1、ADS-43A-HDBK AERONAUTICAL DESIGN STANDARD “DBOOK QUALIFICATION REQUIREMENTS AND IDENTIFICATION OF CRITICAL CHARACTERISTICS FOR AIRCRAFT ENGINE COMPONENTS UNITED STATES ARMY AVIATION AND TROOP COMMAND ST.LOUIS, MISSOURI AVIATION RESEARCH AND DEVELOPMENT CENTER DIRECTORATE FOR ENGINEERING DISTRIBUTION
2、 STATEMENT A. distribution is unlimited. Approved for public release, Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-ADS-43A-HDBK ADS-43A-HDBK This Army Aeronautical Design Standard (ADS) Handbook is prepared under the authorization of Army Materiel
3、 Command (AMC) Regulation 70-32. Any recommended corrections, additions, or deletions which may be used in improving this document should be addressed to: U.S. Army Aviation and Troop Command 4300 Goodfellow Blvd. St. Louis, MO 63120-1798 ATTN: AMSAT-R-E This handbook is for guidance only. This hand
4、book cannot be cited as a requirement. If it is, the contractor does not have to comply. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-ADS-43A-HDBK TABLE OF CONTENTS SECTION 1 GENERAL QUALIFICATION REQUIREMENTS 1.1 INTRODUCTION 1.1.1 Purpose 1.1.2
5、Implementation 1.1.3 Use of Alternate Suppliers / Processors 1.1.4 Definitions 1.2 APPLICABLE DOCUMENTS 1.3 GENERAL REQUIREMENTS 1.3.1 General 1.3.2 Source Control Drawings 1.3.3 Dimensional Substantiation 1.3.4 Material Substantiation 1.3.5 Process Substantiation 1.3.6 Manufacturing Process Control
6、 1.3.7 Flight Safety Parts 1.3.8 Approval to Conduct Testing 1.3.9 Parts Not Requiring Qualification 1.4 TEST REQUIREMENTS 1.4.1 General 1.4.2 Environmental Tests 1.5 APPROVAL OF TEST RESULTS 1.5.1 Test Component Evaluation 1.5.2 Rejection and Retest 1.5.3 Alternate Source Approval 1.5.4 Change in A
7、pproved Sources / Processes PAGE 2 2 3 3 3 4 5 5 5 5 6 6 6 7 7 7 1 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,- ADS-43A-HDBK SECTION 2 IDENTIFICATION OF CRITICAL CHARACTERISTICS 2.1 INTRODUCTION 2.2 CRITICAL CHARACTERISTICS 2.2.1 Materials 2.2.2
8、Manufacturing 2.2.3 Processes 2.2.4 Inspection Methods 2.2.5 Typical Critical Characteristics (Baseline) 2.3 TEST DESCRIPTION Code A Code B Code C Code D Code E Code F Code G Code H Code I Code J Code K Code L Code M Code N Code O 2.3.1 High Cycle Fatigue Tests Seal Tests Bearing Tests Gear Tests En
9、durance Tests Low Cycle Fatigue Tests Engine Performance Tests Special Tests Electronic Control Testing Fuel Control Testing Valve Assembly (Hydraulic assembly, manufacturing or inspection process; operation, software, field maintenance, or depot overhaul requirements, which, if nonconforming, missi
10、ng, or degraded could cause the failure or malfunction of the FSP. Critical characteristics produced during the manufacturing process are termed Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-ADS-43A-HDBK “manufacturing critical characteristics.” Cr
11、itical characteristics which are not introduced during the manufacture of a part but are critical in terms of assemblyhnstallation, for example proper fastener torque, are termed “installation critical characteristics.” Engineering Tests - Tests conducted to assure that parts, components, or assembl
12、ies installed in engines will perform satisfactorily (i.e. endurance tests, interchangeability tests, environmental tests, etc.). First Article Test - Test and evaluation of initial production samples for conformance with specified contract requirements before or, in the initial stage of production.
