Attachment_0010_Quality_Assurance_Provision_(QAP)_MS3314_for_the_MS3314.pdf

QUALITY ASSURANCE PROVISIONS (QAP)

FOR THE

LUG, SUSPENSION (1000 LB CLASS) AIRBORNE EQUIPMENT

QAP MS3314

Rev. G

08 September, 2016

Prepared by:

NAVAL AIR WARFARE CENTER WEAPONS DIVISION

1 ADMINISTRATION CIRCLE

CHINA LAKE, 93555-6100

DISTRIBUTION STATEMENT D: Distribution authorized to the Department of Defense and U.S. DoD contractors only because export of the data is restricted, (determination, June 2016). Other U.S. requests shall be referred to the Naval Air Warfare Center Weapons Division (Code 471600D), China Lake, CA 93555-6100.

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 Administration Act of 1979 (Title 50, U.S.C., App. 2401 et seq.), as amended. 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 the information.

I. QUALITY SYSTEM REQUIREMENTS

A. The Contractor shall implement and maintain a quality system meeting the requirements of ISO 9001-2008

(only design/development exclusions permitted). The quality system shall also implement the following provisions:

1. Subcontractors producing critical and/or major characteristics shall have a quality system compliant to

ISO 9001-2008 (only design/development exclusions permitted).

Note: Throughout this QAP, Subcontractor means any supplier of materials, components, or services other than the Prime Contractor.

2. When property is furnished by the Government, the Contractor shall implement the following:

a. Examination upon receipt, consistent with practicality, to detect damage upon transit;

b. Inspection for completeness, quantity, and proper type;

c. Periodic inspection and precautions to assure adequate storage conditions and to guard against damage from handling and deterioration during storage;

d. Identification and protection from improper use or disposition.

3. Process and Production Control conditions shall include:

a. Documented manufacturing planning for the implementation and control of manufacturing operations.

The planning shall include: a description of operations, facility, environmental equipment, and tooling requirements, associated controls, and a process flow chart to portray the process of fabrication and assembly in terms of key operations.

b. Accountability for all product.

c. Evidence that all manufacturing, test, and inspection operations have been completed in sequence, as planned, or as otherwise documented and authorized.

d. Preparation of documented process monitoring, accountability, and operator instructions for all processes that affect product quality. These instructions are to be accessible at the point where work is performed and shall, as a minimum, contain reference to the following: workmanship standards, manufacturing aids, step-by-step instructions for performing operations, equipment or tools required, special conditions to be maintained, identification of special handling devices, and methods for recording completion of operations.

4. The Contractor’s calibration system shall be in accordance with ANSI/NCSL Z540.3-2006.

5. Control of nonconforming material shall include:

a. Controls applied to suspect product as well as to nonconforming product.

b. The proposed use or repair of product that does not conform to specified requirements shall be submitted to the Government prior to use or repair. Rework and repair shall be in accordance with applicable contract clause. Repetitive non-conformances will not be approved.

c. The Contractor shall promptly notify the Government when a nonconformance is found in the Contractor’s processes or products that may affect product already delivered.

6. Corrective action shall be required of a Subcontractor when it is determined that the root cause of the nonconformity is the responsibility of the Subcontractor.

7. Internal audits shall cover all quality management related processes, activities, and shifts, and shall be scheduled according to an annual plan.

B. The above provisions shall be addressed in the Quality Program Plan.

II. QUALITY PROGRAM PLAN AND INSPECTION AND TEST PLAN

A. Quality Program Plan: The Contractor shall prepare a Quality Program Plan (QPP) in accordance with the applicable Contract Data Requirements List (CDRL), Automated Data List (ADL) and this QAP. The QPP shall provide traceability from the specific quality elements of the contract to the specific Contractor resources (systems, processes, personnel, etc.) that support those elements, and include quality system measures of effectiveness. The QPP provides the Government a basis for assessment of the quality system and evidence of the Contractor's intent to comply with the contract quality requirements.

1. The QPP shall include:

a. A summary of the contract quality requirements, and

b. A relational matrix indicating the general relationship between the applicable quality system elements of the contract and QAP and the Contractor’s quality system procedures/processes. The matrix, or an attachment thereto, shall also identify schedules or quality activities and tasks, which must be coordinated and compatible with other schedules prepared for work under the contract, as well as include the name(s) of the person(s) responsible for accomplishments of activities and tasks.

2. The QPP shall identify the means by which the Contractor will ensure quality system effectiveness and demonstrate comprehensive management and review of data, such that the results may be used to indicate trends and progress in quality processes, fabrication, assembly, test, and acceptance as appropriate to the contract. The QPP shall describe what is measured, how often it is tracked, and who reviews and assures that appropriate action is initiated when trends are unfavorable.

3. A copy of the Contractor’s quality manual that describes the current quality system shall be attached.

B. Inspection and Test Plan: The Contractor shall prepare an Acceptance Inspection and Test Plan (ITP) in accordance with the applicable CDRL. The plan(s) shall be approved by the government prior to production and acceptance of product since the ITP represents the inspection methods for final acceptance. The plan(s) is subject to disapproval when it does not achieve its intended objective of preventing acceptance of nonconforming material. The contractor shall be responsible for any delays resulting from the late presentation of the plan(s) to the government for review and approval and any delays resulting from the presentation of inadequate or unacceptable plan(s).

