Attach_2_Armor_Specifications.doc

N61331-15-R-0015 Attachment 2

SPECIFICATION FOR

PORTABLE COMPOSITE ARMOR

FOR LANDING CRAFT AIR CUSHION

16 July 2004

1. SCOPE

1.1 Scope. This specification establishes the requirements for the design, manufacture, assembly, test, and acceptance of lightweight composite armor used on the Landing Craft, Air Cushion (LCAC).

2. APPLICABLE DOCUMENTS AND DEFINITIONS

2.1 General. The documents listed in this section are needed to meet the requirements specified in sections 3 and 4 of this Product Function Specification Description (PFSD). This section does not include documents cited in other sections of this PFSD 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 shall meet all specified requirements cited in sections 3 and 4 of this PFSD. In the event of conflicts between this specification and referenced documents, the requirements of this specification shall be considered superseding requirements.

2.2 Government documents.

2.2.1 Specifications, standards 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.

SPECIFICATIONS

MILITARY

MIL-PRF-46103E

Performance Specification Armor: Lightweight, Composite

MIL-STD-810

Environmental Test Methods and Engineering Guidelines

ASTM D-635

Standard Test Method for Rate of Burning and/or Extent and Time of Burning of Plastics in a Horizontal Position

MIL-STD-129

Military Marking for Shipping and Storage (Unless otherwise indicated, copies of federal and military specifications, standards, and handbooks are available from the Standardization Documents Order Desk, Building 4D, 700 Robbins Ave., Philadelphia, PA 19111‑5094.)

2.3 Non‑Government publications. None

2.4 Definitions. Unless specified herein definitions shall be in accordance with MIL-PRF-46103E.

Armor plate-of the materials, configuration, and processes used for the production of the armor panel. These shall be clearly identified with a sequential serial number to provide traceability to materials, and processes, and test reports.

Armor Panel-one bonded and completed composite armor plate, designed and constructed generally as per paragraph 3.3 and conforms to NAVSEA drawing 164-7403836 minus the aluminum-alloy-edge protection members.

Armor panel-one completed panel of the series conforming to assembly NAVSEA drawing 164-7403836.

Aluminum-alloy-member-the aluminum-alloy-edge protection members, conforming to above drawing, that are bonded to armor panels.

Neoprene member-the neoprene-channel-edge protection members, conforming to above drawing, that are bonded to the aluminum-alloy-member to form armor-panel assemblies.

Shipset-a complete set of armor panel assemblies ordered under the contract that conform to NAVSEA drawing 164-7403836.

The armor-an armor panel.

Single production run-a single production run is the continuous production of Panels, comprising a lot, using the same materials, production processes and procedures used to manufacture the panels subjected to the ballistics qualification test.

Continuous production -the normal manufacture of batches of panels, which in total comprise a lot.

Yaw-projectile yaw is the angular deviation of the longitudinal axis of the projectile from the line of flight at a point close to the ballistic test panel.

Obliquity-a measure, in degrees, of the extent to which the impact of a projectile, on an armor panel, deviates from a line normal to the target. A projectile fired perpendicular to a target surface has zero degrees obliquity.

Fair impact-a fair impact results when a projectile of less than 30( yaw strikes an unsupported area of the ballistic test panel at 0 ± 5 degree obliquity at least 1.5 inches from the outside edge of the composite component and within ± 2 projectile diameters from a composite joint. Impact will be at a distance of at least three projectile diameters from any previous impacted or disturbed area resulting from an impact.

2.5 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Description. The composite armor defined herein shall be suitable for use on the LCAC vehicle operating in the environments described within this specification.

3.2 Characteristics.

3.2.1 General. Unless specifically excluded or modified by this specification armor supplied under this specification shall comply with all requirements of MIL-PRF-46103E. The armor panel assemblies shall conform to the dimensional requirements of NAVSEA drawing number 164-7403836. The ballistic protection limits shall meet or exceed the values specified in Appendix A of this specification. Ballistic testing facility certification shall be submitted to Naval Surface Warfare Center Panama City (NSWC-PC) for approval prior to any ballistic testing of armor panels manufactured under this specification. A lot shall consist of a maximum of 180 armor panels of the same type, grade, nominal thickness, and construction, which have been sequentially produced in a single production run and submitted for inspection at one time. During ballistic testing, if inspection of the armor panels after any shot reveals that the front and rear layers of the test panel are intact and in good condition, additional shots can be fired into the test panel. Shots shall be spaced at least three caliber diameters away from other shots or their disturbed areas. Ballistic testing for each lot shall be performed to verify each V50 protection ballistic limit. A test report shall be provided.

