verifications. Table 5 delineates performance requirements and the associated verification methods.

Table 5. Requirements & Verifications

Characteristic Requirement

Paragraph

Verification

Paragraph

First

Article

Testing

(FAT)

Lot

Acceptance

Testing

(LAT)

Construction 3.2 4.3 X

Materials Design and

Manufacturing

3.2.1 4.3 X COC

LITE Plate Cover 3.2.2 4.3 X X

Assembly of Components by bonding

3.2.3 4.3 X

Production Data and

Technical Data Package

3.3 4.3 X COC

Workmanship 3.4 4.4 X X

Uniform Areal Density 3.4.1 4.4.1 X

Dimensions 3.4.2 4.4.2 X X

Operating Requirements 3.5 4.5

Ease of Insertion 3.5.1 4.5.1 X X

Color 3.5.2 4.5.2 X X

Labels and Markings 3.5.3 4.5.3 X X

Health & Safety 3.5.4 4.5.4 X

Magnetic Influence 3.5.5 4.5.5 X

Operating Environment

Requirements

3.6 4.6

Weatherometer Resistance 3.6.1 4.6.1 X

Temperature Extreme 3.6.2 4.6.2 X

Fluid Resistance 3.6.3 4.6.3 X

Altitude 3.6.4 4.6.4 X

Temperature Shock 3.6.5 4.6.5 X

Vibration 3.6.5 4.6.6 X

Performance Requirements 3.7 4.7

Areal Density/Weight 3.7.1 4.7.1 X X

Thickness 3.7.2 4.7.2 X X

Durability 3.7.3 4.7.3 X

Ballistic Test Requirements 4.7.4 X X

Req. V50 Ballistic Limit 3.7.4 4.7.5 X

V0 Ballistic Resistance 3.7.5 4.7.6 X X

Backface Deformation 3.7.6 4.7.6 X X

AMSC NA FSC

Shatter Gap 3.7.7 4.7.7. X

Spall, Debris and Residual

Penetrator

3.7.8 4.7.6 X

4.2.1 Order of Testing. Performing the various testing, operating, ownership and support, operating environment, and performance, can occur in any order.

4.2.2 Verification Methods. The types of verification methods included in this section are visual inspection, dimensional measurements, sample tests, component properties analysis, and similarity to previously approved or previously qualified designs.

4.2.3 Responsibility for Compliance. Production items shall meet all requirements specified in

Section 3. The Contractor shall establish and maintain documented procedures for inspection and testing activities in order to verify that the specified requirements for the product are met. The required inspection, testing, and the records to be established shall be detailed in a Process Production Package (PPP) available to the Government as specified in the contract or procuring activity. The inspection set forth in this specification shall become part of the Contractor’s overall inspection procedures or quality system. The absence of any inspection requirements in the specification shall not relieve the Contractor of the responsibility of ensuring that all products or supplies submitted to the Government for acceptance comply with all requirements of the contract. Sampling inspection as part of the manufacturing operations is an acceptable practice to ascertain conformance to requirements, however, this does not authorize submission of known defective material, either indicated or actual, nor does it commit the

Government to accept defective material.

4.3 Construction and Technical Data Package. Verification for all design variants should include but not be limited to, as applicable, the inspection of the criteria outlined in paragraph 4.4.

4.4 Workmanship. Products will be subjected to destructive deconstruction examination and visual examination using nondestructive test methods (radiography, microscopic analysis, liquid penetrant inspection, ultrasonic testing, Computerized Tomography (CT) scanning, and other like technologies) to assess product compliance. Radiographic images of complete end items shall be taken digitally or by the use of radiographic film.

Radiography shall include the entire strike face area of the plate with the radiograph taken from a frontal or rear view. The Government reserves the right to change the shot pattern to target all anomalies, defective conditions, or contaminants highlighted in radiographic, visual, or dimensional inspection. Visual end item inspection shall take place to ensure the entire plate is covered completely with a spall cover, with no rips, tears, cuts, blistering, bubbling, or separation between the materials. A visual defection classification guide can be found in Table 6 below.

Table 6.

Defect Critical Minor Anomaly

(no defect)

AMSC NA FSC

Ceramic Component

Any crack 1

Defects greater than 2.50 inches in length. 2

Defects greater than 0.75 inch in length, but less than or equal to 2.50 in length.