The ITP shall address First Article and Lot Acceptance inspection and test requirements in the following format:

1. General: The ITP shall, at minimum, contain the following:

a. Cover sheet identifying item, contract number, and revision letter and date of the plan.

b. All of the inspections and tests required for acceptance of the item, documented in accordance with the requirements herein.

c. A section of the ITP for inspection and test equipment maintenance, recertification, and recalibration, documented in accordance with the requirements herein.

2. Documenting Tests and Inspections: For each required inspection or test, including those inspections or tests that are contained in specifications, specific instructions shall be prepared and shall contain the following:

a. Identification of the item to be inspected and/or tested, including part number, revision letter, and nomenclature.

b. The location of the characteristic, to include the drawing sheet and zone, a brief description of the characteristic, and for classified characteristics, the classification callout.

c. Criteria for passing or failing the inspection or test (such as the high and low limit for a particular dimension, a particular minimum tensile strength, minimum voltage, etc.).

d. Details of the sampling plan to be used, including, as applicable, lot size, sample size, and verification levels.

e. Identification of inspection and test equipment using appropriate identification data visible on the equipment. Standard instruments such as a caliper or micrometer do not require an individual identification description and can be identified simply as “caliper” or “micrometer.”

f. A written procedure for performing the inspection or test when the characteristic is other than a simple dimension, which is measured by the use of a standard instrument such as a caliper or micrometer.

The procedure may be placed in an appendix of the plan and referenced if the procedure is lengthy or repeatedly used.

g. If a CMM is used to check Classified Characteristics and/or features which cannot be checked with standard measuring equipment such as a caliper or micrometer, describe how the datums were picked up and how each feature is picked up by the CMM. Include the amount/location of probe hits to establish datums and features. For all other characteristics checked with a CMM identify simply as

CMM.

h. The manner in which the result of the inspection or test is to be recorded, such as a particular data sheet. Identify the information to be recorded for each inspection or test, to include but not limited to traceability to item and inspection or test characteristic, inspection or test data to be recorded (attribute or variable data for each reading), traceability to inspection or test equipment, and pass/fail disposition.

3. Inspection and Test Equipment Maintenance, Recertification, and Recalibration Schedule: A separate section, or attachment to the ITP shall address inspection and test equipment maintenance, recertification, and recalibration. For each acceptance gage, or other measurement device (including standard measuring instruments) used for final acceptance, the following information shall be documented:

a. A description of the gage or measuring device, including identification data visible on the equipment.

b. A schedule for recertification of the gage or measurement device in terms of gage passes or time limit.

c. Inspection and test equipment used for acceptance of CRITICAL and MAJOR characteristics shall require design approval in accordance with applicable CDRL. A copy of the approval shall be included.

Inspection and test equipment used for acceptance of other characteristics (i.e., MINOR) shall require approval in accordance with applicable CDRL. A copy of the approval shall be included.

4. The above format shall be used for all required inspection and tests regardless of whether the inspections or tests are performed by a Subcontractor. When inspections or tests are performed by a Subcontractor, all of the above information shall be provided by the Subcontractor or obtained by subsequent receipt test or inspection or final acceptance by the Prime Contractor. When inspections or tests are performed by a Subcontractor, the Prime Contractor shall review the relevant specifications and create a receipt inspection or test review sheet to review the Subcontractor's inspection and test data to ensure conformity to contractual requirements. In-process or statistical production inspections and tests, which are used for purposes of manufacturing material, which will later be verified by an acceptance inspection or test, need not be documented in the plan.

C. Approved inspection and test equipment shall be made available for use by the Government when required to determine conformance with contract requirements. If conditions warrant, Contractor personnel shall be made available for operation of such devices and for verification of their accuracy and condition.

III. INSPECTION AND TEST SAMPLING REQUIREMENTS

A. The Contractor, in performing sampling inspection or test of the product(s) being manufactured/delivered under this contract, shall, as a minimum, comply with the requirements set forth below without jeopardizing quality:

1. Characteristics classified on the drawings or in separate documents as CRITICAL shall be verified 100%.

2. Characteristics classified on the drawings or in separate documents as MAJOR shall be verified by characteristic using MIL-STD-1916, Verification Level (VL)-IV, Table II.

3. Characteristics classified on the drawings or in separate documents as MINOR shall be verified by characteristic using MIL-STD-1916, Verification Level (VL)-II, Table II.

Notes:

1. The above criteria will apply except where sampling plans and acceptance criteria appear in the product and/or affiliated specifications, or where authorization to deviate from these requirements has been obtained in accordance with contract requirements.

2. MIL-STD-1916 will form the basis of the sampling inspection program. Those elements of MIL-STD-1916 related to sampling inspection will also apply (e.g., switching rules, non conformance disposition, etc.) Switching from normal to reduced inspection per MIL-STD-1916 shall be approved by the Government prior to implementation. Reduction of test and inspection requirements will be as defined elsewhere in the QAP and contract.

