NCO Sword specifications USAFA CU 945-05.pdf

US ARMY NCO SWORD, SCABBARD AND COVER

1. SCOPE.

1.1 Scope. This specification covers the requirements for US Army NCO Sword, Scabbard and Cover for the 3rd US Infantry Regiment (The Old Guard).

2. APPLICABLE DOCUMENTS.

2.1 The following documents of the issue in effect on the date of request for proposals, form a part of this specification to the extent specified herein:

STANDARDS:

Federal

FED. TEST METHOD Metals; Test Methods

STD. NO. 151

FED. TEST METHOD Leather; Methods of Sampling and Testing

STD. NO. 311

Military

MIL-STD-105 Sampling Procedures and Tables for Inspection by Attributes

2.2 Other Publications.

2.2.1 American Society for Testing Materials, Methods for Chemical Analysis of

Metals. Application for copies of A.S.T.M. Standards should be addressed to ASTM

International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA, 19428-2959.

3. REQUIREMENTS.

3.1. Sample. Vendor samples are furnished as a guide only. Minor A or B defects (or minor variations from this specification as defined in Table III) may appear in the sample, in which case this specification shall govern. Upon award, the Contracting Officer will issue the vendor a list of defects that must be corrected for preproduction and/or production samples.

Except for such variations, the design, appearance, quality and workmanship in all respects not covered by this specification shall be equal to the sample.

3.2 Preproduction sample approval. When required before production is commenced, the contractor shall submit to the contracting officer for approval, a finished Sword, Scabbard and Cover conforming to the requirements for design, construction and workmanship of this specification.

3.2.1 The vendor shall submit test results covering the physical characteristics of each metal and plating as specified in this specification, along with the preproduction sample.

3.3 Materials.

3.3.1 Sword Blade. The blade shall be forged of corrosion resisting, stainless steel

(Steel type X30Cr13 / W.1.4028 / AISI 420), and shall be carefully tempered, hardened and ground. The blade shall be tapered and have a straight diamond shape. The Rockwell “C" hardness shall be from 48 to 54, measured at three points: 4 inches from the guard, center point of the blade, and 4 inches from the tip. The surface of the blade shall be carefu1ly polished to a bright finish. The blade tongue which holds the guard shall not be hardened.

3.3.1.1 Dimensions. The finished dimensions of Sword blade and hilt shall be in accordance with Table I.

3.3.1.2 Length. The finished blade length and overall length shall be in accordance with Table I.

TABLE I

SWORD MEASUREMENTS

BLADE OVERALL

CLASS LENGTH LENGTH

1. 28" 28” (711 mm) 33-11/16” (856 mm)

2. 29" 29” (737 mm) 34-11/16” (881 mm)

3. 30" 30” (762 mm) 35-11/16” (906 mm)

4. 31” 31” (787 mm) 36-11/16” (932 mm)

5. 32" 32” (813 mm) 37-11/16” (957 mm)

6. 33" 33” (838 mm) 38-11/16” (983 mm)

7. 34" 34” (864 mm) 39-11/16” (1008 mm)

Tolerances are +/- 3/8” (+/- 9 mm)

NOTE: The inside dimension of Scabbard shall be ¼” (6 mm) longer than the blade length.

3.3.1.3 Maker’s Mark. The manufacturer’s Maker’s Mark shall appear on the blade’s ricasso on the back side of the blade. The Maker’s Mark will include the country of origin, shall be acid etched in accordance with commercial practice, and will have a uniform appearance and depth across the etch.

3.3.2 Balance and Weight. The individual components of the sword shall be designed, cast, and assembled where the balance point for a completed 32-inch sword is located not less than 4.5 inches from where the guard meets the blade. The finished complete sword weights shall be per Table II.

TABLE II

COMPLETE SWORD WEIGHTS (WITHOUT SCABBARD)

OVERALL

CLASS WEIGHT

1. 28" 1.30 lbs (590 grams)

2. 29" 1.32 lbs (601 grams)

3. 30" 1.35 lbs (612 grams)

4. 31" 1.37 lbs (624 grams)

5. 32" 1.40 lbs (636 grams)

6. 33" 1.42 lbs (648 grams)

7. 34" 1.45 lbs (660 grams)

Tolerance: +/- 0.1 lbs (+/- 45 grams)

3.3.3 Sword Hilt Components and Assembly. The Sword Hilt assembly shall consist of the following components:

3.3.3.1 End Nut. The end nut shall be made of a solid copper-zinc alloy casting containing 85% copper (material CuZn15, DIN EN 1652). The entire end nut shall first be copper plated with a minimum thickness of 0.00059 inches (15 microns) and then nickel plated with a minimum thickness of 0.0002 inches (5 microns). The end nut shall finally be gold plated with a minimum thickness of 0.00002 inches (0.5 microns) and highly polished.