Defects less than or equal to 0.75 inch in length 201

Defects greater than 0.0625 inch in width 3

Defects greater than 0.03 inch in width, but less than or equal to 0.0625 inch in width

Defects less than or equal to 0.030 inch in width 202

Defects greater than 0.0625 inch in depth 4

Defects greater than 0.030 inch in depth, but less than or equal to 0.0625 inch in depth

Defects less than 0.030 inch in depth 203

All Components Contained within the Plate Covering

More than 10 delamination’s, voids, or under adhered areas, in any combination, between components greater than 0.030 inch but less than or equal to 0.180 inch in any dimension

Any delamination, void, or under adhered areas between components greater than 0.180 inch in any dimension

Any delamination, void, or under adhered areas between components greater than 0.030 inch but less than or equal to 0.180 inch in any dimension

Any delamination, void, or under adhered areas between components less than 0.030 inch in all dimensions

Foreign Object Debris

Any foreign object debris or defect identified that is not associated with the Technical

Data Package

Any item larger than 0.0625 inches in any dimension

Any item greater than 0.030 inches and less than or equal to 0.0625 inches in any dimension

Any item less than 0.030 inches in all dimensions 205

More than one (1) foreign object per insert 8

Four (4) or more shot peen media per insert 106

Three (3) or less shot peen media per insert 206

Finished End Item

Ease of Insertion 9

Weight above threshold 10

Thickness out of tolerance 11

Color COC

Tap Test (X-Ray and CT scan verification required) 12

AMSC NA FSC

Torque Test (X-Ray and CT scan verification required)

Orientation Markings 14

Performance Markings 15

Complete Insert Markings 16

Unique Identification Label (UID) 17

Flammability COC

Personnel Hazard COC

Magnetic Influence 18

Dimensional non-conformance for under length or width

Dimensional non-conformance for over length or width

Dimensional non-conformance for parallelism, perpendicularity, chamfers and radii

Plate not fully covered by spall cover 20

Rips and tears 21

Bubbles or blisters in cover 109

4.4.1 Uniform Areal Density. Dry lay ups for each design shall be examined to visually ensure the plates exhibit uniform areal density (no overlap or underlay, uniform material lengths, and thicknesses, etc.).

4.4.2 Dimensional Measurements. Take physical measurements of each sized LITE Plate to show that all measurements conform to dimensions and tolerances in Drawings (see paragraph 2.2.2). Two length and width measurements shall be made on each sized plate.

The length measurements for both torso and side plates shall be made at the two chamfered edges. For torso plates, the first width measurements shall be no further than

1.0 in (25.4 mm) away from the bottom edge and the second shall be no closer than 7.0 in

(177.8 mm) from the first measurement location. (see paragraph 3.4.2). For side plates, the two width measurements shall be taken at the edges of the tow chamfers.

4.5 Operating Requirements. Complete each test in this paragraph.

4.5.1 Insertion. One barehanded person shall demonstrate insertion of each sized LITE Plate into the corresponding sized Plate Carrier Generation III (PC Gen III) front and back

Outer Vest pocket and front and back inner vest pocket without tools or special aids.

Perform insertion into Government furnished carrier in a maximum of 30 seconds. One barehanded person shall demonstrate the insertion of each sized LITE Side Plate into the corresponding sized PC Gen III side plate pocket without special tools or aids.

4.5.2 LITE Plate Color. Visually inspect the LITE Plate for similarity to the standard sample color as specified by the contract.

AMSC NA FSC

4.5.3 LITE Plate Labels/Markings. Visually inspect for legible, permanent marking and labels on the front and back face surfaces. Visually inspect that labels contain the written instructions and or orientation directions as specified in paragraph 3.5.3.

4.5.4 Health and Safety. Complete the verifications in this paragraph.

4.5.4.1 Flammability. Observe that the LITE Plate does not drip, combust or explode when impacted in ballistic testing. Ballistic testing at the elevated temperature is reserved for

FAT when required.

4.5.4.2 Personnel Hazard. Inspect all material comprising the end item to verify that the LITE

Plate is non-hazardous (e.g., have no toxicological or electromagnetic effects, be non-explosive, be non-carcinogenic, etc.) to the individual wearing the LITE Plate or to other

Marines in the surrounding area. The Contractor shall provide Material Safety Data

Sheets (MSDSs) to the Government for all materials comprising the end item.

