Initial Reliability Requirements

Size: px

Start display at page:

Download "Initial Reliability Requirements"

Hilda McDowell
6 years ago
Views:

1 Summary Initial Reliability Requirements Part, Process or Characteristic Major Minor Raw Material Machined Parts (General Features) Sheet metal fabrication Composite Parts Fastener holes Paint, alodine, anodize, and plating Receiving Inspection of standards Non-destructive test inspection (where permitted) Connector assemblies Printed Wiring Assembly (configuration) Electrical wire wraps Detail 1. RAW MATERIAL - All Metals All Metals (cont d) a. Visual/Dimensional b. Material Test (Inspection) (n)(o) c. Material Test 92 (Laboratory)(a) d. Ultrasonic Insp. (b) 1. A1/A1 Alloy MinThick Plate 1 97 Forgings 1 97 Billets 1 97 Extruded Shapes 1 95 Bar Rod Steel-Low Alloy &Stainless Vacuum Melted Plate - one (1) inch 97 Bar - one (1) inch 95 Forged Billets - one (1) inch 97 Rod - two (2) inch 95 Hexagonal - two (2) inch 95 Flats - one (1) inch 97 Die forgings when drawing specified Air Melted 97

2 Plate - one (1) inch 97 Rectangular two (2) inch 95 Rounds three (3) inch 95 Die forgings when drawing specified Titanium (c) Plate half (½) inch 97 Bar one (1) inch 95 Rounds two (2) inch 95 Forgings one (1) inch 97 Re-forgings one (1) inch 97 Billets in intermediate conversion stage 97 Nonmetallic a. Visual/Dimensional Fuels & Lubricants b. Material Test (Inspection) 92 Elastomers Tapes, Sealants Textiles Chemicals Honeycomb (nonconfigured Castings c. Material Test (Laboratory) (a) 2. Fasteners / Connectors Structural and - structural related (i.e., AN3-AN20, GB23D, GB510E) a. Visual/Dimensional b. Material Test Tensile Strength (1) 160 ksi and above (m) 95 (2) Below 160 ksi 92 c. Material Test (Laboratory ) (e) Functional Systems Avionic Fuel Hydraulic Oxygen Pneumatic (i.e., GF11H, GT515AL, GC830C) 3. Hoses, Seals, & Elastomeric Parts

3 Configured, natural and synthetic material a. Visual/ Dimensional Fasteners, Seals, Clamps, and Brackets b. Material Test (Inspection) 92 c. Material Test (Laboratory)(a) Nonmetallic, rigid a. Visual/ Dimensional b. Material Test Laboratory (g) 5. Functional Components Fuel, Hydraulic, oxygen and Pneumatic system parts (other than category components) 6. Functional Components Avionic, Electrical and Electronic system parts (other than category components) a. Visual / Dimensional Functional Components Fuel, Hydraulic, Oxygen, and Pneumatic INTRICATE ASSEMBLIES 8. Functional Components Avionic Electrical and Electronic system WRA s and Black Boxes 9. Structural Assemblies - Major

4 Modules Sub-assemblies 10. Structural Assemblies - Minor Access Doors Hole Covers b. Material Test (Inspection) 11. Machined parts and Configured honeycomb parts a. Visual/ Dimensional b. Material Test (Inspection) 92 c. Material Test (Laboratory) (k) 12. Stampings Brackets, angles and miscellaneous components of secondary structure (Metallic) b. Material Test (Inspection) 90 c. Material Test (Laboratory) (a) 13. Wire and Cable Avionic, Electrical and Electronic Systems a. Visual / Dimensional 90 b. Material Test (Inspection) Special Requirements of Specific Programs Special requirements and attributes applicable to specific programs shall be noted in an addendum to quality instruction. Such addenda shall be issued by quality engineering