3.3.3.2 Pommel End Cap. The pommel end cap shall be made of a solid copper-zinc alloy casting containing 85% copper (material CuZn15, DIN EN 1652). The entire end cap shall first be copper plated with a minimum thickness of 0.00059 inches (15 microns) and then nickel plated with a minimum thickness of 0.0002 inches (5 microns). The end cap shall finally be gold plated with a minimum thickness of 0.00002 inches (0.5 microns) and highly polished.

3.3.3.3 Grip Assembly. The grip assembly shall consist of an acrylonitrile butadiene styrene (ABS) plastic grip wrapped with silver-plated copper wire in a right hand twist and two grip bands made of copper-zinc alloy containing 85% copper (material CuZn15, DIN EN

1652). The bands shall first be copper plated with a minimum thickness of 0.00059 inches (15 microns) and then nickel plated with a minimum thickness of 0.0002 inches (5 microns). The bands shall finally be gold plated with a minimum thickness of 0.00002 inches (0.5 microns) and highly polished. The finished grip assembly shall be 1-1/16” (+/- 1/16”) wide at the widest point on the grip.

3.3.3.4 Guard. The guard shall consist of a solid copper-zinc alloy curved design with a curved bottom thumb pommel casting containing 85% copper (material CuZn15, DIN EN

1652). The guard shall first be copper plated with a minimum thickness of 0.00059 inches (15 microns) and then nickel plated with a minimum thickness of 0.0002 inches (5 microns). The guard shall finally be gold plated with a minimum thickness of 0.00002 inches (0.5 microns) and highly polished.

3.3.3.4 Clamshell. The clamshell shall consist of a copper-zinc alloy containing 85% copper (material CuZn15, DIN EN 1652) and will be 2.625 inches (2-5/8") long by 2.4375 inches (2-7/16") inches wide. The clamshell shall first be copper plated with a minimum thickness of 0.00059 inches (15 microns) and then nickel plated with a minimum thickness of

0.0002 inches (5 microns). The clamshell shall finally be gold plated with a minimum thickness of 0.00002 inches (0.5 microns) and highly polished.

3.3.3.5 Assembly. All component parts shall be accurately machined for size and fit to assure a solid and proper assembly. The finished mounting shall be clean, smooth and free from dents and other markings that may affect the appearance. When fully assembled, neither the gap between the guard and the pommel end cap nor the gap between the guard and the clamshell shall exceed 0.03125 inches (1/32"). The clamshell shall have the concave curvature towards the sword's blade tip. All components shall be designed and assembled in a manner that allows the user to perform manual of arms with the sword.

3.3.4 Scabbard. The Scabbard shall consist of the following components:

3.3.4.1 Scabbard Body. The scabbard body shall be made from either a polyurethane tube of a thickness not less than 0.04 inches (1 mm) thick or a carbon steel Material AISI 1008 tube of a thickness of 0.04 inches (1 mm). The polyurethane shall have a volume-weight 600 kg/m3, shall be heat resistant up to 212o F (100o C), and shall have surface hardness C67 Shore

D. The tube shall be wrapped in black calf leather with colorfast dye. The calf leather shall have consistent and uniform thickness and finish, without blemishes or scratches. The leather seam shall be placed on the edge of the scabbard that faces to the rear when worn. The seam shall be straight and with no residual glue remaining. The leather shall be completely glued down at the seam without any separation from the tube.

3.3.4.2 Shoe. The shoe shall consist of a copper-zinc alloy containing 85% copper

(material CuZn15, DIN EN 1652). The shoe shall first be copper plated with a minimum thickness of 0.00059 inches (15 microns) and then nickel plated with a minimum thickness of

0.0002 inches (5 microns). The shoe shall finally be gold plated with a minimum thickness of

0.00002 inches (0.5 microns) and highly polished.

