Attachment_0006_Quality_Assurance_Provisions_M70_Cable_Series_15_November_2018_(QAP).pdf

QAP M70 Cable Series Rev. A

15 NOV 2018

QUALITY ASSURANCE PROVISIONS (QAP)

FOR THE

CABLE ASSEMBLY, FUZE CONTROL, M72, M73, M74A

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, October 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 or AS9100C (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 or AS9100C (only design/development exclusions permitted).

Note: Throughout this QAP, Subcontractor means any supplier of materials, components, or services other than the Prime Contractor. Subcontractors are also required to meet all the contractual requirements.

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. 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 nonconformances will not be approved.

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

1. In the event there is a nonconformance of a major or critical characteristic found during the production, the DCMA shall immediately be notified.

2. The contractor shall control the nonconformance in accordance with their quality system.

3. Root cause/corrective action shall be performed on the process to prevent reoccurrence.

The corrective action procedure must be accepted by the Government before production can restart, unless the government authorizes interim procedures while root cause/corrective actions are determined/implemented.

5. 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.

6. 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

A. The Contractor shall prepare a Quality Program Plan (QPP) in accordance with the applicable Contract Data Requirements List (CDRL) 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. 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 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.

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

III. INSPECTION AND TEST PLAN

A. The Contractor shall prepare an 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, Preproduction, 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. This includes NDT procedures, coating procedures, and Welder certification procedures.

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 Coordinate Measuring Machine (CMM) is used to check Classified Characteristics, 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: The Contractor’s calibration system shall be in accordance with ANSI/NCSL Z540.3-2006 or ISO 10012. 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.

B. 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.

IV. STATISTICAL PROCESS CONTROL PROGRAM

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

V. INSPECTION AND TEST REQUIREMENTS PER MIL-STD-1916

A. MIL-STD-1916 Sampling Requirements:

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 either listed or unlisted shall be inspected by characteristic using MIL-STD-1916, Verification Level (VL)-II, Table II.

4. Table II lot inspections may be performed during the production process as lots are being formed when it is not practical to form lots prior to taking samples.

5. Use of Table III or Table IV shall require Government approval and will be based on the contractor meeting the criteria set forth in MIL-STD-1916.

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

4. Criteria for reduction of test and inspection requirements are defined in section VII.

5. Due to 100% inspection of Critical Characteristics being required, Contractors are not required to meet Paragraph 4.4 of MIL-STD-1916.

VI. ACCEPTANCE REQUIREMENTS

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

1. First article and preproduction 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, including final inspection (lot acceptance) 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 and Preproduction 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 Engineering 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 9or preproduction).

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 (or preproduction) shall be at the risk of the Contractor. The Government will not proceed with acceptance of the production lot until first article and preproduction 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 or preproduction failure shall be supplied by the Contractor at their own expense.

d. Disposition of First Article and Preproduction Sample: All first article samples shall be identified, segregated, and retained by the Contractor and made available to the Government representative, upon request, for the duration of the contract. The Government reserves the right to take First Article Test (FAT) samples into permanent possession at any time for the duration of the contract. Final disposition of first article sample will be provided prior to contract completion. Preproduction units successfully passing all required tests and inspections, and approved by the Government, may be delivered under contract, as directed by the PCO.

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 first article testing, preproduction, or 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 (including equipment moved within the plant), 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, preproduction, or Lot Acceptance Test shall be reported by the Contractor in accordance with CDRL requirements.

7. At conclusion of first article testing, preproduction, 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. Prior to the start of preproduction, 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 preproduction units as conforming to the requirements of the ADL and QAP.

2. Production lot size shall be no greater than one month's production or 15,000 cable assemblies, whichever is less, and not less than one day’s uninterrupted production. Any deviation from the lot size requirements specified above will require a written request and Government approval.

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 sampling, inspection, and test requirements set forth within the ADL, Drawings, 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 production, 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.

VII. TEST AND INSPECTION REDUCTION OR ELIMINATION

A. The Government will consider reduction or elimination of selected acceptance test or inspection based upon first article, preproduction, and LAT results when supported by evidence of both process stability and capability. Contractor written requests shall be made through the Procuring Contracting Officer or the Contracting Officer. Approval will be based upon the Contractor’s QPP, SPC, 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 and Government approval. 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, ITP, and SPC 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.

