Attachment_0002_SOW_M830A1_Maintenance_Recap.pdf

Statement of Work Cartridge, 120mm HEAT-MP-T M830A1 (C791)

Recapitalization/Maintenance Program 14 August 2017

1.0 Scope: The Product Manager for Large Caliber Ammunition, Picatinny Arsenal, New Jersey, requires the contractor to conduct a recapitalization/maintenance program on a quantity of approximately 12,000 each M830A1 cartridges. The primary focus of the recapitalization program is to disassemble the cartridge, replace the combustible cartridge case, then reassemble the cartridge using epoxy adhesive to bond the new cartridge case to the existing case adapter/projectile and using the latest configuration spring disc to assemble the cartridge case to a modified case base & seal assembly. The period of performance for this SOW will be approximately 17 months.

2.0 Applicable Documents:

Federal and Military Standards:

MIL-STD-286C Military Standard for Propellants, Solid: Sampling, w/Change 2 Examination, and Testing

FED-STD-595 Federal Standard for Colors Used in Government w/Change Notice 2 Procurement

Military Specifications:

MIL-STD-70983A Military Specification for Cartridge, 120mm, HEAT-MP-T, M830A1, excluding Appendix A

DTL 14000022E Detail Specification Item Specification for the Cartridges, 120mm Target Practice

MIL-A-70625A Military Specification for Automated Acceptance Inspection Equipment, Design, Testing and

MIL-C-70478D Military Specification for Container, Ammunition, Metal for Cartridge, 120mm Tank Ammunition

MIL-P-70786 Military Specification for Pallet, Standard Metal w/Amendment 4

MIL-PRF-46147D Performance Specification Lubricant, Solid Film, Air Cured, w/Amendment 1 Corrosion Inhibiting

Drawings:

12912208 Rev M Cartridge, 120mm HEAT-MP-T, M830A1 12524833 Rev AA Case Base and Seal Assembly 12527480 Rev C Propellant 12912367 Rev C Combination of Adopted Items: Ctg, 120mm, HEAT-MP-T, M830A1 12912376 Rev B Combination of Adopted Items: Ctg, 120mm, HEATP-MP-T, M830A1

W52P1J-16-R-0197 Attachment 0002

(25 Cartridge Per Wood Pallet; Marine Corp Use) 12524967 Rev G Profile & Alignment Gage, Hydraulically Operated Assy 19-48-4079/7 Rev 7 Unitization Procedures for Complete Rounds Packed in Cylindrical Metal Containers on 4-Way Entry Pallets 19-48-4079/7B Rev 8 Unitization Procedures for Complete Rounds Packed in Cylindrical Metal Containers on 4-Way Entry Pallets

Quality Assurance Provisions:

QS12912208 Rev M QAP Cartridge, 120mm HEAT-MP-T, M830A1 QS12524976 Rev H QAP for Casing, Cartridge QS12524833 Rev F QAP for Case Base and Seal Assembly

Commercial Specifications and Standards:

ASTM D610-2008 Standard Practice for Evaluating Degree of Rusting on Painted Steel Surfaces

Engineering Change Proposals:

R06Y2014 R10C3001

3.0 Requirements:

3.1 Teardown. Receive a quantity of approximately 10,779 each unserviceable, Condition Code “F” M830A1 cartridges and a quantity of approximately 1,529 each unserviceable, Condition Code “H” M830A1 cartridges to use to scavenge parts/components. A quantity of 30 each of Lot MHM93K130-003 CC “F”, 30 each of Lot MHM97B136H001 CC “F”, and 60 each of Lot ORI99B130H003 CC “F” cartridges shall be set aside to use as controls for Reassembly/LAP ballistic acceptance testing. These 120 each cartridges shall not be disassembled/torn down.

3.2 Teardown. Develop a detailed procedure for inspection and teardown of M830A1 cartridge, to include preservation and preparation of the case adapter for reuse. The procedure(s) shall be submitted to the PCO for approval at least 60 days prior to the start of the recapitalization/maintenance effort.

3.3 Teardown. Conduct inspection of each of the 10,779 CC “F” cartridges in accordance with criteria in Appendix A to determine if cartridge is suitable for recapitalization, if cartridge is not suitable for recapitalization then determine if any of the components can be used to support recapitalization. Conduct inspection of each of the 1,529 each CC “H” cartridges in accordance with criteria in Appendix A to determine if the cartridge or components can be used to support recapitalization.

3.4 Teardown. Conduct propellant stability testing on a sample of JA2 propellant from each cartridge lot prior to teardown/disassembly of any cartridges represented by the sample. Cartridge lots that are suffixed, for example MHM94B130-001 and MHM94B130-001B are considered a single lot for propellant stability testing. A current propellant stability test is required before the bulk JA2 propellant can be stored.

3.5 Teardown. Teardown/disassemble up to 11,000 each M830A1 cartridges. Twenty-three (23) different cartridge lots will be included in the quantity of 11,000 each cartridges. A listing of cartridge lot numbers and quantity per lot is included at Appendix B. Components to be retained/reused are: Projectile with tracer and case adapter, propellant, and primer. The contractor has the option to retain/reuse the propellant bag or replace with a new propellant bag. These components shall be inventoried to allow these same component lots to be used to reassemble the cartridge lot and to be able to include component lot numbers and quantities for the Ammunition Data Card.

3.6 Teardown. Inspect pallets, top pallet adapters and palletized PA116 shipping and storage containers that the M830A1 cartridges were received in to determine if acceptable for reuse.

Inspection criteria is provided in Appendix C.

3.7 Teardown. Dispose of the combustible cartridge cases that have been disassembled/removed from M830A1 cartridges which were determined to be suitable for recapitalization. These combustible cartridge cases will have cut edges with exposed fibers, which make the cases sensitive to ignition and should be disposed of promptly.

