Attachment 0010 M821A4 Mass Sim Body QAP.docx

QUALITY ASSURANCE PROVISIONS (QAP)

(DARCOM-R-702-10)

1. COMMAND AGENCY:

U.S. ARMY COMBAT CAPABILITY DEVELOPMENT COMMAND

PICATINNY ARSENAL, NJ 07806-5000

INSPECTION SHALL BE CONDUCTED AS SPECIFIED HEREIN AND IN ACCORDANCE WITH REFERENCED DOCUMENTS.

3.

PART I. LIST OF APPLICABLE DOCUMENTS

DRAWINGS

7548319 Box, Fiberboard Ammunition, for Interplant Shipment of Projectiles, Empty 12995075 Vapor Phase Corrosion Inhibitor Bag 13064752 M821A4 Mass Sim Body 13064753 M821A4 Mass Sim Body Paint Assembly

STANDARDS

NON GOVERNMENT PUBLICATIONS

DISTRIBUTION STATEMENT D. Distribution authorized to the Department of Defense and U.S. DoD contractors only to safeguard critical technology as determined on XYZ. Other requests for this document shall be referred to the CAD Division, PM CAS, ATTN: SFAE-AMO-CAS, B162North, Picatinny Arsenal, NJ 07806-5000.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et. seq.) or the Export Administrative Act of 1979, as amended, Title 50, U.S.C., App. 2401 et. seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction of this document.

4. RELEASE

NUMBER

5. DATE

4.RELEASE

NUMBER

5. DATE

REVISION

STATUS

OF

SHEETS

8. REVISION

7. SHEET

8. QAP FOR:

M821A4 Mass Sim Body

CAGE CODE

19200

9. SUBMITTED BY:

10. QAP NO.:

13064753

11. DATE:

09/23/2020

12. APPROVED:

13. RELEASE NO.:

14. PAGE NO.:

15. NO. OF PAGES:

QUALITY ASSURANCE PROVISION (QAP)

PART II. CONFORMANCE PROVISIONS

1. General provisions.

1.1 Classification of characteristics. There are three classes of characteristics covered in this QAP. These are: critical characteristics, major characteristics, and minor characteristics, as defined in MIL-STD-1916.

1.2 Workmanship. All parts shall be fabricated and finished in a thorough, workmanlike manner and all manufacturing, processing and assembly shall be correctly performed. The parts shall be clean and free of burrs, sharp edges, unblended radii, surface defects, cracks, chips, dirt, grease, oil (except where specifically required), rust, foreign matter or any evidence of poor workmanship that could render the system unsuitable for its intended purpose.

1.3 Certification provisions.

1.3.1 Certificate test reports (CTR). The contractor shall make available to the Government a CTR for each lot of items and material by lot number prior to acceptance. This test report is in addition to, and not in lieu of, any rights of the Government under this contract or law. This does not relieve the contractor from inspection throughout the contract production, including recording data and results there from. Recorded data and results shall be made available to the government upon request. A new certification will be required should any changes occur in materials, manufacturing processes, and techniques, which affect characteristics previously certified. A CTR may be used as an element incident to, but shall not be used as the sole basis for, Government acceptance of the contract item(s) unless so indicated in the technical documentation or contract. As a minimum, the report shall contain the following:

a. Name of company and date.

b. Contract number or purchase order number, national stock number and drawing number.

c. Complete nomenclature of supplies together with lot number or other identification. The quantity in each lot or shipment shall be given.

d. All inspections and tests required by contract (i.e., material, processes, performance, functional, etc.) shall be recorded in test reports. These reports shall identify each lot submitted for acceptance by lot number, the specification or drawing, revision and date, grade or type as applicable, number of specimens tested, specified characteristics and requirements, and actual results obtained.

e. Reports of the raw material producer’s chemical mechanical, and physical analyses.

f. A statement, as follows, certifying that material meets all requirements of the contract:

“The undersigned, individually, and as the authorized representative of the contractor, warrants and represents that: All the information supplied above is true and accurate; the material covered by this certificate conforms to all contract requirements (including but not limited to the drawings and specifications); the analyses appearing herein are true and accurate analyses; and this certificate is made for the purpose of inducing payment and with knowledge that the information and certification may be used as a basis for such payment.”

g. Signature and title of certifying official.