3. MIL-STD-1916 is not intended for use with destructive testing. Should sampling with destructive test be required, an accompanying sampling plan will be provided in the technical documentation or herein

4. If the use of an alternate sampling plan (other than those specified herein) is desired, it shall be documented in detail to show factors such as lot size, sample size, acceptance criteria, and operating characteristic curves, and submitted for approval in accordance with the contract requirements.

5. Characteristics other than product attributes-processing requirements specified on drawings that are classified as CRITICAL, MAJOR, or MINOR are exempt from the inspection and test sampling requirements of the plans above (section III). However, these processes shall be controlled in accordance with the inspection system and/or quality program requirements of the contract.

IV. STATISTICAL PROCESS CONTROL PROGRAM

The Contractor's implementation of the Statistical Process Control program (SPC) shall be documented in accordance with the applicable CDRL, and contract clauses.

V. ACCEPTANCE REQUIREMENTS

A. The Contractor shall perform first article and production inspection and tests as described herein.

1. First article components and completed units shall be representative of items to be manufactured during rate production using the same manufacturing facilities, flow processes, procedures, and controls planned for use during rate production. Likewise, inspection and test of first article and preproduction components and completed units shall be performed using the same methods and equipment scheduled for use during rate production.

2. Materials, design, and construction shall be in accordance with the requirements as defined by the contract.

The Contractor shall demonstrate by means of certification that only materials and components conforming to the contract requirements have been used. The Certificate of Conformance (CoC) shall reference all specifications and requirements called out on the drawing (examples include, but are not limited to, raw material, heat treatment, and coatings). The CoC shall also list all specification requirements (examples include, but are not limited to, material chemical composition, mechanical properties, hardness, coating thickness, and environmental tests if required). Traceability of the CoC must also be maintained from initial purchase, through all subsequent processes, to final receipt at the manufacturing facility. Traceability should include invoices showing transfer of material at all steps until the final product. Purchase orders and receiving records should not be included as part of a certificate of conformance unless they are necessary to link the traceability back to the requirement.

3. First Article Approval:

a. If the sample passes the criteria established in the inspections, tests and verification, it will be approved. If the sample fails any of the specified inspections and tests, the results will be evaluated by the Government Procuring Activity. These results, together with the Government engineering analysis of the sample, shall form the basis for corrective action by the Contractor. Depending upon the degree of corrective action deemed necessary by the Government, approval may be:

1. Granted, in which case the Contractor shall have first made the changes required by the

Government prior to the start of regular production.

2. Withheld, and new sample shall be submitted for approval in place of the failed sample. The sample shall be subjected to the examinations and tests in which the failures occurred and any other examinations and tests of the first article inspection as required by the Procuring Contract Officer (PCO).

3. Withheld, and a new sample shall be submitted for approval.

In all cases the Contractor shall comply with the required changes, which are within the scope of the contract requirements to the satisfaction of the Government for future production.

b. Approval, conditional approval, or rejection of the sample will be given by the PCO. Until the sample is approved, further production shall be at the risk of the Contractor. The Government will not proceed with acceptance of the production lot until first article approval is granted.

c. Additional Samples: Additional samples may be required by the PCO as the result of a first article sample failing to meet the contract requirements. Additional samples required as a result of first article failure shall be supplied by the Contractor at their own expense.

d. Disposition of First Article Sample: All first article samples shall be identified, segregated, and retained at the Contractor's plant and made available to the Government representative, upon request, for the duration of the contract. Final disposition of first article sample will be provided prior to contract completion.

4. Reinstitution of Inspections or Tests: Acceptance of first article sample shall not relieve the contractor from meeting all contract or purchase order requirements throughout the life of the contract. When evidence shows failure to continue to meet the first article requirements specified herein, the Government reserves the right to require tightened test or inspection on a lot basis, consisting of the reinstitution of such portions of the first article needed to verify the effectiveness of any corrective action.

5. Supplemental First Article Sample: An additional first article sample or portion thereof may be required by the Contracting Officer in writing when:

a. A major change is made to the technical data package.

b. Whenever there is lapse in production for period in excess of ninety (90) days.

c. Whenever a change occurs in the manufacturing process, material used, drawings, specification, source of supply, process location or inspection processes being performed.

When conditions (a), (b) or (c) above occur, the Government procuring activity shall be notified, in writing.

Written approval from the Government procuring activity shall be required prior to the implementation of any of the aforementioned scenarios.

6. All failures occurring during First Article Test or Lot Acceptance Test shall be reported by the Contractor in accordance with CDRL requirements.

7. At conclusion of first article testing and lot acceptance testing, the Contractor shall prepare test reports in accordance with CDRL requirements. Data generated during inspection and testing will be included with reports.

8. The Contractor is responsible for the performance of all inspections and test requirements herein.

However, the Government reserves the right to perform any of the inspections set forth in this QAP where such inspections and test are deemed necessary to assure products conform to the prescribed requirements.

B. First Article Test (FAT)

1. The Contractor shall manufacture and submit a first article sample. First article examinations, tests, and inspections shall be performed at the Contractor's facility, by the Contractor personnel, and witnessed by Government representatives, to assure sample conforms to all the requirements specified by the contract (e.g., the ADL, all drawings and related specifications and standards, QAP) and accompanied by verifiable inspection results, certified test reports, material certifications, etc.