13、 Flight Safety Part - Any part, assembly, or installation containing a critical characteristic whose failure, malfunction, or absence could cause an uncommanded engine shutdown, and/or catastrophic engine failure resulting in loss or serious damage to an aircraft and/or serious injury or death to th
14、e occupants. NOTE: Refer to MIL-STD-882B for further explanation or aircraft and personal safety hazard severity categories. Part - An essential portion or integral element which cannot be easily further subdivided. Prime Design Contractor - The original end item (i.e. engine) designer and/or manufa
15、cturer who, under Government auspices, selected various subcontractors to furnish parts and components for the total engine assembly. Qualification Requirements - A requirement for testing or other quality assurance demonstration that must be completed by an offeror. Qualification testing performed
16、either as a “Prequalification Test” prior to contract award, or as an “Engineering Test” at the time of First Article Testing (FAT), should be performed as directed by USAATCOM engineering at the time of solicitation. Source Controlled Drawings - Drawings which list such data as physical envelope, m
17、aterials, operating environment, and design parameters. Each part number is normally a different configuration or design, which will perform the functions specified on the drawing. The drawings also list the manufacturing source that is qualified to produce each design. 1.2 APPLICABLE DOCUMENTS The
18、following documents form a part of this specification to the extent specified herein. In the event of a conflict between the documents referenced below and the contents of this specification, the contents of this specification must prevail. In other paragraphs of this specification only the basic do
19、cument number is stated. The revisions and changes for the applicable documents are identified only in this paragraph. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-ADS-43A-HDBK Other applicable documents listed elsewhere in this document: ATCOM Re
20、g 702-7, Flight Safety Parts Program Management AMC 702-32, Critical Safety Items Program Federal Acquisition Regulation, Part 6 and Subpart 9.2 MIL-1-45208, Inspection Requirements (or as specifiedin the contract) AV-E-8593D7 Engines, Aircraft, Turboshaft and Turboprop, General Federal Test Method
21、Standard No. 15 1 Metal, Test Methods of NISO 239.18.199X Scientific and Technical Reports, Elements, Organization MIL-STD-8 1 OC, Environmental Test Methods and Engineering Guidelines ATCOM QE-STD- 1 Flight Safety Parts Quality Systems Requirements ATCOM Competition Advocates Shopping List (CASL) E
22、T-STD 1 Engineering Test Requirements for New Sources MIL-STD-498C Software Development and Documentation Specifications for. and Design (or as specified in the contract) 1.3 GENERAL REQUIREMENTS 1.3.1 General The ETTs, in the FSPIS, provides lists of engine parts, components, and assemblies with th
23、e qualification requirements an alternate source must meet before that source can be approved to manufacture the component. Production components must be manufactured by the altemate source using the same facilities, equipment, and procedures that were used to manufacture the substantiation test art
24、icles (see paragraph 1.3.6). Requirements listed for assemblies include all requirements listed for parts and components used in that assembly. The alternate source must certi they have a quality program established which meets the requirements of MIL-1-45208 or a comparable higher-level non- govern
25、ment quality system before qualification testing may commence. (Mandatory 100% inspection in accordance with MIL-Q-9858A requires a waiver.) This certification should be submitted as part of the inspection report. 1.3.2 Source Control Drawings Source Control Drawings (SCD) list those sources that ar
26、e qualified to produce that particular component. The alternate source must satis all requirements specified by the SCD, any associated procurement specification, and requirements specified herein in order to be approved. Any duplication of requirements may be ignored. A test plan for substantiating
27、 compliance with SCD requirements must be submitted to USAATCOM engineering for approval prior to testing. The required Design Qualification Testing must Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-ADS-43A-HDBK 1.3.3 1.3.4 1.3.5 1.3.6 be performe
28、d as a “Pre-qualification Test” since each vendor provides an entirely different design. Dimensional Substantiation All drawing dimensions, limits, and tolerances must be adhered to. All components listed in the attachments and used for testing in accordance with this document must require substanti
29、ation of all drawing dimensional requirements. The results of this dimensional substantiation should be included in the inspection report and submitted to USAATCOM engineering for approval (see paragraph 1.3.8). Material Substantiation Components must only be fabricated from the material(s) specifie
30、d. Castings and forging must only be procured from sources which have been previously approved by the prime contractor or USAATCOM engineering for each specific part or component. Other material used will be in accordance with all applicable procurement specifications. Substantiation of compliance w
31、ith these requirements is required for all components listed in the ETT in the FSPIS. To access the FSPIS, see the FSPIS Users Guide or contact AMSAT-R-EBS. This substantiation should be included in the inspection report and submitted to the procuring service for approval (see paragraph 1.3.8). Proc
