WS 33077revC (Head Cap) Edited for Machining (003).pdf

INCH-POUN D

DTL WS 33077C

29 September 2004 Superseding

WS 33077B

1 July 1998

DETAIL SPECIFICATION

ITEM SPECIFICATION FOR THE

CAP, HEAD, FOR MK 22 MOD 4 ROCKET MOTOR

Prepared by:

Indian Head Division

Naval Surface Warfare Center

101 Strauss Avenue

Indian Head, MD 20640-5035

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

CAGE CODE 53711

DTL WS 33077C

29 September 2004

SUPERSEDING

WS 33077B

1 JULY 1998

NAVAL SEA SYSTEMS COMMAND

DEPARTMENT OF THE NAVY

ITEM SPECIFICATION FOR THE

CAP, HEAD, For MK 22 MOD 4 ROCKET MOTOR

1. SCOPE

1.1 Scope. This specification establishes the manufacture, acceptance, design, and test requirements for the MK 22 MOD 4 Rocket Motor 17-4 PH Stainless Steel, H 1100, by machined billet Head Cap, herein referred to as the head cap. The head cap is a sub-component of the MK 22 MOD 4 Rocket Motor Assembly. Figure 1 is an illustration of the head cap assembled on the MK 22 MOD 4 Rocket Motor Assembly.

FIGURE 1. Head Cap employed on the MK 22 MOD 4 Rocket Motor assembly.

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. Not applicable.

WS 33077 REV C

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

DRAWINGS

INDIAN HEAD DIVISION, NAVAL SURFACE WARFARE CENTER (CAGE Code 14083)

525-174-0130 Head Cap

(Application for copies of NSWCIHD drawings should be addressed to: Commander, Indian Head Division (Code 4230), Naval Surface Warfare Center, 101 Strauss Avenue, Indian Head, MD 20640-5035.)

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.

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A

370 ASTM

A488/488M

ASTM

A967

ASTM E

1444 ASTM E

Mechanical Testing of Steel Products

Standard Practice for Steel Castings, Welding, Qualifications of Procedures and Personnel

Chemical Passivation Treatments for Stainless Steel Parts

Standard Practice for Magnetic Particle Examination

Standard Practice for Radiographic Examination

(Copies of this document are available online at http://www.astm.org the American Society for Testing and Materials Customer Service, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.)

AEROSPAICE MATERIAL SPECIFICATIONS (AMS)

AMS 2750 Pyrometry

AMS 5355 Steel, Corrosion Resistant, Investment Castings, 16Cr -4.1 Ni - 0.28Cb -

3.2 Cu Homogenization and Solution Heat Treated or Homogenization, Solution, and Precipitation Heat Treated (UNS J92200)

(Application for copies should be addressed to SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001.)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 9000 Series Quality Management and Quality Assurance Standards

(Unless otherwise indicated, copies of the ISO 9000 series are available from: Standardization Documents Order Desk, Bldg. 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094.)

AEROSPACE INDUSTRIES ASSOCIATION OF AMERICA, INC.

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NAS 410 NAS Certification and Qualification of Nondestructive Test Personnel

(Application for copies should be addressed to the Aerospace Industries Association of America, Inc., 1250 I Street, N.W., Suite 1100, Washington, D.C. 20005-3924.)

AMERICAN SOCIETY FOR QUALITY

ANSI/ASQ Zl.4 Sampling Procedures and Tables for Inspection by Attributes

(Application for copies should be addressed to the American Society for Quality, P.O. Box 3005, 611 East Wisconsin Ave., Milwaukee, WI 53201-3005.)

2.4 Order of precedence. 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 First article. Unless otherwise specified in the contract or order (see 6.2), a first article sample shall be subjected to first article inspection in accordance with 4.2. The first article units shall be fabricated from components, material, and processes identical to production units and produced as a master heat (see 3.2.4).

3.2 Design and construction. The head cap shall be a precipitation (H1100) heat treated 17-4 PH stainless steel machined from a solid billet. Solid round bar stock shall be ordered in condition A 17-4 stainless steel.