C. Lot Acceptance Test (LAT)

1. Rate production shall not proceed until the Government accepts the results of FAT units as conforming to the requirements of the ADL and QAP.

2. Production lot size shall be no greater than 1 week’s production and no less than 1 day’s uninterrupted production.

3. Lot acceptance will be conducted by Contractor and/or Defense Contract Management Agency/ Quality Assurance Representative and witnessed by DCMA/QAR.

4. Lot acceptance will be conducted in accordance with the inspection and test requirements set forth within the ADL, QAP, and the approved ITP.

5. Should a failure occur during lot acceptance, the Contractor shall immediately notify, via the DCMA/QAR, the Contracting Office prior to any rework/repair and retest or re-inspection.

D. A Quality System Review concurrent with preproduction test/inspection or first lot acceptance test may be conducted to evaluate the Contractor’s processes and procedures inherent to the quality of items to be delivered under this contract. The review shall be conducted by Government representatives designated by the

PCO.

VI. TEST AND INSPECTION REDUCTION OR ELIMINATION

A. The Government will consider reduction or elimination of selected acceptance test or inspection based upon first article and LAT results when supported by evidence of both process stability and capability. Contractor written requests shall be made through the Administrative Contracting Officer to the Contracting Officer.

Approval will be based upon the Contractor’s quality program plan, statistical process control plan, and implementation and validation of the process control techniques and corresponding results.

B. Product quality is principally the result of process design and control. As such, the Contractor shall develop process and product control methods that limit product variation and provide evidence of product conformance.

Process control techniques include, but are not limited to: calibrated and controlled tooling, Computer Numerical Control (CNC) machining, set-up verification, and statistical process control. Based on process control techniques, complexity of product characteristics, and length of steady state production, the Contractor shall select product characteristics for potential reduction of reliance on acceptance test and inspection. Government representatives may assist the Contractor during post award, first article, and other technical exchanges to identify product characteristics for potential test and inspection reduction or elimination.

C. The Contractor may switch from normal to reduced sampling test and inspection in accordance with the contract provisions. Further reductions or elimination will be based on the Contracting Officer approval of Contractor written requests. Prior to submitting a written request, the Contractor’s QPP, acceptance inspection and test plan, and SPC program plan shall have been approved by the Government. The Government will consider reduction or elimination of selected acceptance test or inspection based upon the process control evidence provided. As a minimum, documentation submitted for evaluation should address the following:

1. Identification of the characteristic(s) for potential reduction, the inspection provision to be replaced, and an evaluation of the protection provided by the alternate methods as compared with the inspection requirement to be replaced.

2. Evidence of process control and capability during production together with adequate criteria, measurement, and evaluation procedures to maintain control of the process.

3. Assessment plan to periodically verify process stability and capability, and requirements for returning to normal acceptance.

4. Corrective action plan to be implemented when evidence of loss of process control or significant process degradation arises. Evidence of loss of statistical control or degradation below a Cpk of 1.33 shall require immediate corrective action in accordance with the statistical process control program.

D. Once the Government approves alternate acceptance methods, reports containing internally generated process control metrics shall be made available upon request.

E. The Government will not consider requests for reduction or elimination of 100% acceptance inspection and testing of parameters or characteristics identified as CRITICAL.

F. The Government reserves the right to withdraw approval of alternate acceptance methods the Government determines provide less assurance of quality than the inspection requirements originally specified or when the inability to maintain process stability and capability becomes apparent. Any break in production greater than 90 days shall require a return to normal acceptance inspection and testing.

VII. DOCUMENTATION REQUIREMENTS

A. Required documentation (e.g., QPP, ITP, SPC, Ammunition Data Cards) shall be submitted in accordance with applicable CDRL. The Contractor shall be responsible for any delays resulting from late submittals or delays resulting from submittal of inadequate documentation.

B. Documentation shall be maintained and updated as necessary. Updates (changes/revisions) shall consist of notes or changes, clearly identified as to where applicable (i.e., system element, page, paragraph number, etc.)

Updates shall be submitted in accordance with CDRL requirements.

C. Magnetic Particle Inspection Procedures: Magnetic particle inspection procedures shall be prepared and submitted in accordance with ASTM-E1444 and ADL requirements. Procedures shall be submitted thirty (30) days after contract award to ensure sufficient time for government review and approval prior to FAT (if required) or initiation of production if FAT is not required. Allow thirty (30) calendar days for Government review.

VIII. SPECIAL REQUIREMENTS FOR MS3314

1. Scope

1.1 This document covers special requirements not normally required by the drawing and provides quality assurance provisions for the fabrication of one type of lug, designated as MS3314 lug, suspension, (1000 lbs) for airborne equipment.

2. Requirements

2.1 Material - Material shall be in accordance with AMS 6415. Bars shall be furnished in rough turned surface condition.

2.2 Suspension Lug - The suspension lug shall comply with all requirements specified on drawing MS3314, and with all requirements specified in applicable specifications.