VIII. DOCUMENTATION REQUIREMENTS

A. Required documentation (e.g., QPP, ITP, PCP, 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 requirement

IX. CABLE ASSEMBLY ACCEPTANCE REQUIREMENTS

1. Scope.

1.1 Scope. The following information establishes the requirements for the manufacture and acceptance of the following bomb fuze control electrical cable assemblies, referred to herein as the cable assembly:

M48 M50 M72 M73c M49 M71 M73 M74a

1.2 Classification. The cable assemblies covered by these acceptance requirements are classified as specified in Table I below

2. Applicable Documents.

2.1 Government Documents.

2.1.1 Deleted

2.1.2 Deleted

2.2 Order of Precedence. In the event of a conflict between the text of these cable assembly acceptance requirements and the references cited herein, the text of this document shall take precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. Requirements.

3.1 Deleted

3.2 Deleted

3.3 Performance Characteristics.

3.3.1 Continuity. The resistance of each conductor between connector terminations of the cable assembly shall be not greater than 1 ohm (see 4.7.1).

3.3.2 Insulation Resistance. The insulation resistance for each conductor of the cable assembly shall be not less than 200 megohms when 500 ±10 Volts Direct Current (VDC) is applied between that conductor and all other conductors shorted together (see 4.7.2).

3.3.3 Pull Resistance. There shall be no mechanical, dimensional or electrical failure of the cable assembly when a force of 25.0 ±0.5 pounds is applied to each plug tip (contacts A and A¹ of figure 1) while the plugs are held by the ground contacts (contacts D and D¹ of figure 1).

After test, the cable assembly shall meet the requirements of 3.3.1 and 3.3.2 (see 4.7.3).

3.3.4 Strength of Spring Clip. The force required to insert the mating component into the spring clip (contact 1 of figure 1) shall be not greater than 35 pounds and not less than 5 pounds (see 4.7.4).

3.4 Environmental Requirements.

3.4.1 Deleted.

3.4.2 Thermal Shock. The cable assembly shall meet the requirements of 3.3.1 and 3.3.2, except that the insulation resistance shall be not less than 20 megohms, after exposure to five temperature cycles between the limits of 160° f (71° c) and -67° f (-55° c) (see 4.7.6).

3.4.3 Salt Spray. The cable assembly shall meet the requirements of 3.3.1 and 3.3.2, except that the insulation resistance shall be not less than 20 megohms, after exposure to salt spray for not less than 48 hours (see 4.7.7).

3.4.4 Humidity. The cable assembly shall meet the requirements of 3.3.1 and 3.3.2, except that the insulation resistance shall be not less than 20 megohms, after exposure to 10 humidity cycles between the limits of 83° F (28° C) and 160° F (71° C) at a relative humidity not less than 95 percent (see 4.7.8)

3.4.5 Salt Immersion. The cable assembly shall meet the requirements of 3.3.1 and 3.3.2; except that the insulation resistance shall be not less than 20 megohms, after the receptacle has been immersed in a salt solution for a period of 24 hours (see 4.7.9).

3.4.6 Deleted.

3.4.7 Fungus Resistance. The cable assembly shall meet the requirements of 3.3.1, 3.3.2, and

3.3.3; except that the insulation resistance shall be not less than 200 megohms, after the cable assembly has been subjected to the fungus resistance test (see 4.7.11).

3.5 Deleted

3.6 Workmanship. The cable assembly shall be constructed and finished in a manner to ensure compliance with all requirements specified herein. All parts and assemblies shall be thoroughly cleaned of metal chips, flux, and foreign matter. Particular attention shall be paid to neatness and thoroughness of assembly including construction of interface assemblies.

The cable assembly shall conform to the standards of workmanship specified on the applicable drawings and specifications specified therein. The standards of workmanship exhibited in any approved first article sample, subject to any qualifications stated in the Government notice of approval, shall establish the minimum workmanship standards for production items where such workmanship is not specifically covered by applicable standards.

4. Additional Quality/Acceptance Provisions.

4.1 Deleted

4.2 Classification of Inspections. The inspection requirements specified herein are classified as follows:

A. First article inspection (see 4.4).

B. Quality conformance inspection (see 4.5).

4.3 Inspection Conditions. Unless otherwise specified herein, all inspections shall be performed in accordance with the following test conditions:

A. Temperature: +68° F (20° c) to +95° F (35° C). Where a temperature is specified, it shall be held within ±4° F (±2.3° C).

B. Relative humidity: ambient conditions of the testing facility.

C. Atmospheric pressure: ambient conditions of the testing facility.

4.4 First Article Inspection. Unless otherwise specified in the contract or purchase order the first article sample as specified in 4.4.1 shall be inspected in accordance with the examinations and tests of Table II, in the order shown. Unless otherwise specified in the contract or purchase order.