3.2.2 Condition. The condition of the head cap shall be homogenization, solution, precipitation (H1100) heat treated in accordance with AMS 5355 at the temperature and time durations of table I.

TABLE I. Heat treatment process.

Heat Treatment Temperature Duration (Minimum)

Homogenization 2100 ± 25°F 3 Hours Cool Below 70°F

Solution 1900 ± 25° F 2 Hours Cool below 70°F

Precipitation 1100 ± 10°F 1.5 Hours Cool below 70°F

3.2.3 Head cap castings. Head cap casts shall be poured in accordance with AMS 5355.

3.2.4 Master heat. Master heats and furnace batches shall conform to AMS 5355. Each master heat shall be qualified in accordance with AMS 5355, except that tensile specimens shall conform to the requirements of 3.2.4.2.

3.2.4.1 Chemical analysis specimens. Chemical analysis specimens shall conform to AMS 5355.

3.2.4.2 Tensile specimens. Tensile specimens shall be machined from head caps which have undergone homogenization, solution, and precipitation heat treatment in accordance with 3.2.5. The tensile specimens shall be machined from the location shown in figure 2. The tensile specimens shall have a round 0. 250" diameter x 1" long gage section and conform to figure 3.

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FIGURE 2. Illustration of the head cap section from which tensile specimens shall be machined.

3.2.5 Heat treatment. All head caps shall undergo the heat treatment after machining in accordance with AMS 5355 at the time and temperature durations specified in table I. The contractor shall furnish to the Government, temperature-time survey charts of each heat treatment. Head caps shall not be quenched. The heating and cooling atmosphere employed in the heat treatment process shall be argon gas, helium gas, or a vacuum. The contractor may submit a head cap or master heat to more than one complete heat treatment process. A complete heat treatment process consists of three phases; homogenization, solution, precipitation heat treatment in accordance with AMS 5355 and the conditions of this specification. The time and temperature records shall be submitted for each heat treatment process a master heat or head cap undergoes. A time and temperature record shall provide the duration and temperatures a head cap or master heat spends at each phase of the heat treatment process. The time and temperature records shall be serialized sequentially to provide traceability to its related heat treatment process and master heat. In the event the heat treatment process specified by this specification is violated, the head cap or master heat shall be resubmitted through a complete heat treatment process by the contractor. At completion of the heat treatment process each head cap shall be inspected for a minimum hardness of 32 HRc. Figure 4 shows the location where the hardness reading shall be taken.

1. A gradual taper shall be machined into the 1.25 length starting from each end and meeting in the middle.

Maximum taper at center shall be 0.001 inch.

2. Specimen shall not contain any visual defects, such as: shrinkage, voids, or machining nicks

3. All dimensions are in inches. Drawing is not to scale.

FIGURE 3. Tensile specimen dimensions.

FIGURE 4. Illustration of location where head cap hardness readings shall be taken.

3.2.5.1 Manufacturing scheme. The contractor shall establish a manufacturing scheme of processes he will use to fabricate head caps. The Government shall review the scheme and its processes prior to full scale production. All First Article hardware and subsequent production head caps will be manufactured to this process. Once First Article testing is complete and accepted by the Government, no changes to the manufacturing process will be allowed without the Government's notification. Once the Government has been notified, the Government will review these changes to determine whether additional First Article Tests (FATs) are required. The manufacturing scheme shall be available to the Government upon request. The contractor shall not provide the Government head caps produced from manufacturing schemes or processes that have not been validated through First Article Testing. At a minimum, the manufacturing scheme shall specify head cap manufacturing processes in chronological order with the following control factors:

a. Type of batch furnace and its capacity

b. Type and size of furnace charge

c. Time molten metal is in furnace

d. Furnace atmosphere

e. Fluxing or deoxidization procedure

f. Number of ladles used in pour

g. Mold refractory formulation

h. Mold back-up material

i. Heat treatment furnace(s) and its capacity

j. Mold preheat and metal pouring temperatures. Variations of ± 25°F (± 14°C) from established limits are permissible.