2.3 Mechanical Strength Properties

2.3.1 Pull Test - Suspension lug shall be capable of withstanding a load of 27,000 pounds, minimum, in direction “W” without permanent deformation and a load of 35,000 pounds, minimum, in the same direction without fracture or cracking, when tested as specified in 3.4.2 (see FIGURE I).

2.3.2 Pull Test - Suspension lug shall be capable of withstanding a load of 18,000 pounds, minimum, in direction “X” without permanent deformation and a load of 24,000 pounds, minimum, in the same direction without fracture or cracking, when tested as specified in 3.4.3 (see FIGURE I).

2.3.3 Deflection Test - Suspension lug shall be sufficiently ductile to withstand a deflection of 0.1 inch, minimum, measured at the center of the cross bar in direction “Y” without fracture or cracking, when tested as specified in 3.4.4 (see FIGURE I).

2.3.4 Impact Test - Suspension lug shall be subjected to an impact load of 200 foot pounds, minimum, applied in the “Z” direction without any evidence of failure, when tested as specified in 3.4.5 (see FIGURE I).

2.4 Magnetic Particle - The suspension lug shall show no evidence of cracks, seams, laps or other detrimental defects when tested as specified in 3.4.6.

2.5 Identification and Marking - After having successfully passed the magnetic particle test, the letter “M” shall be marked, after plating, with green indelible ink on the surface directly above the threaded portion of the lug in 1/8 inch high letter.

2.6 Salt Spray - The plated suspension lug shall show no evidence of white salts or evidence of corrosion of the base metal after being exposed to salt spray containing 5 percent sodium chloride, for a minimum of ninety-six

(96) hours when tested as specified in 3.4.7.

2.7 First Article Testing - These ADL requirements make provisions for the first article testing. Submission of first article quantity by the contractor shall be as specified in the contract and this ADL.

2.8 Workmanship - All parts and assemblies shall be free of burrs, chips, sharp edges, cracks, unblended radii, surface defect, dirt, grease, rust, corrosion product and other foreign material. The cleaning method used shall not be injurious to any of the parts nor shall the parts be contaminated by the cleaning agent.

2.9 Design and Construction

2.9.1 Forging - The suspension lugs shall be constructed from forgings in accordance with AMS-F-7190, Grade A. induction heating shall be used. note that AMS-F-7190 Grade A requires 100% screening of raw forgings.

2.9.2 Finish - All lugs will be either cadmium plated in accordance with AMS-QQ-P-416, type II, Class 2 or zinc plated in accordance with ASTM B633, Type II, SC3. Cadmium plating in accordance with AMS-QQ-P-416, Type II, Class 2 will not be more than o.ooo8 inches thick. Zinc plating in accordance with ASTM B633, Type II, SC3 will not be more than o.ooo8 inches thick. Acid pickling for cleaning is prohibited. Acid dip of 20 seconds maximum for surface activation after bake and before plating is allowed. Dip and plating process to have low hydrogen content. The cleaning method used shall not be injurious to any of the parts nor shall the parts be contaminated by the cleaning agent. Barrel plating is prohibited.

2.9.2.1 Embrittlement Relief - Within 4 hours after plating, all lugs shall be baked at 375°F ±25°F for a minimum of 6 hours.

2.9.3 Threads - Thread dimensions and designations shall be in accordance with FED-STD-H28.

2.9.4 Gages and gaging for unified screw threads shall conform to FED-STD-H28, System 22.

2.10 Heat Treat - Lugs will be heat treated to Rockwell Hardness of HRC 38-44 in accordance with SAE AMS-H-6875. 100% of the suspension lugs shall be subjected to the hardness test in accordance with ASTM E18, prior to plating.

2.11 Lug holes shall be broached or machined to achieve 125 RMS surface finish under lug bail.

2.12 Lugs shall be heat treated as specified in 2.10, prior to thread forming.

2.13 Repair - Repair or heating for straightening, or bending is not permitted.

2.14 Lotting - Lugs furnished under this ADL will be grouped into lots for testing, inspection, identification and shipment.

2.15 Production - Production lot tests, inspections and evaluations will be performed on every lot of lugs by the contractor.

3.1 General Quality Assurance Provisions - Unless otherwise specified in the contract or purchase order, the supplier is responsible for the performance of all inspection requirements as specified herein. Except as otherwise specified, the supplier may utilize his own facilities or any commercial laboratory acceptable to the government. The government reserves the right to perform any of the inspections set forth in this ADL where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements. Reference shall be made to standard ISO 9001:2008 in order to define terms used herein.

3.1.1 Submission of Product - at the time the completed lot of product is submitted to the government for acceptance the contractor shall supply the following information accompanied by a certificate which attests that the information provided is correct and applicable to the product being submitted:

a. A statement that the lot complies with all of the quality assurance provisions specified within this ADL.

b. Number of units of product inspected.

c. Results obtained, by defect code, for all inspections performed.

d. Drawing, ADL number and date, together with an identification and date of changes.

e. Certificates of conformance on all material purchased by the contractor when such material is controlled by government or commercial specifications referenced in any of the contractual documents.

f. Number of items in the lot.

g. Date submitted.

The certificate shall be signed by a responsible agent of the certifying organization. The initial certificate submitted shall be substantiated by evidence of the agent's authority to bind his principal. Substantiation of the agent's authority will not be required with subsequent certificates unless, during the course of the contract, this authority is vested in another agent of the certifying organization.

