QAP_11580542E.pdf

QUALITY ASSURANCE PROVISION REVISION STATUS

QAP & DRAWING NUMBER: 11580542 ERR No. QAP Date Rev. DWG Date DWG Rev.

FOR: Forging, Rotary Forge Preform 59255 950130 ORIG 921120 X0 END ITEM: Cannon, 105mm Gun:

M68A2

L1Q1032 011231 D 951201 NEW

DRAWING CAGE CODE: 19206 L08T1009 090923 E 090923 A

IF THERE IS A CONFLICT BETWEEN THE QAP AND THE DRAWING, THE DRAWING TAKES PRECEDENCE

TACOM – ARDEC – QUALITY ENGINEERING & SYSTEMS ASSURANCE

BENET LABORATORIES SUPPORT, WATERVLIET, NY 12189-4000

PREPARED BY CAGE CODE: 1NUW7

SUBMITTED BY: JEFFREY PAINE

APPROVED BY: ERIC SWORD SHEET: 1 of 6

AMSRD-AAR-QEW-B Form 317-E, 2 September 2007

DISTRIBUTION STATEMENT A: UNLIMITED

PART I – LIST OF APPLICABLE DOCUMENTS

NUMBER NOMENCLATURE

QAP-APPENDIX-WVA General Requirements for Quality Assurance Provisions

REFERENCED SPECIFICATIONS & STANDARDS

ASTM A 381 Standard Specification for Metal-Arc-Welded Steel Pipe for Use with High- Pressure Transmission Systems

ASTM A 388/A 388M Standard Practice for Ultrasonic Examination of Heavy Steel Forgings ASTM A 751 Standard Test Methods, Practices, and Terminology for Chemical Analysis of

Steel Products ASTM E 8/E 8M Standard Test Methods for Tension Testing of Metallic Materials ASTM E 23 Standard Test Methods For Notched Bar Impact Testing Of Metallic Materials ASTM E 2375 Standard Practice for Ultrasonic Testing of Wrought Products MIL-DTL-13931 Cannon: General Specification for NAS 410 Certification & Qualification of Nondestructive Test Personnel NCSL Z540.3 Requirements for the Calibration of Measuring and Test Equipment

PART II – QUALITY PROVISIONS

NUMBER NOMENCLATURE

1 The contract requirements and inspection provisions contained in QAP-APPENDIX-WVA form part of this QAP.

2 Quality conformance inspection shall consist of inspection of all contract quality requirements in accordance with QAP-APPENDIX-WVA and this QAP.

3 FIRST ARTICLE INSPECTION: When specified in the contract, the First Article Inspection shall be conducted in accordance with QAP-APPENDIX-WVA and STM-1.

Inspection equipment used shall be capable of repeatable measurements by various experienced inspection/test personnel, to an accuracy of 10% of the total tolerance of the characteristic being inspected. In the event the contractor desires relief from this requirement, a technically supported request for relief or waiver shall be submitted to the procuring activity.

Where SMTE is specified, the manufacturer can use any inspection method that meets the accuracy requirement above. In addition, when approved by the procuring activity, the characteristic can be inspected using a qualified tool (tool control) in lieu of inspecting the characteristic. The inspection results for the qualified tool shall be provided to the procuring activity upon request. Functional gages may be used when approved by the government.

FOR: Forging, Rotary Forge Preform 59255 950130 ORIG 921120 X0 END ITEM: Cannon, 105mm Gun:

M68A2

L1Q1032 011231 D 951201 NEW

APPROVED BY: ERIC SWORD SHEET: 2 of 6

AMSRD-AAR-QEW-B Form 317-E, 2 September 2007

DISTRIBUTION STATEMENT A: UNLIMITED

6 When characteristics are inspected using approved functional gages, the inspection shall be performed at sampling frequency A and attribute data is authorized. If the specified gages are not used, variable data shall be required and the sampling rate shall be as specified for each characteristic. Characteristics with a sampling frequency of C shall be considered Minor characteristics if functional gages are not used.