4.5.5 Magnetic Influence. The LITE Plate shall be tested for magnetic influence using magnetic and lensatic compasses. The LITE Plate shall not cause any deviation of the compass needle.

4.6 Operating Environment Requirements. Perform each verification in this section and then perform ballistic testing IAW 4.7.6 with Threat 2, as specified. Any failure to meet the ballistic requirement specified in 3.7.5 shall constitute a test failure. Any internal component voids, delamination’s, or critically sized foreign objects observed via radiographic or CT scanning post conditioning will be targeted for the first shot during ballistic testing. Furthermore, any degradation in spall cover color shade will not be classified as a defect. The number of tests required for this demonstration shall be specified in the contract as a pre-production item.

4.6.1 Weatherometer Resistance. The LITE Plate shall be tested for weather resistance IAW

American Association of Textiles Chemists & Colorists (AATCC) Test Method #169 with the following modifications. Pre-conditioning and post-conditioning radiographic images shall be taken of the LITE Plate. Upon completion of the test, the LITE Plate shall be visually examined and failure to meet any of the requirements in 3.6 shall constitute a test failure.

4.6.1.1 Modifications to AATCC Test Method # 169:

a. The test apparatus shall be either a test chamber type 1A or 1B. Type 1B shall be equipped with a three-tiered inclined specimen rack. The apparatus shall be equipped with an automatic light monitor and shall be capable of automatically controlling irradiance, temperature, and humidity. The apparatus shall be maintained IAW the manufacturer’s recommendations.

b. The weathering test cycle shall be 40 minutes of light, 20 minutes of light with water spray on the specimen, 60 minutes of light, and 60 minutes of darkness with no spray.

AMSC NA FSC

The test cycle shall be repeated until the total energy exposure is equal to 100 kilojoules per square meter (m2).

c. The irradiance level shall be 0.55 Watts/square meter/nanometer (W/m2/nm) ± 0.01

W/m2/nm bandpass at 340 nm.

d. The glass filter combination shall be quartz inner filter and a borosilicate type “S” outer filter.

e. The relative humidity (RH) shall be 50% ± 5% during the light cycle and not lower than 95% during the dark cycle.

f. The control set points shall be as follows:

Table 7.

Dark Cycle Light Cycle

Black Panel 100.4 F (38 C) 170.0 F (77 C)

Conditioning Water 104.0 F (40 C) 127.4 F (53 C)

Wet bulb depression* 32.0 F (0 C) [95% RH] 50.0 F (10 C) [50% RH]

*As a guide only; adjust to achieve required relative humidity

g. The LITE Plate shall be mounted on the outside of the rack. After the required exposure period, the LITE Plate shall be removed from the apparatus and allowed to dry and condition at ambient conditions.

h. After the LITE Plate has been conditioned in the weatherometer and after passing visual examination tests following removal from the weatherometer, the LITE Plate shall be tested to establish a V0 ballistic resistance at 0 degree obliquity within 24 hours + 0.50 hours after removal from the weatherometer. Testing shall be conducted

IAW 3.8.3 for Threat 2, as specified.

4.6.2 Temperature Extreme. The finished LITE Plate shall be heated in an oven operating at

155 + 5 ºF for a minimum of 6 hours (+ 15min) (Ref. MIL-STD-810G_CHG-1). Pre-conditioning and post-conditioning radiographic images shall be taken of the LITE Plate samples. The test specimen shall then be ballistically tested IAW 3.7.5 with Threat 2, as specified. Subject LITE Plate (different to those subjected to high temperatures) to cold exposure at minus (-) 55 ºF + 5 ºF for minimum 6 hours (+ 15min) then ballistically test

IAW 4. with Threat 2, as specified. After each exposure, the LITE Plate will be examined for evidence of delamination, component separation, blistering, or any other visual defects. Upon completion of the test, the LITE Plate shall be visually examined and failure to meet any of the requirements in 3.4 shall constitute a test failure. The ballistic tests shall be completed within 30 minutes after each exposure.