4.4.1 First Article Sample. Prior to the start of regular production, contractor shall manufacture and submit a first article sample consisting of the quantities specified in Table II.

TABLE II FIRST ARTICLEINSPECTION (FAI)

FAIPhases Item

Description

Examination or Test

Requirement

Paragraph

Method

Paragraph

Quanity

Inspected 1/

Criteria 4/

I - Components Accent Reject

7542952

* Below

11002581

A

B

C

Receptacle, Materials, Design

Molded and Construction

Detail Parts Materials, Design and Construction

Lock Ring Materials, Design

3.2

4.5.4

10 of each

II-Fuze Plug Assembly

7542943 c

D

Fuze Plug

Assembly Design

Continuity

Insulation

Resistance

Pull

3.3.1

3.3.2

3.3.3

4.7.1

4.7.2

4.7.3

40 3/

20 31 ill-Cable Assembly

7542966 c

D

E

Packaged

Cable

Assemblie

Packaging s

{Construction Design and

Workmanship

Continuity

Insulation

Strength of

Spring Clip

3.6

3.3.1

3.3.2

3.3.4

4.5.8

4 5.4

4 5.4

4.7.1

4.7.2

4.7.4

100 6/

40 51

* 7542945, 7542946, 7542948, 7542949, 7542950, 7542953, 7542954, 7542957, 7542958, 7542960, 7542961, 7542962, 7542963, 923AS735

1/ The quantity inspected column of this Table II Indicates the number of cable assemblies inspected from first article sample for specified characteristics.

2/ The same cable assemblies are utilized for 3.3.3 and 3.4.3 requirements testing. These tests are destructive.

Tested cable assemblies are to be removed from the inspection lot for the balance of the tests.

3/ Fuze plug assemblies shall comply with 7542943 drawing requirements with the following exception: cordage Lengths shall be no less than four (4) inches.

4/ Where the same cable assembly is utilized for two different destructive tests (see 2/), the accept/reject criteria applies to the combined total rejects encountered during those two tests, not to the rejects for each individual test.

5/ these 40 cable assemblies shall comply with drawing 7542966 requirements with the following exception: cable assemblies will be assembled without fuze plug ends (cordage lengths only). Cordage lengths shall be no less than four (4) inches.

6/ Although 100 cable assemblies will be packaged for the FAI, the total FAI quantity shall be 120. There will be 20 additional cable assemblies remaining that are not packaged.

4.4.2 Deleted

4.4.2.1 Deleted

4.4.3 Deleted

4.5 Quality Conformance Inspection. Quality conformance inspection shall be performed as specified in 4.5.1.1 through 4.5.8. Unless otherwise specified in the contract or purchase order the examinations and tests specified in visual examination (4.5.4) and inspection lot quality conformance tests (4.5.5) shall be conducted by the contractor under the observation of the Government inspector.

4.5.1 Deleted

4.5.1.1 Preparation of Inspection Lot Prior To Testing. The Top Seal Assembly, drawing 7542961, shall not be installed until after the quality conformance inspection has been completed.

4.5.2 Deleted

4.5.3 Normal Inspection Lot Sampling. Inspection lot sampling shall be in accordance with Section V of this document. Inspection of the inspection lot sample is applicable to 4.5.4, 4.5.5.3, 4.5.5.4, 4.5.5.5, 4.5.5.6, and 4.5.5.7, herein. Verification Level (VL)-IV shall be used for tests specified in 4.5.5.3, 4.5.5.4, 4.5.5.5 and 4.5.5.6.

4.5.4 Visual Examination. The cable assembly shall be visually and dimensionally examined to determine compliance with MIL-STD-1916 and applicable drawings specified herein. Any of the characteristics may be examined on a higher assembly level than is indicated in the classification of characteristics if desired by the contractor, but in no case shall they be examined on a lower assembly level for acceptance inspection.

4.5.5 Inspection Lot Quality Conformance Tests. The cable assemblies shall be subjected to the following inspection lot quality conformance tests. Tests shall be performed by the contractor. Cable assemblies exposed to the strength tests of 4.7.3 and 4.7.4 and to the environmental tests of 4.7.6 and 4.7.8 shall be considered expended and shall not be returned to the inspection lot.

4.5.5.1 Continuity Test. There shall be 100 percent inspection of the entire inspection lot for conformance to the requirements of 3.3.1 (see 4.7.1). Failure of any cable assembly to meet this requirement shall be cause for rejection of that cable assembly.

