1、-II NOT MEASUREMENT “SENSITIVEIMIL-P-9400C“14November 1991SUPERSEDINGMIL-P-9400B26 Aprl1 1977MILITARY SPECIFICATION,-.PLASTIC LAMINATE ANO SANDi41CtlCONSTRUCTION PARTS ANO ASSEMBLY,AIRCRAFT STRUCTURAL , PROCESS SPECIFICATION REQUIREMENTS“Thisspecification is approved ,for use by all Departments andA
2、gencies of the Department of Defense.1. SCOPE1.1 . This specification provides detailed instructions for thepreparation of, and requirements to be included in, process specificationsrequired for the processing, inspection, pre-ftt, and assembly of structuralplastic laminate and sandwich construction
3、 parts for aircraft.1.2 Classification. This specification covers the foliowing types andclasses of parts:Type I - Plastic laminate (6.2.8).Type II - Sandwich constructed pirts of plastic laminates(Type 1) and nonmetallic or metallic cores (6.2.18).2. APPLICABLE DOCUMENTS2.1 Specifications and,stand
4、ards. The following specifications and standards form a part of this document to the extent specified herein. Unlessotherwise specified, the issues of these documents are those listed in theissue of the Department of Defense Index of Specifications and Standards(DODISS)”and supplement thereto, cited
5、 in the solicitation.SPECIFICATIONSMFLITARYMIL-A-83377 Adhesive Bonding (Structural) for Aerospace and OtherSystems, Requirements forBeneficial comments (recommendations, additions, deletions) and any pertinentdata which may be of use in improVing this document should be addressed to:Commanding Offi
6、cer, Systems Engineering an! Standardization Department(Code 53), Navai Air Engineering Center, i+kehurst, NJ 08733-5100, by usingthe Standardization Document Improvement Proposal (DD Form 1426) appearing atthe end of this document or by letter.AMSC N/A AREA CMPSDISTRIBUTION STATEMENT A. Approved fo
7、r public release; distribution is unlimlted.,.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-. . .MIL-I-45208;:b.cSizel maximum.Location, 1Imitation.Repairable or nonrepairable. :3.6.1.10 Delamination and non-bonds. Delamination(s) are defined as th
8、eseparation of-the lavers of materjal in a lamlnate. A non-bond indicates thatthe l“amitiatenever banded during ,the cycle cure. The following shal1 bespecified in the contr prcs spec:a; Size, maximum.b. Location, depth and proximity to other defects or to edge.43.6.1.11 Foreign matter. There shal1
9、be no foreign objects orsubstances in the laminate part which will cause structural or electricalnonserviceabi 1ity of the part. Foreign matter shal1 b.edefined as anymaterial not jnciuded jn the contr prcs spec or engineering drawing. Foreignmaterial in the lay-up area shall be demonstrated to be d
10、etectable byproduction non-destructive inspection (NDI) techniques (3.10.2) . Maximumallowable foreign material sizes shal1 be determined by the contractor forvarious materials, and inclusions exceeding these sizes shall requireengineering disposition.3.6.1.12 Breakout and splintering. Breakout is d
11、efined as fiberseparation or breakage of surface piies at drilled or machined edges.Splintering is a combination of crackirigand delamination of the outer skin. ,Breakout and splintering shall be minimized through control of feeds andspeeds, machine tool/drilI bit replacement, and backside support w
12、herepossible.criteria:a.b.c.d.For each breakout and splintering area, specify rejectable defectSize.Location.Number, maximum per area.Repairable or nonrepairable.3.6.1.13 Bridginq. A condition where fibers do not move into or conformto radji and corners during molding, resulting In voids and dimensi
13、onalcontrol problems.3.6.1.14 Fiber distortion. An abrupt change in fiber orientation.3.6.1.15 Resin rich areas. Localized area filled with resin and lackingreinforcing material .3.6.2 Sandwich construction (Type 11) defects. The minimum requirementsfor the sandwich parts and the maximum allowable a
14、nd,repairable defects forstructural zones shall be as specified b the prime contractor. Any sandwichparts having defects in nature, size, lotation or extent beyond approvedrepairable conditions shal1 be disposed of, as applicable, in accordance withMIL-STO-1520. Oefects to be specified are as follow
15、s:3.6.2.1 Unbended areas. The following limits shall be given forI 8.IIProvided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-,.IIIII1.UIL-P-9400C“.unrepaired unbended areas between the, of core.b: .Size,maximum.laminate (skIn) and core, between Piecesand m
16、etal . The following shall bearea between skin and core and betweenc. Location, (including proximity to other defects,holes).3.6.2.2 Laminate (skin) defects. Skin defects shallextent specified in 3.6.1.3.6.2.3 Core crushes. Core crushes are defined as adistortion or compression of the core.edges or
17、fasteerbe allowed to thetcollapse,3.6.2.4 Cell distortion. Cell,distortion and variation of ribbondirection shall be defined.3.7 Mechanical and physical requirements.3.7.1 Cured iaminates (Type I). The mechanical and physical propertiesof the laminate in 4.3.3.I.2, where applicable, shall be tested
18、for inaccordance with and defined in the applicable laminate specification.3.7.2 Bonded sandwich construction (Type 11). The mechanical propertiesfor sandwfch construction in 4.3.3.1.2 shall be tested for in accordance withand defined in the applicable sandwich specification. The requirements of3.7.