3.2.2 Performance and Performance Requirements

a. Ballistic resistance. The armor shall have a ballistic protection limit as specified in Appendix A of this document

b. Areal density. The areal density of the armor shall not exceed 9.0 lb/ft2.

3.2.3 Performance characteristics.

3.2.3.1 Dimensions and configuration. The armor panel assemblies shall conform to the dimensional standards dictated in NAVSEA Drawing 164-7403836 and the following:

a. The armor shall have a maximum thickness of 1.00 inch excluding the aluminum alloy edge protection member(s) and neoprene edge protection member(s).

b. Thickness measurements shall be taken on each armor panel at 4 random locations with one additional measurement taken at the approximate center of the panel.

c. The armor panel assembly shall have an edge thickness of 1.375 inch including the aluminum alloy edge protection member(s) and neoprene edge protection member(s).

3.2.4 Structural criteria

3.2.4.1 Static strength. In addition to any structural requirements dictated in MIL-PRF-46103E the armor and its edge protection members shall withstand, without excessive deformation, yielding (i.e., 0.2 percent proof strain), or loss of utility, the yield loads and shall withstand, without failure, the ultimate loads resulting from the following:

Craft acceleration:

3.2.4.2 Water impacts. Limit loads from water impact pressures applied to the entire surface as equivalent static loads are as follows:

a. 15.0 Ib/in2 on forward-facing armor of control module.

b. 13.5 Ib/in2 on outboard-facing armor of control module.

c. 4.5 Ib/in2 on inboard-facing armor of control module.

d. 7.5 Ib/in2 on outboard-facing engine module armor.

e. 13.5 Ib/in2 on outboard-facing armor of the personnel and equipment module.

Yield and ultimate factors of safety of 1.0 and 1.5, respectively, shall be applied to the above limit loads.

3.2.5 Dry weight. The contractor shall supply the weight of each armor panel assembly to NSWC-PC.

3.2.6 Environmental conditions. The Government intends to conduct environmental testing in accordance with MIL-PRF-46103E. Additionally the Government intends to conduct testing of the armor and its edge protection provisions to confirm it can withstand the following environmental conditions, without impairment or degradation of performance. Environmental conditions, where indicated, shall be evaluated in accordance with the applicable requirements of MIL-STD-810 as follows:

Condition Method Procedure

Humidity 507.1

IV

Fungus 508.2 I Salt fog 509.1 I

Dust (fine sand) 510.1 I

Ambient temperature shall be -30°F to +200°F (for periods not exceeding 30 minutes duration at no load). All environmental tests shall be conducted on the first article unit as described in paragraph 6.7.

3.3 Design and construction. The contractor shall select the methodology of construction provided these methods are capable of yielding uniform properties in the completed structure and that all structural interfaces have no unbound areas. The armor panels shall be sized in accordance with NAVSEA Drawing 164-7403836 and shall comply with any additional requirement described in this specification:

3.3.1 Materials. Unless otherwise specified, the armor plating materials are the prerogative of the contractor as long as all of the performance, operating, environmental, and identification marking requirements are fully met.

3.3.1.1 Edge Protection. The armor shall be provided with channel style edge protection fabricated of 5000-series aluminum. Edge protection channels shall cover the entire perimeter of the panel as detailed in NAVSEA drawing 164-7403836. Sharp edges and burrs shall be removed from all armor edge protection channels and associated corners. A channel style edge protection fabricated of “60 Shore A” neoprene rubber shall be bonded to the aluminum edge channel as detailed in NAVSEA drawing 164-7403836.

3.1.1.2 Maximum Tile Size. The maximum size of any tile used in the construction of the armor panels shall be as follows. Maximum dimension of any tile edge shall be five inches. The maximum surface area of any tile shall be 25 square inches.

3.3.2 Identification and marking

3.3.2.1 Markings. The manufacturer’s code (part) number, contract number, serial number, date of manufacture, the part number as shown on NAVSEA drawing 164-7403836, as well as the number of this specification and designation as “BACK” shall be permanently marked on the rear of each armor panel assembly.

3.3.3 Workmanship. The armor panel assemblies shall conform to the quality and grade of product established by this specification.

4. VERIFICTION

4.1 Responsibility for inspection. Verification provisions shall be in accordance with the requirements of MIL-PRF-46103E.

4.1.2 Ballistic laboratory approval. Ballistic testing shall be performed in certified laboratories. Proof of ballistic laboratory certification shall be submitted to NSWC-PC prior to commencement of any ballistic testing. The Government shall be provided no less then 10 working days notice of a scheduled ballistic test and will have the option of witnessing the test at their sole discretion.

