ATPD-2352T - Transparent Armor - 8May2011 - Distribution Code A.pdf

Comments, suggestions, or questions on this document should be addressed to U.S. Army RDECOM, Tank Automotive Research, Development and Engineering Center, ATTN: RDTA-EN/STND/TRANS MS #268, 6501 E. 11 Mile Road, Warren, MI 48397-5000 or sent by email to usarmy.detroit.rdecom.mbx.tardec-standardization@mail.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https://assist.dla.mil.

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

METRIC

ATPD-2352T

8 May 2013

SUPERSEDING

ATPD-2352R

26 April 2010

PURCHASE DESCRIPTION

TRANSPARENT ARMOR

This specification is approved for use by the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC), Research, Development and Engineering Command (RDECOM), Department of the Army, and is available for use by all Departments and Agencies of the Department of Defense.

mailto:usarmy.detroit.rdecom.mbx.tardecstandardization@mail.mil https://assist.dla.mil/

ATPD-2352T

i

CONTENTS

PARAGRAPH PAGE

1. SCOPE

1.1 Scope

1.2 Material selection

2. APPLICABLE DOCUMENTS

2.1 General

2.2 Government documents

2.2.1 Specifications, standards, and handbooks

2.2.2 Other Government documents, drawings, and publications

2.3 Non-Government publications

2.4 Order of precedence

3. REQUIREMENTS

3.1 Tests

3.2 Design and declarations

3.2.1 Ballistic protection classes

3.2.2 Construction and materials

3.2.2.1 Materials compatibility

3.2.3 Transparent plies

3.2.4 Edgework

3.2.5 Areal density

3.2.6 De-icing

3.2.7 Allowable defects

3.2.8 Marking

3.2.9 Tolerance

3.3 Environmental

3.3.1 Temperature extremes

3.3.1.1 Low temperature

3.3.1.2 High temperature

3.3.2 Humidity

3.3.3 Reserved

3.3.4 Temperature shock

3.3.5 Sun exposure weathering

3.3.6 Abrasion resistance

3.3.6.1 Threat surface abrasion resistance

3.3.6.2 Interior surface abrasion resistance

3.3.7 Exposure to chemicals

3.3.7.1 Cleaning spray

3.3.7.2 Inner surface exposure to chemicals

3.3.7.3 Outer surface exposure to chemicals

3.4 Optical

3.4.1 Luminous transmittance

3.4.1.1 Night vision goggles (NVG)-weighted transmittance

ii

3.4.2 Haze

3.4.3 Optical deviation

3.4.4 Optical distortion

3.5 Ballistic protection

3.6 Rock strike and scratch resistance

4. VERIFICATION

4.1 Tests

4.1.1 Classification of inspections

4.1.2 First article test (FAT)

4.1.2.1 Remediation of failed first article testing

4.1.3 Production control test

4.1.3.1 Control test deficiencies

4.1.4 Production inspection

4.1.5 Responsibility for tests

4.1.6 Responsibility for compliance

4.2 Design

4.2.1 Construction and materials process changes

4.2.2 Reserved

4.2.3 Allowable defects

4.2.4 Marking

4.2.5 Tolerance

4.2.6 De-icing

4.3 Environmental conditions

4.3.1 Temperature Extremes

4.3.1.1 Low temperature

4.3.1.2 High temperature

4.3.2 Humidity

4.3.3 Reserved

4.3.4 Temperature shock

4.3.5 Sun exposure weathering

4.3.6 Abrasion resistance

4.3.6.1 Threat surface abrasion resistance

4.3.6.2 Interior surface abrasion resistance

4.3.7 Exposure to chemicals

4.3.7.1 Cleaning spray

4.3.7.2 Inner surface exposure to chemicals

4.3.7.3 Outer surface exposure to chemicals

4.4 Optical

4.4.1 Luminous transmittance

4.4.1.1 NVG-weighted transmittance

4.4.2 Haze

4.4.3 Optical deviation

4.4.4 Optical distortion

4.5 Ballistic qualification

4.5.1 Ballistic test report

iii

4.5.2 Ballistic test procedure, KE bullet, ambient temperature

4.5.3 Ballistic test procedure, KE bullet, high temperature

4.5.4 Ballistic test procedure, KE bullet, low temperature

4.5.5 Ballistic test procedure, FSP

4.5.6 Ballistic test acceptance criteria

4.6 Rock strike and scratch resistance

4.6.1 Low velocity impact resistance

4.6.2 Scratch propagation resistance

4.7 Ballistic testing facility

5. PACKAGING AND MARKING

5.1 Preservation, packing and marking

5.1.1 Military requirements

5.1.1.1 Dirt and contaminants

5.1.1.2 Deterioration protection

5.1.1.3 Physical damage protection

5.1.1.4 Packaging

5.1.1.5 Unit package

5.1.1.6 Contractor packaging responsibility

5.1.2 Commercial packaging requirements

5.1.2.1 Contractor packing responsibility, commercial packing

5.1.3 Wood heat treating

5.2 Packing

5.2.1 Military Level A packing

5.2.2 Military Level B packing

5.2.3 Commercial packing

5.2.4 Shipping containers

5.2.4.1 Unitization

5.3 Marking

5.3.1 Marking limitations

6. NOTES

6.1 Intended use

6.1.1 Security requirements

6.2 Acquisition requirements

6.3 Structural integrity

6.4 Alternate ballistic testing facility

6.5 Laboratory accreditation

6.6 Definitions

6.6.1 Definitions from ASTM C1036

6.6.2 Definitions from ASTM C1172

6.6.3 Clouding

6.6.4 Complete Penetration (CP)

6.6.5 Composition

6.6.6 Coupon

6.6.7 Crack

6.6.8 Crazing

iv

6.6.9 Delamination

6.6.10 Fair impact

6.6.11 Fragment simulating projectile

6.6.12 Insects or other organic matter

6.6.13 Interlayer

6.6.14 Interlayer striae

6.6.15 Open gaseous inclusion

6.6.16 Partial penetration (PP)

6.6.17 Protection class

6.6.18 Ream

6.6.19 Strike surface

6.6.20 Striking or impact velocity

6.6.21 Surface defects

6.6.22 Transparent armor (TA)

6.6.23 Unfair impact

6.6.24 Yaw angle

6.6.25 Yaw card

6.7 Subject term (key word) listing

FIGURES

FIGURE 1 Definition of TA areas FIGURE 2 Multi-hit pattern, Protection Classes 1 thru 4 FIGURE 3 Multi-hit pattern, Protection Class 5 FIGURE 4 Multi-hit pattern location on production part, Protection Classes 1 thru 4 FIGURE 5 Multi-hit pattern location of production part, Protection Class 5 FIGURE 6 Pattern for low velocity impact tests

TABLES

TABLE I Chemical exposure requirement for inner surface TABLE II Chemical exposure requirement for outer surface TABLE III First article tests TABLE IV Ballistic test articles required and acceptance criteria TABLE V Production quality control tests TABLE VI Production inspection TABLE VII Maximum allowable defects TABLE VIII High temperature test profile TABLE IX Humidity test profile TABLE X Relative spectral irradiance (spectral power distribution) of CIE Standard

