1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2017 SAE International All rights reserved. No part of this p
3、ublication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-497
4、0 (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/AS5830A AEROSPACE STANDARD AS5830 REV. A Issued 2006-09 Revised 2017-05 Superseding AS5830 Coup
5、ling Assembly, Threadless, Flexible, Fixed Cavity, Current Carrying, Self-Bonding, Procurement Specification RATIONALE This specification provides a conductive, self-bonding, flexible assembled coupling capable of meeting the electrostatic bonding and current carrying requirements of low pressure fl
6、uid systems. 1. SCOPE This aerospace specification defines the requirements for a threadless, flexible, conductive, self-bonding coupling assembly which, when installed on fixed cavity ferrules, provides a flexible, current carrying connection for joining tubing and components in aircraft fuel, vent
7、 and other systems. The assembled coupling is designed to provide interchangeability of parts and components between qualified manufacturers for the service life of the aircraft system. The assembled coupling is for use from -65 to +200 F at nominal operating pressures (125 psig for -08 through -64
8、and 30 psig for -72 through -88). This aerospace specification is a departure from prior qualification practices for assembled couplings. Prior practice sought to validate this type of assembled coupling design by conducting a sequence of tests on sets of coupling assemblies. There were multiple tes
9、t sequences and each was conducted on a different set of coupling assemblies. Each of these test sequences challenged a particular design feature of the coupling assembly. No single coupling assembly was expected to survive all of the required tests. FAR 23.954, FAR 25.954 and FAR 25.981 certificati
10、on requirements have identified the need for high-current capable flexible fluid couplings. The coupling assembly does not require inspection and maintenance to remain current capable for the life of the aircraft. It is important to simulate the in-service wear and damage experienced by the assemble
11、d coupling if it is to remain capable of carrying current for the life of the aircraft. The test procedures in this specification simulate a worst case wear and damage condition for the assembled couplings. Interchangeability of vendor parts must be qualified by design, test and/or analysis. CAUTION
12、: Although the AS5830 coupling and sleeve will fit on AS1650 ferrules due to the use of common O-rings, the combinations of these parts are not qualified. Using AS5830 parts on AS1650 ferrules may result in leakage and/or premature failure of the joint and does not produce a high current capable joi
13、nt. WARNING: The use of AS1650 parts with AS5830 ferrules is not qualified. Assembly of worn AS1650 parts with AS5830 ferrules may be possible but could result in leakage and/or premature failure of the joint and does not produce a high current capable joint. SAE INTERNATIONAL AS5830A Page 2 of 34 1
14、.1 Product Classification The assembled coupling shall be of the integral electrical bonded type and all components shall be interchangeable with components from other qualified part manufacturers. The assembled coupling shall be capable of handling electrical currents for waveforms of ARP5412 as de
15、scribed in 4.6.5. 1.2 Assembled Coupling Types The assembled coupling shall be rated for the current carrying capability based on material construction and for up to 30 years of service life. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this document to the extent
16、 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 references cited herein, the text of this document takes prec
17、edence. 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, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-497
18、0 (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 AS478 Identification Marking Methods AS568 Aerospace Size S
19、tandard for O-rings AS4060 Tube Fitting Swaged Joint, Roller Expander, Manual Process, Requirements for ARP5412 Aircraft Lightning Environment and Related Test Waveforms ARP5416 Aircraft Lightning Test Methods AS5831 Assembled Coupling, Threadless-Flexible, Fixed Cavity, Current Carrying, Self Bondi
20、ng, Envelope Dimensions AS5832 Assembled Coupling Components, Threadless-Flexible, Fixed Cavity, Current Carrying, Self Bonding AS5833 Male Ferrule, Threadless-Flexible, Fixed Cavity, Current Carrying, Self Bonding, Swaged AS5834 Sleeve, Threadless-Flexible, Fixed Cavity, Current Carrying, Self Bond