3.8 LAP. Conduct moisture testing on sample of propellant from each lot to confirm moisture content meets the requirement on drawing 12527480. Control exposure of propellant to moisture and other contaminates during the teardown/disassembly process and reassembly/LAP process.

3.9 LAP. Rework loose case adapters by applying adhesive (PN 12524908) at the interface between the obturator and case adapter.

3.10 Component. Purchase combustible cartridge case, PN 12524976, in accordance with QAP 12524976. Exceptions to MIL-DTL-244 in regards to nitrocellulose fiberization quality requirements are included in Appendix D.

3.11 Component. Modify case base & seal assembly to meet PN 12524833, Rev AA. The groove in the case base & seal assemblies recovered from tear down will have the smaller spring disc/retaining ring groove. This groove will need to be extended to meet the PN 12524833, Rev AA requirements. After machining, clean the groove with a solvent, and apply a Dry-Film- Lubricant IAW MIL-PRF-46147 for corrosion protection. The touch up coating shall be smooth and free of excessive material, runs, or other imperfections and shall show good adhesion to the base metal. The groove does not need to be sandblasted before application.

3.12 Component. Purchase miscellaneous parts to support reassembly/Load, Assemble, Pack. This includes but is not limited to the primer oring, spring disc, retaining ring, cartridge case epoxy coating, and bonding adhesive.

3.13 LAP. Develop a detailed procedure for reassembly (Load, Assemble, and Pack) of the M830A1 cartridge. The procedure shall be submitted to the PCO for approval. Procedure shall include rework of loose adapters.

3.14 LAP. Reassemble (LAP) M830A1 cartridges using the existing projectile with tracer and case adapter, propellant, primer, and propellant containment bag, with a new cartridge case (PN 12524976), modified case base & seal assembly (PN 12524833), and the new configuration spring disc (PN 12990826).

3.14.1 Replace Note 3 on Drawing 121912208 with the following: Bond cartridge casing (PN 12524976) painted in accordance with paragraph 3.1.4 to the existing painted adapter.

Bonding surfaces must be clean and dry prior to bonding. Mix Adhesive and Hardener (PN 12524908) in equal parts by weight until uniform in color. Adhesive and Hardener shall be applied to both bond surfaces and the joint mated within 1 hour after mixing.

Immediately after adhesive application, the skived surfaces shall be pressed together firmly, securely clamped in position and remain undisturbed for the duration of the curing process. Excess adhesive shall be wiped from exterior surface without the use of solvent.

The curing process shall consist of an oven cure at 60oC maximum (1 hr minimum). The bonded joint must withstand a tensile pull of 8900 Newton minimum.

3.14.2 Weight of Propellant. The contractor shall conduct two Charge Establishment/Charge Verification tests to determine the charge weight of the propellant used for reassembly/LAP. Of the 23 cartridge lots, there are two propellant suppliers, Hercules and Radford. The charge weight for both suppliers was consistent, in other words the charge weight for all Hercules lots (MHM cartridge lots) was 7.12 kg and the charge weight for all Radford lots (ORI cartridge lots) was 7.15 kg. One CE/CV test shall be conducted with Hercules propellant and one CE/CV shall be conducted with Radford propellant. The results of the Hercules CE/CV test will be used to determine the charge weights for all MHM recapitalized cartridge lots, and the results of the Radford CE/CV test will be used to determine the charge weight of all ORI recapitalized cartridge lots. If the contractor deems it necessary, the Hercules propellant lots may be re-blended into one lot and the Radford propellant lots may be re-blended into one lot. If the propellant is not re-blended, the original propellant lot shall be returned to the recapitalized cartridge lot from which it came and shall be loaded to the newly established charge weight.

For each CE test the contractor shall provide 3 each cartridges at 95%, 100%, and 105% (a total of 9 cartridges for each CE test) of the estimated charge weight. For each CV test the contractor shall provide 31 cartridges to the estimated charge. After analysis of the CE data, the contractors shall provide the recommend charge weight to the PCO. Test personnel at Yuma will modify the CV cartridges to the recommended weight.

3.3 LAP. Pack out the recapitalized M830A1 cartridges in the inspected/acceptable palletized PA116 shipping and storage containers. The preference is to repackage cartridges only in the NSN 1315- 01-333-0534, COAI 12912367 configuration, which is 1 each cartridge per PA116 container, 30 containers/cartridges on a metal pallet.

3.4 LAP. Prepare and submit new Ammunition Data Cards (ADC) for the suffixed lots. Clause CS 7200, 52.246-4535 has been included in Section E of this contract. When annotating the authorization for use of suffix on the ADC please identify the specific case number assigned and provided by the PCO. The new ADC shall include a description of the recapitalization/maintenance effort and identification of new component lot numbers and quantities.

3.5 Disposal. Dispose of spring disc, retaining ring, and primer o-ring that were disassembled/removed from M830A1 cartridges determined to be suitable for recapitalization as these components will not be reused for reassembly of the cartridge. Disposal of cartridge case is addressed under the teardown section since these are energetic and made need to be disposed of promptly.

3.6 Dispose of inert residual components from teardown that could not be utilized to reassemble cartridges. Residual energetic material including projectiles with tracers and case adapters, propellant, or primers shall be packaged and shipped to Letterkenny Munitions Center for disposal. The contractor shall prepare and ship this energetic material to LEMC and the USG will be responsible for the receipt and demil costs. Any cartridge, that upon inspection was determined unsuitable for teardown shall be returned to the USG so it will be put into the U.S. Army Demilitization Account for disposal.

3.7 LAP. Rework. Clause ES7012, 52.246-4528 has been included in Section E of this contract. The following exception to this standard clause is provided here. Clause ES7012, 52.246-4528 Section (2)(b) states, “Rework procedures along with the associated inspection procedures shall be documented by the Contractor and submitted to the Government Quality Assurance Representative (QAR) for review prior to implementation. Rework procedures are subject to the QAR’s disapproval.” For this contract, rework procedures along with the associated inspection procedures, shall be submitted to the PCO for review and approval prior to implementation/use.