Illuminant A TABLE XI Night vision goggle response function (Gen III with PVS14 lens)

1. SCOPE

1.1 Scope. This specification covers the performance requirements for transparent armor (TA) used for windows of armored ground military vehicles and other Army structures.

The requirements of this document are applicable when specified on the part drawing or by the procuring activity. Transparent armor is the technical term for protective transparencies also commonly known as ballistic resistant windows. In the event of a conflict between this document and the procurement documents, the procurement documents shall take precedence.

Caution: The ballistic tests mandated by this document are defined by statistical requirements for consistency. They do not guarantee that all windows of all configurations will survive ballistic impacts not defined by this specification. This specification makes careful definition of distance to edges and window size. Windows not conforming to these definitions must be individually qualified to the ballistic requirements of the system for which the specific windows are being purchased.

1.2 Material selection. This document does not intend to restrict the use of the many materials and processes used in the design and manufacture of transparent armor; it is important to note that their proper selection is required in order to achieve the performance, reliability and longevity requirements of this document.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract (see 6.2).

COMMERCIAL ITEM DESCRIPTIONS

A-A-52557 - Fuel Oil, Diesel; for Posts, Camps and Stations A-A-52624 - Antifreeze, Multi-Engine Type A-A-59133 - Cleaning Compound, High Pressure (Steam) Cleaner

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-PRF-680 - Degreasing Solvent MIL-PRF-2104 - Lubricating Oil, Internal Combustion Engine, Combat/Tactical Service MIL-DTL-5624 - Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL-PRF-6083 - Hydraulic Fluid, Petroleum Base, for Preservation and

Operation MIL-PRF-10924 - Grease, Automotive and Artillery MIL-D-16791 - Detergents, General Purpose (Liquid, Nonionic) MIL-G-21164 - Grease, Molybdenum Disulfide, for Low and High

Temperatures, NATO Code Number G-353 MIL-PRF-24139 - Grease, Multipurpose, Water Resistant MIL-DTL-62420 - Periscope, Tank

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-129 - Military Marking for Shipment and Storage MIL-STD-130 - Identification Marking of U.S. Military Property MIL-STD-662 - V50 Ballistic Test for Armor MIL-STD-810 - Environmental Engineering Considerations and Laboratory

Tests MIL-STD-1275 - Characteristics of 28 Volt DC Electrical Systems in

Military Vehicles

DEPARTMENT OF DEFENSE HANDBOOKS

MIL-HDBK-722 - Glass

(Copies of these documents are available from http://quicksearch.dla.mil/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

COMBAT SUPPORT AND COMBAT SERVICE SUPPORT

Security Classification Guide For Combat Support and Combat Service Support Armoring Systems, 6 April 2007

(Copies of this document are available from Program Executive Office, Combat Support and Combat Service Support (CS&CSS), ATTN: SFAE-CSS-TV, Warren, MI 48397-5000) http://quicksearch.dla.mil/

U.S. ARMY TACOM DRAWINGS

DTA184044 - TACOM Protection Classes

NOTE: DTA184044 is classified SECRET. Unless specified by the procuring agency, the latest revision of this drawing will apply. Proof of proper authorization and security clearance shall be required to obtain copies.

(Copies of this drawing can be obtained from the Standardization Office, Tank Automotive Research, Development and Engineering Center, ATTN: RDTA-EN/STND/TRANS MS #268, 6501 E. 11 Mile Road, Warren, MI 48397-5000 or can be requested by sending an email to usarmy.detroit.rdecom.mbx.tardec-standardization@mail.mil.)

2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract (see 6.2).

ASTM INTERNATIONAL

ASTM F428 - Intensity of Scratches on Aerospace Glass Enclosures ASTM F548 - Intensity of Scratches on Aerospace Transparent Plastics ASTM F801 - Measuring Optical Angular Deviation of Transparent Parts ASTM D975 - Diesel Fuel Oils ASTM D1003 - Haze and Luminous Transmittance of Transparent Plastics

(DoD adopted) ASTM C1036 - Flat Glass (DoD adopted) ASTM C1172 - Laminated Architectural Flat Glass ASTM D1655 - Aviation Turbine Fuels ASTM F2156 - Measuring Optical Distortion In Transparent Parts Using

Grid Line Slope ASTM D4169 - Performance Testing of Shipping Containers and Systems ASTM D4814 - Automotive Spark-Ignition Engine Fuel ASTM D3363 - Film Hardness by Pencil Test

(Application for copies of these documents should be addressed to the American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, www.astm.org)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 3290-2 - Rolling bearings - Balls - Part 2: Ceramic balls

(Copies of this document are available from www.iso.org or www.ansi.org or ANSI Customer Service Department, 25 W. 43rd Street, 4th Floor, New York, NY 10036.)

mailto:usarmy.detroit.rdecom.mbx.tardecstandardization@mail.mil http://www.astm.org/ http://www.iso.org/ http://www.ansi.org/

SAE INTERNATIONAL

ANSI/SAE Z26.1-1996 - American National Standard for Safety Glazing

Materials For Glazing Motor Vehicles and Motor Vehicle Equipment Operating on Land Highways - Safety Standard

(Copies of this document are available from www.sae.org or SAE Customer Service, 400 Commonwealth Drive, Warrendale, PA 15096-0001.)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Tests. Unless otherwise specified by the part drawing or the procuring agency (see 6.2), samples of production parts or coupons shall be subjected to testing and inspection in accordance with section 4.

