Professional Documents
Culture Documents
Raytheon - Control of Product Manufacturing Processes For Suppliers and Outside Production
Raytheon - Control of Product Manufacturing Processes For Suppliers and Outside Production
Engineering Specification
BS25691 Rev 8
Control of Product Manufacturing Processes
For
Suppliers and Outside Production
DOC153925 R8
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 2 of 68
Title Page Rights Apply
Revision History
Revision Written by Date Approved Description of Changes
Michael Granite 02-10-2005 See Electronic Last Revision: Revision 7
8 Approvals
Summary of Changes:
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 3 of 68
Title Page Rights Apply
Table of Contents
Page
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 4 of 68
Title Page Rights Apply
List of Figures
Page
List of Tables
Page
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 5 of 68
Title Page Rights Apply
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 6 of 68
Title Page Rights Apply
1. SCOPE
1.1 Purpose
The purpose of this Raytheon Aircraft Company (RAC) Engineering Specification is to define and
provide the manufacturing practices and special processing requirements for materials and parts
produced by suppliers and outside manufacturers for RAC.
NOTE
This document is proprietary. Refer to Raytheon
Aircraft Company (RAC) Proprietary Data statement
on the Cover page of this document.
1.2 Applicability
This specification is applicable to all RAC suppliers and outside manufacturers that supply materials and
parts to RAC. This document is not applicable to any RAC in-house operations.
NOTE
Should a conflict develop between this document and
RAC Engineering drawings, the more stringent
requirement shall be followed. Deviations to this
shall be addressed to RAC Engineering.
If no process and/or inspection requirements are
provided on the RAC Engineering drawings, then the
requirements of this Specification shall apply.
1.3 Limitations
The following limitations are also applicable to this document:
This document is not applicable to any RAC in-house operations.
This document shall be used in conjunction with RAC Engineering Type Design documents.
RAC Engineering documents typically note or reference specifications and other documents for
control of material and processing operations. When this occurs, the latest released revision of
the referenced document is considered to be the revision in effect unless otherwise specified.
It shall be the responsibility of the Supplier or Outside Manufacturer to maintain on file the current
released revision of all documents referenced for contracted work with RAC. This shall include,
but not be limited to Government, Military, and Federal specifications, consensus specifications,
industry standards, specifications, documents, and applicable/required RAC drawings and
documents.
It shall be the responsibility of the Supplier or Outside Manufacturer to ensure that all sub-tier
suppliers and manufacturers are furnished with all RAC Engineering requirements and all
applicable drawings and documents.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 7 of 68
Title Page Rights Apply
RAC shall provide the Supplier and Outside Manufacturer with the latest revisions to required
RAC documents. It shall be the responsibility of the Supplier and Outside Manufacturer to ensure
that all sub-tier suppliers and manufacturers receive these latest revisions.
The Document number and Revision Level and all applicable documents and specifications
shall be listed (documented) on all Certificates of Compliance from the suppliers and their
subtier suppliers.
When encountering processes and practices where Government, Industry, and/or RAC
documents do not exist as a guide in these processes and practices (e.g. Light Chemical Etching
of Aluminum, Chromic Dip for Lead Alloys), Best Industry Practices shall be use. Contact RAC
if questions should arise.
In the event a referenced document has been superceded, the superceding document shall be
used to the extent implied. All questions shall be directed to RAC Supply Chain Management.
In the event a reference document has been canceled without a supercedure or replacement
document being identified, RAC Supply Chain Management shall be notified immediately in order
to determine disposition.
RAC Engineering drawings that begin with the 45A, 8888 or MUV prefix and reference
Mitsubishi Heavy Industries (MHI) specification P9000 or other Pxxxx series specifications
shall refer to RAC Engineering specification BS24457 to determine the applicable and approved
process specifications to be used. The reference on all other RAC Engineering drawings to MHI
Pxxxx series specifications, with the exception of the documents listed in Section 2 Applicable
Documents shall be referred to RAC for applicability and approval.
Any reference on any RAC Engineering drawings to P1920 specification shall be referred to
RAC for applicability and approval.
All processes and specifications referenced on 25 prefix series engineering drawings (RAC
Hawker, except for Hawker Horizon) shall be referred to RAC for disposition.