k. Solidification and cooling procedures

l. Homogenization, solution, and precipitation heat treatment procedures

m. Furnace heating and cooling medium

n. Furnace construction, controls, and head cap arrangement that shall ensure temperature uniformity

o. Recording and sensing instruments which shall assure a consistent heating and cooling atmosphere paul.vansant Highlight paul.vansant Highlight paul.vansant Highlight paul.vansant Highlight paul.vansant Highlight paul.vansant Highlight paul.vansant Highlight paul.vansant Highlight

p. Rate of heating or cooling, as applicable, for each thermal treatment

q. Furnace calibration and temperature survey data as specified by AMS 2750

r. Cleaning operations

s. Methods of inspection

t. Certification and qualification of non-destructive test facilities and personnel in accordance with

NAS 410.

3.2.5.2 Furnace survey, calibration, and tests. Furnace surveys and calibration of temperature controllers and recorders shall be in accordance with AMS 2750 and appendix thereto. Pyrometric equipment shall be calibrated and heat treating equipment shall be tested in accordance with AMS 2750 and appendix thereto.

3.2.5.3 Control records. Records of system accuracy tests, furnace temperature surveys, calibration of control and recording instruments, types of furnace atmospheres, thermal processing control employed, data, time, temperature, and quenchant used in heat treating head cap shall be on file and available for review by contractors and Government representatives for five (5) years. In addition, heat treaters of final parts shall keep furnace recorder charts for five (5) years.

3.2.5.4 Marking. All head caps shall be serialized and shall be continually sequential throughout production. The contractor shall etch or steel stamp the serial number onto the head cap at the location specified by Note 9 of Drawing 525-174-0130. Head cap serialization shall start with the first article head caps. The serial number shall contain the following information: last four digits of the contract number, serial number of the casting billet starting with number one, and heat treat lot number. The heat treat lot number shall be traceable to the heat treat certification. The head cap serial number shall appear as follows (example):

Contract number Billet Casting serial number Heat treat lot number

0199 0234 HT045

3.2.6 Head cap casting soundness. Magnetic particle inspection shall be performed on final machined head caps in accordance with ASTM E1444. Surface and subsurface regions shall meet the quality of 3.2.6.1. In addition to the requirements of 3.2.6.1, the machined surface quality shall be such that it shall not have cracks, voids, pits, or scratches and shall meet the surface finish requirements of Drawing 525174-0130. NOTE: Acceptable x-ray discontinuities, if machined into, could result in rejectable surface discontinuities.

3.2.6.1 Surface and subsurface quality. Head cap surfaces shall not have material discontinuities greater than the severity levels allowed by table II.

TABLE II. Maximum allowable discontinuity sizes (in inches) and distribution.

Type of Discontinuity Grade A Size Distribution1

Nonmetallic inclusion, rounded:

Surface 0.031 dia. D-3 Subsurface2 0.047 dia. D-3

Gas hole porosity/discrete shrinkage cavities/shrinkage sponge areas:3

Surface 0.031 dia. D-3 Subsurface2 0.047 dia. D-3

Cracks, hot tears, or cold shuts 0

Microshrinkage (microporosity), maximum cluster diameter4 0.063 D-3 Alloy or metallic phase segregation:

Surface 0.125 Subsurface 0.250 paul.vansant Highlight paul.vansant Highlight paul.vansant Highlight paul.vansant Highlight

1 Distribution designations signify the following:

D-2 Discontinuities no closer to each other than two times the maximum size.

D-3 Discontinuities no closer to each other than three times the maximum size.

2 Magnetic particle inspection only.

3 The limits for gas hole porosity for the individual grades do not apply if the voids are less than one half the maximum sizes specified and are well dispersed.

4 Shrinkage discontinuities are not allowed if within 0.5 inch of an outer edge of a casting section.

3.2.6.2 Radiographic characteristics. Radiographic inspection shall be performed on as-cast head caps. Gates, sprues, and risers shall be removed prior to radiographic inspection. Radiographic inspections shall confirm the requirements of 3.2.6.2. Head caps shall not have material discontinuities in excess of the severity levels allowed by table III.