3.2 Design and declarations. First article and production control tests must be accompanied by a declaration of TA composition. The contractor’s declaration must declare the material type (materials such as but not limited to glass, transparent ceramic, polyurethane, or polycarbonate) and nominal thickness for each layer, including interlayers. Declaring a layer to be a plastic or adhesive is not sufficient. Layers must be listed individually and sequentially, beginning with the strike surface. The nominal thickness of the laminated TA must also be provided. Coatings and surface treatments such as hard coatings and washes need to be declared though not specifically defined. However, the declaration must list an identifier or code that is traceable to company process control specifications, and declarations must indicate that the process control specification for the supplied transparent armor is fixed and in control. After FAT approval, no material or process changes that may affect product performance, including ballistic integrity and environmental durability, shall be made without the procuring activity approval.

3.2.1 Ballistic protection classes. TACOM has established protection classes based on threat munitions. The protection classes and their corresponding test projectiles with proofing test velocities are listed on drawing DTA184044. The drawing is classified SECRET. The protection class shall be used in place of describing the threat munitions and their specific performance objectives in the contract or detailed specification for the particular transparent armor system (see 6.2). See 6.1.1 for further guidance.

http://www.sae.org/

3.2.2 Construction and materials. The contractor shall select the methodology of construction and the materials, provided these methods and materials are capable of yielding uniform and reproducible test properties as specified in this document.

3.2.2.1 Materials compatibility. Materials must be compatible with each other in all states that they may contact one another. Materials shall be selected so that no materials induce failure nucleation processes, such as embrittlement, of another component of the TA.

3.2.3 Transparent plies. The transparent plies used in the lamination shall be specially selected transparencies conforming to Type I or Type II, Class 1, quality–q3 of ASTM C1036.

The outer ply shall be a material chosen for abrasion resistance and the inner ply shall be chosen for spall resistance.

3.2.4 Edgework. For handling purposes, flares shall be ground and glass edges shall have a light seam. All edges except for FAT ballistic coupons shall be sealed to ensure protection of the bond line(s) and underlying materials from the environmental (rain, ice, dust, etc.) conditions and other contaminants of 3.3.7.1, 3.3.7.2 and 3.3.7.3.

3.2.5 Areal density. The armor shall be of the minimum practicable density, except where the product drawing specifies the TA thickness, while meeting the ballistic and performance requirements specified by the part drawing or the procuring agency (see 6.2).

When the procuring agency specifies the weight of the TA assembly, weight variations greater than 3% shall be cause for rejection of the part.

3.2.6 De-icing. Transparent armor may have a built-in electric de-icing system when specified on the part drawing (see 6.2). The de-icing system shall be capable of clearing 80% of Area C, as shown on figure 1, at ambient temperatures down to -25 °C. (see 4.2.6)

3.2.7 Allowable defects. Unless otherwise specified (see 6.2), minor imperfections that do not affect serviceability shall be permitted. Short interlayers no greater than 7 mm from the edge shall be permitted and not recorded as a delamination. Defects shall not exceed allowable limits indicated in table VII. (see 4.2.3)

3.2.8 Marking. Individual TA shall be clearly and permanently marked in accordance with MIL-STD-130 and shall include the marking “THREAT SIDE” and the TA vendor identification (CAGE code) and production date (see 6.2). Marking shall be readable from the vehicle exterior. (see 4.2.4)

3.2.9 Tolerance. The part drawing dimensions controlling the overall size and shape of the TA assembly are considered major dimensions and shall be inspected.

3.3 Environmental.

3.3.1 Temperature extremes.

3.3.1.1 Low temperature. The TA shall meet allowable defects requirements (see 3.2.7) and optical requirements (see 3.4) after prolonged exposure, in accordance with MIL-STD-810 Method 502, Procedure I (Storage), to temperatures as low as -54±4 °C. (see 4.3.1.1)

3.3.1.2 High temperature. The TA shall meet allowable defects requirements (see 3.2.7) and optical requirements (see 3.4) after exposure to three 24 hour cycles from MIL-STD-810 Method 501, Procedure I (Storage), climatic category A2 (Basic Hot) Induced conditions with a maximum temperature of 63 °C. (see 4.3.1.2)

3.3.2 Humidity. The TA shall meet allowable defects requirements (see 3.2.7) and optical requirements (see 3.4) without moisture buildup following high temperature-humidity exposure modified from MIL-STD-810 Method 507, Procedure II (Aggravated). (see 4.3.2)

3.3.3 Reserved.

3.3.4 Temperature shock. The TA shall withstand sudden changes in surrounding air temperature and shall not be damaged when surrounding air temperature changes between -30±3 °C and 60±3 °C in less than 5 minutes in accordance with MIL-STD-810 Method 503, Procedure I-C (Multi-cycle shocks from constant extreme temperature). After experiencing temperature shock, the TA shall meet the allowable defects requirements of 3.2.7 and optical requirements of 3.4. (see 4.3.4)