21、ing AS5835 Coupling Body, Threadless-Flexible, Fixed Cavity, Current Carrying, Self Bonding AS5836 Fitting End, Threadless-Flexible, Fixed Cavity, Current Carrying, Self Bonding, Male and Female Design Standard AS5837 Male Ferrule, Threadless-Flexible, Fixed Cavity, Current Carrying, Self Bonding, B
22、utt Welded SAE INTERNATIONAL AS5830A Page 3 of 34 AS5838 Female Ferrule, Threadless-Flexible, Fixed Cavity, Current Carrying, Self Bonding, Swaged AS5839 Female Ferrule, Threadless-Flexible, Fixed Cavity, Current Carrying, Self Bonding, Butt Welded AS5840 Elbow, Threadless - Flexible, Fixed Cavity,
23、Current Carrying, Self Bonding AS5841 Tee, Threadless - Flexible, Fixed Cavity, Current Carrying, Self Bonding AS5842 Union, Bulkhead, Threadless - Flexible, Fixed Cavity, Current Carrying, Self Bonding AS5843 Elbow, Bulkhead, Threadless - Flexible, Fixed Cavity, Current Carrying, Self Bonding AS700
24、3 Nadcap Program Requirements AS7112 National Aerospace and Defense Contractors Accreditation Program Requirements for Fluid System Components AS7112/2 National Aerospace and Defense Contractors Accreditation Program Requirements for Fittings and Other Machined Components AS9103 Aerospace Series - Q
25、uality Management Systems - Variation Management of Key Characteristics 2.1.2 U.S. Government Publications Copies of these documents are available online at www.faa.gov. 14 CFR Code of Federal Regulations, Aeronautics and Aerospace AC25.981-1B Advisory Circular, Fuel Tank Ignition Source Preventive
26、Guidelines Copies of these documents are available online at http:/quicksearch.dla.mil. MIL-HDBK-831 Test Reports, Preparation of MIL-STD-129 Military Marking for Shipment and Storage MIL-STD-130 Identification Marking of U.S. Military Property MIL-STD-810 Environmental Engineering Considerations an
27、d Laboratory Tests MIL-STD-889 Dissimilar Metals 2.1.3 Uniform Classification Committee Publications Available from Uniform Classification Committee, 202 Chicago Union Station, Chicago, IL 60606. Uniform Freight Classification Rules 2.1.4 PRI Publications Available from Performance Review Institute,
28、 161 Thorn Hill Road, Warrendale, PA 15086-7527, Tel: 724-772-1616, www.pri-network.org. PD2001 Tasks tube and end cap. /3/ AS1730 interface with appropriate thread and dimensional changes for designated tube size. SAE INTERNATIONAL AS5830A Page 17 of 34 4.4.4 Test Set Up The manufacturers shall pre
29、pare test fixtures that provide support to the complete test assembly to meet the requirements for each test. Each fixture may contain as many basic tube setups as is necessary while still maintaining test requirements. The manufacturer designed test fixtures shall support the Figure 4A and 4B test
30、specimens. It shall be the responsibility of the manufacturer to validate compliance with test requirements. Each complete test assembly, as shown in Figure 2, consists of one center tube assembly (Figure 4A), two end tubes (Figure 4B), two end cap assemblies (as required) and necessary clamp suppor
31、ts. The test specimens shall remain connected when transferring sections between test setups. In transitioning to and from test setups specimens shall not be disconnected and movement shall be minimized to retain material collected in other life testing. Figure 4A - Center tube assembly Figure 4B -
32、End tube assembly Figure 4 SAE INTERNATIONAL AS5830A Page 18 of 34 The end cap assemblies used for pressure impulse testing shall incorporate AS1730 or similar sealing features. Detail part definitions shall be defined by the manufacturer and shall be similar to an AS1732 Body, an AS1734 Nut, and an
33、 AS1737 Ferrule sized per Table 6 and shown in Figure 9A, 9B, 9C, and 10. The end cap assemblies for tests other than the pressure impulse test may be manufacturer optional design. The end cap assemblies shall provide a fluid seal capable of pressurization in excess of 1000 psig for -08 through -64
34、and 250 psig for -72 through -88. The end cap assemblies shall provide a threaded port for the attachment of a fluid fitting (size -04 to -08) or a manufacturer defined pressure transducer. It shall be the responsibility of the manufacturer to validate compliance with specification requirements of t
35、heir test setups. AMS-R-25988 O-rings with sizes per AS568 shall be used for all test specimens when required. Metallic or rigid non-metallic 1.25 inch thick clamp blocks shall be utilized to support test specimens for the impulse testing. Clamp blocks for vibration and lightning testing may be 1.00
