ASTM F2449-2005(2008) Standard Specification for Manufacturer Quality Assurance Program for Light Sport Gyroplane Aircraft.pdf

1、Designation: F 2449 05 (Reapproved 2008)Standard Specification forManufacturer Quality Assurance Program for Light SportGyroplane Aircraft1This standard is issued under the fixed designation F 2449; the number immediately following the designation indicates the year oforiginal adoption or, in the ca

2、se of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon () indicates an editorial change since the last revision or reapproval.1. Scope1.1 This specification sets minimum requirements for lightsport gyroplane or gyroplane compone

3、nt quality assurance andproduction acceptance programs.1.2 This specification applies to light sport gyroplane air-craft seeking civil aviation authority approval in the form offlight certificates, flight permits, or other like documentation.This specification applies to kit and ready to fly aircraf

4、t.1.3 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory requirements prior to use.2. Reference

5、d Documents2.1 ASTM Standards:2F 2352 Specification for Design and Performance of LightSport Gyroplane AircraftF 2415 Practice for Continued Airworthiness System forLight Sport Gyroplane Aircraft3. Terminology3.1 Definitions:3.1.1 LSG (light sport gyroplane)used in this specifica-tion to refer to bo

6、th light sport gyroplanes and gyroplane kits.3.1.2 LSGA (light sport gyroplane aircraft)rotary-wingaircraft designed in accordance with Specification F 2352 thatis manufactured and delivered ready to fly.3.1.3 LSG kit (light sport gyroplane kit)complete orgyroplane or gyroplane accessory designed in

7、 accordance withSpecification F 2352 that is manufactured and delivered as akit.3.1.4 manufacturerany entity engaged in the productionof a LSG.3.1.5 permanent recordwhere specified in this specifica-tion, applicable quality assurance records shall be kept for eachLSGA produced for as long as the rel

8、ative airworthinesscertificate remains in effect.3.1.6 reserved holding areafor rejected parts, materials,and assemblies, an area for the containment of rejectednon-airworthy items awaiting proper disposition, where suchrejected items shall not be distributed for use on a LSGA.3.1.7 satellite manufa

9、cturing, assembly, and distributionfacilitiesrefers to facilities being operated by commercial orprivate entities that, though authorized by the original manu-facturer, are not directly associated with or controlled by theoriginal manufacturer.3.1.8 secure storage areafor accepted parts, materials,a

10、nd assemblies, an area of storage where the preservation ofthe contents to required design specifications is reasonablyassured until distributed for use on a LSGA.3.2 Acronyms:3.2.1 AOIAircraft Operating Instructions3.2.2 MRBMaterials Review Board3.2.3 QAMquality assurance manual; the documentationo

11、f the quality assurance program that prescribes the methods ofinspections and acceptance criteria3.2.4 QAPquality assurance program; describes theplanned actions used by the manufacturer of a LSGA to verifyand ensure the proper production thereof3.2.5 QARquality assurance record; the quality assuran

12、cerecord associated with each LSGA produced.4. Significance and Use4.1 The purpose of this specification is to provide theminimum requirements necessary for the establishment of aquality assurance program for a light sport aircraft manufac-turer or component supplier.5. Quality Assurance Program (QA

13、P)5.1 Manufacturers of LSG shall develop a Quality Assur-ance Program (QAP) in accordance with the criteria of thisspecification.1This specification is under the jurisdiction of ASTM Committee F37 on LightSport Aircraft and is the direct responsibility of Subcommittee F37.50 on Gy-roplane.Current ed

14、ition approved May 15, 2008. Published July 2008. Originallyapproved in 2005. Last previous edition approved in 2005 as F 2449 05.2For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStandards volume informat

15、ion, refer to the standards Document Summary page onthe ASTM website.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.5.2 Quality Assurance Manual (QAM)Each manufacturershall document the QAP in the form of a Quality AssuranceManual (

16、QAM).5.3 Quality Assurance Administration (QAA)The manu-facturers administration charged with QAP implementationmay include employees, officials, agents, consultants, or as-signs. The QAM shall identify the person(s) within themanufacturing QAA.5.4 Quality Assurance Record (QAR):5.4.1 The acceptance

17、 date, origin, and certifications ofmaterials fabricated into structurally critical LSGA airframecomponents shall be recorded (see Note 1).NOTE 1The intent of this record is to provide a means for themanufacturer to identify and reduce the number of LSG within a fleet thatmay be affected by a materi