TABLE III. Maximum permissible radiographic severity level for discontinuities in steel castings up to 2 inches (51mm) in thickness per ASTM E446.

Code or Category Discontinuities Grade B Grade C

A Gas porosity 1 2 B Sand spots and inclusions 1 2

CA Shrinkage 1 2 CB Shrinkage 1 2 CC Shrinkage 1 2 CD Shrinkage 1 2 D Crack None None E Hot tear None None F Insert None 1 G Mottling Not to exceed contract or drawing requirements

Not to exceed contract or drawing requirements

Notes for table III:

1. An area of like size to the reference radiograph shall be the unit area by which the production radiograph is evaluated. If the production radiograph shows a discontinuity that is equal to or better than the severity level of the reference radiograph, the casting shall be acceptable. If the production radiograph shows a discontinuity of greater severity than the reference radiograph, the casting shall be rejected.

2. When two or more types of discontinuities are present (in an area equal to the reference radiographic plate area) to an extent equal to the maximum permissible severity level for each type, the casting shall be rejected.

3. Numbers in the table are ASTM radiographic plate numbers for a particular type and severity of discontinuity. A low number indicates fewer, smaller discontinuities while a higher number indicates more numerous, larger discontinuities.

4. The smallest resolvable indication size, below which indications are considered non-interpretable, shall be

0.015 inch.

5. Gas holes, sand spots, and inclusions allowed by this table (even those smaller than the maximum allowable size) shall be cause for rejection when closer than twice their maximum dimension to an edge.

Exceptions to this note based on the class and grade of the casting are shown below: 1/ paul.vansant Highlight paul.vansant Highlight paul.vansant Highlight paul.vansant Highlight

Class 1 – No exceptions from note 5.

Class 2 – No exceptions from note 5 for Grade A and Grade B areas, or other areas that are specified critical or highly stressed. Otherwise, the note 5 discontinuities are acceptable if they are separated from the edge by a distance equal to or greater than the discontinuity’s maximum dimension.

Class 3 – Gas holes, sand spots, and inclusions, of the maximum size allowed by the table, shall be cause for rejection if they are closer than one diameter of their maximum dimension to an edge. This does not apply to gas holes, sand spots, and inclusions smaller than the maximum allowable size.

Class 4 – Edge of part discontinuities are acceptable if they are not crack-like, linear, or round with protruding linear indications.

1/ The term ‘edge’ refers to the outer boundary of the radiographic image of the casting. This interpretation need only be made in the standard exposures (views) defined by the approved radiographic technique.

Additional radiographic exposures, to determine the distance from the surface of each gas hole, sand spot, or inclusion in other orientations, are not required.

3.2.7 Weld repair. Weld repair, if performed, shall be in accordance with ASTM A488/A488M. After weld repair, a head cap shall undergo a full heat treatment cycle (homogenization, solution treatment, and precipitation hardening) in accordance with 3.2.5. The weld repair shall not have discontinuities in excess of table IV. All head caps shall be x-rayed after weld repair and heat treatment.

TABLE IV. Maximum allowable weldment discontinuity sizes (in inches) and distributions.

Type Of Discontinuity Grade A Size Distribution1

Cracks, weld, or base metal (longitudinal, transverse, star or crater, underbead, underside, etc.) 0

Weld undercutting or lack of bead-edge fusion: D-5 Base metal less than 0.188 inch thick 0.016 deep

0.125 long Base metal 0. 188 inch thick and over 0.031 deep

0.125 long Weld metal voids or inclusions, rounded:

Base metal less than 0. 188 inch thick 0.016 dia. D-5 Base metal 0. 188 inch thick and over 0.031 dia. D-5 Weld metal voids or inclusions, elongated:

Base metal less than 0. 188 inch thick 0.063 long D-5 Base metal 0. 188 inch thick and over 0.125 long D-5

1 The distribution designation, D-5, signifies that discontinuities are to be no closer than 5 times the maximum size.

3.2.8 Passivation. All final machined head caps shall be passivated in accordance with ASTM A967 except that salt spray and copper sulfate tests shall not be employed.