Proof Testing On many parts and assemblies, RAC Engineering drawings and specifications
require a proof load test be performed to ensure the integrity of the a braze joint. When proof load
testing is specified, a proof load test shall be performed and verification of this test shall be
included with the part/assembly certification documents.
1.4 Abbreviations, Acronyms, Symbols, and Definitions
This section contains a listing with explanation of uncommon abbreviations, acronyms, symbols, and
defined terms that are contained in this document. Many detailed definitions are provided for specific
words, terms, and processes and are located in the applicable Sections and Sub-sections of this
document.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 8 of 68
Title Page Rights Apply
BROKEN EDGE, BREAK EDGE, OR BREAK SHARP EDGE To place a radius or chamfer at the
intersection of two planes or surfaces.
SHALL The term shall, when used in this document, expresses a requirement that is binding.
MAY and SHOULD The terms may and should, when used in this document, expresses non-
mandatory or required items and/or tasks. Even though these items and/or tasks are not
required, it is recommended that they be accomplished.
BEST INDUSTRY PRACTICE Used to describe a situation where certain processes and practices
have no specific documentation on how to be performed. When this occurs, common industry
processes and practices are to be used. These processes and practices shall be approved by
RAC prior to use.
RAW MATERIAL - At RAC, raw material is defined as sheet (rolled product 0.249 inch or less in
thickness), plate (rolled product 0.250 inch and greater in thickness), extrusion, tubing, bar,
forgings, castings, etc., of all alloys, of all material alloy families utilized in the manufacture of
parts.
MILL - At RAC, a mill is the producer or production facility of the material that processes the raw
material (i.e. ingot, billet) into the finished form (i.e. extrusion, sheet, plate, casting, or forging).
FINE GRAINED Unless specified otherwise by contractual or governing documents, fine grained is
defined as material having an average grain size number of No. 5 or greater in accordance with
ASTM Specification E-112. (i.e. the larger the number listed, the finer the grain.)
2. APPLICABLE DOCUMENTS
The following documents/specifications are applicable to this specification and may be referenced within
this specification:
2.1 Government/Military
Military:
MIL-A-8625 Anodic Coatings for Aluminum and Aluminum Alloys
MIL-C-5541 Chemical Conversion Coatings for Aluminum and Aluminum Alloys
MIL-C-8514 Coating Compound, Metal Pretreatment, Resin-Acid
MIL-C-14550 Copper Plating (Electrodeposited)
MIL-DTL-16232 Phosphate Coating, Heavy, Manganese or Zinc Base (for Ferrous
Metals)
MIL-DTL-81706 Chemical Conversion Materials for Coating Aluminum and Aluminum
Alloys
MIL-L-23398 Lubricant, Solid Film, Air Cured, Corrosion Inhibiting
MIL-L-46010D Lubricant, Solid Film, Heat Cured, Corrosion Inhibiting
MIL-PRF-23377 Primer Coatings, Epoxy, High-Solids
MIL-PRF-3150 Lubricating Oil, Preservative, Medium
MIL-S-5002 Surface Treatments and (Inorganic) Coatings for Metal Surfaces of
Weapons Systems
MIL-S-5059 CRES Steel Plate, Sheet, & Strip
MIL-S-6721 CRES Steel Plate, Sheet, & Strip
MIL-S-6758 Steel, Chrome-Molybdenum (4130) Bars & Forging Stock
MIL-S-7952 Carbon Steel Sheet & Strip
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 9 of 68
Title Page Rights Apply
Military:
MIL-T-8606 TUBING, STEEL, CORROSION-RESISTANT
(18-8 STABALIZED AND EXTRA LOW CARBON)
MIL-T-8808 CRES Steel Tubing
MIL-S-18729 Steel, Plate, Sheet, Alloy (4130) Aircraft Quality
MIL-STD-1500 Cadmium-Titanium Plating, Low Embrittlement, Electrodeposition
MIL-STD-1907 Inspection, Liquid Penetrant and Magnetic Particle, Soundness,
Requirements for Materials, Parts, and Weldments
Federal:
O-F-499 Flux, Brazing
QQ-C-390 Copper Alloy Castings
2.2 Industry
American Welding Society (AWS)
AWS A5.8 Filler Metals for Brazing
AWS C3.4 Torch Brazing
AWS C3.5 Induction Brazing
AWS D17.1 Fusion Welding in Aerospace Applications
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 10 of 68
Title Page Rights Apply
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 11 of 68
Title Page Rights Apply
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 12 of 68
Title Page Rights Apply
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 13 of 68
Title Page Rights Apply
3. 3. REQUIREMENTS
The following sub-sections provide information and requirements for the many manufacturing practices
and processes covered by this specification.