4.5.5.2 Insulation Resistance Test. There shall be 100 percent inspection of the entire inspection lot for conformance to the requirements of 3.3.2 (see 4.7.2). Failure of any cable assembly to meet this requirement shall be cause for rejection of that cable assembly.

4.5.5.3 Humidity Test. Twenty five percent of the inspection lot sample shall be subjected to the tests of 4.7.1 and 4.7.2 following the humidity test of 4.7.8 with the following changes: the maximum temperature of step 2 of the humidity test procedure of 4.7.8 shall be changed from 160° F to 120° F, step 5 shall require only one cycle, and step 6 shall specify testing of the cable assembly in not greater than 15 minutes of removal from the humidity chamber and shall meet the requirements of 3.3.1 and 3.3.2. Preconditioning is not required. Failure of any cable assembly to meet this requirement shall be cause for rejection of the entire lot.

4.5.5.4 Thermal Shock. Twenty-five percent of the inspection lot sample shall be tested for conformance to the requirements of 3.4.2 (see 4.7.6). Not greater than one failure shall be permitted (see 4.5.5.7).

4.5.5.5 Pull Test and Strength of Spring Clip Test. Twenty-five percent of the inspection lot sample shall be tested for both the pull test (4.5.5.5.1) and strength of spring clip test (see 4.5.5.5.2). The entire quantity shall be subjected to both tests even if a failure occurs during one of the test procedures. If more than one failure occurs on one cable each failure will be counted separately.

4.5.5.5.1 Pull Test. The inspection lot sample shall be tested for conformance to the requirements of 3.3.3 (see 4.7.3).

Not greater than one failure shall be permitted with respect to dimensional changes of the fuze plug caused by induced pull-test stresses. No failures shall be permitted with respect to the requirements of 3.3.1 or 3.3.2 (see 4.5.5.7).

4.5.5.5.2 Strength of Spring Clip Test. The inspection lot sample shall be tested for conformance to the requirements of

3.3.4 (see 4.7.4). Not greater than one failure shall be permitted (see 4.5.5.7).

4.5.5.6 Remaining Inspection Lot Hardware. If the QCI sample passes the test called out in 4.5.5.3, 4.5.5.4, and 4.5.5.5, the remaining twenty-five percent of the inspection lot can be shipped with production.

4.5.5.7 Total Rejects. The combined total rejected cable assemblies in 4.5.5.3, 4.5.5.4, 4.5.5.5, and 4.5.5.6 shall be not greater than a total of two. Failures of the inspection lot sample to meet the requirements of 4.5.4, 4.5.5.3, 4.5.5.4, 4.5.5.5 and 4.5.5.6 shall be cause for rejection of the entire inspection lot.

4.5.5.8 Failed Inspection Lots. Inspection lots which failed the tests specified in 4.5.5.3, 4.5.5.4, 4.5.5.5, and 4.5.5.6 shall be reported to the contracting officer by the contractor with a recommendation for their disposition.

4.5.6 Deleted

4.5.7 Engineering Control Sample. Two cable assemblies selected at random from each accepted lot or selected as specified by the Government Technical Agency shall be shipped to the Government Technical Agency designated by the procuring activity.

4.5.8 Inspection of Packaging. Inspection of the preservation, packing, container marking shall be performed to determine compliance with the requirements of section 5 herein. Inspection sampling shall be in accordance with Section V of this document and the classification of characteristics (Major) of Table III below.

4.6 Examination and Test Equipment Accuracy. Examination and test equipment shall be of sufficient accuracy and quality to permit performance of the required inspection. Examination and test equipment shall be marked to indicate the limit of acceptance for each examination and test, but shall not be so marked as to reveal classified security information. Unless otherwise specified herein, meters and other measuring devices used shall be accurate to within ± 2 percent over the testing range, and test voltages shall be accurate to within ± 5 percent.

Unless otherwise specified in the contract or purchase order, testing devices used for the pull test (see 4.7. 3) and strength of spring clip test (see 4.7.4) shall be submitted to and approved by the Government Technical Agency prior to use.