3.2.9 Metallurgy. All head caps shall possess the minimum material properties specified in table V. Tensile and hardness tests of 4.3.2.4 through 4.3.2.4.2 shall confirm this requirement. Tensile test specimens shall conform to 3.2.4.2.

TABLE V. Head cap minimum material properties.

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Characteristic Requirement Tensile Strength 130 Ksi (896 MPa) Yield Strength at 0.2% offset 120 Ksi (827 MPa) Elongation in 4D 8% Reduction of area 15% Hardness 32 HRc

3.2.10 Traceability. All head caps shall be traceable to their casting Bar Stock forming lot.

4. VERIFICATION

4.1 Classification of inspections. The inspection requirements specified herein are classified as

a. First article inspection (see 4.2).

b. Quality conformance inspection (see 4.3).

4.1.1 Quality Assurance Program. The contractor shall provide and maintain a quality assurance program in accordance with ISO 9000 series (or equivalent) unless otherwise specified in the contract or order (see 6.2).

4.1.2 Production lot definition. A production lot shall be defined as all head caps contained in a single heat treat lot/batch and it shall consist of no less than 25 nor more than 500 head caps. The lot acceptance sample for mechanical property testing shall be 7 head caps with two tensile specimens per head cap.

4.1.3 Inspection and test conditions. Inspection and test conditions are to be as specified in the applicable test method.

4.1.4 Summary reports. At the completion of first article testing and prior to full scale production the contractor shall provide the Government a first article test report. The contractor shall forward to the Government a quality conformance summary report for each master heat. The first article and quality conformance test reports shall consist of the following information:

a. Serial numbers of the head caps covered by the report.

b. Results of the tests and inspections of:

Table VII for the first article test report Table VIII for the quality conformance test report

c. Certificates of compliance or failure reports for the requirements listed in table VI.

d. Written procedures for radiographic and magnetic particle inspection. Radiographic inspection procedures shall conform to ASTM E1742. Magnetic particle inspection procedures shall conform to

ASTM E1444.

4.2 First article inspection. Unless otherwise specified in the contract or order (see 6.2), first article inspections and tests shall be performed by the contractor, after award of contract and prior to production, at a location acceptable to the Government. First article inspections and tests shall be performed on ten (10) head caps which have been produced by machine from a single billet as a master heat with equipment and procedures to be used in production in accordance with the process outlined in 3.2.5.1. The head caps shall undergo the tests specified in table VII in the exact sequence shown. Failure of any head cap to pass first article tests shall be cause for first article rejection.

4.2.1 Manufacturing process validation. The Government shall review the scheme (see 3.2.5.1) and its processes prior to full scale production. Review of the manufacturing scheme and quality audits of 4.2.1.1 through 4.2.1.3 shall provide the basis for the Government's concurrence. Once the Government has reviewed this information, the paul.vansant Highlight

Government will determine whether additional FATs are required. The Government shall perform manufacturing process validations as frequently as it deems necessary to assure process consistency throughout production.

TABLE VI. Requirements warranting a certificate of compliance or failure report.

Requirement Section First Article Inspection 3.1 Design and Construction 3.2 Composition 3.2.1 Condition 3.2.2 Head Cap Casting 3.2.3 Master Heat and Melt Qualification 3.2.4 thru 3.2.4.2 Heat Treatment 3.2.5 thru 3.2.5.3 Casting Soundness 3.2.6 Surface Quality 3.2.6.1 Radiograph Characteristics 3.2.6.2 Weld Repair 3.2.7 Passivation 3.2.8 Metallurgy 3.2.9

TABLE VII. First article test (FAT) matrix.

1 First Article tensile tests shall be conducted in accordance with 4.3.2.4.2, Tensile test, except that 2 specimens shall be taken from each of 4 head caps.