3.1 Raw Material
General
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 14 of 68
Title Page Rights Apply
Raw material utilized for fabrication of RAC parts shall be procured only from producing mills approved
by RAC. A listing of RAC approved raw material mills is located at the Supply Chain Management web
site.
For definitions of Raw Material, Mill, and Fine Grained see sub-section 1.4.
a. Mill Test Reports
A copy of the original producing mill test report for the raw material shall be included in the certification
documents submitted with the part order. A material distributor generated conformance of the raw
material is not an acceptable substitute for a copy of the original mill test report. Commercial grade raw
materials that do not include references to government or other aerospace specifications, shall be
accompanied by certificates of conformance.
b. Material Substitution
RAC approved material substitutions are contained in Tables 5 through 13 and table 16. Substitution of
material alloy, temper, controlling specification, thickness or diameter, and/or product form other than
those allowed by this specification, is not acceptable without the written consent of RAC. See Raw
Material Modification Form and Example in Appendix A.
For raw material supplied to RAC for RAC produced parts, alternate thickness shall be approved by
RAC Process Engineering and Manufacturing before purchasing materials.
If the size (thickness or diameter) of an approved substituted aluminum and copper alloy material is
different from the material listed on the RAC Engineering drawing, the tensile and yield strength
properties of the material must be compared for acceptability. The tensile and yield strength properties
of the substituted material for a specified size shall be equal to or exceed the tensile and yield strength
properties of the original material listed on the RAC Engineering drawing.
Example 1: A three inch thick 7075-T7351 aluminum alloy plate per AMS-QQ-A-250/12 shall not be
substituted for a 0.250 inch thick 7075-T73 aluminum alloy sheet per AMS-QQ-A-250/12
as called out on the RAC Engineering Drawings. Even though the 7075-T7351 alloy is the
same, the tensile strength and yield strength properties of the 3-inch material (Minimum
Tensile Strength Requirement of 64 ksi and Minimum Yield Strength Requirement of 49
ksi) is less than that of the 0.250 inch material (Minimum Tensile Strength of 69 ksi and
Minimum Yield Strength of 57 ksi) and therefore cannot be substituted, but one inch thick
material (Minimum Tensile Strength Requirement of 69 ksi and Minimum Yield Strength
Requirement of 57 ksi) per AMS-QQ-A-250/12 could be substituted. This also applies
when substituting different, but approved alloys.
Example 2: A 1.5 inch diameter heat treated C95500 copper alloy per ASTM-B-505 can be substituted
for a 1.375 inch diameter C95300 Type I copper alloy per QQ-C-390 and BS25691 Table
13. The alloys are different, but approved, and the mechanical properties for the heat
treated C95500 copper alloy per ASTM-B-505 (Minimum Tensile Strength Requirement of
110 ksi and Minimum Yield Strength Requirement of 60 ksi) exceed the mechanical
properties for the C95300 Type I copper alloy per QQ-C-390 (Minimum Tensile Strength
Requirement of 65 ksi and Minimum Yield Strength Requirement of 25 ksi)
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 15 of 68
Title Page Rights Apply
Size substitution (thickness or diameter) of an approved substituted carbon ferrous alloy (i.e. 4130 or
4340 carbon steel) is acceptable for a different size material, other than the material listed on the RAC
Engineering drawing if the different size material meets the specified mill surface finish requirements
and one of the three following conditions:
The different size material is rough machined, receives a final heat treatment and is final machined
to the RAC Engineering drawing. Reference Subsection 3.1.c. Special Requirement for 4130 Steel
Bar Stock and Table 2. Maximum Cross Section Thicknesses (inches) to Achieve Specified Heat
Treat Range.