7 All inspection and test equipment shall be calibrated in accordance with the requirements of NCSL Z540.3. Proof of calibration shall be provided upon demand.

8 MATERIAL CAPABILITY DEMONSTRATION. This demonstration shall be performed by the contractor and is required to ensure that the material quality is adequate to provide successful further processing and testing. The contractor must complete the demonstration for each heat utilizing at least one prolongation forging. The number of sample forgings and their ingot locations shall be based upon the heat size using STP-1 of this QAP. The requirements for these demonstrations are divided into two areas: macroetch examination and mechanical property testing The failure of any one of these areas shall result in the rejection of the whole heat or the rejection of all heats when reduced sampling is in effect. Failure is defined as one or more of the prolongation results not meeting the drawing/contractual requirements after initial processing in accordance with the drawing. Reprocessing and/or retesting of the prolongation, for any reason, may be performed only after permission has been granted by the PCO where the contractor has provided written details and corrective action of the failure.

PART III – INSPECTION REQUIREMENTS

SAMPLE SIZE FOR PRODUCTION SHALL BE AS LISTED IN THE FREQUENCY TABLE,

ACCEPT ON ZERO DEFECTS

NUMBER OF PARTS IN

LOT

NUMBER OF PARTS

TESTED FOR SAMPLE

FREQUENCY A

NUMBER OF PARTS

TESTED FOR SAMPLE

FREQUENCY B

NUMBER OF PARTS

TESTED FOR SAMPLE

FREQUENCY C

Up to 8 ALL ALL 5 9 to15 ALL 13 5

16 to 25 ALL 13 5 26 to 50 ALL 13 7 51 to 90 ALL 13 11

91 to 150 ALL 13 11 151 to 280 ALL 29 13 281 – Over ALL 8% 4%

FOR: Forging, Rotary Forge Preform 59255 950130 ORIG 921120 X0 END ITEM: Cannon, 105mm Gun:

M68A2

L1Q1032 011231 D 951201 NEW

APPROVED BY: ERIC SWORD SHEET: 3 of 6

AMSRD-AAR-QEW-B Form 317-E, 2 September 2007

DISTRIBUTION STATEMENT A: UNLIMITED

SHEET 1 OF DRAWING

MAJOR, Type 1

All major type 1 characteristics are sampled at sampling rate A or B. Variable data required. SMTE can be used.

NUMBER CHARACTERISTICS LOCATION SAMPLE

FREQUENCY

INSPECTION

METHOD

101 Wall Thickness Variation .15

MAX

NOTE 4 A SMTE

102 127.30 MIN

F-7 A SMTE

SHEET 1 OF DRAWING

MAJOR, Type 2

All major type 2 characteristics are sampled at sampling rate A or B. Variable or attribute data is authorized.

SMTE can be used.

NUMBER CHARACTERISTICS LOCATION SAMPLE

FREQUENCY

103 Ultrasonic Inspection NOTE 3A A ASTM A 388/A 388M

104 Macroetch, Top End of Preform

NOTE 3B A ASTM A 381

105 Macroetch, Bottom End of Preform

NOTE 3B A ASTM A 381

106 Workmanship IAW MIL-DTL- 13931

ALL A Visual

Marking (Complete & Legible) NOTE 6 A SMTE

SHEET 1 OF DRAWING

OPTIONAL PROLONGATION METHOD

(ONE PER HEAT)

MAJOR, Type 1

All major type 1 characteristics are sampled at sampling rate A or B. Variable data required. SMTE can be used.