4.2 Inspections.

4.2.1 Inspection lots. A production lot, as used in MIL-PRF-46103E shall not exceed 180 armor panel assemblies manufactured for delivery under this contract. The first 180 armor panel assemblies manufactured will be considered the initial production lot. The random sample size for initial production lot shall be four armor panel assemblies. The random sample size selected for inspection for production lots shall be two armor panel assemblies.

4.2.2 Dimensional inspection for end item. The armor panels assemblies shall conform to the dimensional requirements of NAVSEA Drawing No. 164-7403836 within the tolerances specified therein.

4.3 Testing. Testing of random armor panel assemblies shall be in accordance with MIL-PRF-46103E for Initial Production Lots and Production Lots After Initial Lot. The randomly selected armor panel assemblies subjected to testing in accordance with this para shall be replaced at the contractor’s expense in order to provide the full number and quantity of panels required to satisfy the craft sets ordered under this RFP.

4.4 Test Methods

4.4.1 Ballistic test for armor. The ballistic test shall be conducted in accordance with Appendix A of this document, and the ballistic protection limits shall meet or exceed the values specified in Appendix A of this document. The areal density shall be reported for each ballistic test armor panel. (NOTE: Appendix A is classified CONFIDENTIAL AND IS NOT INCLUDED IN THIS STATEMENT OF WORK. Requests for a copy of Appendix A must be made to Michael Riley, Code E34, NSWC PCD, Panama City, Florida 32407. Phone 850.234-4418, email address michael.d.riley3@navy.mil )

4.4.2 Temperature extremes test. The Government intends to conduct the following test on the first article unit described in para 6.7: The armor panel assembly, less the spall cover (unless the spall cover is an integral part of the armor panel) and spall cover edge strip, will be heated in an oven operating at 160° ± 5°F (71° ± 2°C) for 6 ± 0.25 h. The test specimen will then be allowed to cool to room temperature followed by cold exposure at -65° ± 5°F for 6 ± 0.25 h. The specimen will be allowed to warm to room temperature and will then be examined at edges for evidence of delamination. There shall be no delamination within the composite structure.

5. DOCUMENTATION

5.1 Test Procedures

5.1.1 The test procedure to be utilized for ballistic testing shall be per Appendix A of this document.

5.2 Test Reports

5.2.1 A test report shall be provided for all production testing. The test report shall comply with the requirements of Data Item Description DI-NDTI-80604. Ballistics test reports shall be classified "Confidential" and shall include calculations of the V50 protection ballistic limits. The test reports shall be subject to approval by NSWC-PC for format and content. The test reports shall be submitted to NSWC-PC within five days of test completion.

6. NOTES

6.1 Intended use. The armor panel assemblies covered by this specification is intended for use in applications where resistance to armor-piercing projectiles and limited multi-hit capability are required. The armor will be exposed to an extremely harsh marine environment including salt spray and high velocity sand particles.

6.2 Ordering data. Not applicable.

6.3 Certification testing. The certification test is intended to ascertain that fabrication procedures are capable of producing satisfactory armor. This test need not be repeated so long as the design and materials of the parts being produced remain unchanged, except as may be required in 4.1,4.3, and 4.4.

6.4 Definitions. See paragraph 2.3 and MIL-PRF-46103E.

6.5 Disposition of ballistic test panels Any test armor panel assembly selected in accordance with 4.2.4 and 4.2.5 of MIL-PRF-46103E shall be considered representative of the lot they were selected from. On completion of testing the ownership of these panels remains with the manufacturer and the panels will be subject to replacement as per para 4.3 of this specification.

6.6 Mold release agents. Manufacturers are advised not to use mold release agents that are difficult to wash off or which are known to interfere with adhesive bonding.

6.7 First article inspections. The item covered by this specification requires first article inspection and approval by NSWC-PC. The first article shall be one complete armor panel assembly. The first article shall be inspected for compliance with this specification. Subject to passing first article inspection, this panel assembly will be delivered to NSWC-PC. Manufacture of production panels shall not commence until NSWC PC has advised the contractor of successful completion of the first article inspection which shall include any necessary environmental testing.

6.8 Flammability. ASTM D-635 should be used to measure and describe the properties of materials, products, or systems in response to heat and flame under controlled laboratory conditions and should not be used for the description or appraisal of the fire hazards of materials, products, or systems under actual fire conditions.

6.9 NSWC-PC. The following definition applies:

Naval Surface Warfare Center Panama City

Code E34

Panama City, FL 32407

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