3.8 LAP. If necessary, submittal of Requests for Variance (RFV) shall be in accordance with DI-

SESS-80640D.

3.9 LAP. During reassembly/LAP, one of the three designated lots, which had cartridges set aside to use as ballistic test controls (reference paragraph 3.1) will be required to be reassembled/LAP each month. For example, Lot MHM93K130-003 will be reassembled the first month, Lot MHM97B136H001 will be reassembled the second month, and Lot ORI99B130H003 will be reassembled the third month. During the reassembly/LAP of each of these designated lots, a random sample of 30 each cartridges shall be pulled to serve as the ballistic acceptance sample for all M830A1 lots reassembled/LAP that same month. The Contractor is required to ship the 30 rds set aside as controls, and the 30 round reassembly sample to Yuma Proving Ground. The U.S.

Government will provide cartridges to use as warmers/spotters during the test and will be responsible for conducting the test and providing test results to the Contractor to support acceptance of the M830A1 recapitalized cartridges represented by the test. The one month timeframe used in this paragraph is an approximate period of time but is intended to be 30-45 calendar days of continuous, homogeneous reassembly/LAP, with breaks for weekends and holidays. Given there are 23 different M830A1 lots to be recapitalized of varying lot sizes it is expected that 4-7 different lots could be LAP’d in a 30-45 calendar day period. The US Government has selected the lots with the largest quantity for the ballistic testing but reserves the right to adjust the lot the random sample of reassembled cartridges is pulled from based on the results/yield from the teardown. This will not change the controls, the controls will not change from those designated in paragraph 3.1.

4.0 Quality.

4.1 LAP. Inspection Requirements. Recapitalized cartridges shall be subjected to inspections required by QAP 12912208.

4.2 Teardown. Propellant Stability Testing shall be conducted in accordance with MIL-STD- 286C. As stated in Supply Bulletin SB 742-1 paragraph 13-9, the following shall be used to categorize the propellant stability. Only propellant with Category A effective stabilizer shall be used to support reassembly/LAP:

Category Effective Stabilizer A 0.30 or more C 0.29 – 0.20 D Less than 0.20

Category A – acceptable stabilizer loss; safe for continued storage Category C – significant stabilizer loss. Lot does not represent an immediate hazard but is approaching hazardous stability condition. Loss of stabilizer does not adversely affect functioning in an uploaded configuration Category D – Unacceptable stabilizer loss.

4.3 LAP. The propellant moisture content shall be determined in accordance with MIL-STD-286

Method 101.5 or Method 103.5.

4.4 LAP. First Article Acceptance Testing (FAAT)

4.4.1 Contractor is required to submit a First Article Acceptance Test Plan for a reassembled/Load, Assemble, Packed M830A1 cartridge in accordance with DI-NDTI- 81307A.

4.4.2 FAAT Special Instructions.

4.4.2.1 Cartridge Case

4.4.2.1.1 If a current supplier for the Case, Cartridge PN 12944287, is utilized for purchase of cartridge cases the requirement for compositional and dimensional FAAT can be requested to be waived provided the supplier has not had a lapse in production of the same or similar cartridge cases of over 365 days or any changes to the process or raw materials.

Further, the requirement to conduct ballistic lot acceptance testing of the cartridge case is waived.

4.4.2.1.2 If a new supplier is utilized for purchase of cartridges cases (P/N 12524976), in addition to the inspections required in accordance with QAP 12524976, the contractor is required to conduct a ballistic FAAT in accordance with DTL14000022E paragraphs 4.6.2 and 4.6.3. Additionally, the contractor is required to conduct a ballistic FAAT in accordance with DTL14000022E Table II Note 2 to assure compliance with DTL14000022E Table II Critical 4 (Residue, burning/smoldering) and Major 116 (Residue, non-burning) for operative bore evacuator performance at all operational temperatures. The U.S. Government will provide a sufficient quantity of Cartridge, 120mm, TPCSDS-T, M865, with the legacy cartridge case, to support ballistic test requirements. The Contractor is responsible to disassemble the M865 cartridge, reassemble with the sample cartridge case, and conduct the testing. Prior to conduct of the FAAT, the contractor shall submit a FAAT plan in accordance with DI-NDTI-81307A and receive formal approval from the USG contracting officer. The contractor shall submit a FAAT report in accordance with DI-NDTI-80809B. In the event of a conflict between the requirements in DTL14000022E and those of the SOW, the requirements of the DTL14000022E take precedence.

4.4.2.2 Case Base & Seal Assembly

4.4.2.2.1 A 10 piece modified FAAT will be required to ensure the modified retaining ring groove meets all drawing requirements.

4.4.2.3 Epoxy Coating.

4.4.2.3.1 If a current supplier is utilized for the purchase of the two-part epoxy coating the requirement for a dimensional and ballistic FAAT can be requested to be waived provided the supplier has not had a lapse in production over 365 days or any changes to the process or raw materials.

4.4.2.3.2 If a new supplier is utilized for the purchase of the two-part epoxy coating (P/N 12912373 and 12953391), in addition to the two-part epoxy inspections required in accordance with this SOW, the contractor is required to conduct a ballistic FAAT in accordance with DTL14000022E paragraphs 4.6.2 and 4.6.3. Additionally, the contractor is required to conduct a ballistic FAAT in accordance with DTL14000022E Table II Note 2 to assure compliance with DTL14000022E Table II Critical 4 (Residue, burning/smoldering) and Major 116 (Residue, non-burning) for operative bore evacuator test performance at all operational temperatures. The M865 legacy configuration shall be used as the combustible cartridge casing test configuration. The U.S. Government will provide a sufficient quantity of Cartridge, 120mm, TPCSDS-T, M865, with the legacy cartridge case, to support ballistic test requirements. The Contractor is responsible to disassemble the M865 cartridge, reassemble with an epoxy coated sample cartridge case, and conduct the testing. Prior to conduct of the FAAT, the contractor shall submit a FAAT plan in accordance with DI-NDTI-81307A and receive formal approval from the USG contracting officer. The contractor shall submit a FAAT report in accordance with DI-NDTI-80809B. In the event of a conflict between the requirements of DTL14000022E and those of the SOW, the requirements of DTL14000022E take precedence.