NUMBER CHARACTERISTICS LOCATION SAMPLE

FREQUENCY

108 8.00 MIN

G-4 A SMTE

109 11.00 MIN

G-3 A SMTE

FOR: Forging, Rotary Forge Preform 59255 950130 ORIG 921120 X0 END ITEM: Cannon, 105mm Gun:

M68A2

L1Q1032 011231 D 951201 NEW

APPROVED BY: ERIC SWORD SHEET: 4 of 6

AMSRD-AAR-QEW-B Form 317-E, 2 September 2007

DISTRIBUTION STATEMENT A: UNLIMITED

NUMBER CHARACTERISTICS LOCATION SAMPLE

FREQUENCY

110 1.00 MIN

F-3 A SMTE

111 2.00 MIN

F-3 A SMTE

112 9.00 MAX

F-2 A SMTE

113 Yield Strength (.1% Offset):

162,000 to 180,000, Specimen 1

NOTE 5C A ASTM E 8/E 8M

114 Reduction in Area: 30% MIN, 115 Charpy Impact Resistance:

18 ft-lbs MIN @ 40F ± 2F, NOTE 5C A ASTM E 23

116 Yield Strength (.1% Offset):

162,000 to 180,000, Specimen 2

117 Reduction in Area: 30% MIN, 118 Charpy Impact Resistance:

18 ft-lbs MIN @ 40F ± 2F, NOTE 5C A ASTM E 23

ALL SHEETS OF DRAWING

MINOR

NUMBER CHARACTERISTICS LOCATION SAMPLING FREQUENCY

299 Unless otherwise specified in this

QAP or in the contract, all drawing requirements (Including Applicable Drawing Notes) not elsewhere listed in Part III of this QAP are classified as

MINOR.

ALL These characteristics accepted based on results of a 1st piece check performed within the last six months. Any characteristic found to be out of tolerance during the 1st piece check shall be inspected at sampling level C

FOR: Forging, Rotary Forge Preform 59255 950130 ORIG 921120 X0 END ITEM: Cannon, 105mm Gun:

M68A2

L1Q1032 011231 D 951201 NEW

APPROVED BY: ERIC SWORD SHEET: 5 of 6

AMSRD-AAR-QEW-B Form 317-E, 2 September 2007

DISTRIBUTION STATEMENT A: UNLIMITED

PART IV – CERTIFICATIONS

Number CERTIFICATION (Documentation Must Be Provided)

Gage Accuracy: Certificate that all gages used shall meet the requirements of Quality Provision 4 of this

QAP.

1ST Piece Check Inspection Results:

Date of inspection – Must be within the previous 6 months

List of all MINOR characteristic that were found to be out of tolerance.

303 Preform to be produced by forging process (1.5:1 area reduction, MINIMUM)

304 Material Vacuum degassing of each heat required.

Chemical composition shall meet the requirements of NOTE 2.

The percentage of the alloying elements, listed in NOTE 2, shall be shown.

305 Ultrasonic Inspection:

Personnel qualifications IAW NAS 410, level 2 or 3 Procedure IAW ASTM A 388/A 388M Acceptance requirements IAW ASTM E 2375, Class A

PART V – TEST METHODS AND PROCEDURES

NUMBER

TITLE DETAILS

STM-1 First Article Requirements Two ROTARY FORGE PREFORM FORGINGS, 11580542,, shall be furnished for 100% inspection of all requirements, to assure compliance with QAP(s), specification(s), drawing(s), and the contract.

FOR: Forging, Rotary Forge Preform 59255 950130 ORIG 921120 X0 END ITEM: Cannon, 105mm Gun:

M68A2

L1Q1032 011231 D 951201 NEW

APPROVED BY: ERIC SWORD SHEET: 6 of 6

AMSRD-AAR-QEW-B Form 317-E, 2 September 2007

DISTRIBUTION STATEMENT A: UNLIMITED

STP-1 Material Capability Testing

One perform per heat shall be produced with the prolongation shown in the :OPTIONAL PROLONGATION METHOD” OF 11580542.

Remove the prolongation and heat treat as follows:

Austenitize at 1550F ± 25F for one hour MIN at temperature

Quench in water to less than 150F

Temper at 1000F to 1200F for two hours MIN at temperature.

Quench in water

Manufacture and test two transverse tensile specimens per ASTM E 8/E 8M and two Charpy V-Notch specimens per ASTM E 23.