36、 inch thick. Clamp blocks may utilize rigid metallic or non-metallic inserts for test tube clamping. Clamp blocks shall be replaced if damaged during testing. Clamp blocks shall be removed and replaced with minimum disturbance and without removal or disassembly of the test specimens. Users shall be
37、notified of the failure. If any of the components in the test rig, except the test specimens, are damaged during testing the damaged components shall be replaced and testing resumed. Users shall be notified of the failure. Users shall make the final determination that the test was properly conducted
38、 and restarting the test is appropriate. Users shall have access to the failed parts and all other related materials to determine that the failed parts did not influence the test. Initial setup shall have one test specimen with its clamshell coupling split line parallel (0 degree 10 degrees) to the
39、test plate surface. The second test specimen shall have the clamshell coupling split line normal (90 degrees 10 degrees) to the test plate surface as shown in Figure 3. O-rings may be replaced as necessary with user concurrence and shall be documented in the test report. All coupling debris shall re
40、main untouched when the O-ring is replaced. The O-ring groove may be cleaned prior to installation of the replacement O-ring. Testing shall use propylene glycol per ASTM D6210 or equivalent (except the solution shall be greater than 65% propylene glycol). The test fluids used in each test shall be d
41、ocumented in the qualification test report. 4.4.5 Test Sequence Life cycle qualification testing shall be performed per the sequences shown in Table 5A and 5B. The specimens shall not be disassembled for the entire test sequence except for the coupling Repeated Assembly test in 4.6.11 and Re-examina
42、tion of Product in 4.6.12. Life Cycle Test Schedule and Sequence Tests: Eight test specimens for each coupling size being qualified shall be subjected to qualification tests in the order specified in Table 5A. All eight test specimens shall be tested without replacement. AMS-R-25988 O-ring seals wit
43、h sizes per AS568 shall be used for all test specimens when required. SAE INTERNATIONAL AS5830A Page 19 of 34 4.4.6 Test Report a. Test Samples and Data for Users: When the tests are conducted at the manufacturers laboratory, the following shall be required. 1. Test Sample: The test specimens shall
44、be made available for user inspection when requested. 2. Test Data: The user approved qualification test plan with the approval correspondence Three sets of assembly drawings: The assembly drawings shall have a cut-away section showing all details in their normal assembled position and shall list pa
45、rt numbers of all details and subassemblies. b. Test Report: The test report shall be in accordance with MIL-HDBK-831, which shall include a report of all tests and an outline description of the test setup and test conditions, as well as meeting the following requirements. 1. Required Report Informa
46、tion: The qualification test report shall contain a test summary of all qualification tests at the beginning of the report. The summary of test results shall also reference the page number and section number that detail the summarized result. 2. Proper report format with page identification for docu
47、mentation and references in addition to the general requirements established in MIL-HDBK-831. 3. Calibration information (calibration date, required calibration date, parameter being calibrated, etc.) for all testing equipment. 4. Material traceability, dimensional inspections (with a drawing showin
48、g the dimension being inspected) and component traceability for all parts used in the qualification testing program. 5. Test requirements and actual test conditions and results for each test, such as temperature, pressure, total cycles, voltage, current, resistance values, etc. 6. Provide scaled imp
49、ulse pressure axis labels; pressure on vertical axis, time on horizontal axis. 7. Provide scaled vibration test traces with input and response traces. 8. Provide a list of failures with failure conditions and photographs of failed components. 9. Provide copies to users of all correspondence related to notification of failure, noting time, date and circumstances of failure. 10. Failure analysis, mode of failure and corrective ac