2.2 Rejection. If any sample item fails to comply with any of the applicable requirements, the first article sample shall be rejected. The Government reserves the right to terminate inspection upon any failure to comply with any of the requirements.

CAGE CODE

16.

REVISION

SYMBOL

AND DATE

10. QAP NO.

11. PAGE NO.

QUALITY ASSURANCE PROVISION (QAP)

2. First article.

2.1 Submission. Unless otherwise specified, a first article sample consisting of the sample items in quantities as specified herein shall be submitted for inspection and approval in accordance with the terms of this contract. The sample items will be subjected to any or all of the conformance inspections listed in Part III of this QAP and may be inspected for compliance with any or all of the requirements of the applicable drawing(s) and specification(s). The certification requirements of Part IV apply.

Sample items Drawing Sample quantity M821A4 Mass Sim Body 13064752 10 Qualification of permanent marking process 13064752 See Part III Paragraph 501

3. Verification. Verification inspection shall consist of inspection of all conformance characteristics contained in Part III, Inspection Requirements, and Part IV, Certification Provisions, of this QAP. Failure to comply with the conformance criteria specified shall be cause for rejection of the lot or quantity represented. All other characteristics that are not specifically listed thereof are subjected to control under the contractor’s quality program or inspection system.

3.1 Lot formation. Inspection lots shall comply with the lotting requirements of MIL-STD-1916, paragraph 4.2.2, formation and identification of lots or batches.

3.2 Attributes sampling inspection. The provisions/procedures of MIL-STD-1916 are applicable to this QAP. Unless otherwise specified, attributes sampling for the conformance characteristics listed in Part III herein shall be in accordance with MIL-STD-1916, using the verification level cited in the conformance criteria columns of Part III. The procedure in MIL-STD-1916 for normal inspection shall be used at the start of production for current or previous suppliers of the item.

3.3 Alternative verification provisions. Unless otherwise specified, alternate acceptance procedures may be proposed as specified by the contractor-proposed provisions of MIL-STD-1916 - in lieu of the inspection provisions contained herein when such alternative(s) provide an equivalent or better level of quality and provided they have been described in a written proposal which has been approved by the Government.

3.4 Tool control inspection. Acceptance by form tool measurements (punches, dies and drill bits) may be proposed, provided the contractor establishes a correlation between the tool dimension and the component dimension prior to substitution. At a minimum for tool control, one shell body from each machine in operation at the start of each workday, every four hours or fraction thereof, and whenever tooling/equipment/process is changed/repaired/adjusted shall be selected and gaged. Prior to any tooling change/repair/adjustment the last body produced from the old tooling shall be gaged. At a minimum, all material produced since the last satisfactory sample shall be considered defective and screened whenever a non-conforming characteristic is found.

3.5 Inspection equipment. Unless otherwise specified herein or within the contract, all inspection equipment required to perform the examinations and tests in this QAP shall be designed, documented and maintained by the contractor, including any fixtures necessary to accommodate the test procedures. Inspection equipment shall incorporate the appropriate measurement capability, precision and accuracy to assure rejection of all nonconforming products.

CAGE CODE

16.

REVISION

10. QAP NO.

11. PAGE NO.

QUALITY ASSURANCE PROVISION (QAP)

PART III. EXAMINATION PROVISIONS

1. Classification of conformance characteristics.

a. Material from each mill heat of steel Drawing 13064752

MAJOR:

Macroetch Bar stock cracked on outside 1/ 100% Visual

1/ Specimens shall be selected from the reduced product of each mill heat of steel.

CAGE CODE

16.