3.3.5 Sun exposure weathering. Transparent armor shall show no evidence of crazing, delamination, discoloration or other physical deterioration when exposed to an irradiance level of 1120 W/m² per MIL-STD-810 Method 505, Procedure II (Steady State (actinic effects)) for fifty-six (56) 24-hour cycles. Irradiance shall be normal to the strike face of the TA. After exposure, the TA shall meet the allowable defects requirements of 3.2.7 and the requirements of 3.4.1, 3.4.1.1, and 3.4.2. (see 4.3.5)

3.3.6 Abrasion resistance.

3.3.6.1 Threat surface abrasion resistance. The threat surface (also called strike face or exterior surface) material shall satisfy the light scattering requirement described in ANSI/SAE Z26.1 for safety glazing material after undergoing the safety glazing material abrasion resistance test of ANSI/SAE Z26.1. (see 4.3.6.1)

3.3.6.2 Interior surface abrasion resistance. The interior surface shall satisfy the light scattering requirements described in ANSI/SAE Z26.1 for Item 4A (rigid plastics) after undergoing the rigid plastics abrasion resistance test of ANSI/SAE Z26.1. (see 4.3.6.2)

3.3.7 Exposure to chemicals.

3.3.7.1 Cleaning spray. The inner and outer surfaces of the TA assembly shall meet the performance requirements of 3.4 and shall show no evidence of damage, including clouding or cracking, after the portion of the assembly within the edge sealing surface is exposed to agents conforming to A-A-59133. (see 4.3.7.1)

3.3.7.2 Inner surface exposure to chemicals. The inner surface of the TA assembly shall meet the performance requirements of 3.4 after exposure to the materials shown in table I. After exposure, no evidence of clouding or cracking shall be visually observable. (see 4.3.7.2)

TABLE I. Chemical exposure requirement for inner surface.

Group Exposure to one member of each of the following groups must be tested

1 • One percent solution of nonabrasive soap in deionized water (i.e., potassium oleate or equivalent)

2 • Kerosene No. K-1 or K-2 3 • Undiluted denatured alcohol (Formula SD No. 30)

• Isopropanol and glycol ether (concentrations no greater than 10% or less than 5% by weight)

• Isopropanol, glycol ether, and ammonium hydroxide (isopropanol and glycol ether solvents in concentrations no greater than 10% or less than 5% by weight each or/and ammonium hydroxide no greater than 5% or less than 1% by weight)

• Ammonium hydroxide (concentrations no greater than 5% or less than 1% by weight)

These concentrations simulate commercial windshield cleaners.

5 • Cleaning solvent Type I or Type II per MIL-PRF-680

3.3.7.3 Outer surface exposure to chemicals. The outer surface of the TA assembly shall meet the performance requirements of 3.4 after exposure to vapors of, or being placed in direct contact with, the materials shown in table II. After exposure, no evidence of clouding or cracking shall be visually observable. (see 4.3.7.3)

TABLE II. Chemical exposure requirement for outer surface.

Group Exposure to one member of each of the following groups must be tested

• Fuel per A-A-52557 (DF-2, DF-1, or DF-A)

• Fuel per ASTM D975 (Commercial Diesel No. 1-D or No. 2-D)

• Fuel per MIL-DTL-5624 (Grade JP-4 or JP-5)

• Fuel per ASTM D1655 (Commercial Turbine Jet-A or Jet A-1)

2 • ASTM D4814 (MOGAS)

• Regular Automotive Gasoline or Hydraulic fluid per MIL-PRF-6083

3 • Anti-freeze per A-A-52624 4 • Detergent, liquid Type I or Type II per MIL-D-16791

• Grease (molybdenum disulfide per MIL-G-21164)

• Lubricant oil Grade 30 or NDO (per MIL-PRF-2104)

• Grease, automotive/artillery (per MIL-PRF-10924)

• Grease, automotive MP (per MIL-PRF-24139)

3.4 Optical.

3.4.1 Luminous transmittance. The integrated luminous (photopic) transmittance of transparent armor shall not be less than 75% for Protection Classes 1 and 2, 60% for Protection Class 3, 50% for Protection Class 4, and 20% for Protection Classes 5 and 6. When TA with a de-icing system is tested, the requirement values shall be reduced by 5 percentage points. When testing the luminous transmission of a single element (or bonded pair) before and after other tests, the luminous transmission shall not change by more than 3 percentage points. (see 4.4.1)

3.4.1.1 Night vision goggles (NVG)-weighted transmittance. The NVG-weighted integrated spectral transmission shall not be less than 50% for Protection Classes 1 and 2, 30% for Protection Class 3, 20% for Protection Class 4, and 10% for Protection Classes 5 and 6.

When testing the NVG-weighted transmittance of a single element (or bonded pair) before and after other tests, the NVG-weighted transmittance shall not change by more than 3 percentage points. (see 4.4.1.1)

3.4.2 Haze. Haze shall be less than 3%. (see 4.4.2)

3.4.3 Optical deviation. Unless otherwise specified by the procuring activity, the optical deviation of a parallel light at normal incidence to the glass shall not exceed 5 minutes of arc over the Area C (see figure 1) when tested in accordance with 4.4.3.

3.4.4 Optical distortion. Optical distortion shall be no worse than that indicated by a line slope ratio of 1:20 over Area C (see figure 1) when tested in accordance with ASTM F2156.

(see 4.4.4)

3.5 Ballistic protection. The TA shall, at a minimum, provide protection from the threat rounds corresponding to the protection class specified in the purchase document (see 6.2). Each multi-hit pattern shall be on a single coupon. The protection class threat specifications are found on drawing DTA184044, which is classified SECRET. The multi-hit patterns and location are not classified and are shown as figures 2 and 3 in this document. Figures 4 and 5 may be used by the ballistic test facility when recommending multi-hit patterns for undersized parts (samples).

The procuring activity shall specify the protection class as noted on each part drawing (see 6.2).