3.2 First Article Inspection

3.2.1 Submission - Prior to initiating regular production, the contractor shall submit ninety (90) suspension lugs for first article inspection, in accordance with the provisions of 3.2.2.

The first article sample shall consist of material that has been produced by the contractor or furnished by a supplier and manufactured using the same production processes, procedures, and equipment that will be used in fulfilling the contract. The first article sample, or portion thereof, as directed by the contracting officer, shall also be submitted whenever there is a lapse in production for a period in excess of 90 days, or whenever a change occurs in manufacturing process, material used, drawing, ADL or source of supply so as to significantly affect product uniformity as determined by the government prior to submission the contractor shall inspect the sample to the degree necessary to assure that it conforms to the requirements of the contract and submit a record of this inspection with the sample. A sample containing known defects shall not be submitted unless specifically authorized by the contracting officer.

3.2.2 Inspections to be performed - Each part will be subjected by the contractor to any or all of the examinations or tests in 3.3.2, 3.3.3 of this ADL and any or all requirements of the applicable drawing.

3.2.2.1 During the government procuring activity first article verification the contractor's gages and other measuring and test devices necessary to assure that supplies conform to the technical requirements will be verified. The government procuring activity reserves the right to perform any of the inspections set forth in the specifications and or drawings as necessary to assure supplies conform to prescribed requirements. This shall include but not be limited to the use of government operated inspection laboratories. The contractor's measuring and test equipment shall be made available for use by the government representatives to determine conformance with contract requirements. In addition, contractor's personnel shall be made available for operation of such devices and for verification of their accuracy.

3.2.3 Rejection - If the part fails to comply with any of the applicable requirements, the first article sample shall be rejected. The government reserves the right to terminate its inspection upon observing any nonconformance of the sample to the specified requirements. In the event of rejection, the government reserves the right to require the contractor to take corrective action and submit a new first article sample or portion thereof.

until a first article sample is accepted, the contractor is in no way authorized by the government to initiate regular production unless otherwise directed by the contracting officer.

3.3 Inspection Provisions

3.3.1 Lot Formation - For test purposes a lot is defined as a group of lugs treated at one time in one furnace, and all of which are subjected to the same heat treat operations. Heat treat lots which have passed all magnetic particle, hardness and tensile requirements may be combined into inspection lots of not more than one week's production for visual and dimensional requirements, marking and shipment. All lugs in an inspection lot shall contain the ammunition lot number in accordance with MIL-STD-1168. Lot number stamping shall be in accordance with drawing MS3314 and

FIGURE II.

3.3.2 Conformance Inspection Requirements - Lot sampling of product for visual and dimensional requirements shall be in accordance with QAP, inspection will be by class of characteristics.

3.3.2.1 Suspension Lug (see drawing MS3314)

CHARACTERISTIC NO. CHARACTERISTIC METHOD OF

INSPECTION

C1. PITCH DIAMETER OF THREAD

MINIMUM (1.6914 MIN) ................ GAGE

C2. MAGNETIC PARTICLE (M) TEST

(SEE 3.4) ............. NDI

MAJOR:

M 10l. PITCH DIAMETER OF THREAD, MAXIMUM (1.6959 MAX) ................ GAGE

M 102. MAJOR DIAMETER OF THREAD,

MAXIMUM (1.750 MAX) ................. GAGE

M 103. LENGTH OF FULL THREAD,

MINIMUM (.594 MIN) .................. GAGE

M 104. TOTAL LENGTH (2.375 + .060) ......... GAGE

- .000)

M 105. HEIGHT OF HOLE (1.000 + .031) ....... GAGE

- .000)

M 106. SYMMETRY OF OUTSIDE WIDTH OF WEB

WITH THREAD .... GAGE

M 107. SYMMETRY OF THICKNESS OF WEB

WITH THREAD .... GAGE

M 108. SYMMETRY OF HOLE WITH

THREAD ....... GAGE

M 109. OUTSIDE WIDTH OF WEB (.422 + .OOO) .. GAGE

- .030)

M 110. WIDTH OF HOLE (.720 + .030) ......... GAGE

- .000)

M 111. FLAT ACROSS INSIDE WIDTH'OF

WEB AT TOP, MIN (.480 MIN) .......... GAGE

M 112. FLAT ACROSS INSIDE THICKNESS

OF WEB AT TOP, MIN (.140 MIN) ....... GAGE

M 113. THICKNESS AT TOP OF WEB •............ GAGE

(.550 + .000)

- .031)

M 114. RADIUS INSIDE SURFACE OF WEB

IMPROPER (1/8 R ± 1/64) ............. GAGE

M 115. IDENTIFICATION LOT NUMBER

MISSING ............................. VISUAL

M 116. MAJOR DIAMETER OF THREAD

MINIMUM (1.7386 MIN) ................ GAGE

M 117. BAKE AFTER PLATING .................. VISUAL

MINOR:

201. ANGLES ON SIDE OF WEB, MAXIMUM

(5 1/2 MAX) ......................... GAGE

202. PROTECTIVE FINISH MISSING OR

INCOMPLETE •................•........ VISUAL

203. MARKING MISSING, MISLEADING OR

UNIDENTIFIABLE ...................... VISUAL

204. EVIDENCE OF POOR WORKMANSHIP

(SEE 2.8) .•................•....•... VISUAL

205. MACHINED SURFACE ROUGHNESS

(125 MAX) .......................•... GAGE/VISUAL

206. FORGED SURFACE ROUGHNESS

(250 MAX) ..............•............ GAGE/VISUAL

207. CHAMFER FIRST THREAD (.062 X 60° ±3°)

ALTERNATE (.062 X 45° ±3° ) ........... GAGE/VISUAL

208. RADIUS AT TOP OF WEB

( . 203 R ±. 015) ..................... GAGE

209. RADIUS UNDER BAIL

( . 0 94 ±. 031) . . . . . . . . . . .. GAGE

3.3.2.2 All listed minors on drawing MS3314 inspected per QAP.

3.3.3 Testing

3.3.3.1 First Article Sample - Sample suspension lugs submitted in 3.2.1 shall be subjected to the following tests.

3.3.3.1.1 Hardness Test (see drawing MS3314) - Each of

the ninety (90) samples shall be subjected to this test.

3.3.3.1.2 Mechanical properties Test - Sixteen of the suspension lugs shall be subjected to the following tests.

3.3.3.1.2.1 Pull Test in "w" direction (see 2.3.1) - Four

(4) suspension lugs shall be subjected to this test. (see FIGURE I)

3.3.3.1.2.2 Deflection Test in “y”" direction (see 2.3.3)

- Twelve (12) suspension lugs shall be subjected to this test. (see FIGURE I)

3.3.3.1.2.3 Pull Test in "X" direction (see 2.3.2) - Four

(4) suspension lugs (not used in 3.3.3.1.2.1 and 3.3.3.1.2.2) shall be subjected to this test. (see FIGURE I)

3.3.3.1.2.4 Impact Test in "Z" direction (see 2.3.4) -

four (4) suspension lugs shall be subjected to this test. (see FIGURE I)

3.3.3.1.3 Magnetic Particle Test (see 2.4) - Each of the

ninety (90) suspension lugs shall be subjected to this test.

3.3.3.1.4 Salt Spray Test (see 2.6) - Six (6) of the

suspension lugs shall be subjected to this test.

3.3.3.1.5 Decarburization (see 2.10) - Two (2) of the suspension lugs shall be tested for decarburization after heat treat and prior to plating.

3.3.3.1.6 Plating Thickness (see 2.9.2) - Two (2) of the suspension lugs shall be tested for plating thickness.

3.3.3.2 Regular Production

3.3.3.2.1 Sampling for acceptance tests - with the exceptions of magnetic particle and hardness tests, acceptance tests are considered destructive and lugs which have been used for these tests will not be delivered as part of the contract quantity. For acceptance tests one (1) random sample, in accordance with ANSI/ASQ-Z1.4 level 1, normal inspection, shall be selected.

3.3.3.2.2 Magnetic Particle Test (see 2.4) - this test shall be performed 100 percent. This test shall be performed as specified in 3.4.6. Any lug which fails to comply with the specified requirement shall be classified defective and removed from the lot.

3.3.3.2.3 Hardness Test (see drawing MS3314) -

100% of the lugs from the sample shall be hardness tested, this test shall be performed as specified in 3.4.1.

3.3.3.2.4 Salt Spray Test (see 2.6) - one

(1) per 500 suspension lugs shall be selected from the quantity of lugs all plated at the same time and shall be subjected to the test. This test shall be performed as specified in 3.4.7. If any lug fails, the entire plated quantity shall be rejected. This test is considered destructive and the lugs shall not be returned to the lot.

3.3.3.2.5 Mechanical Properties of lug, suspension - The following tests shall be performed in the order listed using the sample selected in paragraph

3.3.3.2.1. Divide the sample into four equal parts (samples a, b, c and d).

3.3.3.2.5.1 Sample A - Pull test in "W" direction (see 3.3.1) - Each lug of the sample shall be subjected to this test. The test shall be performed as specified in 3.4.2. If any lug fails, the entire lot represented by the sample shall be rejected. This test is considered destructive and the samples shall not be returned to the lot.

(see FIGURE I)

3.3.3.2.5.2 Sample B - Deflection test in "Y" direction (see 3.3.3)

- Each lug of the sample shall be subjected to this test. The test shall be performed as specified in 3.4.4. If any lug fails, the entire lot represented by the sample shall be rejected. This test is considered destructive and the samples shall not be returned to the lot.