The different size material is heat treated to the final strength requirements and final machined to the
RAC Engineering drawing requirements. Reference Subsection 3.1.c. Special Requirement for 4130
Steel Bar Stock and Table 2. Maximum Cross Section Thicknesses (inches) to Achieve Specified
Heat Treat Range.
The tensile and yield strength properties of the different size material meets or exceeds the tensile
and yield strength properties of the original material listed on the RAC Engineering drawing.
Notes a through f per Table 10 Ferrous Alloy Bar Substitution Table, and a through b per Table 11
Ferrous Alloy Sheet, Plate, and Strip Substitution Table apply to substitution of Carbon Ferrous Alloy
Material.
EXAMPLE : The RAC Engineering drawing calls out for a 0.375-inch diameter 4130 steel bar per MIL-
S-6758 in the C4 mill surface condition, which is heat treated to a 110 140 ksi final heat
treat and machined to a final diameter of 0.313 inch with a 125 RMS surface finish.
The supplier would like to substitute a 0.313 inch 4130 steel bar per MIL-S-6758 in the E4
mill surface condition. The material can be heat treated to the final strength requirement,
but this is an unacceptable substitution since the Procured finish will not be removed
completely by machining. Therefore the part will not meet the RAC Engineering drawing
requirement and the substitution is not acceptable.
The supplier may substitute a 0.383 inch 4130 steel bar per MIL-S-6758 in the E4 mill
surface condition. The material is heat treated to the final strength requirement, and the
Procured finish will be removed completely by machining. The part will meet RAC
Engineering drawing requirement and the substitution is acceptable.
Size substitutions for CRES ferrous alloys (i.e. 300 and 400 series stainless steels) are not allowed
without written approval from RAC Engineering.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 16 of 68
Title Page Rights Apply
For round bar stock two inches or less in diameter, and square or rectangular bar stock two
inches or less in both cross-section dimensions, heat treatment to the 110-140 ksi range shall
normally be performed on the raw bar stock material prior to machining.
For round bar stock over two inches in diameter, and square or rectangular bar stock with either
cross-section dimension exceeding two inches, parts/material shall be rough machined to a cross-
section dimension of two inches or less prior to heat treatment to the 110-140 ksi range.
d. Direct Purchase Program
Castings and forgings procured by RAC subtier suppliers shall have casting/forging supplier supporting
certification documentation/test material required by the Engineering drawing, including x-rays when
applicable. Further information is provided in Sub-section 4.3 addressing the direct purchase
program for castings and forgings.
3.2 Machining
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 17 of 68
Title Page Rights Apply
Heat Treat
Typically, ferrous alloys should be planned to receive heat treatment in the raw stock form. When
section thickness exceeds hardenability of the material for the required strength level, parts may be
rough machined prior to heat treatment. Heat treatment of finish machined parts is not permissible
unless authorized by RAC. Additional information is provided in the section addressing ferrous alloy
heat treatments included in this document.
Hardness Testing
Parts manufactured from ferrous alloys shall be 100 percent hardness tested to verify material heat
treat conformance to drawing requirements unless a sampling plan for the engineering drawing part
number is approved by RAC. As an exception, some engineering drawings allow alternate test
methods to verify response to heat treatment. Hardness testing shall be performed in a manner
(hardness scale selection and test location) to preclude indentation damage that may affect function of
the part.
Magnetic Particle Inspection
Following machining, magnetic particle inspection shall be performed in accordance with ASTM
E1444. Acceptance criteria for magnetic particle inspection shall be MIL-STD-1907, Grade A.
Magnetic particle inspection shall be performed in the proper sequence within the overall
manufacturing process. Parts exempt from magnetic particle inspection shall be listed in BS25707.
Additional information is provided in the section addressing magnetic particle inspection included in
this document.
3.3 Forming
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 18 of 68
Title Page Rights Apply
permissible if performed within the restrictions outlined in the hot form section of this document.
Suppliers performing hot forming of ferrous sheet material require special process approval by RAC.