Parts that are too small for reliable four-shot multi-hit patterns will be tested using coupons per 4.5.a. See 3.2.1 and 6.1.1 for other guidance on classification issues. (see 4.5)

3.6 Rock strike and scratch resistance. The TA shall provide resistance to scratch and low velocity impact damage and propagation. (see 4.6)

4. VERIFICATION

4.1 Tests. This program is a series of tests to satisfy the requirements at minimum cost.

Testing is performed by both the contractor and the Government to provide the verification data.

Any subcontracted laboratory or contractor in-house laboratory doing work to prove compliance to this document shall be accredited to ISO/IEC 17025 (latest revision) by a recognized assessment agency such as A2LA or LAB (see 6.5).

4.1.1 Classification of inspections. The inspection requirements specified herein are classified as follows:

a. Ballistic qualification (see 4.5)

b. First article test (see 4.1.2)

c. Production control test (see 4.1.3)

d. Production conformance inspection (see 4.1.4)

4.1.2 First article test (FAT). All new contracts are required to perform a FAT, unless otherwise specified by the procuring activity (see 6.2). On contracts containing multiple part numbers of the same TA composition (see 3.2), meaning the same front-to-back recipe but differing lateral dimensions, FAT shall be conducted only for one part number unless otherwise specified by the procuring activity. Test items conforming to the product drawings of items of the size and type shall be provided for non-ballistic testing and shall be submitted for FAT in addition to the standardized ballistic test coupons required per table IV. The number of samples required for each test is given in table III. Non-ballistic tests may be completed sequentially using the same parts or coupons or may be completed concurrently using different parts or coupons. Coupons may not be used for a test which explicitly requires a part (see table III). For a TA design to pass the non-ballistic tests, either all samples must meet the requirement or the average measurement of the specified number of samples must meet the requirement (see table III). FAT ballistic test coupons shall be identical in composition, stacking order and construction to the intended production lot (see 3.2 and 4.5). The FAT ballistic acceptance criteria are found in 4.5. Tests that are performed on samples prior to contract award will not be used as a substitute for FAT unless the tests were performed and documented to all FAT requirements, including the design and declaration (see 3.2).

4.1.2.1 Remediation of failed first article testing. If the first article test is disapproved for not meeting requirements, the contractor, upon Government request, shall submit additional first article samples and support, in the same level and manner as the original FAT. Before resubmitting, the contractor shall make any necessary changes or modifications to the TA.

Before resubmitting additional FAT samples, the contractor shall furnish the Government information concerning previous rejection, and the action taken to correct the failures. All costs related to the first article tests or building additional FAT samples are to be borne by the contractor. Production shall not begin until the approval of the FAT samples has been obtained.

TABLE III. First article tests.

Title

Samples Required

(Pass/Fail unless noted)

Section 3 Section 4 Pre-Production Parts unless noted

Design Documented 3.2 4.2 Part Allowable defects 2/2 3.2.7 4.2.3 Part

Marking Inspection 3.2.8 4.2.4 Part

Luminous transmittance 2/2 3.4.1, 3.4.1.1

4.4.1,

4.4.1.1 Part or Coupon

Haze 2 Avg. 3.4.2 4.4.2 Part or Coupon Optical deviation 2/2 3.4.3 4.4.3 Part Optical distortion 2/2 3.4.4 4.4.4 Part

Chemical 2/2 3.3.7 4.3.7 Part De-icing 2/2 3.2.6 4.2.6 Part

Low temperature 2/2 3.3.1.1 4.3.1.1 Part High temperature 2/2 3.3.1.2 4.3.1.2 Part

Humidity resistance 2/2 3.3.2 4.3.2 Part Temperature shock 2/2 3.3.4 4.3.4 Part

Tolerance Inspection 3.2.9 4.2.5 Part Ballistic (cold, ambient, and hot) 34 (per table IV) 3.5 4.5 Coupon

Abrasion resistance – Threat surface 3 Avg. 3.3.6.1 4.3.6.1

Coupon, size determined by test facility

Abrasion resistance – Interior side 3 Avg. 3.3.6.2 4.3.6.2

Coupon, size determined by test facility

Sun exposure weathering 3/3 3.3.5 4.3.5

Part or Coupon, size determined by test facility Rock strike and scratch resistance 4 (per 4.6) 3.6 4.6 Coupon

TABLE IV. Ballistic test articles required and acceptance criteria.

Protection Class First Article Testing Control Testing

ALLTEMP Ambient Temperature Only

Ambient Temperature Only

Samples Required 29 plus 5 spares, Coupons

29 plus 5 spares, Coupons

10 plus 2 spares, No-Frame Samples

Test matrix KE bullet, ambient

KE bullet, hot KE bullet, cold

FSP

Pass Fraction¹ KE bullet, ambient

KE bullet, hot KE bullet, cold

FSP

¹The pass fraction is the number of samples that must pass the ballistic test by receiving no complete penetrations.

TABLE V. Production quality control tests.

Title Section 3 Section 4 Production Parts Unless Noted

Ballistic (ambient only) 3.5 4.5.2, 4.5.5 Part¹ Luminous transmittance 3.4.1, 3.4.1.1 4.4.1, 4.4.1.1 Part or Coupon

Haze 3.4.2 4.4.2 Part or Coupon Optical deviation 3.4.3 4.4.3 Part Optical distortion 3.4.4 4.4.4 Part

Abrasion resistance 3.3.6 4.3.6 Coupon ¹A defrosting film is not required for the ballistic test.

TABLE VI. Production inspection.

