SAE AS 7510-2017 Coupling Assembly Threadless Flexible Self-Locking Fixed Cavity High Conductivity Self-Bonding Part Specification.pdf

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4、70 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/AS7510 AEROSPACE STANDARD AS7510 Issued 2017-09 Superseding AS5830 Coupling Assembly, Threadle

5、ss, Flexible, Self-Locking, Fixed Cavity, High Conductivity, Self-Bonding, Part Specification RATIONALE New part specification to supersede AS5830. TABLE OF CONTENTS 1. SCOPE 4 1.1 Equipment Description and Functionality 4 1.2 Manufacturers Responsibility . 5 2. REFERENCES 6 2.1 Applicable Documents

6、 6 2.1.1 SAE Publications . 6 2.1.2 U.S. Government Publications 7 2.1.3 Uniform Classification Committee Publication 7 2.1.4 ASTM Publications 7 2.1.5 PRI Publications 7 2.1.6 ASME Publications 8 2.1.7 ANSI Accredited Publications . 8 2.1.8 AIAA Publications 8 2.1.9 American Welding Society Publica

7、tion . 8 2.2 Definitions . 8 3. TECHNICAL REQUIREMENTS 10 3.1 Design and Fabrication . 10 3.1.1 Assembled Coupling . 12 3.1.2 Dimensions . 14 3.1.3 Weights . 15 3.1.4 Identification of Product. 15 3.1.5 Workmanship 15 3.1.6 Cleaning 15 3.1.7 Materials and Finishes 15 3.1.8 Interchangeability 15 3.1.

8、9 Production Acceptance Testing 16 3.2 Quality Assurance . 16 3.3 Requirements for Qualification 16 3.3.1 Manufacturers Qualification . 17 3.3.2 Product Qualification . 17 3.3.3 Change Approval 17 SAE INTERNATIONAL AS7510 Page 2 of 119 3.3.4 Qualification by Analysis . 17 3.3.5 Dissimilar Materials

9、. 17 3.3.6 Federal Aviation Administration Requirements . 17 4. QUALIFICATION TESTING 18 4.1 General Test Conditions . 18 4.1.1 Assembly of Test Specimens 18 4.1.2 Test Fluid 18 4.1.3 Test Fluid Leakage Limits During Testing. 18 4.1.4 Ambient Test Conditions . 18 4.1.5 General Tolerances . 18 4.1.6

10、Qualification Calibration 19 4.1.7 Test Inspection Methods . 19 4.2 Qualification Performance Testing and Sequences 19 4.2.1 Life and Non-Life Environmental Exposure Test Group . 21 4.2.2 Stand Alone Vibration Test Group 22 4.2.3 Static Load Capability Test Group 23 4.2.4 Fatigue Load Cycling Test G

11、roup . 24 4.3 Complete Test Assembly Configurations 25 4.4 Test Fixture Configurations . 28 4.4.1 Life and Non-Life Environmental Exposure Test Fixture: (configurations -1 and -2) 28 4.4.2 Lightning Strike Test Fixtures . 29 4.4.3 Random Vibration and Engine Blade Loss Vibration Test Fixture 30 4.4.

12、4 Static Shear Test Fixture Assembly 32 4.4.5 Static Tensile Test Fixture Assembly 33 4.4.6 Dynamic Shear Test Fixture Assembly . 34 4.4.7 Pressure Impulse Test Fixture Assembly . 34 4.5 Performance Tests 35 4.5.1 Examination of Product . 35 4.5.2 Electrical Bonding . 35 4.5.3 Pressure Leakage . 36

13、4.5.4 Proof (Positive and Negative) and Burst Pressure . 36 4.5.5 Lightning 36 4.5.6 Sinusoidal Resonance Survey and Dwell . 38 4.5.7 High Temperature Aging . 40 4.5.8 Low Temperature Aging 40 4.5.9 Pressure Impulse Fatigue Testing 40 4.5.10 Corrosion Testing 42 4.5.11 Repeated Assembly 42 4.5.12 Dy

14、namic Shear Testing . 42 4.5.13 Continuous Electrical Bonding 46 4.5.14 Stand Alone Random Vibration . 47 4.5.15 Stand Alone Windmilling Vibration 51 4.5.16 Static Tensile . 53 4.5.17 Static Shear . 54 4.6 Qualification Test Report. 56 5. PREPARATION FOR DELIVERY . 58 5.1 Packaging . 58 5.2 Marking

15、58 5.2.1 Packaging Identification 58 6. NOTES 58 6.1 Ordering Data 58 6.2 Revision Indicator 58 SAE INTERNATIONAL AS7510 Page 3 of 119 APPENDIX A COMPLETE TEST ASSEMBLY DETAIL COMPONENT DEFINITION 59 APPENDIX B TEST FIXTURE ASSEMBLY DRAWINGS . 62 Figure 1 Assembled flexible coupling; exploded view .