2 Weld repair inspection is only applicable on head caps which have undergone weld repair.

4.2.1.1 Master heat evaluation. These tests and inspections shall verify that the head caps meet requirements of

3.2 through 3.2.4.1. The Government will perform the tests and inspections where specified. The master heat evaluation tests and inspections shall be as follows:

a. The Government will audit the contractor’s process for employment of techniques (specified in the head cap manufacturing scheme) to meet 3.2 through 3.2.4.2.

b. The contractor shall provide certificates of compliance for 3.2.1 and 3.2.4 to the Government.

Heap Cap Number Inspection of Test 1 2 3 4 5 6 7 8 9 10

Test Method

Process Validation A A A A A A A A A A 4.2.1 Master Heat B B B B B B B B B B 4.2.1.1 Thermal Control C C C C C C C C C C 4.2.1.2 Heat Treatment D D D D D D D D D D 4.2.1.3 Casting Soundness E E E E E E E E E E 4.3.2.1 Radiographic Inspection F F F F F F F F F F 4.3.2.2 Mechanical Property 4.3.2.4 Hardness G G G G G G G G G G 4.3.2.4.1 Tensile1 H H H H 4.3.2.4.2 Visual & Dimensional Inspection H H H H H H 4.3.2.3

Weld Repair2 I I I I I I 4.3.2.5 Passivation J J J J J J 4.3.2.6 paul.vansant Highlight paul.vansant Highlight paul.vansant Highlight paul.vansant Highlight

4.2.1.2 Thermal process control evaluation. The contractor shall make the following certifications available to the Government:

a. Thermal process controls, reporting instrumentation, and pyrometry conformance to AMS 2750.

b. Accuracy tests and calibration of thermal process controls, reporting instrumentation, and pyrometry to

AMS 2750.

4.2.1.3 Heat treatment process validation. The Government will perform the following tests and inspections to confirm 3.2.5 through 3.2.5.3:

a. Audit of the contractors manufacturing scheme, heat treatment process, and thermal process survey data

b. Mechanical properties tests of 4.3.2.4.

4.3 Quality conformance inspection. Quality conformance inspection shall consist of tests and inspections specified in table VIII. The tests and inspections shall be performed in the order shown in table VIII. The inspection procedures to be used shall be submitted to the contracting activity for review. An inspection lot shall consist of all head caps from a single master heat presented for quality conformance inspection at one time. A test or inspection failure shall cause rejection of the inspection lot. The contractor shall provide the Government a report specifying the cause of each test or inspection failure and actions implemented that eliminated the cause before all subsequent inspection lots are submitted for acceptance.

TABLE VIII. Quality conformance test table.

Examination or Test Requirement Paragraph Test Paragraph Master Heat Evaluation 3.2.1 and 3.2.4 4.2.1.1 Casting Soundness 3.2.6 and 3.2.6.1 4.3.2.1 Radiographic 3.2.6.2 4.3.2.2 Metallurgy Hardness Tensile

3.2.9 4.3.2.4

4.3.2.4.1 4.3.2.4.2

Visual & Dimensional Inspection 3.2.5.4 and Drawing 525-174-0130 4.3.2.3 Weld Repair 3.2.7 4.3.2.5 Passivation 3.2.8 4.3.2.6

4.3.1 Quality conformance samples. Sample selection and production lot acceptance or rejection shall be in accordance with Single Sampling (Sl) of ANSI/ASQC Z1.4. The contractor shall exercise Standard Process Control (SPC) over casting/heat treat process. The contractor shall provide the following:

a. Certified chemical analysis for each casting lot, and

b. Mechanical properties for each specimen, identifiable to the head cap/heat treat lot/cast lot.

4.3.2 Tests.

4.3.2.1 Surface quality inspection. All head caps shall be visually inspected to verify conformance to 3.2.6 through 3.2.8. The contractor shall perform magnetic particle inspection. Magnetic particle inspection techniques shall be in accordance with ASTM E1444.