4.7 Methods of Inspection.

4.7.1 Continuity Test. The resistance between the connector terminations of each conductor of the cable assembly shall be measured to determine conformance to 3.3.1. Testing shall be in accordance with the following (see figure 1 for complete identification):

Contact A to contact 1 Contact A to contact A¹ Contact B to contact B¹ Contact C to contact C¹ Contact C to contact 2 Contact D to contact D¹ Contact D to contact 3

4.7.2 Insulation Resistance Test. A voltage of 500 ±10 VDC shall be applied between one conductor of the cable assembly and all other conductors which have first been shorted together. The resistance shall be measured to determine compliance with 3.3.2. This test procedure shall be repeated with the voltage applied between another conductor and the remaining three until all four conductors have been so tested.

4.7.3 Pull Resistance Test. The fuze plug shall be mounted with the ground contact d rigidly fixed. The plug tip contact A shall then be subjected to a pull of 25.0 ±0.5 pounds not less than one time. The distance from the ground contact to the tip of the plug shall be measured before and after the pull resistance test. The test shall then be repeated for the remaining fuze plug, where contact D¹ is rigidly fixed and plug tip contact A¹ is subjected to the 25-pound pull force (see 4.5.5.5). After the pull test, the cable assembly shall be subjected to the tests of 4.7.1 and 4.7.2 and shall meet the requirements of 3.3.3.

4.7.4 Strength Of Spring Clip Test. The spring clip of the cable assembly shall be tested using the mating pin shown in figure 2. The pointed pin fixture of the testing device shall be inserted and the insertion force measured. The cable assembly shall meet the requirements of 3.3.4.

4.7.5 Deleted.

4.7.6 Thermal Shock. The cable assembly shall be subjected to the thermal shock test, method 107 of MIL-STD-202, test condition a, except that for step 3, the temperature shall be 160° F (71° C). At the completion of the test period, the cable assembly shall be tested in not greater than one hour in accordance with 4.7.1 and 4.7.2 and shall meet the requirements of 3.4.2. All visible evidence of surface moisture shall be removed from contact areas by blowing or air drying before the tests of 4.7.1 and 4.7.2 are performed. Rinsing in distilled water is permitted prior to drying.

4.7.7 Salt Spray Test. The cable assembly shall be subjected to the salt spray test, method 101 of MIL-STD-202, test condition b, for 48 hours and shall meet the requirements of 3.4.3. At completion of the test period, all visible evidence of surface moisture and all salt deposits shall be removed by rinsing in distilled water and blotting. Not greater than 15 minutes after exposure to salt spray, the assembly shall be subjected to the tests of 4.7.1 and 4.7.2.

4.7.8 Humidity Test. Except as otherwise specified herein, the cable assembly shall be subjected to 10 cycles of the humidity test of 4.7.8.1 below. At the completion of the test period, all visible evidence of surface moisture shall be removed from contact areas by blowing or air drying. Rinsing in distilled water is permitted prior to drying.

The assembly shall then be tested not greater than one hour following exposure to humidity.

4.7.8.1 Humidity Test.

4.7.8.2 General. The humidity exposure shall be conducted with the test item non-operating unless specifically required otherwise by the detail equipment specification or the procuring agency. For the majority of applications, it is intended that demonstration of satisfactory equipment operation within one hour from the completion of the 10th humidity cycle will, for all practical purposes, satisfy the operational requirement.

4.7.8.2.1 Preconditioning. The cable assembly shall be stabilized and maintained at -65° F (-54° C) for not less than two hours, then shall be stabilized and maintained at +160° F (+71° C) for not less than two hours.

4.7.8.3 Humidity Cabinet. The chamber and accessories will be constructed such that the generation of humidity shall introduce no contaminants, including water droplets and entrainments, into the test exposure area. The required increases in moisture vapor content shall be accomplished by low pressure steam or vapor from distilled, deionized or demineralized water having a ph value of 6.0 to 7.2 measured at 23° C (74° F). Air velocity throughout the test exposure area shall not exceed 150 feet per minute except at a wet bulb sensor where the velocity across the wick shall be not less than 900 feet per minute. The test exposure area shall be maintained at the prevailing local atmospheric pressure.

4.7.8.4 Test Procedure:

Step 1- place the test item in the test chamber. Prior to starting the test, the internal chamber temperature shall be at standard ambient with uncontrolled humidity.

Step 2- gradually raise internal chamber temperature to 71° C (160° F) and the relative humidity to 95 percent over a period of 2 hours.

Step 3- maintain the final condition of step 2 for not less than 6 hours.

Step 4- maintain 85 percent or greater, relative humidity and reduce internal chamber temperature in 16 hours to 28° ±10° C (82° ±18° F).

Step 5- repeat steps 2, 3, and 4 for 10 continuous cycles (not less than 240 hours). Figure 3 is an outline of the humidity cycle for this procedure.