16、 4 Figure 2 Assembled coupling design installation limits . 11 Figure 3 Assembled coupling configurations 12 Figure 4 Life cycle configuration (a) complete test assembly (as assembled and exploded views) . 26 Figure 5 Dynamic shear test configuration (a-1) complete test assembly (exploded view) 26 F

17、igure 6 Random and windmilling test configuration (b) complete test assembly (as assembled and exploded views) 27 Figure 7 Static shear test configuration (c) complete test assembly (as assembled and exploded views) 27 Figure 8 Pressure impulse test configuration (d) complete test assembly (as assem

18、bled and exploded views) . 28 Figure 9 Life cycle and non-life cycle test fixture 28 Figure 10 Life and non-life environmental exposure test fixture configurations (-1) and (-2) . 29 Figure 11 Lightning strike test fixture, configuration (-1) . 29 Figure 12 Lightning strike test fixture, configurati

19、on (-2) . 30 Figure 13 Random vibration and engine blade loss vibration test fixture for sizes -48 and smaller . 30 Figure 14 Random vibration and engine blade loss vibration test fixture clamp spacing for sizes -48 and smaller . 31 Figure 15 Random vibration and engine blade loss vibration test fix

20、ture clamp spacing for sizes -56 and -64 . 31 Figure 16 Static shear test fixture assembly . 32 Figure 17 Static shear test fixture assembly setup . 32 Figure 18 Static tensile test fixture assembly 33 Figure 19 Dynamic shear test fixture assembly 34 Figure 20 Pressure impulse test fixture assembly

21、34 Figure 21 Electrical bonding setup 35 Figure 22 Sinusoidal resonance survey and dwell test setup . 39 Figure 23 Pressure impulse profile trace (typical) . 41 Figure 24 Unsupported 90 elbow loading 43 Figure 25 Dynamic shear test, composite load profile 43 Figure 26 Dynamic shear test reinforcemen

22、t insert placement (optional). 44 Figure 27 Dynamic shear system schematic example 45 Figure 28 Continuous electrical bonding random vibration spectrum . 46 Figure 29 Continuous electrical bonding test setup 47 Figure 30 High energy random vibration spectra 48 Figure 31 High energy random vibration

23、test setup 49 Figure 32 Wide span random vibration spectra 50 Figure 33 Wide span random and windmilling vibration test setup (size -56 and -64 shown) 50 Figure 34 Windmilling sinusoidal test levels 52 Figure 35 Static tensile test setup . 53 Figure 36 Static shear coupling rotational orientation .

24、55 Table 1 Assembled coupling functional limits 5 Table 2 Coupling physical requirements 12 Table 4 Component production acceptance tests 16 Table 5 Qualification performance testing and sequence 21 Table 6 Life cycle test sequence detail 21 Table 7 Non-life cycle test sequence detail . 22 Table 8 R

25、andom and windmilling vibration test sequence detail . 23 Table 9 Static load capability test group detail . 23 Table 10 Dynamic shear test sequence . 24 Table 11 Pressure impulse fatigue test sequence . 25 Table 12 Sinusoidal resonance dwell vibration levels 38 Table 13 Sinusoidal resonance dwell t

26、imes . 38 Table 14 Static tensile limit and ultimate load requirements 53 Table 15 Static shear limit and ultimate loads and pressures . 54 SAE INTERNATIONAL AS7510 Page 4 of 119 1. SCOPE This SAE Aerospace Standard (AS) defines the requirements for a threadless, flexible, high conductive self-bondi

27、ng coupling assembly which, when installed on defined ferrules, provides a flexible connection for joining ducting and components in pressurized fluid systems. The assembled coupling is designed to provide interchangeability of parts and components between qualified manufacturers for use from -65 to

28、 +265 F at 130 psi nominal operating pressures and for the service life of the aircraft system. Figure 1 - Assembled flexible coupling; exploded view FAR 23.954, FAR 25.901, FAR 25.954 and FAR 25.981 certification requirements have identified the need for high current capable flexible fluid assemble

29、d couplings. The coupling assembly does not require inspection and maintenance to remain current capable for the life of the aircraft. This specification provides two test philosophies necessary for low pressure couplings: 1. EME/lightning testing of assembled couplings to demonstrate electrostatic