REVISION

10. QAP NO.

11. PAGE NO.

QUALITY ASSURANCE PROVISION (QAP)

PART III. EXAMINATION PROVISIONS (CONTINUED)

b. M821A4 Mass Sim Body Drawing 13064752

MAJOR:

Mechanical properties Diameter at basic length rear of obturator groove Pitch diameter of rear thread Major diameter of rear thread Projected runout of rear thread (2 places) Diameter of boattail at basic length (2 places) Bourrelet diameter Angle at rear of obturator groove Width of obturator groove Diameter of obturator groove Length of rear thread boss Length from front face to obturator groove face Diameter of ogive at basic length (2 places) Length from front face to bourrelet Diameter of internal cavity Length from forward face to aft face Length of forward thread Pitch diameter of forward threads Minor diameter of forward threads Projected runout of forward threads (2 places) Burrs in threads Radius at base of body cavity Radius between base and sidewall of body cavity Weight

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

503/504 Gage Gage Gage Gage Gage Gage Gage Gage Gage Gage Gage Gage Gage Gage Gage Gage Gage Gage Gage Visual Gage Gage Gage

MINOR:

CAGE CODE

16.

REVISION

10. QAP NO.

11. PAGE NO.

QUALITY ASSURANCE PROVISION (QAP)

PART III. EXAMINATION PROVISIONS (CONTINUED)

c. M821A4 Mass Sim Body Body Paint Assembly Drawing 13064753

MAJOR:

Exterior paint on thread(s) or indicated surfaces Paint thickness, min.

Salt spray and paint adhesion tests

VL-IV

1/ 2/ Visual 506/507

1/ See Part III Paragraph 505 2/ See Part III Paragraphs 506 and 507

d. Packaging of projectile body in VpCI Bag and fiberboard box for interplant shipment of empty projectiles

Drawing 13064752

MAJOR:

VpCI bag(s) missing, damaged, or improperly closed Body(ies) improperly oriented Partition(s) missing, incorrect, or damaged Box improperly sealed Material(s) incorrect

VL-IV

VL-IV

VL-IV

VL-IV

VL-IV

Visual Visual Visual

Improper assembly of box Incorrect quantity in box Marking incorrect, missing, or illegible Pad(s) missing or damaged (if applicable) Improper assembly of box

VL-II

VL-II

VL-II

VL-II

VL-II

Visual Visual Visual Visual Visual

CAGE CODE

16.

REVISION

10. QAP NO.

11. PAGE NO.

QUALITY ASSURANCE PROVISION (QAP)

PART IV. CERTIFICATION PROVISIONS

NUMBER CHARACTERISTIC CERTIFICATION METHOD TEST DATA TO COMPLY WITH

301 Steel CTR Dwg. 13064752 302 VpCI bag CTR Dwg. 12995075 303 Box, Fiberboard Ammunition CTR Dwg. 7548319

PART V. TEST METHODS AND PROCEDURES

501. Qualification of permanent marking process. If the permanent marking method is engraved or stamped using a method other than low-stress lettering, a minimum of ten (10) shell bodies shall be marked in a continuous operation using the proposed process parameters. The first and last bodies shall be circumferentially cross-sectioned through the body through a line of text. A segment of the marking cross section representing at least 0.375 inches of linear length of text shall be prepared metallographically in accordance with ASTM E3 (ground, polished, and etched) to reveal the microstructure. When examined under suitable magnification, verify the markings meet the requirements of Drawing 13064752 and are free of defects - including but not limited to cracks, sharp tips (not rounded) at the root of the markings, foreign matter, inclusions, excessive depth, or any feature more than two (2) times deeper than it is wide. Failure of any specimen to comply with all requirements shall result in rejection of the process represented by the sample. After qualification, no changes shall be made to the parameters without concurrence from the government technical agency or re-qualification of the process.

502. Macroetch test. Macroetch verification shall be in accordance with either MIL-S-50783 or MIL-S-70703 for material made by the strand cast process, as applicable. Specimens shall be prepared in accordance with ASTM E340. For steel not produced by the strand cast method, full section macroetch cross sections shall be evaluated from reduced product representing the top and bottom of the first, middle, and last ingots from each mill heat of steel; steel ingot casting and top and bottom discard practices shall be uniform for the entire heat represented. Failure of any specimen to meet the macroetch requirements specified on Drawing 13064752 shall be cause for rejection of the entire mill heat of steel represented.

