MK_117_-_Nozzle_First_Article_Test_Plan_071007.pdf

FIRST ARTICLE TEST PLAN FOR MK 117 NOZZLE ASSEMBLY

1.0 General

a. The standard quantity of nozzles to be submitted for inspection under this test plan shall be ten (10). The units submitted shall be manufactured using the same supplies, processes, and procedures that the vendor will be using for production units.

b. Eight (8) of the nozzles shall be "end item" units in accordance with the contract requirements.

c. Two (2) of the nozzles shall be machined into tensile test bares in accordance with contract requirements.

2.0 Tests To Be Preformed By NSWC, I.H. On The Eight Finished Units

a. All eight units shall be dye penetrant tested and evaluated, in accordance with MIL-STD-2175, class 1 for surface cracks and/or any surface irregularities.

b. All eight units shall be radiographically inspected, to enclosure (1), in accordance with MIL-STD-2175, class 1, using reference radiographs ASTIVI E446.

c. All eight units shall undergo a full dimensional and surface finish inspection.

d. After the units have successfully passed tests 2.0, a, b, and c of this test plan, four of the eight nozzles shall be motor loaded with Condition Code A hardware and propellant grains. Two motors shall be conditioned to -40 ºF, two shall be conditioned to +140 ºF in accordance with MIL-P-85759. All four shall then be statically fired in accordance with MIL-P-85759.

e. After successful static firing, the four nozzles, at the discretion of

IHDIVNAVSURFWARCEN, will be re-examined for steps 2.0 a, b and c of this test plan. Unless a catastrophic failure occurs, such as a burn through or explosion, the units shall not be rejected for data gathered after they are ballistically tested.

3.0 Metallurgical Testing Performed By IHDIVNAVSURFWARCEN, On The Two Nozzle Castings

a. The two castings shall be metallurgically tested for compliance to contract requirements.

b. Two tensile specimens shall be machined from each of the two nozzles castings for a total of four tensile specimens.

c. The tensile and yield strengths, percent elongation and reduction in area shall be measured from each bar and compared to Chart United Hardness Scale Conversion.

d. Metallographic specimens shall be prepared, in accordance with ASTM E3, and examined to verify proper grain size and microstructure.

4.0 Examination Of Vendor X-Ray Film (All Nozzles)

a. Vendor X-Ray film and read sheets on all ten nozzles shall be reviewed in accordance with MIL-STD-2175, class 1. At a minimum, the following items shall be examined: format (are X-Ray films shoot at X-Ray45OX defects called out correctly).

5.0 Examination Of Certifications And Data (All Nozzles)

a. The following certifications shall be reviewed for information content and format:

- Material certification (chemical composition)

- Heat treat certifications

- Heat treat charts

- Dye penetrant certifications

- X-Ray certifications

- Blowout disk

- Graphite insert

- Plating

6. 0 Application Of This Test Plan

a. Indian Head Division, Naval Surface Warfare Center, (IHD/NSWC) reserves the right to omit certain steps based on how much past experience the vendor has in casting and machining Nozzle Assemblies for the MK 117 Mod 0 Rocket Motor..

COST ESTIMATE FOR THE FIRST ARTICLE TEST PLAN

1. The following is an estimated cost for testing first article MK 117 sample nozzle assemblies manufactured in accordance with drawing 1638AS121.

2. The costs are as follows:

Cost Description $1,532 X-ray film, x-raying the nozzle assemblies, and reading/inspecting the x-ray films on 10 samples

$3,475

Full dimensional and material hardness test on 10 samples

$14,000 Ballistic testing on 2 of 10 samples

$240 Review all vender certifications

$1,596

Cost of 10 nozzle assemblies

$2,000 Review all data and generate first article test report

$720 Inspection of vendor submitted x-ray films and read sheets

$2,500 Salt spray test

$26,063 Sub total

Additional cost of qualifying a new un-proven vendor

$15,544 Pre-award survey cost for overseas company

$7,669

Pre-award survey cost for domestic company

$7,669

Miscellaneous engineering cost for assisting vendor to produce quality hardware. This cost will be added to the applicable pre-award survey cost

$56,945 Total