30、capabilities are retained through simulated service life test sequences to meet commercial airplane FAR 25.981 certification requirements. 2. Grouping and goal posting of coupling test specimens based on size and material similarities. The assembled couplings intended application and usage is for, b

31、ut not limited to, commercial and military aircraft. Components defined herein and qualified to the performance capabilities and regulatory compliance requirements will support their use in fuel and other fluid conveyance systems. This specification requires manufactures to be qualified and accredit

32、ed to Performance Review Institute (PRI)/National Aerospace and Defense Contractors Accreditation Program (Nadcap) requirements. 1.1 Equipment Description and Functionality The assembled couplings may be used in pressurized and unpressurized sections of the aircraft, including fuel tanks, strut and

33、pylon, cabin areas, flight deck, and cargo compartments. It is critical that components delivered following qualification by the manufacturers be produced with the same documented processes subject to approved revisions to ensure the post qualified products meet the same part performance requirement

34、s as those originally qualified. The performance requirements and testing constraints within this specification were developed using aircraft system OEM and supplier experiences and guidance for aircraft fuel component and system usage provided in ARP8615. Qualified manufacturers shall control, main

35、tain, and document product processes for all aspects of the production and assembly of their respective parts. The documentation shall include the processes and procedures of sub-tier manufacturers. Manufacturers are responsible for the processes, products, and product quality provided by part and p

36、rocess manufacturers of their assembled couplings. Manufacturers shall provide process control documents for Nadcap audit review upon request. Due to materials and production processes O-rings have functional life limitations and may necessitate replacement over the functional life of the assembled

37、coupling. SAE INTERNATIONAL AS7510 Page 5 of 119 Table 1 shows system operating conditions and functional limits based on material and functional capabilities. The static internal pressure requirements for the assembled couplings are listed in Table 2. Table 1 - Assembled coupling functional limits

38、Material Size Range System Pressure (PSI) Ambient Temperature Range (F) Fluid Temperature Range (F) Aluminum -08 to -64 130 -65 to 265 -65 to 265 It is important to simulate the wear and damage experienced by the assembled coupling in service if it is to remain electrical current capable for the lif

39、e of the aircraft. The test procedures in this specification simulate a worst-case wear and damage condition for the assembled couplings based on a 20 to 30 year service life. CAUTION: Although visually similar, AS7510 parts are not compatible with AS1650 parts. AS7510 parts should not be intermixed

40、 with AS1650 parts. Intermixing between AS7510 and AS1650 does not produce a qualified joint and may result in loss of electrical bonding, excessive fluid leakage, and/or part damage. The assembled coupling shall be of the self-locking coupling integral electrical bonded type and all components shal

41、l be interchangeable with components from other qualified part manufacturers. The assembled coupling shall be capable of handling electrical currents for waveforms of SAE ARP5412 as described in 4.5.5. The design, component functionality reviews, Failure Mode and Effects Analysis (FMEA), fault tree

42、analysis (FTA), redundancy analysis, and qualification test results of the assembled coupling shall provide validation for use in fluid systems requiring FAR 23.954, FAR 25.603, FAR 25.605, FAR 25.901, FAR 25.954 and FAR 25.981 certification review. The assembled coupling shall not present any condi

43、tion where a single point failure will result in the loss of the functional, fluid handling, or electrostatic capabilities of the device, or compromise the flight safety of the aircraft. The regulations establish requirements such that the failure of a single component or part of an assembly shall n

44、ot result in the loss of the functional capabilities of the assembled coupling nor cause an electrical spark of sufficient energy to ignite a flammable fuel mixture. The architecture and design of the coupling shall provide redundant or separated features for locking and hinge to ensure a part failu

45、re does not lead to loss of the assembled coupling capabilities. 1.2 Manufacturers Responsibility The qualified manufacturer for this specification shall have overall responsibility for: a. Design b. Test c. Manufacture d. Qualification e. Satisfactory operation of the equipment as required for cert

46、ification by various airworthiness authorities including the Federal Aviation Administration (FAA), European Joint Aviation Authority (JAA), Civil Airworthiness Administration (CAA), and similar administrations. SAE INTERNATIONAL AS7510 Page 6 of 119 2. REFERENCES 2.1 Applicable Documents The follow

47、ing publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and re

48、ferences 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. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001,

49、Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. AMS-R-25988 Rubber, Fluorosilicone Elastomer, Oil-and-Fuel-Resistant, Sheets, Strips, Molded Parts, and Extruded Shapes AMS-WW-T-700 Tube, Aluminum and Aluminum Alloy, Drawn, Seamless, General Specification for ARP4761 Guidelines and Methods for Conducting the Safety Assessment Process on Civil Airborne Systems and Equipment ARP926B Fault/Fai