3.3.4.3 Mouthpiece. The mouthpiece shall consist of a copper-zinc alloy containing

85% copper (material CuZn15, DIN EN 1652). The front side of the mouthpiece shall have a silver-soldered hook made of the same material. The mouthpiece shall first be copper plated with a minimum thickness of 0.00059 inches (15 microns) and then nickel plated with a minimum thickness of 0.0002 inches (5 microns). The mouthpiece shall finally be gold plated with a minimum thickness of 0.00002 inches (0.5 microns) and highly polished.

3.3.4.4 Liner. The conical-shaped liners inside the scabbard body shall be made from

1 mm (0.04 inch) thick brown cellulose-sheet, according to EN 60641. The liners shall extend the total inside length of the scabbard body. One liner shall have a foam (ISO 845, 22 g/m3) reinforcement in the center to give better hold to the sword when inserted into the scabbard.

The foam shall be 0.4 inch thick and 7 inches (+/- 0.5 inch) long. The liners shall fit the inside of the scabbard body without being loose.

3.3.4.5 Scabbard Fitting Screws. The fittings shall be attached to the scabbard body with gold-plated fillister machine screws on the rear surface of the scabbard body. The screws shall be countersunk at or below the fitting surface. The screw and fitting hole shall be free of burrs.

3.3.4.6 The finished scabbard shall be clean, smooth and free from pits, dents and any other imperfection that may affect the appearance.

3.3.5 Plating. All copper plating shall be a minimum of 0.00059 inches (15 microns) in thickness, nickel plating shall be at least 0.0002 inches (5 microns) thick, and the gold plating shall be at least 0.00002 inches (0.5 microns) thick.

3.3.6 Felt Cushion. Each sword shall have a washer cushion made of white felt 0.1 inches (2-3 mm) thick with a density of 0.2 – 0.4 g/m3. The washer shall act as a cushion between the base of the guard and the mouthpiece of the scabbard.

3.3.7 Cover. Each sword and scabbard shall be provided with a dark blue polyester/cotton cloth cover to fit the assembled sword and scabbard. The cover shall have a drawstring.

3.3.7.1 The cover shall be vat dyed dark blue color. The fabric shall be free from any imperfections that may affect the appearance or serviceability of the cover. The fabric shall have the following physical characteristics:

a. Content: 80% polyester, 20% cotton

b. Weight: No less than 4.5 ounces per yard (60-inch goods)

c. Texture: At least 45 yarns in the warp and 45 yarns in the filling

3.4 Workmanship. The quality of manufacture shall be controlled to guarantee conformity with the standard of workmanship established in this specification. The finished sword, scabbard and cover shall be clean and free from any defects that may affect appearance or serviceability.

3.4.1 Construction. The construction of components and assemblies of the items covered herein shall conform to the requirements of this specification. Components shall be free from split, puncture, malformation or fracture.

3.4.2 Soldering. Soldering shall be complete, sound, uniform and free from burn-through areas, pits, slag inclusion, porosity, cracks, fractures, flash and excess flux deposits.

3.4.3 Removal of burrs, sharp edges, and flash lines. All burrs, sharp edges, and flash lines shall be removed prior to plating and polishing.

4. QUALITY ASSURANCE PROVISIONS.

4.1 Supplier's Responsibility. The supplier is responsible for the performance of all inspection requirements as specified herein. Except as otherwise specified, the supplier may utilize his own or any other inspection facilities and services acceptable to the Government.

Inspection records of the examination and tests shall be kept complete and made available to the Government as specified in the contract or order. The Government reserves the right to perform any of the inspections set forth in the specification where such inspections are deemed necessary to assure that supplies and services conform to prescribed requirements.

4.2 Inspection for Purposes other than Acceptance.

4.2.1 Preproduction Sample. When required, the preproduction sample shall be inspected for compliance to design, construction, workmanship and appearance.

4.3 Inspection for Acceptance. Unless otherwise indicated hereinafter, inspection shall be in accordance with MIL-STD-105. Inspection level will be Level III. Acceptable quality levels will be 2.5 DHU for majors, 15.0 DHU for majors and minor A's combined, and 40.0

DHU for totals for defects listed in Table III. Defects with an asterisk (*) in classification column will be classified as a major defect when affecting appearance or serviceability seriously; as a minor A defect when affecting appearance or serviceability, but not seriously.

4.3.1 Sampling for Testing. The sample unit for testing of each component shall be the quantity necessary to perform all required tests one time each.

