19_Attachment_SPMYM4-16-Q-0696.doc

KAron Quality Assurance Requirements

1. Kamatics is to provide verification that surface roughness inspections have been performed prior to the coating application, and that the surface profile meets the visual standards as displayed in Kamatics’ process area.

After cathodic disbondment testing, several of the test panels experienced significant areas of disbondment. After closer inspection it was found that these areas have a much smoother surface than what is required in order to achieve good adhesion.

Kamatics has responded by saying that the surface profile is highly controlled with visual standards displayed in the process area and with inspections performed by trained operators. Kamatics also said inadequate roughening is very uncommon, but that they will reiterate the importance of surface roughening prior to KAron V application.

2. Kamatics is to provide verification that the KAron V layer has been applied to a satisfactory thickness and to ensure that proper cleaning steps are performed while applying the KAron V material.

After Cathodic Disbondment Testing, a majority of the test panels sprayed with KAron V material showed significant porosity in the coating. This indicates poor or inconsistent coating applications, or some type of surface contamination prior to coating.

Kamatics believed the test panels to be thin by their processing standards and could possibly be distorted during preparation for coating. This would cause inconsistent thicknesses of the KAron V material, but Kamatics did not consider this inconsistency to have a negative effect on the test results.

3. Kamatics is to provide verification that final curing of the bearing liners has been completed and meets 100% of the requirements of their application process.

Through a certain thermal analysis technique, NRL discovered that samples of the KAron V material were not fully cured. NRL baked one sample at 150oC for 30 minutes and retested it several days later. The second test indicated that that sample was now fully cured.

Kamatics has claimed that while their processes regarding final curing are highly controlled and guarantee full curing, this step was inadvertently omitted for the test panel processing plan.

4. Kamatics is to provide verification that the maximum allowable rotational torque is no more than 15 ft-lbs.

5. Kamatics is to provide verification that where NICUAL material to QQ-N-286 is utilized, it shall comply with the requirements of revision F, dated November 29, 1990.

Contract Number:

Kamatics QA Verifications of KAron V Application Process Record the item number of the piece being processed for KAron V coating and document satisfactory (SAT) results of the requirements listed in the table below.

Item Number:

NOTE:

Requirements 1) and 2) must be performed prior to the KAron V material is applied to the substrate

(SAT)

1) Substrate surface profile has been inspected and meets standards

2) Substrate surface has been properly cleaned and is free of any contaminants

3) KAron V coating thickness is sufficient and consistent across entire surface

4) Final curing procedure of KAron V material has been performed in its entirety

5) Maximum rotational torque applied is 15 ft-lbs.

6) Where NICUAL material to QQ-N-286 is utilized, it shall comply with the requirements of revision F, dated November 29, 1990.