5 NOTES FOR TABLE 1 (a) When specified in the applicable Inspection Operation Sheet (IOS) or directed by the Laboratory, the required specimen(s) representing each batch or lot shall be submitted to the Laboratory for testing. (b) Material which has not been ultrasonically inspected at the Seller s facility or does not conform to the receiving criteria shall be ultrasonically inspected as follows: (1) (Class A - special and Class AA) designated material as per the Engineering drawing shall be inspected 100% in accordance with GSS (2) (Class A or B) designated material as per the Engineering drawing shall be inspected as per a sampling plan established by Quality Engineering in accordance with MIL-STD-105. (c) When material print calls for Class A - Special, the parts must be inspected 100% pr GSS (d) DELETED (e) When the results of Material Test(s) (inspection) indicate the need for additional evaluation, a sample(s) shall be supplied to the Laboratory as per the Laboratory s requirements. (f) DELETED (g) Acceptance may be accomplished by the destructive testing of one piece per lot, when so specifically designated by the Inspection Operation Sheet (IOS) or directed by the Laboratory. (h) As specified in the Master Inspection List (MIL) or directed by Quality Engineering. (j) DELETED (k) Test specimen(s) of the type, size and quantity designed in the applicable process specification shall be forwarded to the Laboratory for evaluation. (l) Deleted (m) AQL noted is applicable only when a Certificate of Compliance (C of C) is included with the lot, otherwise 100% inspection is required. (n) Material test inspection shall not be required for raw steel material unless received in the final temper designation as directed by Quality Laboratory Operations and noted on the receiving report. (o) Material test inspection shall not be required for and raw material tested by Quality Laboratory Operations unless otherwise stipulated by the Laboratory and noted on the receiving report.

6 TABLE 2 INSPECTIONS - CLASSIFICATION OF CHARACTERISTICS CHARACTERISTIC CRITICAL MAJOR MINOR A MINOR B 1. Dimensions Linear Less than to to Over Angular Less than 2 2 to 0.5 Over 0.5 to Less than and Over 2. THREADS Class III Class II 3. SURFACE FINISH Less than 4 4 to 16 Over 16 to 64 Over FIT & GEOMETRY Alignment, Backlash Concentricity, Contour, End-Play, flatness, and less to Over Parallelism; radial T.T.R T.T.R. T.T.R. Play, Run-out, Square Straightness 5. GEARS & OTHER DENTATED PARTS Testing Pitch Radius (TPR) Max. Composite Radial Variation (MCR) Precision II Precision 1 Commercial Commercial Max. Tooth-to-tooth or Higher III and IV II and Lower Variation (MTT) Tooth Form, Depth & Thickness; Pitch, Pressure Angle, Number All Precision All Commercial of Teeth Classes Classes 6. OPITAL Astigmatism, Parallax, Front-to Back Definition, Equiv. Focal Focal Length, Distortion Length, Free Aperture, Resolution Functional Light Transmission 7. ELECTRICAL Less than 0.6% 0.6 to 2.0% 2.1 to 16.0% Over 16%

7 TABLE 2 INSPECTIONS - CLASSIFICATION OF CHARACTERISTICS CHARACTERISTIC CRITICAL MAJOR MINOR A MINOR B 8. MECHANICAL PROPERTIES (HEAT TREATMENT) Steel 220 ksi and Below 220 ksi above Aluminum All 9. OTHER PARAMETERS Unless otherwise indicated by the Engineering Drawing or the Inspection Operation Sheet (IOS), the following types of characteristics shall be categorized into one of the above classifications, based upon seriousness of the defect and its potential impact upon satisfactory end-use of the part. Cleanliness - Micro Contaminants [measured in Parts per Million (PPM)]. Defects - Surface and Subsurface: Cracks, Porosity, Shrinkage, Voids Encapsulation - (Potting): Lack of Adhesion, Incomplete, Cracked, Excessive Finish - (Protective): Poor Adhesion, Porosity, Wrong Color Functional Performance: Per values of Specification or Test Procedure Joining Bonding Voids, Crushed Core, Lack of Bond, Brazing Flux Inclusions, Oxide Inclusions, Soldering, Cold or Excessive Filler Metal, Welding, Wicking, Lack of Penetration, Undercutting, Porosity, Excessive Indentation, Cracks Weight - As designated by drawing or specifications

Cast Steel Propellers W27. (May 2000) (Rev.1 May 2004)

Cast Steel Propellers W27. (May 2000) (Rev.1 May 2004) (May 2000) (Rev.1 May 2004) Cast Steel Propellers 1. Scope 1.1 These unified requirements are applicable to the manufacture of cast steel propellers, blades and bosses. 1.2 Where the use of alternative