4.6.3 Fluid Resistance. Conduct this test at fluid and ambient temperatures between 60 ºF - 80

ºF. Contaminate one LITE Plate for test with each of the following fluids listed in Table

AMSC NA FSC

8. Pre-conditioning and post-conditioning radiographic images shall be taken of the LITE

Plate samples. The test specimen shall be ballistically tested within 30 minutes after each exposure. Upon completion of the test, the LITE Plate shall be visually examined and failure to meet any of the requirements in 3.4 shall constitute a test failure.

Table 8.

Conditioning Test Description Duration

Salt Water (4.6% NaCl)

Submerge LITE Plate in a container.

After removal from container, LITE

Plate shall be held vertically to drip dry.

2 hours + 15 min

Drip Dry: 5 min

Lubricating Oil (30

Weight – Commercial

Grade SE or better)

LITE Plate will be dipped in oil to cover the entire surface

(front/back/sides etc.) for no extended period of time.

Duration N/A

F-24

LITE Plate will be dipped in F-24 to cover the entire surface

(front/back/sides etc.) for no extended period of time.

Duration N/A

4.6.4 Altitude Test. Place the LITE Plate in an ambient air pressure chamber to simulate a

40,000 foot (12192 m) altitude. The air pressure then shall be changed to simulate a

15,000 foot (4572 m) altitude. When the air pressure reaches the simulated 15,000 foot

(4572 m) level, a complete visual inspection will be performed. The change rate of the ambient air pressure is 1,500 ft./min - 2,000 ft./min (457.2 m/min – 609.6 m/min). Pre-conditioning and post-conditioning radiographic images shall be taken of the LITE Plate samples.

4.6.5 Temperature Shock. Tests shall be performed IAW method 503.5 of MIL-STD-

810G_CHG-1 Procedure I-A (ambient, cold, hot, ambient) using -25 ºF and +120 ºF for the extreme temperatures. Pre-conditioning and post-conditioning radiographic images shall be taken of the LITE Plate samples. The test item shall be stabilized at the appropriate temperature for a minimum of two hours before cycling to the other temperatures. Upon completion of the test, the LITE Plate shall be visually examined and failure to meet any of the requirements in 3.4 shall constitute a test failure.

4.6.6 Vibration Test. Testing shall be conducted IAW MIL-STD-810G_CHG-1, Method 514.6, Procedure II for Loose Cargo with modifications. The vibration test shall approximate the various environments in which the LITE Plate will be subjected. Pre-conditioning and post-conditioning radiographic images shall be taken of the LITE Plate samples. The

LITE Plate shall be positioned strike face down and have the top and bottom of the plate parallel to the X-axis (see Figure 4) with vibration caused from motion in the Y and Z-axis. The LITE Plate shall be placed in a wooden box, 1 in (25.4 mm) larger than the plate in all directions, and then mounted to the Vibration Table. The simulation of the loose cargo environment requires the use of a package tester that imparts a 1 in (25.4

mm) peak-to-peak, circular synchronous motion to the table at a frequency of 5 hertz

AMSC NA FSC

(Hz) for one hour. Upon completion of the test, the LITE Plate shall be visually examined and failure to meet any of the requirements in 3.4 shall constitutes a test failure.

Figure 4.

4.7 Performance Requirements. Complete each test in this section.

4.7.1 Weight. The LITE Plate weight shall meet the physical weight measurement requirements as identified in Table 1. Each LITE plate size shall be examined for weight.

Weight shall be taken on a tarred scale and to the nearest .0001 pound (0.4536 gram).

4.7.2 Thickness. Take thickness measurements of each sized LITE Plate to show that all measurements conform to dimensions and tolerances stated in paragraph 3.7.2.

Measurements shall be made with a measuring device capable of reaching all required points of measure and record to the nearest 0.01 in. For torso plates, measure thickness in seven locations; approximately near the center (at least 3.5 in from any edge) and near each of the six corners (1/4 in – 1 in from the edge). For side plates, measure thickness in

5 locations; approximately near the center (at least 3.0 in from the edge) and near each of the four corners (0.5-1.25 in from the edge).