503. Hardness screening. All forgings shall be hardness screened to verify the consistency of the material, verify the heat treatment uniformity, and to select the forgings for tensile testing (see 504). The hardness screening shall be performed as specified in either ASTM E10 for Brinell hardness or ASTM E18 for Rockwell hardness, using any automated hardness tester. In addition, the following requirements apply:

a. The surface of the forging in the area to be hardness tested shall be prepared by machining or grinding to a depth sufficient to remove the decarburization zone. Hardness indentations shall be completely removed from the finished machined body.

b. The hardness tester calibration shall be tested at start up, at least once each four (4) hours of continuous operation, or after a layoff of three (3) or more hours.

c. The forging shall be fixtured so that no rocking, shifting or deflection of the forging will occur during the test.

d. Hardness readings shall be taken at least ten indenter ball diameters apart.

e. The hardness tester shall not produce indentations deeper than 50% of the indenter ball diameter or 25% of the wall thickness of the body in that zone.

f. With the automated hardness tester, the hardness readings for an acceptable body shall be between 25-80% of the full scale capability of the test equipment.

g. When using the Brinell hardness test, perform as specified in ASTM E10, except that the minimum dwell time shall be five (5) seconds.

CAGE CODE

16.

REVISION

10. QAP NO.

11. PAGE NO.

QUALITY ASSURANCE PROVISION (QAP)

The hardest and softest forgings of the first heat treat batch of bodies from each heat of steel shall be sectioned and machined into tensile specimens for testing in accordance with 504. If a continuous furnace is used, the hardest and softest forgings shall be selected from the first hour of production. If both tensile specimens from the hardest and softest forgings meet all required mechanical properties, the hardness range represented shall be used as the accept/reject criteria for the hardness tests of all remaining forgings processed from the same heat of steel, provided that they have also been processed with the same parameters. Forgings whose hardness falls outside of the range associated with the acceptable mechanical properties shall be removed from the lot. If a harder or softer forging is found, at the option of the contractor, that forging may be sectioned and tensile tested. If all required mechanical properties have been met, the acceptable hardness range will be extended accordingly. However, if a tensile specimen from the new hardest or softest forging fails to meet either the required minimum yield strength or the required minimum elongation, this and all forgings from the proposed hardness range extension shall be removed from the lot. If, for any reason, the heat treat parameters are changed, a new acceptable hardness range shall be established.

504. Tension test. Each heat treated forging selected for tension testing shall have two longitudinal specimens taken from both the rear taper and bourrelet region, 180 degrees apart, for a total of four specimens. See FIGURE 1. Samples shall be the largest obtainable flat or round specimens as specified in ASTM E8.

Figure 1. Tension Test Sample Preparation

Tension test to determine mechanical properties shall be performed in accordance with ASTM E8. Elongation shall be measured to the nearest thousandth of an inch (0.001 in) prior to conversion into percent elongation. Percent elongation shall be recorded to the nearest tenth (0.1) of a percentage. If the materials properties are not met, the batch of heat treated bodies shall be rejected.

505. Paint thickness. The paint thickness measurement shall be performed for First Article, each day of painting, and whenever a change is made to the painting process. Six (6) specimens shall be selected consisting of randomly chosen body assemblies which have been processed through all the same cleaning, phosphating, painting and drying steps at the same time using the same equipment as other production body assemblies. The samples shall be taken from each continuous final paint operation up to 24 hours long. Two body assemblies shall be taken during the first (30) minutes of painting, two during the middle of the painting operation, and two during the last (30) minutes of painting. Two paint thickness readings shall be taken on opposite sides of the ogive, bourrelet and rear taper of each body selected (6 readings per body, total). The bodies may be the same as those selected for salt spray or paint adhesion testing. Paint thickness readings may be averaged in each of the three zones.