Title Section 3 Section 4 Production Parts Unless Noted

Allowable defects 3.2.7 4.2.3 Marking 3.2.8 4.2.4

Tolerance 3.2.9 4.2.5

4.1.3 Production control test. Transparent armor shall be subjected to the production control tests as specified in table V. Control tests shall occur for every production order and shall be carried out by the contractor under Government surveillance, except for ballistic tests which are conducted by the Government (see 4.5). Unless otherwise specified by the procuring activity, contracts containing multiple part numbers of the same recipe, neglecting the presence of de-icing elements, with different lateral dimensions must only conduct control testing on one part number. Ballistic production control tests shall occur every three months or 2000 production parts, whichever occurs first. Changes to the frequency of production control testing must be approved by the procuring agency. The Government reserves the right to conduct ballistic tests of production parts at any time during a production order (see 6.2). For ballistic testing, actual production parts shall be submitted unless the production part is smaller than 240 mm x 365 mm for Protection Classes 1 through 4, 5b and 6a, or 320 mm x 485 mm for Protection Class 5a. If actual production parts are smaller than these dimensions, coupons sized in accordance with 4.5a shall be submitted.

4.1.3.1 Control test deficiencies. Control test deficiencies (ballistic and non-ballistic) shall be evidence that end items produced since the last acceptable control test and end items produced after the selection of the control test items may be similarly defective. The contractor may provide evidence satisfactory to the Government Quality Assurance Representative that previously produced end items and units representing the control test are not similarly defective.

In the event that the defect(s) exists beyond the control test lot, the contractor shall correct all defective items at no additional cost to the Government. The contractor shall not provide additional product for acceptance until the control test is successfully completed. If there is a failure with the initial samples submitted for a ballistic control test, one additional test sequence for the failed test shall be required to determine if there was a ballistic test anomaly or if there is a quality assurance deficiency in the product. Additional samples shall be submitted to retest the failed threat. Failure of the initial control test and the additional test shall constitute failure of the control test. Parts produced since the previous control test or FAT shall be quarantined and isolated until the reason for test failure is identified and the decision of the procuring activity is obtained.

4.1.4 Production inspection. Production inspection (control inspections) of TA shall be conducted by the contactor in accordance with table VI. The emphasis shall be on measurement and interface/visual criteria. The number of samples required for a production inspection and frequency of inspections is at the contractor’s discretion. No matter what method or frequency of inspection is used, it is the producer’s responsibility to ensure that all parts meet the requirements.

4.1.5 Responsibility for tests. Unless otherwise specified in the contract or purchase order, the contractor is responsible for performing FAT, control testing and inspections (examinations and tests) except for the ballistic testing which will be performed at TARDEC- Warren, RDTA-RS. Except as otherwise specified in the contract or purchase order, the contractor may use his own or any other facilities suitable (see 4.1 and 6.5) for the performance of the non-ballistic tests and inspections specified herein, unless disapproved by the Government.

The Government reserves the right to witness or perform any of the inspections or tests set forth in this specification where such inspections or tests are deemed necessary to ensure supplies and services conform to prescribed requirements.

4.1.6 Responsibility for compliance. All items shall meet all requirements of Sections 3 and 5. The inspection set forth in this specification shall become a part of the contractor’s overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of ensuring that all products or supplies submitted to the Government for acceptance also comply with all requirements of the contract. Sampling inspection, as part of manufacturing operations, is an acceptable practice to ascertain conformance to requirements, however, this does not authorize submission of known defective material, either indicated or actual, nor does it commit the Government to accept defective material.

4.2 Design. The TA shall be visually examined for compliance with the requirements for design and serviceability (see 3.2.2, 3.2.3, 3.2.4, and 3.2.7).

4.2.1 Construction and materials process changes. Following FAT approval, if any changes are made to the manufacturing process, place of manufacture, form, fit, supplier, source of materials, reliability, durability, performance, or components of the TA, the contractor shall notify the procuring activity. The items produced under the changed process may be subject to FAT. The contractor’s quality program must control the lots of interlayer materials used, and the program must provide assurance to the Government that as the lot changes, the interlayer materials are functionally the same or the Government may require FAT for the subsequently produced parts.

4.2.2 Reserved.

4.2.3 Allowable defects. Conformance to 3.2.7 shall be verified by visual inspection for the defects specified in table VII. Unless otherwise specified (see 6.2), minor imperfections that do not affect serviceability shall be permitted. Short interlayers no greater than 7 mm (approximately 0.25 in.) from the edge shall be permitted. For inspection purposes, the TA is divided into three zones or grading areas. Area A is the edge to be concealed at assembly by the frame or gasket and is zero unless specified by the procuring activity (see 6.2). Area B is the area within 50 mm of the concealed edges, and Area C is the remaining central area (see figure 1). Observation of defects exceeding what is allowable, as indicated in table VII, shall constitute failure.

FIGURE 1. Definition of TA areas.

TABLE VII. Maximum allowable defects.

Types of defects Maximum allowable (See Section 6 for definitions) Area C Area B

Delamination or bond separations Not allowed Not allowed Cracking, crazing, or clouding Not allowed Not allowed Gaseous inclusions .062 in. (1.6 mm) .093 in. (2.4 mm) Open gaseous inclusions .045 in. (1.2 mm) .062 in. (1.6 mm) Stones and knots .031 in. (0.8 mm) .045 in. (1.2 mm) Digs .062 in. (1.6 mm) .093 in. (2.4 mm) Inside dirt .093 in. (2.4 mm) .093 in. (2.4 mm) Ream and string Shall not be evident at an angle greater than 30° between line of sight and the glass surface, with indirect daylight.

Scratches and rubs Use ASTM F548 for plastics and ASTM F428 for glass.

Scratches meeting F428-level 6 are acceptable but level 7 are unacceptable. Scratches in Area B shall be less than 2 inches long. Scratches in Area C shall be less than 1 inch long. Scratches on the safe side are not permitted.

Crush Shall not be detectable at distances greater than 10 ft (3.0 m), with indirect daylight.

Lint and Hair Area C, lint and hair barely noticeable at 3 ft (0.9 m) looking through the glass at a patterned background with indirect daylight. Area B, lint and hair may be noticeable under same conditions. Reference ASTM C1172

Insects or other organic matter Shall not be detectable at distances greater than 3 ft (0.9 m) looking through and perpendicular to the glass, with indirect daylight.