4.4.2.3.3 Oil Resistance Testing. This test is applicable to first article inspection only. The sample cartridge cases shall be introduced into the cartridge coating process. They shall be allowed to dry for twelve (12) hours minimum prior to testing. One test sample 50mm x 50mm shall be cut from each of the coated cases. A drop of hydraulic oil of type MIL-H-46170, MIL-H-6083 and VV-L-800 shall be applied to the coated surface of the sample. One drop of each samples, and allowed to stand for a minimum of eight (8) hours.

The samples shall then be wiped with a dry rag and subjected to visual inspection for any evidence of degradation of the coating which shall cause the sample to be classed defective.

As an alternative method, a taped off 50mm x 50mm section on the combustible cartridge case may be used in lieu of cutting a 50mm x 50mm section. Three (3) sections, one each for the three (3) types of hydraulic oil, may be taped off on each case.

4.4.2.4 Reassembly/LAP

4.4.2.4.1. If a current 120mm LAP supplier is utilized for the reassembly of the

M830A1 cartridge, LAP/reassembly shall be evaluated in accordance with QAP 12912208.

A ballistic FAAT is not required.

4.4.2.4.2. If a new supplier is utilized for the reassembly of the M830A1 cartridge, in addition to the inspections required in accordance with QAP12912208, the contractor is required to conduct a ballistic FAAT in accordance with DTL14000022E paragraphs 4.6.2 and 4.6.3. Additionally, the contractor is required to conduct a ballistic FAAT in accordance with DTL14000022E Table II Note 2 to assure compliance with DTL14000022E Table II Critical 4 (Residue, burning/smoldering) and Major 116 (Residue, non-burning) for operative bore evacuator test performance at all operational temperatures.

The M865 legacy configuration shall be used as the test configuration. The U.S. Government will provide a sufficient quantity of Cartridge, 120mm, TPCSDS-T, M865, with the legacy cartridge case, to support ballistic test requirements. The Contractor is responsible to disassemble the M865 cartridge, reassemble with a sample of newly epoxy coated cartridge case, and conduct the testing. Prior to conduct of the FAAT, the contractor shall submit a

FAAT plan in accordance with DI-NDTI-81307A and receive formal approval from the USG contracting officer. The contractor shall submit a FAAT report in accordance with DI-NDTI- 80809B. In the event of a conflict between the requirements of DTL14000022E and those of the SOW, the requirements of DTL14000022E take precedence.

4.4.2.5 Government Furnished Cartridge Requirements. The contractor is responsible to identify the quantity and configuration (legacy or ACS) of M865 cartridges required to support ballistic FAAT 120 days in advance of the need for these cartridges.

4.5 LAP. Critical Characteristics.

4.5.1 The following characteristics, apply to components to be purchased in support of this SOW or to Reassembly/LAP and are classified as “critical”:

4.5.1.1 Cartridge – Propellant impurity, 100%, propellant shall be screened using acceptable method(s) such as visual inspection, metal detectors, magnetically, electronic scanning, x-ray scanning, mechanical screening, etc. (Reference QAP 12912208, Part III)

4.5.2 Clause ES 6550, 52.246-4553 has been included in Section E of this contract. Contract Data Requirements List (CDRL) DI-SAFT-80970A, DI-MGMT-81986, and DI-MGMT- 81996 are required to be submitted.

4.5.3 There are additional critical characteristics associated with the M830A1 Cartridge but these can only be observed during ballistic testing. The Contractor will be held responsible if the following occurs during ballistic firing.

4.5.3.1 Case base and seal assembly obturation. The case base and seal assembly shall seal the breech of the weapon against leakage of combustion gases generated when a cartridge is fired.

Any evidence of gas leakage caused by obturation failure shall be cause for rejection of the lot or first article sample. Evidence of obturation failure includes one or more of the following:

Evidence of gas leakage in rubber seal Evidence of gas leakage in base steel or protective plating

After the cartridge has been fired, physical examination of the extracted case base and seal assembly shall be conducted to ascertain visual evidence of gas leakage.

4.5.3.2 There shall be no burning/smoldering residue exceeding one second in duration after the cartridge has been fired. Any test cartridge exhibiting evidence of burning or smoldering residue lasting greater than two seconds shall be cause for rejection of the lot or first article sample. An infrared (IR) black and white video camera, and an IR color video camera shall be used to observe burning/smoldering residue and gas leakage. The IR cameras shall have frame speeds of no less than 30 frames per second. Position the IR black and white camera behind the breech so that it records a full view down the tube. Position the color IR camera to flank the black and white IR camera. External light sources shall be minimized during camera operation to make burning/smoldering residue and gas leakage more easily observed. The filter shall be removed from the black and white IR video camera to maximize its spectral response.

4.6 LAP. AIE/AAIE requires government review and approval prior to use on this contract.

AIE/AAIE shall be submitted for review and approval to the AMSRD-AAR-QEM-E with a cover letter notification sent to the PCO (DI-QCIC-81960). Approval of the AIE/AAIE will be transmitted to the contractor via PCO letter.

4.6.1 The contractor shall establish and maintain a documented system for the identification and approval of AIE/AAIE to include the calibration and verification of inspection equipment as necessary to meet contract requirements.