18、als anomaly that would require correctiveaction, thereby reducing the economic impact of such corrective action.This paragraph should not be construed as a requirement for specific partstraceability.5.4.2 Manufacturer maintains a Quality Assurance Record(QAR) for each LSG produced. Each QAR consists

19、 of:5.4.2.1 Applicable final inspection records, check, and testdocumentation from the production acceptance procedures (seeSection 8),5.4.2.2 A copy of the Manufacturers Statement of Compli-ance, and5.4.2.3 The aircraft configuration at delivery point includingassociated parts lists and installed e

20、quipment lists for continuedsafety monitoring.NOTE 2Each item in 5.4.1 includes the LSG serial number andmanufacturing date.5.5 Quality Assurance RevisionsA system shall be imple-mented to ensure that only the latest revisions to the QAM arein use.5.6 Quality Assurance AuditsThe manufacturer shall c

21、on-duct an annual QAP audit. The manufacturer maintains auditrecords. The manufacturer resolves any non-compliance issuesfound in the QAP audit and makes revisions to the QAM whereappropriate.6. Engineering and Manufacture6.1 Compliance RecordThe manufacturer records andkeeps design compliance docum

22、entation for each configurationof light sport gyroplane aircraft or product manufactured inaccordance with Specification F 2352. Each record shall con-sist of the following.6.1.1 A description of the configuration, including installedequipment list and associated parts, and6.1.2 The current revision

23、 of required documentation pro-vided with the aircraft.6.2 Configuration ControlAll LSG configurations in pro-duction must have a Compliance Record for the currentSpecification F 2352.6.3 Production DocumentationThe manufacturer main-tains a production documentation record including any revi-sions.

24、Examples of production documentation include:6.3.1 Parts lists,6.3.2 Process routes,6.3.3 Component and assembly drawings,6.3.4 Manufacturing instructions and specifications, and6.3.5 Tooling and gage drawings.6.4 Special ProcessesThe QAP controls all special pro-cesses and services used to produce

25、structurally critical LSGAairframe components, such as welding, brazing, heat treatment,plating, structural composites, adhesives bonding, and so forth.Each process and service must be in accordance with appro-priate recorded specifications detailing quality standards andrequirements for periodic in

26、spection of solutions, gages, andother critical equipment.7. Quality Assurance Inspections7.1 Manufacturers implement and document an inspectionprocedure verifying product conformity to production specifi-cations in accordance with 6.1.7.1.1 Conforming, non-conforming, and items awaiting in-spection

27、 must be separated or clearly distinguishable. Itemsfound nonconforming are evaluated by a Material ReviewBoard (MRB) in accordance with 7.4 or rejected in accordancewith 7.5.7.2 Receiving InspectionThe manufacturer implements apurchase procedure that ensures clear specification of all itemsordered.

28、 Items from outside vendors are inspected for conform-ance to specifications immediately when received.7.3 Acceptance of Conforming ItemsConforming itemsare distributed as required or placed in a secure storage area forfuture use.7.4 Evaluation of Non-Conforming Items by a MaterialsReview BoardA Mat

29、erials Review Board (MRB) may deter-mine the nature of non-conforming items. The MRB consistsof one or more manufacturer-designated technical representa-tives. The QAM identifies all MRB representatives. If analysis,additional inspection, functional checks, repair, rework, adap-tation, and so forth

30、assure item meets design requirements, theMRB may authorize usage of the item. If not, the item isrejected in accordance with 7.5. The manufacturer keeps apermanent record on the nature of non-conforming itemsevaluated and accepted by the MRB.7.5 Rejection of Non-Conforming ItemsThe manufacturerdocu

31、ments and implements a process for disposing of non-conformance items. Examples of how an item may be deemednon-conformant includes damage, shelf life-limits, and otherdeviations. Otherwise serviceable but non-conforming itemsmay be returned to the supplier. Unserviceable items must bemutilated, des

32、troyed, or sufficiently marked as rejected. Thisprocess must ensure the item can no longer be used on anyaircraft. The item can be held in a reserved area prior todisposal.8. Production AcceptanceNOTE 3The following criteria should not be construed as require-ments for specific features to be includ

33、ed on a LSGA. When a requirementspecifies a feature that does not exist on a LSGA, the requirement does notapply.8.1 Final InspectionsManufacturer shall verify andrecord that a shop order for each LSGA produced has beencompleted prior to conducting the following production accep-tance procedures.F 2

34、449 05 (2008)28.2 LSG KitManufacturer shall verify and document theproper production process completion prior to the distributionof any LSG kit or subsystem kit. The manufacturer providesLSG kit builder appropriate production acceptance flight andground test procedures described below.8.3 LSGAManufa