19、1 shall also be met.3.8 Electrical requirements (where applicable) The laminate orsandwich construction parts shal1 conform to the electrical requirements ofthe applicable laminate or sandwich construction specifications.3.9 Dimensional requirements. The iaminate (Type 1) and sandwichconstruction (T
20、ype 11) parts shall meet the dimensional requirements”of thedrawings, specification or contract for the specified ,parts.- 3.10 Inspection and testing. The contractors inspection and testingprogram shalI meet the requirements of MIL-I-45208. Visual and nondestructiveinspection.methods shal1 be descr
21、ibed in detail in the contr prcs spec ascontained herein.3.10.I Visuai inspection. Visual inspection procedures to detectsurface defects such as in 3.6 shall be described in detail 3.10.2 Nondestructive testng and inspection. !nondestructiveinspection and testing program shal1 be established in acco
22、rdance withMIL-I-6870. Methods and equipment used for nondestructive inspection shall bedescribed in detail . All nondestructive testing shal be performed inaccordance with the contr prcs spec. The appropriate nondestructive testingmethods shall be determined for al1 zones of structure to ensure rej
23、ectabledefects may be found. Sampling plans shall be defined based on structuralzones (see 3.6.1) and may be used for nondestructive testing. All samplIng9Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-, . -”I.“ .MIL-P-9400C.“ !,plafjsshall identify
24、 the statistical risk of not detecting a ejectable defect. )3.10.2.1 Ultrasonic inspection and testing. The following equipment,methods and standards shalI be described:a.b.“c.d.e.f.9.h.i.1:m.n.o.P.,Infpection method type.Manufacturer and model numbers of instrumentation (include recordlngequipment,
25、 alarm equipment and electronic distance-amplitude !correction equipment).Description of manipulating and scan ing equipment.Couplant.Method of establ ishing scan sensitivconcave and convex surfaces, if applScanning plan.Reference standards.ty and index determinatio forcabie.Disconti”nuity evaluatio
26、n procedure.Attenuation - dB loss (thick section), dB loss (thin section).Criteria for flaw type, size, and number. “Description of recording methods and how traceabi iity is estabiished.Sampling plan,Part positioning including water path length and sound entry angle.Set up calibration using the app
27、iicable reference standard.Any special requirements relative to the specific technique (suchas. when usina focused transducers the waterpath shali be such as toposition the Focal point to miximize detection of the maximum (orsmaller) allowable size defect at any depth and location in thestructure).A
28、ny other pertinent data.3.10.2.2 Radiographic testinq and inspection. . The following equipmentmethods and standards shali be described: -,a.b.-:- e.f.:.:k.1.m.n.Manufacturer and modei numbers of equipment, KVP rating, focal sposize, and tube head type.Reference standards or radiographs.Kilovoltage.
29、Level of exposure (duration) in mi11iampere minutes or Curies.Focal film distance.Film density range in the area of interest.Film brand, type and size.Screens (type and thickness).Penetrameter thickness; type, number, and placement.Quality levei of penetrameter.Film processing (manual or automatic).