4.6.2 AIE designs shall include sufficient information to permit accurate and timely evaluation by the Government. All AIE designs shall be in the same units of measure as specified on the drawing. As a minimum, the submission shall contain the following information:

Contract Number Item Model Number/Part Number Component or Assembly Drawing Number and Revision Appropriate Defect Characteristic Operating Instructions/Calibration Instructions Recall Procedures Any Manuals or Literature Required to Operate and Maintain the System Personnel Qualifications Necessary to perform the inspection or operate the equipment.

AAIE designs shall include the minimum information above in addition to: An evaluation and apportionment of system reliability, considering operational reliability, decision making reliability, handling/inspections accuracy, calibration/verification cycles, configuration control methods and recall procedures for product which requires re-inspection

4.6.3 Automated AIE (AAIE) shall utilize failure safe designs whereby the decision making logic and the material handling devices shall normally operate in a reject mode until an accept mode signal is obtained. AAIE shall be qualified IAW MIL-A-70625A. AAIE designs which inspect for metallic contamination of the propellant and utilize eddy current/magnetic inspection are exempt from the requirement to operate in the reject mode until an accept signal is obtained.

4.6.4 The Government reserves the right to requalify any previously qualified AIE/AAIE used for the performance of this contract at any time throughout the life of the contract. All cost associated with such requests shall be borne by the Government. The Government reserves the right to disapprove at any time the use of any AIE or AAIE not meeting the contractual requirements.

4.6.5 Qualification and Certification of Non-destructive Test personnel: Personnel operating NDT AIE in support of this contract shall be certified and qualified IAW AIA/NAS 410.

4.6.6 If a current supplier is used for the purchase of new cartridge, and/or purchase of epoxy paint and/or Load, Assemble and Pack the requirement to submit AIE and AAIE designs for approval can be requested to be waived. This request should include a listing a previously submitted and approved AIE/AAIE and the applicable contract.

4.7 LAP. Contractor Component Acceptance Testing

4.7.1 If a new supplier is utilized for the cartridge case (P/N 12524976), for each cartridge case lot used towards M830A1 recapitalization, the contractor shall conduct component-level ballistic acceptance testing in accordance with DTL14000022E paragraph 4.6.2, in addition to DTL14000022E Table II Note 15 to assure compliance with DTL14000022E Table II Major 116 (Residue, non-burning). The M865 legacy configuration shall be used as the test configuration for cartridge case acceptance testing. The U.S. Government will provide a sufficient quantity of Cartridge, 120mm, TPCSDS-T, M865, with the legacy cartridge case, to support ballistic test requirements. The Contractor is responsible to disassemble the M865 cartridge, reassemble with a sample of epoxy coated cartridge case, and conduct the testing. This data shall include individual shot data and summary level compilation results recorded to the accuracy limits of the test equipment. The contractor shall review and validate the test data to verify accuracy and completeness. The test data shall be submitted as required by DI-MISC-80246 prior to use of the component to support M830A1 reassembly. Test data can be provided electronically or via

CDROM.

4.7.2 If during Contractor component level ballistic lot acceptance testing, a component fails to meet DTL 14000022 requirements, e.g., residue in excess of 0.5 grams, burning residue, evidence of gas leakage on case base & seal assemble, the Government shall be notified of these failures, be provided the test data on these failures, and be provided corrective actions. The contractor shall submit test incident reports in accordance with DI-SESS-80255A.

4.7.3 Government Furnished Cartridge Requirements. The contractor is responsible to identify the quantity of M865 cartridges required to support cartridge case ballistic lot acceptance testing 120 days in advance of the need for these cartridges.

4.8 LAP. Cartridges selected for ballistic acceptance testing will be subjected to testing in accordance with the following paragraphs of MIL-C-70983. The sample is required to meet the requirements shown below in order for the cartridge represented by the sample to be acceptable for DD250.

Paragraphs identified as "Recapitalization Testing" shall be tested to evaluate the efforts related to the recapitalization effort, e.g. teardown, reassembly, selection of charge weight, etc. If the requirement is not met, the contractor shall conduct a failure analysis to determine the root cause. If it is determined the root cause was not related to the recapitalization process the contractor will not be held responsible. Ship a random sample of 30 each recapitalized cartridges from a single U.S.

Government designated lot to Yuma Proving Ground to serve as the ballistic acceptance sample for all M830A1 cartridges LAP’d that same month.

3.4.1 Target Impact Dispersion. For Information Only.

3.4.1.1 Erratic Flight. Recapitalization Testing

3.4.2 Muzzle Velocity. Recapitalization Testing

3.4.3 Chamber Pressure. Recapitalization Testing 3.4.4 Differential Pressure. Recapitalization Testing 3.4.5 Firing time. For Information Only

3.4.6 Tracer Function. For Information Only

3.4.7.1 Primer parts separation. For Information Only

3.4.7.2. Primer gas leakage. For Information Only

3.4.8 Misfire. For Information Only

3.4.9 Premature function. For Information Only

3.4.10 Cartridge Chambering

3.4.11.1 Propulsion/ignition system residue and flareback unconditioned case

3.4.11.3 Flareback. For Information Only

3.4.12 Metal Parts Security. For Information Only

3.4.13.1 Case Base and Seal Assembly Function – Obturation. Recapitalization Testing

3.4.13.2 Case Base and Seal Assembly Function – Soundness. Recapitalization Testing 3.4.13.3 Case Base and Seal Assembly Function – Extraction. Recapitalization Testing 3.4.13.4 Case Base and Seal Assembly Function – Primer retention. Recapitalization Testing 3.4.14 Early Burst. For Information Only

3.6.1 Workmanship – General. The paragraph in MIL-C-70983 is modified for this recapitalization program as follows: The combustible cartridge case and case base and seal assembly shall be free from cracks, burrs, chips, scratches, gouges, dirt, grease, rust, or any other foreign materials.