35、cturer verifies proper production pro-cess completion prior to distribution of flight-ready LSGA. Thefollowing ground check and flight test procedures shall beconducted and documented for each flight-ready LSGA.8.3.1 Ground CheckPrior to flight testing, the manufac-turer conducts a thorough ground i

36、nspection of each LSGAproduced to verify at least the following:8.3.1.1 Weight and BalanceLoad distribution limits andweight and balance conforming with the AOI and PracticeF 2415.8.3.1.2 Systems CheckThe proper function of all switchesand circuits, instrumentation, brakes, and any other appropriate

37、systems shall be verified.8.3.1.3 Flight Controls CheckAll flight controls shall bechecked for smooth and proper function and proper maximumdeflections. Control system connections and safeties shall bechecked and verified intact.8.3.1.4 Seats and Safety BeltsSeats and pilot restraintsystem shall be

38、checked for security and visual defects.8.3.1.5 Engine CheckEngine checks and procedures shallbe performed to verify:(1) Proper engine installation,(2) Proper servicing of all engine fluids,(3) No apparent fuel, oil, or coolant leaks, as appropriate,(4) Propeller installation and pitch adjustment, a

39、s appli-cable,(5) Performance of an engine “run-in” with adjustments, asrequired,(6) Tachometer indicates engine idle RPM and maximumstatic RPM within manufacturers published limits,(7) Proper function of engine instrumentation,(8) Proper function of ignition system(s), and(9) Proper function of ind

40、uction heating system.8.3.1.6 Placards CheckA check verifies all required plac-ards, switch, and instrument markings in place.8.3.2 Preflight InspectionVerifies the following:8.3.2.1 All required documentation on board,8.3.2.2 All visible surfaces free of deformation, distortion,or other evidence of

41、 failure or damage,8.3.2.3 Inspection of all visible fittings and connections fordefective or insecure attachment, and8.3.2.4 Complete walk-around inspection in accordancewith the AOI.8.3.3 Taxi TestAfter completion of the ground check, ataxi test shall verify:8.3.3.1 Brake function,8.3.3.2 Landing

42、gear tracking and steering, and8.3.3.3 Proper compass readings, verified by a reference,and corrected with compass card if needed.8.3.4 Flight TestAfter completion of the taxi test, a flighttest shall be conducted.8.3.4.1 Operational Safety Flight TestSafe flight opera-tion of each completed LSGA sh

43、all be verified to includeacceptable handling and control characteristics, engine opera-tion, airspeed indications, and overall suitability for normalflight in accordance with the AOI. The flight test procedure atleast includes recorded verification of:(1) Takeoff runway wind, outside air temperatur

44、e, andpressure altitude,(2) Verification that takeoff distance meets that published inthe AOI,(3) Verification that the climb rate meets or exceeds thatpublished in the AOI,(4) Appropriate response to flight controls in all configu-rations,(5) Handling and control characteristics,(6) No unusual perf

45、ormance or handling characteristics,and(7) Proper engine operating temperatures.8.3.4.2 Design Confirmation Flight TestEach completedLSG or a random sample at frequency determined by manu-facturer, and for the first production unit of each configuration,a test flight will verify production uniformit

46、y and compliancewith Specification F 2352.8.4 Instrument CalibrationAny aircraft instrument requir-ing periodic calibration shall have a current calibration.8.5 Resolution of DiscrepanciesManufacturer developsand implements correction procedure for anomalies foundduring ground checks or flight testi

47、ng.8.5.1 Non-ComplianceAny aircraft which fails a produc-tion acceptance test shall be physically tagged as non-compliant. Anomalies can be reworked in accordance withresolution of discrepancies procedures. Each reworkedanomaly must be re-evaluated.8.5.1.1 Non-Compliance TagA non-compliance noticemu

48、st be attached to the aircraft in clear view of a potentialoperator.8.6 Production Acceptance DocumentationA writtenchecklist may be used as a method of documenting productionacceptance inspections, checks, and tests.9. Assignment of QA Duties and Responsibilities9.1 LSG Manufacturers may assign QA

49、duties and respon-sibilities to outside parties for the purpose of establishingsatellite manufacturing, assembly, or distribution facilities, or acombination thereof. However, this does not relieve the manu-facturer of overall QAresponsibility for the accomplishment ofthese activities.10. Keywords10.1 gyroplane; light sport aircraftF 2449 05 (2008)3ASTM International takes no position respecting the validity of any patent rights asserted in connection with any item mentionedin this standard. Users of this standard are expressly adv