Step 6- within 1 hour following the completion of the 10th cycle, the cable assembly shall be tested in accordance with 4.7.1 and 4.7.2 and shall meet the requirements of 3.4.4. The test item shall then be inspected for corrosion or other forms of deterioration. (see notes (a) and (b)).

Note: (a) excessive moisture may be removed from the exterior surfaces of the test item prior To measurements by wiping the external surfaces only. The test item shall not be turned upside down.

(b) the test item shall also be examined for evidence of entrapped moisture. Presence of entrapped moisture may be cause to consider the test item has failed the test provided such entrapment could adversely affect the equipment.

4.7.9 Salt Immersion Test. The receptacle of the cable assembly shall be immersed to a depth of not less than 6 inches in a not less than 10 percent solution of sodium chloride for a period of not less than 24 hours. At the completion of the test period, all visible evidence of surface moisture shall be removed from contact areas by blowing or wiping. Rinsing in distilled water is permitted prior to drying. The assembly shall then be tested not greater than 1 hour following salt immersion in accordance with 4.7.1 and 4.7.2 and shall meet the requirements of 3.4.5.

4.7.10 deleted

4.7.11 Fungus Resistance Test. The cable assemblies shall be tested in accordance with MIL-STD-331, Test C5. The contractor shall prepare a certificate of compliance for each first article sample stating that all material used is either fungus resistant or in compliance with MIL-STD-331, Test C5. Due to the length of time required by this test, a conditional acceptance of the first article sample may be given pending the results of the test if the contractor has submitted a satisfactory certificate (see 3.4.7).

5. Packaging.

5.1 Preservation. The same requirements shall be applicable to both level A and level B packing.

5.1.1 Interior Packaging. Interior packaging shall be as follows:

A. A Protector Tube (see drawing 7542963) shall be placed on each fuze plug. Cordage shall be folded in approximately 8-inch folds so that the wrapper covers the cordage lengthwise. The wrapper shall be placed around the folded cordage with the corrugations inward. One end of the wrapper shall be held in place with receptacle, but shall not cover it. The wrapper shall be held in place with gummed Kraft tape of not less than 1-inch width and 60- pound per ream basis weight.

B. The wrapper shall consist of a single face corrugated material with Kraft paper backing 8 by 6 inches with corrugations parallel to the longer dimension.

C. One Receptacle Lock Ring (see drawing 11002581) shall be placed on the small end of each receptacle.

The ring shall be held in place by putting one or more sheets of cellophane, as required, over the receptacle before putting the ring in place. One sheet of the cellophane shall be long enough to fold back and cover the ring during insertion of the cable assembly into the envelope. Alternatively, polyethylene, vinyl, saran, or cellulose acetate may be used in place of cellophane. Each envelope end shall be opened on a suitable mandrel and the wrapped cable assembly shall be inserted with lock ring in place, receptacle first, into the envelope. The envelope shall be closed with heat seal. The corners shall be folded back as required and the folded envelope shall be inserted into partitions in the carton or shipping container, as applicable.

D. The envelope shall comply with Type I, Class B specified in MIL-B-117. The inside dimension shall be

3.75 inches wide by 12.0 inches long. The envelope shall be formed by heat sealing with not less than .125 inch width seal. A lip of not less than .0625 inch shall be provided for easy opening.

5.2 Packing. Packing shall be level A or B as specified in the contract or purchase order and shall be as specified herein.

5.2.1 Level A. The shipping container shall be a box complying with style RSC or CSSC of ASTM D5118/D5118M.

The fiberboard shall conform to type (CF), class (WR/FR), variety (SW), grade V3C, A or C flute or type (SF), class (WR), grade V3S of ASTM D4727/D4727M. The inside dimensions shall be 22.5 inches by 11.25 inches by 9.875 inches deep. The shipping container shall be divided into 50 equal cells formed by full height, half-slotted partitions for 50 cable assemblies. The partitions shall be fabricated from the same material as the containers. The shipping container shall be sealed with pressure-sensitive tape complying with ASTM D5486, type 1, class 1 or 2. The tape shall not be 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 carton not less than 3 inches onto the container ends.

5.2.2 Level B. The shipping container shall be a box complying with style RSC or CSSC of ASTM D5118/D5118M.

The fiberboard shall conform to type (CF), class (D/FR) variety (SW), grade 200, A or C flute of ASTM D4727/D4727M. The inside dimensions shall be 22.5 inches by 11.25 inches by 9.85 inches deep.