3.6.2 Workmanship – Cartridge case paint

3.6.3 Workmanship – Cartridge case cracks

3.7 Propellant contamination

5 Delivery Requirements

5.1 Teardown. Submit a detailed procedure for inspection and teardown of cartridges for Government review and approval within 60 days of contract award (ref Para 3.2).

5.2 Teardown. Submit propellant stability test results to the Government within 185 days of contract award (ref Para 3.4).

5.3 LAP. Submit AIE/AAIE for approval within 180 days of contract award or at least 60 days prior to the planned component and/or LAP FAAT (ref Para 4.6).

5.4 LAP. Submit propellant moisture test results to the Government within 245 days of contract award (ref Para 3.8)

5.5 LAP. Submit a detailed procedure for reassembly/LAP of the M830A1 cartridge for Government review and approval within 135 days of contract award or at least 60 days prior to the planned LAP FAAT (ref Para 3.13).

5.6 LAP. Submit a critical defect plan for Government review and approval 120 days prior to the start of reassembly/LAP operations (ref Para 4.5.2).

5.7 LAP. Ship 39 each recapitalized containing Hercules propellant lot for CE/CV testing to Yuma Proving Grounds within 245 days of contract award (ref Para 3.14.2).

5.8 LAP. Ship 39 each recapitalized containing Radford propellant lot for CE/CV testing to Yuma Proving Grounds within 245 days of contract award (ref Para 3.14.2).

5.9 LAP. Ship a random sample of 30 each recapitalized M830A1 cartridges, from a single lot of recapitalized cartridges that were reassembled/LAP’d in the first month of reassembly/LAP to the Yuma Proving Ground within 330 days of contract award (ref Para 4.9).

5.10 LAP. Ship a random sample of 30 each recapitalized M830A1 cartridges, from a single lot of recapitalized cartridges that were reassembled/LAP’d in the second month of reassembly/LAP to the Yuma Proving Ground within 375 days of contract award (ref Para 4.9).

5.11 LAP. Ship a random sample of 30 each recapitalized M830A1 cartridges, from a single lot of recapitalized cartridges that were reassembled/LAP’d in the third month of reassembly/LAP to the Yuma Proving Ground within 405 days of contract award (ref Para 4.9).

5.12 LAP. DD250 approximately 3,500 each recapitalized cartridges within 410 days of contract award or within 30 days after notification of ballistic acceptance, whichever is the later date.

5.13 LAP. Ship a quantity of approximately 3,500 each recapitalized cartridges to Crane Army Ammunition Activity, using a Government funded shipping document, within 30 days of

DD250.

5.14 LAP. DD250 approximately 2,700 – 3,500 each recapitalized cartridges to within 450 days of contract award or within 30 days after notification of ballistic acceptance, whichever is the later date.

5.15 LAP. Ship a quantity of approximately 2,700 - 3,500 each recapitalized cartridges to Tooele Army Depot, using a Government funded shipping document, within 30 days of

DD250.

5.16 LAP. DD250 the balance of up to approximately 2,500 each recapitalized cartridges within 480 days of contract award or within 30 days after notification of ballistic acceptance, whichever is the later date.

5.17 LAP. Ship the balance of up to approximately 2,500 each recapitalized cartridges to McAlester Army Ammunition Plant within 30 days of DD250.

5.18 Submit the following reports to allow the Government to track/trace the GFM cartridges provided for maintenance/recapitalization:

a. Teardown. Provide report on number of CC “F” cartridges determined to be suitable for maintenance/recapitalization. It is assumed, all cartridges suitable for maintenance/recapitalization will be disassembled, if the number of cartridges disassembled is different explain why. Report required 245 days after contract award.

b. Teardown. Provide report on number of CC “H” disassembled and used to support recapitalization. Report required 245 days after contract award.

c. Teardown. Provide report on the number of CC “F” and/or CC “H” cartridges remaining (not torn down, not recapitalized, can be returned to Army Field Service for Demil).

Report required 450 days after contract award.

d. Teardown. Provide report(s) on the number of combustible cartridge cases destroyed.

e. LAP. Provide inventory, indicating serviceable (useable) and unserviceable (unusable), on the residual components. Inventory should include the following components:

Projectile with tracer and case adapter

Primer

Propellant

Case Base & Seal Assembly

Spring Disc

Wood Pallets

Metal Pallets

Pallet Adapters

PA116 Shipping & Storage Containers

Upon receipt of this inventory, a separate modification will be awarded for disposal of these components.

f. Disposal. Provide report on the GFM components destroyed. Report required 180 days after contract modification and authorization for demil is awarded.

g. Deliver residual energetic material to LEMC 60 days after contract modification and authorization for demil is awarded. Complete shipping address will be provided with the contract modification.

5.19 LAP. Submit a sample ADC for Government review and approval. Sample ADC required 210 days after contract award.

6 Special Instructions

6.1 GFM.

6.1.1 A quantity of approximately 10,779 each M830A1 cartridges in CC “F” will be provided as

GFM. Cartridges will be provided within 120 days of contract award. Receipt date is negotiable depending upon inspection and teardown schedule.

6.1.2 A quantity of approximately 1,529 each M830A1 cartridges in CC “H” will be provided as GFM. Cartridges will be provided within 120 days of contract award. Receipt date is negotiable depending upon inspection and teardown schedule.

6.1.3 There will be two different NSNs provided for recapitalization. NSN 1315-01-333-0533, COAI 12912376, packaging configuration is 1 ea cartridge per PA116 container, 25 containers/cartridges on a wood pallet. NSN 1315-01-333-0534, COAI 12912367, packaging configuration is 1 ea cartridge per PA116 container, 30 containers/cartridges on a metal pallet.

6.2 The preference is for the deliverable M830A1 cartridges to be packed out in the NSN 1315-01- 333-0534, COAI 12912367 configuration, i.e, 30 per metal pallet. The contractor shall package recapitalized assets in the COAI 12912367 pallets until expended before using the alternative pallets.