4.3.2 Examination of the End Item. The contractor shall inspect the finished swords for compliance with this specification prior to submitting them to the United States

Government for final inspection and acceptance.

4.3.3 Final Inspection. The passing as satisfactory of the preproduction sample or any detail of construction or material shall not be construed as relieving the contractor of responsibility for faulty workmanship or material which may be discovered at any time prior to final acceptance.

4.3.3.1 The point of final inspection and acceptance of the finished articles shall be as specified in the contract or order.

4.4 Tests. All tests shall be conducted in accordance with the test methods specified herein.

4.5 Defects.

TABLE III CLASSIFICATION

Blade MAJOR MINOR A MINOR B

Bent or distorted and not fitting the scabbard correctly.

X

Edge nicked affecting appearance. X

Edge not uniform in thickness on both sides of blade.

X

Blade length which is more than 3/8 inch shorter or longer than the specified class length.

X

Maker’s Mark not uniform in depth and appearance.

X

Not polished to bright finish. X

Blemishes. X

Felt cushion

Omitted. X

Not the proper size or thickness. X

Sword Hilt Assembly

Grip not made of ABS plastic as specified. X

Grip and guard not assembled properly.

X

Incorrect shape and clearness of design.

Not properly plated. X

Gap where the guard and pommel end cap join exceeds 1/32".

X

Gap where the guard and clamshell join exceeds 1/32".

X

Wire wraps on grip loose or incorrect color.

X

Guard

Incorrect shape. X

Clamshell curvature not concave towards blade.

X

Clearness of design is poor. X

Not properly plated. X

Scabbard

Incorrect shape and clearness of design. X

Polyurethane not used for scabbard tube. X

Poor leather quality. X

Leather seam is not uniformly glued with leather separating from the tube.

X

Leather seam not straight. X

Excess glue visible at leather seam. X

Incorrect size and failure to allow insertion of sword freely and securely.

X

Too tight to insert sword properly or withdraw properly.

X

The scabbard has incorrect liner. X

Scabbard liner does not have foam reinforcement.

X

Shoe Fitting

Not plated properly. X

Scabbard screw not countersunk to a level at or below the fitting surface.

X

Burr remaining on screwhole or screw. X

Mouthpiece

Silver-soldered joint noy uniform in appearance.

Not plated properly. X

Scabbard screw not countersunk to a level at or below the fitting surface.

Burr remaining on screwhole or screw. X

General

Finish not clear, containing scars and blemishes and not properly polished.

X

Length of completed sword not in conformance to Table I.

X

Weight of completed sword not in conformance to Table II.

X

Balance point of 32” completed sword outside of tolerance.

X

Cloth Cover

Any seam or stitch type operation omitted. X

Improper seams or stitching resulting in badly twisted, pleated or bulging seams on outside of cover.

X

Thread breaks or ends of joining seams

(when not caught in other seams) not securely backstitched.

X

Multiple skipped stitches, loose or tight stitch tension resulting in an unsatisfactory seam.

X

On outside, any open seam.

Note: One or more broken or 2 or more continuous skipped or run off stitches constitute an open seam.

X

Any raw edge on outside. X

Component and Assembly

Any component part omitted. X

Any defects of component or assembly, definitely affecting serviceability, including manual of arms.

Any defect of component or assembly affecting appearance of limiting serviceability (Unless otherwise classified herein).

5. PREPARATION FOR DELIVERY:

5.1 Packaging. Each sword and scabbard shall be put into a cloth cover and then packaged by inserting each one snugly in a box or in a spiral or convolute wound tube.

5.2 Packing. Unless otherwise specified in procurement documents, swords shall be packed in a manner which will insure acceptance and safe delivery at destination. As far as practicable, supplies of one type and class only shall be packed in containers which (together with packaging, wrapping and inner packing) conform to carrier rules and regulations as applicable to the mode of transportation selected.

6. NOTES.

6.1 Patent Notice. When Government drawings, specifications and other data are used for any purpose other than in connection with a definitely related Government procurement operation, the United States Government thereby incurs no responsibility nor any obligation whatsoever; and the fact that the Government may have formulated, furnished, or in any way supplied the said drawings, specifications or other data is not to be regarded by implication or otherwise as in any manner licensing the holder or any other person or corporation or conveying any rights or permission to manufacture, use or sell any patented invention that may in any way be related thereto.