3.3.3.2.5.3 Sample C - Pull test in "X" direction (see 3.3.2) - Each lug of the sample shall be subjected to test. The test shall be performed as specified in 3.4.3. If any lug fails, the entire lot represented by the sample shall be rejected. This test is

3.3.3.2.5.4 Sample D - Impact test in “Z” direction (see 3.3.4) - Each lug of the sample shall be subjected to test. The test shall be performed as specified in 3.4.5. If any lug fails, the entire lot represented by the sample shall be rejected. This test is

3.4 Test Methods and Procedures - The test method and procedure described in each of the following tests represent only one method and one procedure which has been proven in use and is approved by the government for government acceptance purposes. Producers and manufacturers have the option of using substitute methods and procedures only after obtaining government approval. Government approval will be based on an evaluation to determine that the substitute method and procedure will result in equal or better quality evaluation than that specified herein. Tensile tests shall be conducted using a test fixture designed to simulate a bomb rack hook with a load bearing hook width of 0.406 inches. The thread in the test fixture will have a pitch diameter of 1.7013 (min.) and a minor diameter of 1.6696 (min.)

inches. The length of thread engagement between the lug and the test fixture shall not exceed 0.500 inch.

3.4.1 Hardness Test - Prior to plating, 100% of the suspension lugs shall be subjected to the hardness test in accordance with ASTM E18.

3.4.2 Pull Test in “W” direction - Prior to plating, the suspension lugs shall be assembled into an approved test fixture and then subjected to a steady pull, for a minimum of one (1) minute, in direction “w” as shown in FIGURE I. this test is considered destructive and the samples shall not be returned to the lot.

3.4.3 Pull Test in “X” direction - Prior to plating, the suspension lugs shall be assembled into an approved test fixture and then subjected to a steady pull, for a minimum of one (1) minute, in direction “x” as shown in FIGURE I. this test is considered destructive and the samples shall not be returned to the lot.

3.4.4 Deflection Test in “Y” direction - Prior to plating, the suspension lugs shall be assembled into an approved test fixture and then subjected to a steady load, for a minimum of one (1) minute, in direction ”Y” as shown in FIGURE I. this test is considered destructive and the samples

3.4.5 Impact Test in “Z” direction - Prior to plating and testing, the suspension lugs shall be notched as shown in FIGURE I and then shall be temperature conditioned at minus 65 plus or minus 5 degrees Fahrenheit for a minimum of 15 minutes, and then subjected to an impact load of 200 ft lbs applied in direction “Z” as shown in FIGURE I. the impact shall be produced by a body weighing 20 lbs falling free through a distance of 10 feet. The impact shall be applied by an anvil having a flat surface 1/4 inch in diameter and a minimum hardness of Rockwell c60. This test is considered destructive and the samples shall not be returned to the lot.

3.4.6 Magnetic Particle Test before plating - Suspension lugs shall be tested as specified in ASTM E1444 except that the lugs shall be magnetized in two planes. In the first plane, the lugs shall be hung on a bar through the loop and the bar ends clamped between the electrodes. The lugs shall then be magnetized with 1000 to 1200 amperes. Upon completion of the first magnetization, the lugs shall then be magnetized through the base perpendicular to the threads. The lugs shall be inspected as specified in ASTM E1444 after they have been magnetized in each plane. The wet fluorescent procedure and continuous application method shall be used.

3.4.7 Salt Spray - The suspension lugs shall be subjected to salt spray testing in accordance with ASTM Bl17 for a minimum of ninety-six (96) hours.

the appearance of white salts or evidence of corrosion of the base metal shall be cause for rejection. This test is considered destructive and the samples

3.4.8 Machining and Threading process shall be controlled by use of Statistical Process Control in accordance with the QAP.

4. Preparation for Delivery

4.1 preservation and packing - the suspension lugs shall be preserved and packed in accordance with MIL-STD-2073-1 Level B. Threads of each lug shall be protected from damage during handling and transit by use of protective dividers within the container.

The shipping and storage container shall be a box complying with style RSC/0201 per ASTM D5118/D5118M. The fiberboard shall conform to type (CF), class (WR), variety (SW), grade W5c (275 PSI dry bursting strength) per ASTM D4727/D4727M. The inside box dimensions shall be 11.25 inches by 9.5 inches by 5.375 inches deep. A fiberboard sheet shall divide the box into two layers. Each layer shall be divided into 30 equal cells formed by full height, half- slotted partitions for 60 lugs. The partitions and layer divider shall be fabricated from corrugated fiberboard of the same type, class, variety and grade as the box. The box bottom and second layer shall be lined with polyethylene sheet per A-A-59135 Class 1. The box flaps shall be secured with reinforced gummed tape complying with ASTM D5749, Type 1. The tape shall be not less than 3 inches wide. The tape shall be centered the full length of the outer flap seams and extend over each end of the box not less than 3 inches onto the box ends. Tape shall be properly moistened and sufficiently compressed to ensure tight adhesion to the container.

Unit Load 64 boxes configured in 4 layers of 16 boxes each shall be banded and shrink wrapped to a 40 x 48 pallet. A partial unit load of 1, 2 or 3 layers may be shipped.

Container Marking Marking of the container shall comply with MIL-STD-129. The characters shall be approximately .25 inch, but not less than .125 inch. 2D bar coding applies.

4.1.1 Marking - Marking shall be as specified in drawing MS3314.

5. Notes

5.1 Intended use - The suspension lugs covered by this ADL are intended to support airborne equipment hung from aircraft suspension racks.

5.2 Classifications of Characteristics - The characteristics verified by the tests and inspections herein are classified as critical, major or minor in accordance with DOD-STD-2101. The fact that a drawing requirement is not listed in here does not relieve any producer from meeting these requirements.