Quality Assurance FA.pdf

This document is a U.S. Air Force Quality Assurance Requirements specification (LPF-QAR-003) establishing guidelines for preparing first article test plans and reports for F100 engine parts.

The specification mandates comprehensive testing of first article quantities as defined by contract, with one article subject to complete destructive testing including all test procedures, while remaining articles undergo only nondestructive testing portions. Testing requirements encompass dimensional conformance with finish specifications, nondestructive inspections (FPI, ultrasonic, eddy current, x-ray, visual), material properties verification (mechanical, metallurgical, chemical), and conformance to all referenced processes, specifications, and standards. All first articles must be serialized and subject to 100% dimensional inspection with tabular documentation of all measurements, tolerances, and instruments used. Calibration of all tooling and gaging must be traceable to NIST per ISO 10012-1. Nondestructive inspections require 100% coverage with Pratt & Whitney-approved sources, Level II or III inspectors as applicable, and current master/transfer master calibrations. Visual inspections must reference applicable Pratt & Whitney Visual Inspection Standards with photographic standards included where required. Material properties testing must verify composition, heat treatment conditions, microanalytical results, and mechanical properties per specifications; suppliers' certifications may be insufficient, requiring redundant testing. Contractors must deliver the First Article Test Plan (FATP) per contract schedule with detailed testing instructions, followed by the First Article Test Report (FATR) including all laboratory results from contractor facilities and sub-vendors. Destructive testing remnants and one nondestructively tested article marked "UNSERVICEABLE - Condition Code 'R'" must be delivered with the report. All first and production articles must be newly manufactured under the current contract from materials meeting drawing requirements; subcontractors must be pre-identified, and source changes require OC-ALC/LPFR authorization.