4.3.2.2 Radiograph inspections. All head caps shall be radiographically inspected to verify conformance to

3.2.6.2. The contractor shall radiographically inspect the head caps in accordance with the procedures of ASTM E1742 subject to the following conditions:

a. The contractor shall develop radiographic test techniques for the head cap in accordance with ASTM E1742. The test techniques shall be written and presented to the Goverment for review. The contractor shall use only Government approved test techniques to perform radiographic inspections. The contractor shall contact the Government if additional test techniques are required. Once the Government has been notified, the Government will review these changes to determine whether additional FATs are required.

b. At a minimum, the head cap radiographic inspection shall cover the four orientations shown in figure 5.

c. Non-film techniques shall not be used.

d. Radiographic quality level shall be two percent (2-2T) or better.

FIGURE 5. Minimum head cap radiographic coverage orientations.

4.3.2.3 Visual inspection. Visual inspections shall be used to verify the requirements of 3.2.5.4 through 3.2.8.

4.3.2.4 Mechanical properties. Mechanical properties inspections shall consist of tensile and hardness testing. The tests shall establish whether the head caps meet the requirements of 3.2.9.

4.3.2.4.1 Hardness test. All head caps shall undergo a hardness inspection. The hardness test shall be performed in accordance with ASTM A370. The hardness readings shall be taken from the section of the head cap shown in figure 4. The hardness test shall verify the hardness requirement of 3.2.9.

4.3.2.4.2 Tensile test. Two tensile test specimens shall be machined from each of the seven head caps selected from the production lot. No more than one head cap from any given casting lot shall be selected for tensile testing. The test specimens shall conform to 3.2.4.2. The contractor shall tensile test a tensile test specimen from each head cap in accordance with ASTM A370. The remaining seven tensile test specimens (in the case of First article testing, four tensile specimens) shall be forwarded to the contracting agency. (Refer to 6.5 for tensile test specimen packaging instructions.) The tensile tests shall verify that the tensile specimens and the head caps they represent meet the requirements of 3.2.9. The acceptance and retest criteria shall be as follows:

a. Test Success - All four tensile specimens tested meet the requirements of 3.2.9.

b. Test and Consequent Lot Failure - If any of the four tensile specimens tested fail to meet the requirements of 3.2.9. Failure of the tensile test shall result in rejection of the inspection lot.

c. No Test - Examination of the failure surface indicates that porosity caused the test failure. A retest may be performed. From the head cap which the material properties were unconfirmed, two additional tensile specimens shall be machined and tested in accordance with 4.3.2.4.2. Only two retests shall be performed. The contractor shall provide the Government one tensile test specimen from each retest performed.

4.3.2.5 Weld repair inspection. Surface quality inspection (4.3.2.1) and radiographic inspections (4.3.2.2) shall verify that head cap weld repairs meet the requirements of 3.2.7.

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4.3.2.6 Passivation inspection. Salt spray or copper sulfate tests (ASTM A967) shall not be employed as an inspection technique. Otherwise, the requirements of 3.2.8 shall be verified through visual examination and water immersion or high humidity test in accordance with ASTM A967. The contractor shall use actual production parts (not test specimens) for the test.

5. PACKAGING

5.1 Packaging. For acquisition purposes, the packaging requirements shall be as specified in the contract or order (see 6.2). When packaging of materiel is to be performed by DoD or in-house contractor personnel, these personnel need to contact the responsible packaging activity to ascertain packaging requirements. Packaging requirements are maintained by the Inventory Control Point’s packaging activities within the Military Service or Defense Agency, or within the military service’s system commands. Packaging data retrieval is available from the managing Military Department’s or Defense Agency’s automated packaging files, CD-ROM products, or by contacting the responsible packaging activity.

6. NOTES

(This section contains information of a general or explanatory nature which may be helpful, but is not mandatory.)

6.1 Intended use. The head cap interfaces with the Mk 22 MOD 4 Rocket Motor lockwire and motor tube to form a pressure vessel. The head cap was designed for military use and has no commercial application.