30、Description of marker positioning.Acceptance criteria.Sampiing plan. !3.10.2.3 O however, this does not authorize submission of knowndefective material, either indicated or actual, nor does it commit theGovernment to accept defective material .4.2 Process specification. The primary and continuing pu
31、rpose of theacceptance tests is to ensure that al1 the requirements and procedures of theapproved contr prcs spec are continuously complied with during the productionof parts. This shall be accompl Ished by periodic review of the productionprocesses, inspection methods, controls, and other iternscov
32、ered by theprocess specification for conformance with the requirements of the latter.The process specification shall contain all the general requirements forsampling, inspection and testing. Specific and detailed requirements shall beas specified on the engineering drawing.,.4.3 Classification of in
33、spection. The inspections, which includeexaminations and tests, performed under this specification shall be classifiedas contained.herein.4.3.I Incomnq material inspection. The incoiningmaterial inspection,including sampling and testing, of all materials or laminates to be used inthe fabrication of
34、all laminates (Type I) or sandwich construction (Type II)shall be in accordance with their applicab,l,especification (3.1.3).“4.3.2 First article inspection. Prior to fabrication of productionparts, fabrication procedures for each part”shall be verified to assureconformity with the engineering drawi
35、ng requirements as wel1 as the physicaland mechanical requirements. The contractor shall specify and define a ftrstpart to be prepared In accordance with 3.5 on the tooling to be used inmanufacturing the contracted part. Conformance with the requirements of 3.6and 3.9 shall be verified by visual ins
36、pection (3.10.1) and nondestructiveinspection (3.1O.2). Following testing.to 3.6 and 3.9, the part shal”lbe cutinto specimens for testing for conformance with the requirements of 3.7 and3.8. A destructive test plan shall be submjtted to the procuring activity forapproval. The first article destructi
37、ve testplan shall include, but 1s notllmited to,the requirements of 4.3.3.1.2 (including photomlcrographs) andother tests required to verify part Integrity. Additlonal mechanlcal propertytests representative of the critical failure mode for ,crlti.calzones (see6.2.4) of the part shall also be conduc
38、ted. For bucklIng critical structure,the compression strength and niodulus test shall be conducted. First article,iII 12Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-. . . . . . . . . . . . . MIL-P-9400C“inspectIon shalI be performed for al1 new to
39、oling, or for any major change in,? design,.materials, or process which could alter the properties or performance,? of the finished part.4.3.3 Production inspection.,4.3.,3.J.Process control testing.,.4.3.3.1.1 Samplinq. Unless otherwise specified in the contract, thefabricator shal1 specify and def
40、ine the size, source and sampling rate ofspecimens for testing for conformance to the requirements of 3.7, 3.8 and3.9. Critical parts (see 6.2.4) shall be tested 100 percent. Specimen shall:consist of tab ends, cut-outs or cut-offs of production parts or eleme s, ortest panels from a typical lay-up
41、of the part from the same bag, tool andprocessing conditions.4.3.3.2 . Test methods shall be described in the contr prcs specif not shown in the applicable laminate or sandwich specification (see 3.7).The followlng physical and mechanical property values shall be determined:a. Laminates.1. Degree of
42、 cure.2. Interlam!nar shear strength (short beam shear).3. Void content.4. Ply orientation.5. Critical mechanical property tests (where applicable andapproved by the procuring activity).Ply orientation/stacking shall be determined through the use ofphotomicrographs or other suitable methods to deter
43、mine conformance of thepart with the engineering drawing or Part specification.b. Sandwich construction.1. Sandwich flexure.2. Flatwise tension.I 4.3.3.2 Documentation. All parts shall be accompanied by a travelerI sheet through production and final inspection. The traveler sheet shallcvtitaincheck-
44、off inspection Doints for each steo in the manufacturlna andinspection processes.” A minimum check off inspeton shall contain tiefollowing:a. Incoming material inspection (4.3.1).b. First article inspection (reproduction) testing (4.3.2).c. Any deviation from process (3.1.2).ie. Any abnormal ity or
45、otherwise deviation/substitution from therequired process.d. Process control testresults (4.3.3.1).e. Facilities (4.3.4) and tooling inspection (4.3.5).f. Repairs (4.4), retest (4.5), and rejection (4.6), if applicable.9. Final quality assurance verification.4.3.3 .2.1 Cure records. Time, temperatur
46、e, vacuum and pressurecharts (see 3.5.3) shall accompany each traveler sheet or the records13recordedshall beProvided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-. .MIL-P-9400Cmaintained with adequate traceab!11ty In accordance WIth the contract.,; 4.3.4
47、Facilltiisinspection. An insection plan shall “beestablishedand described In detail in the contr prcs spec for the periodic verificationof cleanliness and to verify the proper control of the facilities andoperations. Such Inspection shal1 cover areas used for the storage, cutting,1ay-up and crjng of
48、 material and the fabrication .ofcured parts. The timeand date cSfthe last inspection shall be “documented (4.3.3.2). Conditionsfound during such inspection whiclimay be detrimental to the finished partsha1 be recorded and corrective actions described. Such records shal1 bemade avaiIable, in accorda
49、nce with the contract, to the purchaser uponrequest. ,. ,!4.3.5 ,Tmlinq inspection. An inspection plan shall be established anddescribed for the periodic inspection of critical tooling (3.4.3). Suchinspection.,shaliinclude verification of dimensional accuracy and examinationfor tool wear and distortion. The time and date of the last inspection shallbe documented (4.3.3.2).4.4 Repairs. The contractor wi11 supply the actions required to