CAGE CODE

16.

REVISION

10. QAP NO.

11. PAGE NO.

QUALITY ASSURANCE PROVISION (QAP)

PART V. TEST METHODS AND PROCEDURES (CONTINUED)

506. Paint adhesion test. Prior to salt spray testing, two (2) of the specimens randomly selected from the five above must only pass an adhesion test using the procedures and pass-fail criteria specified in TT-C-490. If both specimens pass the adhesion test, the three (3) remaining specimens shall be scored lengthwise down the entire body using a precision scribing tool/insert or equivalent in preparation for the salt spray test.

Figure 2. Salt Spray Test Preparation

507. Salt spray sampling. In performing the following tests, TT-C-490 shall apply unless specified otherwise herein. The tests (See 4.5.4) shall be performed for first article inspection, each day of painting during production and whenever a change is made to the paint process, until all samples from five (5) consecutive days of painting have passed the test. Thereafter the sample frequency may be reduced to twice per week during continuous days of painting. Five specimens shall be selected (three for salt spray, and 2 for paint adhesion), consisting of randomly chosen body assemblies which have been processed through all the same cleaning, phosphating, painting and drying steps at the same time using the same equipment as other production body assemblies. The samples shall be taken from each continuous final paint operation up to 24 hours long. One body assembly shall be taken during the first thirty (30) minutes of painting, one during the last thirty (30) minutes and the others at any other time.

CAGE CODE

16.

REVISION

10. QAP NO.

11. PAGE NO.

QUALITY ASSURANCE PROVISION (QAP)

PART V. TEST METHODS AND PROCEDURES (CONTINUED)

The salt solution, test equipment and drying procedures shall be in accordance with ASTM B117, Salt Spray (Fog) Testing, unless specified otherwise herein. Specimens shall be positioned between 15 and 30 degrees from vertical during the test. No coating of any kind shall be permitted over the paint on stamp marks of the specimens prior to testing, however areas in contact with racks or supports, unpainted surfaces and areas within 3/16 inch of unpainted surfaces may be protected. Blisters which are present when the test is over are to be counted within five (5) minutes of removal from the test chamber. See 6.8 for definitions of blisters and spots. Body assemblies shall be tested at the concentration and duration specified on Drawing 13064753. After testing, any body assembly which fails for any of the following reasons, shall cause rejection of all parts painted since the last successful test and a return to the original sampling plan if failure occurred during reduced sampling. The failure criteria in paragraphs a-i below applies to the traditional significant surface (60 degrees on either side of the scribe mark, see Figure 1), unless a noticeable problem that was not caused by part orientation is observed outside the 120 degree zone.

a. The paint shows more than 1/8 inch creepage, blistering or loss of adhesion of paint from the scribe mark, stamp mark, or edge.

b. There are more than five (5) blisters, total.

c. Any blister exceeds 1/16 inch average diameter.

d. Any pit exceeds 1/8 inch average diameter.

e. There are four (4) or more scattered pits exceeding 1/16 inch average diameter.

f. There are three (3) or more spots within one square inch.

g. There are two (2) spots within one square inch in three (3) or more places.

h. There are more than seven (7) scattered spots, total.

i. There is evidence of rust under the paint (a brown discoloration showing through the paint) in excess of ¼ inch in diameter total area.

j. There is some variation of the above or an unlisted defect which the Government representative deems excessive.

508. Workmanship. All parts shall be free of damage such as dents, dings, gouges, and other similar defects. Threads shall be undamaged, free of burrs, and shall be full for the entire length or depth excluding lead-in and lead-out. Damage or burrs that interfere with assembly of the go gage shall be considered major defects. Parts shall be free of sharp edges that may be injurious to personnel handling the item. Parts shall be clean and free of corrosion, chips, grease, cleaning fluid residue, and other foreign matter. Any cleaning method used shall not be injurious to the parts. Markings shall be complete, accurate, and sharply defined.

CAGE CODE

16.

REVISION

10. QAP NO.

11. PAGE NO.

image2.png image1.emf