6.2 Acquisition requirements. Acquisition documents must specify the following:

a. Title, number, and date of the specification.

b. Whether a first article sample is required (see 3.1).

c. If a quality assurance program in accordance with ISO 9000 series (or equivalent) is not required (see 4.1).

d. Items of data required for each first article and production lot (see 4.1.3).

e. First article test facility (see 4.2).

f. Quality acceptance test facility (see 4.3).

g. Sampling sizes for acceptance tests (see 4.3).

h. Packaging and marking requirements (see 5.1, 6.5 and 6.6).

i. Safety precautions (see 6.8).

6.3 Consideration of data requirements. The following data requirements should be considered when this specification is applied on a contract. The specific acquisition should be reviewed to ensure that only essential data are requested/provided. To ensure correct contractual application of the data requirements, a Contract Data Requirement (DD Form 1423) must be prepared to obtain the data, except where DOD FAR Supplement 27.475-1 exempts the requirement for a DD Form 1423.

Reference Paragraph Data Requirement

3.2 Chemical Composition of Materials

3.2.5, 4.1.3 Test/Inspection Reports 3.2.5.1, 4.2.1 Process Certifications 3.2.5.4, 4.1.3 Serial Number Listing 3.2.7, 4.3.2.5 Weld Map

4.1 Quality Assurance Program Report

4.1.3 Certification Data/Report

4.1.3, 4.3.2.2 Radiographic Inspection Plan 4.1.3,4.2 First Article Data and Certificates

Reference Paragraph Data Requirement

4.2.1.2 Heat Treat Charts

4.2.1.2 Heat Treat Certifications

4.3.2.1 Magnetic Particle Certification

4.3.2.2 X-rays and Read Sheets

4.3.2.4 Mechanical Properties Certification

4.3.2.6 Passivation Certification

6.4 First article. When a first article inspection is required, the contracting officer should provide specific guidance to offerors that the items should be a first article sample and the number of items to be tested as specified in 4.2. A first article sample is required from each supplier who has not produced the MK 22 MOD 4 Head Cap. If production has been interrupted for more than 6 months or changes are requested in production methods, a first article sample may be required. The contracting officer should also include specific instructions in acquisition documents regarding arrangements for examinations, approval of first article test results, and disposition of first articles. Requests for proposals should provide that the Government reserves the right to waive the requirement for samples for first article inspection to those companies who have provided acceptable head caps which have been previously acquired or tested by the Government. Companies/offerors should not submit alternate bids unless specifically requested to do so in the solicitation.

6.5 Government tensile test specimen packaging. The tensile test specimens should be placed in individual plastic sealable bags. The bags should be marked with the head cap casting billet lot number and heat treat lot number after machining identification number which the tensile test specimen represents. The marking should be made with indelible black ink. In addition to the head cap identification number, bags containing a retest tensile specimen should identify whether the tensile specimen is representative of the first or second retest. The remaining pieces of the head cap should be retained by the manufacturer for the duration of the contract. The manufacturer should retain head cap pieces that result from quality conformance metallurgical tests only.

6.6 Marking. In addition to any special marking required by the contract or order, interior and exterior containers should be marked in accordance with MIL-STD-129 and include the following:

a. Purchase order number

b. Drawing number

c. Specification number

d. Head cap lot and serial number.

6.7 Advisory information.

6.7.1 Microstructure. The microstructure of this part should be a fine grained, tempered martensitic structure with little or no retained ferrite dendrites.

6.7.2 Head cap dimensional inspection reference. The Government uses the head cap's 0.219 inch diameter hole as the reference datum for dimensional inspection.

6.7.3 Acceptable Quality Level (AQL). The following AQL of 1.0 and c=0 should be considered when writing purchase order or contract.

6.8 Safety precautions. The safety precaution requirements of the "Contractors' Safety Manual for Ammunition, Explosives and Related Dangerous Material" (DOD 4145.26M) are applicable and should be specified in the contract as required by the Federal Acquisition Regulation (FAR) 23.3.

NOTE: When this document is used as part of the description of work to be accomplished by a Government activity, the safety precaution requirements of "Ammunition and Explosives Ashore" (OP5) should be made applicable.

paul.vansant Highlight

6.9 Supersedure information. WS 33077C incorporates Engineering Change Proposal (ECP) IH04033 dated 15 August 2004.