6.3 Review of the Ammunition Data Cards for those lots that have a parent lot quantity and a suffixed lot quantity, e.g., MHM94B130-001 and MHM94B130-001B, show that the reason for the suffix and segregation of the parent from the suffix will no longer apply after recapitalization. For reassembly, these parent and suffixed lots can be combined when recapitalized.

6.4 Lot suffixes shall be assigned for each lot and provided at time of contract award.

6.5 The Acceptance Inspection Equipment requirements stated in paragraph 4.6 of this SOW are identical to the requirements included in the FY12-16 120mm Tank Training Ammunition contracts and are intended to allow existing AIE/AAIE submissions to be rolled over for use on this effort if the same supplier is utilized.

APPENDIX A

Cartridge Recapitalization Inspection Criteria

A.1 If a cartridge has any one of the following conditions it CANNOT be recapitalized:

Nose Tip Damaged (broken off, bent, dented) Nylon Band damaged to the point of precluding chambering Proximity Sensor Damaged Pitting Corrosion on Projectile Projectile partially or completely separated from case cap/adapter Case cap/adapter damaged, e.g., punctured, cracked, or split Case Base & Seal Assembly rubber seal torn or separated

A.2 Cartridges with the following conditions can be reworked/recapitalized:

Case Base & Seal Assembly separated from cartridge case Combustible Cartridge Case punctured, cracked, split. (Ctg Case being replaced) Combustible Cartridge Case discolored or softened (Ctg Case being replaced) Case cap/adapter discolored Case cap/adapter with missing protective coating Skive Joint separated (Ctg Case being replaced) Case cap/adapter is loose at the projectile interface Primer above flush (primer being removed, reused, reinstalled) Primer stake missing or does not engage primer (primer being removed, reused, reinstalled) Non-removeable corrosion on primer (replace with cannibalized primer from a cartridge with a bad projectile/case cap.

A.3 Primer Inspection Criteria:

Primers with corrosion on the center electrode shall not be considered for recapitalization.

Primers with damage to the exterior threads that prevent the primer from interfacing with the case base & seal assembly shall not be used for recapitalization Primers with burrs on the exterior threads shall be deburred and used for recapitalization Primers with scratches on the aft face shall be evaluated for rework Primers with missing lacquer plugs shall not be considered for recapitalization

A.4 Propellant Inspection Criteria:

If the JA2 propellant grains are clumped together, this could be an indication that this cartridge was subjected to unusual conditions. None of the propellant from a cartridge where clumping is observed should be considered for recapitalization.

If the JA2 propellant grains are unusual in color, none of the propellant from this cartridge should be considered for recapitalization If the JA2 propellant stability test result is Category “C”, propellant represented by the sample shall not be used for recapitalization

A.5 Propellant Bag Inspection Criteria: Propellant bag shall be free of rips and tears.

APPENDIX B

Listing of Lot Numbers and Corresponding Quantity Intended for Maintenance/Recapitalization

CC “F” CC “F” CC ”H” CC “H” Propellant Propellant Wood Metal Wood Metal Lot Charge Weight (kg)

MHM93J130-002 315 2 317 HCL92H-071407 7.12

MHM93J131-002 508 86 594 HCL92H-071407 7.12

MHM93K130-003 1108 64 1172 HCL92H-071407 7.12

MHM93K131-003 416 87 503 HCL92H-071407 7.12

MHM93K131-004 355 2 357 HCL92H-071407 7.12

MHM93M130-004 732 5 737 HCL92H-071407 7.12

MHM94B130-001/B 39 41 80 HCL92H-071407 7.12

MHM94B130-005/A/B 89 110 2 201 HCL92H-071407 7.12

MHM94C132H001/A 1 304 23 328 HCL92H-071407 7.12

MHM94C133-002 271 220 491 HCL93J-071429 7.12

MHM96K135-003A 28 12 40 HCL94J-G71455 7.12

MHM96L135-004/A 542 2 554 HCL94M-071456 7.12

MHM97A135H005A 390 271 661 HCL94M-071456 7.12

MHM97B136H001 1445 3 157 1605 HCL94M-071456 7.12

MHM97C136H002A 362 17 379 HCL94M-071456 7.12

TOTALS For MHM 129 6776 177 927 8019

ORI98L130-001 178 178 ARV98-071899 7.15

ORI99A130-002 62 4 66 ARV98-071899 7.15

ORI99B130H003 1926 319 2245 ARV98-071899 7.15

ORI99F131-001/A 79 288 30 397 ARV98-071899 7.15

ORI99G131-002 409 38 447 ARV98-071899 7.15

ORI99K132H001 39 39 ARV00A-G71992 7.15

ORI01K133H001 690 34 724 ARV01C-080645 7.15

ORI05J134-004 203 203 ARV98E-071899 7.15

Totals for ORI 282 3592 30 395 4299

Total (MHM+ORI) 411 10368 207 1322 12,308

Lot Number

APPENDIX C

Pallet and Shipping & Storage Container Inspection Criteria

The palletized shipping & storage containers in which the M830A1 cartridges were received are intended to be reused to package the refurbished cartridges. These packaging “sets”, e.g., pallets, pallet adapters, metal containers and internal packaging, shall be visually inspected in accordance with the paragraphs below:

C.1 PA116 Shipping & Storage Container

C.1.1 Rust is permissible on the stacking surfaces of the container. No rust is permissible on the open end of the body that makes contact with the cover gasket on either the OD or ID within an area 3/8 inch from the body open-end,which does not affect sealing of the can, is acceptable.