4.7.3 Durability. Demonstrate the durability of the LITE Plate by performing drop tests under the following conditions. The plates shall be inserted into a vest or plate pocket (herein after referred to as "the system") and tested. The Drop test shall be conducted in accordance with the general guidelines of MIL‐STD‐810G, Test Method 516.6, Procedure IV. The system shall be subjected to a 122‐cm (48‐in.) drop. The system shall be allowed to fall freely onto the impact surface, which shall be 5‐cm (2‐in.) thick plywood backed by concrete. The armor plates shall be exposed to a second drop test without the vest or plate pocket. The LITE Plate strike face should be pointing down, and the impact zone should be clear of debris before each drop. Impacts shall occur as near as

AMSC NA FSC

possible to the center of the LITE Plate strike face (not an edge). A radiographic image of the LITE Plate shall be inspected to identify any cracks, delaminations, or indentations on the LITE Plate surface between each drop. Ballistic testing shall be performed IAW 4.7.6 with Threat 2, as specified. The first test shot shall be taken at the most severely damaged area of the LITE Plate specimen as identified by the radiographic image but no closer than 1.5 in (38.1 mm) from any edge. If no damage is visible, the first shot shall be taken near the impact location (center or crown of the strike face). The second test shot shall be located 1.5 in + 0.75 in (38.1 mm + 19.05mm) from any edge and 5.0 in - 6.0 in (127 mm

– 152.4 mm) from the first impact.

4.7.4 Ballistic Test Criteria and Set Up. For all V50 BL and V0 acceptance tests, the following test set up and minimum information is required by the government to validate performance:

a. Armor description including design code, size, dimensions, thickness, weights of all components of the LITE Plate system.

b. Test projectile Threat 3ode, weight, and reference weight.

c. Temperature and humidity measurements.

d. Yaw angle.

e. Angles of target obliquity.

f. All velocity measurements of each test shot used to test the LITE Plate (regardless of whether that particular velocity was used in the V50 or V0 determination). Ensure proper drag table for each threat is used to calculate impact velocity.

g. PP (Partial Penetration; with shootpack ply count as applicable) and CP (Complete

Penetration) next to each shot velocity as determined.

h. Back Face Deformation measurements in mm with significant digits recorded only to the accuracy of the measuring device.

i. Spall and debris ejection count (when required).

j. Name of organization/company performing tests.

k. Type of gun barrel, caliber, propellant type, propellant weight, twist rate, and gun barrel serial number.

l. Calculated V50 BL. In a situation where the V50 BL or V0 data sheet would compromise the Security Classified Guide for Armor Materials, the data sheet should exclude the specific projectile used during testing.

m. Shootpack or specified soft armor backing design, weight, and total ply count.

n. Clay type, drop temperatures, locations, depth, and clay box number.

o. Remarks or notes for all testing anomalies, unfair hits, etc.

p. All shot locations.

q. Revision #/level of all ballistic test software used by test lab (i.e. FARO software including smoothing function, drag calculation software, etc.)

r. Time and date of clay calibration drops and ballistic shots.

s. Photos of clay calibration drop locations, ballistic impact locations on the plate, and any anomalies.

4.7.4.1 Projectile Velocity Determination. Projectile velocity measurements methods that utilize either contact screens or radar will be used. Contact screen methods that employ either

AMSC NA FSC

high velocity lumiline screens or electrical contact screens activated by a passing projectile opening or closing a circuit are preferred. An electric counter type chronograph calibrated to microseconds, will also be used in conjunction with the contact screen method. Doppler radar capable of accurately measuring the projectile striking and residual velocities can also be used. Personnel conducting ballistic testing should be properly trained in velocity measurement determination using the Doppler radar equipment. Radiographic equipment calibrated to capture the projectile at calibrated time intervals of flight may also be used.

4.7.4.2 Weapon Mounting Configuration. The spacing from the weapon muzzle to the first pair of triggering devices shall be sufficient to prevent damage from muzzle blast and obstruction from smoke in case optical devices are used. Recommended distances can be found in USATECOM TOP 4-2-805. Spacing between triggering devices is a function of the expected velocity of the projectile being fired. In many instances, physical restriction, such as short overall distance from muzzle to test sample dictates the spacing of the triggering devices. The last pair of triggering devices shall be placed at least four (4) ft.

(122 cm) in front of the test sample and should be protected from possible damage resulting from fragments.

4.7.4.3 Environmental Test Conditions. All ballistic tests shall be performed in a standard atmosphere of 68 ± 10 degree Fahrenheit and 50 ± 20% relatively humidity.