32、ess Substantiation The service life of engine components, particularly high speed rotating parts, is greatly affected by the processes performed during the manufacture of these parts. It is imperative that all processes are performed in a manner virtually identical to that established during the dev
33、elopment of these components. All processes used in the fabrication of engine components must be performed by sources which have been previously approved by the prime contractor or USAATCOM engineering for each specific part or component. Other processors may be approved by the prime contractor or U
34、SAATCOM engineering upon request or, if the need arises. This includes heat treat, shot peen, finishes, forming, welding, coatings, plating, and all other processes used to manufacture the part. The component must also be subjected to all inspections (e.g., Nondestructive Inspection (NDI) required b
35、y the drawing. Verification of compliance with process requirements and documentation of all inspection results is required for all components listed in the ETT in the FSPIS. Engine low cycle fatigue (LCF) spin pit testing may be required to substantiate parts lives in some cases. These should be in
36、cluded in an inspection report and submitted to USAATCOM engineering for approval (see paragraph 1.3.8). No new sources for processing engine parts will be approved until they have met all of the above requirements. Manufacturing Process Control 6 Provided by IHSNot for ResaleNo reproduction or netw
37、orking permitted without license from IHS-,-,-ADS-43A-HDBK 1.3.7 1.3.8 1.3.9 1.4 1.4.1 A manufacturing and quality control process sheet listing the sequence of operations, operation descriptions, parameters, inspection stations and criteria, and specific equipment used to produce the component shou
38、ld be included in the inspection report and submitted to USAATCOM engineering (see paragraph 1.3.8). Upon acceptance of FAT for the component by USAATCOM engineering the process sheet including all changes made during the substantiation effort must be classified as “frozen planning.” Any proposed ch
39、anges to the frozen planning must be submitted to USAATCOM engineering for approval. Flight Safety Parts Drawings of components and assemblies that are classified as FSP containing critical characteristics and are identified in the ETT in the FSPIS, may have additional requirements as specified in A
40、TCOM Reg 702-7 and the STDP. Substantiation of conformance of all FSP critical characteristics to drawing requirements, specifications, acceptance test procedures, and detailed plans for the 100% inspection of critical characteristics, or a previously approved statistical substitute, should be inclu
41、ded in the inspection report and submitted to USAATCOM engineering for approval. Approval to Conduct Testing Alternate sources must not commence qualification testing until an inspection report substantiating that all requirements of this section have been met, has been submitted to and approved by
42、USAATCOM engineering. Upon receipt of approval, the alternate source may begin testing. The test plan may be submitted as part of the inspection report. Standard required tests are detailed in subsequent sections of this specification. Parts Not Requiring Qualification Testing Certain engine parts,
43、components, and assemblies do not require qualification testing. Alternate sources of these items must be approved by having met the requirements provided in the CASL and STDP and by receipt and approval of documentation of compliance with the above requirements from USAATCOM engineering. With the e
44、xception of FSP, manufacturing process sheets are not required for these items. These requirements may be substantiated as part of the FAT. TEST REQUIREMENTS General Certain components listed in the ETT require qualification testing in addition to substantiation of the dimensional and metallurgical
45、requirements. The inspection report 7 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-ADS-43A-HDBK must be approved by USAATCOM engineering before testing commences. The alternate source must submit a test plan detailing the proposed test procedure(s
46、), pasdfail criteria, testing and measuring equipment to be used, test location and dates, test article inspection plans, and test quality assurance provisions to USAATCOM engineering. Qualification testing can commence only after this test plan is approved. Required testing includes endurance, oper
47、ational, interchangeability, and fatigue testing and is described in Section 2. Other tests, at the discretion of the USAATCOM engineering, may be added as part of the qualification requirements. Approval of the alternate source should be contingent upon successhl completion of the applicable test(s
48、) conducted in accordance with the approved test plan, examination of the component by USAATCOM engineering, and upon receipt and approval by USAATCOM engineering of a test report and inspection report which documents all testing and results. Test plans must be in accordance with contract requiremen
49、ts, and test reports in accordance with NISO 239.18.199X, or per contract. 1.4.2 Environmental Testing Components may require environmental tests as specified in the Engine Model Specification, AV-E-8593, or as determined by USAATCOM engineering. A new source for such components may also be required to demonstrate that the component does not alter engine operations. Such tests may include high and low air temperatures or