C.1.2 The remainder of the external container body should be evaluated for the degree of rust. The maximum cumulative rust on each container shall not exceed an area 1.5 inches square (reference grade 7 of ASTM-D610), not including the stacking surfaces. Any single rust spot or blister should not exceed 1/8 inch in diameter. Fore rework of rust inside the lip of the container it is acceptable to lightly scuff the surface with sandpaper and repaint approximately one inch of the interior of the can mouth. No field marking is allowed on the containers, but minor over spray of a different color or visible paint from a scratch is acceptable.

C.1.3. At the discretion of the contractor, containers that do not meet the above criteria should be either spot refurbished or totally refurbished to the degree necessary to meet the criteria. Corrosion resistance testing is not required on refurbished containers.

C.1.4 Containers that exhibit dents to the body or damage to the extent that it interferes with removal, insertion, or free movement of the internal components should be reworked if possible. Containers with dented rims and/or rings should be reworked to ensure stacking with other surrounding containers is not compromised. If, despite rework, stacking is compromised the container shall be discarded.

C.1.5 Containers that meet the criteria for reuse but are contaminated with dirt or dust to the extent that it could interfere with the application of stencils should be cleaned.

C.1.6. Containers must meet the requirements from palletization per MIL-C-70478, Appendix A, paragraph 50.2.4.

C.1.7. Container Cover. The handle shall move freely and the grip shall not be twisted or bent beyond approximately 3/8 inch. If the cable is frayed or the pin is deformed on the D- Handle cover, it is not acceptable for reuse and should be repaired or replaced. Refurbished D-Handle covers may have the spring clip and wire rope assembly painted. The acceptance criteria for the painted spring clip is that is can be insert into the handle holes. Both the D- Handle cover and the older style cover may be repaired and reused as necessary. Total rust surface area of the flat exterior of the cover shall not exceed ½ square inch. Rust is permissible on the contact area of the handle and shaft. Caked on mud or dirt on the cover is not acceptable. Any minor or slight deformation of the rim that will not affect gasket replacement or reuse is acceptable. Covers with excessive dirt or mud and covers with field markings shall be cleaned and painted. At the discretion of the contractor, both types of covers may be spot refurbished without removal of the base cushion. The base cushion shall be removed if the entire cover is being refurbished. Replacing the spring does not require that the clamp be painted. The total rust surface area of the cover is not applicable to a replaced clamp.

C.2. Internal Packaging Components. Internal packaging components may remain in the container and be inspected as described below:

C.2.1 Components that are difficult to remove from the container or are damaged, e.g, torn, cut, cracked, incomplete, badly contaminated with dirt or sand, etc, such that it may effect the item’s function or reliability shall not be reused, unless cleaned and/or repaired prior to reuse.

C.2.2 Base cushions are acceptable so long as tears, gouges, or residual adhesive do not interfere or prevent proper fit to the container cover or against the cartridge case base.

C.2.3 Projectile supports that have scratches and/or chips in the plastic that do not effect fit or function are acceptable.

C.2.4 Rust stains on the exterior of the sleeves and strap assembly and/or plastic parts that will not come in contact with the cartridge, e.g., a rust stain that does not penetrate to the ID of the sleeve, are acceptable. A piece of the sleeve from edge that has a tear equal to, or less than 1 inch deep, and no more than 2 inches circumferentially is allowed provided it does nto effect the insertion or removal of the cartridge and will not damage the combustible cartridge case during insertion or removal.

C.2.5 Rust stains on the ends of the foam sleeve and/or projectile supports are acceptable as long as no rust stains/marks are on the interior of the foam sleeve and strap.

C.2.6 If the strap has a nick or cut which does not exceed 30% of the web of the strap, it is acceptable for use. A strap cut more than 30% will be scrapped. It may be repaired at the discretion of the contractor by sewing a lapped joint of approximately ¾ inch. The minimum remaining loop of repaired strap is 14 inches measured from the front edge of each patch.

The maximum strap length from the front edge of the patch should not exceed 17.62 inches.

C.2.7 Minor rust on the yoke assembly is acceptable, except in the threaded area.

C.2.8 No visual sign of moisture shall be apparent on the external or interior of the foam components. Wet components shall be dried, e.g, air dried, prior to packaging for reuse.

C.2.9 Any container damage that would prevent the insertion of a 120mm cartridge, projectile support, and foam sleeve into the containers; or any damage that would affect resealing of the cover is not acceptable. At the discretion of the contractor, if it can reasonably be determined that the interior of the container and internal packaging components meet acceptance criteria without removal from the container, removal of the inserts is not required.

C.2.10 If the seal screw from the yoke assembly shows signs of corrosion near the oring groove or threads it shall not be used.

C.3 Metal Pallet and Pallet Adapter. Shall be IAW MIL-A-70788 appendix for pallet adapter (AC200000469) and MIL-P-70786, appendix for metal pallet (AC200000431).

Reference MIL-C-70478, appendix A.

C.4. Wood Pallet C.4.1 All wooden blocks/spots must be present, properly secured in position and not broken.

C.4.2 All deck boards (top and bottom) and stringer boards must be present and properly secured in position. Broken boards are not allowed. Splits are acceptable provided the boards remain secure and are not loose.

C.4.3 The top outer deck boards may be split, curled, or otherwise deformed by the strapping from previous use provide it does not affect stacking of the containers on the pallet. The bottom layer of containers should “nest” flat on the pallet deck.

C.4.4. Plywood dunnage must be present and properly secured to the pallet deck in two places. Pallets with one plywood dunnage piece IAW the latest revision of 19-48-4079/7B may be used for palletization of both the PA116 and PA171. Pallets with two plywood pieces can only be used for the PA116 palletization.

C.4.5 Hardwood side buffers must not be broken. Minor damage that does not affect placement of the containers is acceptable.

C.4.6 There shall be no exposed nail points or heads.

C.4.7 Additional nails may be added to the pallet and dunnage as required.

C.4.8 The bottom deck boards are allowed to have the outboard end (outside the post)…