Surface defects Shall not be detectable at distances greater than 10 ft (3.0 m).

Interlayer striae Shall not be detectable at distances greater than 10 ft (3.0 m) looking perpendicular to the glass, with indirect daylight.

Cracks No cracks shall be allowed in area A, B, or C.

Note 1: Defects or imperfections not specifically mentioned shall be compared to the imperfection they most closely resemble. Imperfection(s) include any related distortion to the area surrounding the imperfection.

Note 2: Areas of concentrated imperfections shall be no larger or more detectable than individual imperfections.

Note 3: Windows shall be examined while in the vertical position looking from the safe side through to the strike face (as viewed from the inside of the vehicle) in front of a patterned background where the light measured at the strike face shall be 160 foot candles (per ASTM C1036). The window shall be evaluated at a distance of 3 feet, perpendicular to the surface for 10 seconds. It is important that the observer look at the background rather than looking at the window surface.

4.2.4 Marking. Conformance to 3.2.8 shall be verified by visual examination.

Observation of marking that does not include all required information, is not permanent or that is not readable from the exterior of the vehicle shall constitute failure.

4.2.5 Tolerance. Verify that the TA meets the part drawing dimensional requirements.

4.2.6 De-icing. To determine conformance to 3.2.6, the TA shall be subjected to the following conditions:

a. The TA shall be placed in a temperature chamber and conditioned at a temperature of -25±4 °C for a minimum period of 12 hours.

b. A coating of ice shall be formed on the threat surface of the windshield(s) as follows:

The windshield(s) shall be sprayed with 0.05 mL of water per square centimeter of threat surface area applied by means of a spray gun with 345±35 kPa (50±5 psi) air pressure at the device, measured while spraying to form an even coating of ice over the entire glass surface. The spray nozzle (adjusted to full fan pattern and maximum flow) is held perpendicular to and 200 to 250 mm from the strike face, and stroked back and forth evenly in horizontal overlapping layers until the specified quantity of water is applied. Upon completion of the icing process, wait 25±5 minutes before the start of the de-icing test. The windshield(s) shall remain in the temperature chamber at -25±4 °C until the test is completed.

c. With the coupon or part vertical, apply 26±1 V DC for 60 minutes (steady state voltage limit per MIL-STD-1275) to the de-icing element. An ice removal tool may be used on the exterior face of the TA to remove ice that is floating (not frozen) onto the glass surface. The tool may not be used to chisel ice still frozen to the exterior surface to meet this requirement.

d. At the end of the 60 minute test period the de-iced pattern is photographed, the TA gently wiped with a cotton rag, and the TA photographed. The clear de-iced area must be no less than 80% of Area C (see 3.2.6).

e. The windshield(s) shall then be returned to standard ambient temperature and visually inspected for conformance to the allowable defects requirements of 3.2.7 and the optical requirements of 3.4.

4.3 Environmental conditions. The environmental capabilities of the TA shall be verified through analysis and testing for discrete environments.

4.3.1 Temperature Extremes.

4.3.1.1 Low temperature. The TA shall be placed in a temperature chamber and subjected to the conditions adapted from MIL-STD-810 Method 502, Procedure I (Storage). A temperature of -54±4 °C shall be maintained for a period of 24 hours. The TA shall be returned to standard ambient temperature at the conclusion of this period. The TA shall then be inspected for conformance to the allowable defects requirements of 3.2.7 and the optical requirements of 3.4.

4.3.1.2 High temperature. The TA shall be subjected to the conditions adapted from MIL-STD-810 Method 501, Procedure I (Storage), climatic category A2 (Basic Hot) Induced.

Three cycles of the profile in table VIII shall be used. The suggested temperature and relative humidity variability are ±2 °C and ±5%, respectively. At the conclusion of three test cycles, the TA shall be returned to standard ambient temperature and visually inspected for moisture buildup. The TA shall be inspected for conformance to the allowable defects requirements of

3.2.7 and the optical requirements of 3.4.

TABLE VIII. High temperature test profile.

Time Temperature Relative Humidity Time Temperature Relative

Humidity Hours °C % Hours °C % 0100 33 36 1300 61 6 0200 32 38 1400 63 5 0300 32 41 1500 63 5 0400 31 44 1600 62 6 0500 30 44 1700 60 6 0600 31 43 1800 57 6 0700 34 32 1900 50 10 0800 38 30 2000 44 14 0900 42 23 2100 38 19 1000 45 17 2200 35 25 1100 51 14 2300 34 28 1200 57 8 2400 33 33

4.3.2 Humidity. To determine conformance to 3.3.2, the TA shall be exposed to five modified cycles of the profile of MIL-STD-810 Method 507, Procedure II (Aggravated). The profile for the modified cycle is given in table IX. The TA shall then be allowed to return to standard ambient conditions and shall be visually inspected for moisture buildup. The TA shall be inspected for conformance to the allowable defects requirements of 3.2.7 and the optical requirements of 3.4.

TABLE IX. Humidity test profile.

Time Temperature Relative

Humidity Hours °C %

0 30 95 2 60 95 32 60 95 40 30 95 48 30 95

4.3.3 Reserved.

4.3.4 Temperature shock. Conformance to 3.3.4 shall be verified by subjecting TA to the testing described in MIL-STD-810 Method 503, Procedure I-C (Multi-cycle shocks from constant extreme temperature). The temperature extremes used for the test shall be -30±3 °C and 60±3 °C, and the minimum temperature stabilization period shall be 18 hours at each temperature extreme. The test cycle shall begin at either temperature extreme, and the transfer time between temperature conditions shall be no longer than 5 minutes. The TA shall be subjected to five thermal cycles. After completion of the temperature shock test, nonconformance with the optical requirements of 3.4 or the allowable defects requirements of

3.2.7 as a result of the test shall constitute failure.

4.3.5 Sun exposure weathering. Conformance to 3.3.5 shall be verified by conducting sun exposure testing on TA in one of the following conditions:

a. 3 pieces of TA in the form of actual production parts (see 6.2)

b. 3 sets of each combination of bonded pair and adhesive or full thickness test coupon laminations of 100±5 mm x 100±5 mm. All materials and substrate-adhesive combinations used in the TA recipe shall be tested (to include all adhesive materials and, if part of the deliverable requirements, the de-icing element). Edge treatment or sealing to be used on the production parts is suggested but not required.

Transparent armor production parts or sample coupons shall be exposed to an irradiance level of 1120 W/m2 in accordance with MIL-STD-810 Method 505, Procedure II (Steady State (actinic effects)) for fifty-six (56) 24-hour cycles. Irradiance shall be normal to the strike face of the TA.

Airflow shall be applied as described in the test procedure to maintain the thermal response or peak response temperature that would be attained under natural conditions. After exposure, nonconformance to the allowable defects requirements of 3.2.7 or nonconformance with the optical requirements of 3.4.1, 3.4.1.1, and 3.4.2 shall constitute failure. Luminous transmittance shall be determined before and after testing. In the event that the acquisition activity waives the requirement for the sun exposure testing, then the contractor shall certify that no material that degrades when subjected to solar exposure for a minimum period of five years was used for this production lot.

4.3.6 Abrasion resistance.

4.3.6.1 Threat surface abrasion resistance. Three sample coupons of the threat surface material shall be tested in accordance with the safety glazing material abrasion resistance test (Test 18) of ANSI/SAE Z26.1. Noncompliance with the light scattering requirement stated in the ANSI/SAE Z26.1 test procedure after test completion shall constitute failure.

4.3.6.2 Interior surface abrasion resistance. Three sample coupons of the interior or spall liner surface material shall be tested in accordance with the plastics abrasion resistance test (Test 17) of ANSI/SAE Z26.1, including the modified procedure for Item 4A rigid plastics.

Noncompliance with the light scattering requirements stated in ANSI/SAE Z26.1 test procedure for Item 4A rigid plastics after test completion shall constitute failure.

4.3.7 Exposure to chemicals.

4.3.7.1 Cleaning spray. To determine conformance to 3.3.7.1, the portion of the TA assembly within the sealing surface (see figure 1) shall be exposed to a water jet or steam spray using agents conforming to A-A-59133. The jet shall be applied perpendicular to the TA at a distance no less than 1 ft (0.305 m) or farther than 2 ft (0.610 m) from the TA surface at a cleaning rate of 1 ft²/min (0.0929 m²/min) for a period of 10 minutes. The water jet shall be derived from a nozzle having an orifice diameter of 0.25 inch (6.35mm) and a nozzle pressure of 110 lb/in² gage (about 760 kPa). After the TA has been water rinsed and air dried, nonconformance to the optical requirements of 3.4 or debonding of the seal due to the tests of

4.3.7 shall constitute failure.

4.3.7.2 Inner surface exposure to chemicals. To determine conformance to 3.3.7.2, expose the assembly to the chemicals specified in table I in accordance with the chemical resistance (nonstressed) test (Test 19) of ANSI/SAE Z26.1 except for the requirement to immerse the specimen. The chemical shall be applied with a soft, 13 mm wide brush, wet brush before each stroke. Coat the entire surface for a period of one minute. The edges of the specimen may be wiped after the chemical has been applied to the surface. The chemical shall remain on the specimen for one hour; reapply if necessary to keep the surface wetted. After the one hour exposure, wipe with absorbent cotton. After exposure, nonconformance to the allowable defects requirements of 3.2.7, nonconformance to the optical requirements of 3.4, or debonding of the seal due to the tests of 4.3.7 shall constitute failure.

4.3.7.3 Outer surface exposure to chemicals. To determine conformance to 3.3.7.3, expose the assembly to the vapors (volatile chemicals) of or in direct contact (non-volatile chemicals) with the chemicals specified in table II for a minimum period of 48 hours. Testing shall be done at a temperature between 22 °C and 24 °C and at 50±2% relative humidity. After exposure, nonconformance to the allowable defects requirements of 3.2.7, nonconformance to the optical requirements of 3.4, or debonding of the seal due to the tests of 4.3.7 shall constitute failure.

4.4 Optical.

4.4.1 Luminous transmittance. Conformance to 3.4.1 shall be verified by determining luminous (photopic) transmittance in accordance with MIL-DTL-62420. Spectral transmittance shall be measured at wavelength intervals of 10 nm or less over the 380 to 930 nm band at normal incidence. Luminous visible light transmittance corresponding to daylight vision is determined by integration of individual photopic transmission values in the 380 to 760 nm range, as discussed in MIL-DTL-62420. To aid in these calculations, the relative spectral irradiance (spectral power distribution) of CIE Standard Illuminant A is tabulated in table X for the range necessary for photopic calculations. Integrated luminous (photopic) transmittance values lower than the levels specified in 3.4.1 for each protection class shall constitute failure.

TABLE X. Relative spectral irradiance (spectral power distribution) of CIE Standard Illuminant A.1

Wavelength (nm)

CIE

Illuminant A Relative SPD

Wavelength (nm)

CIE

Illuminant A Relative SPD

Wavelength (nm)

CIE

Illuminant A Relative SPD

380 9.795 570 107.184 760 232.115 390 12.085 580 114.436 770 237.008 400 14.708 590 121.731 780 241.675 410 17.675 600 129.043 790 246.116 420 20.995 610 136.346 800 250.329 430 24.671 620 143.618 810 254.314 440 28.703 630 150.836 820 258.071 450 33.086 640 157.979 830 261.602 460 37.812 650 165.028 840 264.909 470 42.869 660 171.963 850 267.994 480 48.242 670 178.769 860…