3.3.4 Extrusion
Non-ferrous extrusions (aluminum alloys, magnesium alloys, copper alloys, titanium alloys, etc.) may
be formed at room temperature by conventional methods such as hydroform, stretch form, brake form,
roll form, hand form, joggle die, etc. The forming process shall be controlled to preclude excessive
thinning. Localized heating and/or part heating to facilitate forming is not allowed without written
approval of RAC. Extruded non-ferrous material requires penetrant inspection in all formed areas.
Additional requirements for hot forming of extrusion material are provided in the hot form section of this
document. Suppliers performing hot forming of extrusion material require special process approval by
RAC.
3.4 Edge Conditions
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 19 of 68
Title Page Rights Apply
Maximum: X = 20% of the material thickness for thicknesses of 0.075 inch and less.
For material thickness greater than 0.075 inch, X shall not exceed
0.015 inch.
Exception: When breaking the edges of fastener holes in material that is 0.080 inch
Thick or less, R and X shall not exceed 10% of the material thickness.
Requirements/Limitations Sheet Metal Parts (not routed or milled)
Radius Minimum: R = 0.001
Maximum: R = 20% of the material thickness for thicknesses of 0.075 inch and less.
For material thickness greater than 0.075 inch, R shall not exceed
0.015 inch.
Refer to SAS03-003 for additional information pertaining to edge conditions not noted on
Engineering.
X
R
45 Edge Radius
Edge Chamfer
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 20 of 68
Title Page Rights Apply
Requirements/Limitations
Suppliers performing silver brazing shall be approved for the specific silver braze process by
RAC.
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 21 of 68
Title Page Rights Apply
Silver brazing shall be performed in accordance with RAC engineering drawing referenced
specifications.
The mating surfaces and adjacent areas of all parts to be joined, including the braze filler
material, shall be physically and chemically clean. Within allowable considerations, the
supplier shall select the cleaning process best suited for a given part. Aqueous degreasing is
the preferred method of cleaning details prior to braze, however this does not preclude the use
of solvent cleaners.
Abrasive media blasting for cleaning prior to silver brazing is permitted only on carbon and low
alloy steels and is limited to steel grit blasting only.
No abrasive blasting is permitted on stainless steel or nickel alloys.
It shall be the responsibility of the supplier to ensure that the braze alloy selected is in
compliance with engineering drawing requirements.
It shall be the responsibility of the supplier to maintain on file all records and certifications
associated with the braze filler material.
Braze alloy shall be properly stored, dated, and otherwise controlled in accordance with
applicable specification requirements.
Where joint filler grooves are specified, filler metal per Standard Drawing 111503 and/or
Standard Drawing 111524 is placed as directed by the RAC Engineering Drawing. If no
grooves are specified, the filler metal shall be placed at the edge or end of the joint, or
manually fed into the joint during the brazing operation.
It shall be the responsibility of the supplier to verify proper joint gap for the braze alloy and
braze method employed.
After the joint is air cooled, the part shall be thoroughly cleaned to remove all traces of the
brazing flux. Flux residue can cause corrosion and affect subsequent processing of the part.
All required proof load testing shall be performed and verification shall be included with part
certification documents (reference Sub-section 1.3 Limitations).
Parts that have been silver brazed cannot be heat treated, high temperature stress relieved, or
subjected to thermal processing that involves high temperatures. Temperatures involved with
such operations can cause melting of the braze alloy and degradation of the braze joint.
When corrosion protection is required, parts shall be coated with protective oil (i.e., parts that
would be shipped without any type of protection such as plating, etc.).
3.5.3 Copper, Nickel Brazing
General
Copper and nickel brazing are processes in which parts are joined together utilizing a copper or nickel
braze filler material. Copper or Nickel braze filler material in the form of powder, wire or paste is
positioned on the part within and/or adjacent to the joint to be brazed. The part is heated to a
temperature of approximately 2,040F for copper brazing and 2,150F for nickel brazing, in a vacuum
furnace. At braze temperature, the braze material melts and flows into the joint by capillary action.
Copper brazing is normally limited to joining ferrous materials (primarily carbon steels and low alloy
steels). Nickel brazing is normally used as a method of assembly for corrosion resistant alloys (nickel
alloys, and heat resistant alloys).
Requirements/Limitations
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 22 of 68
Title Page Rights Apply
Suppliers performing copper and nickel brazing shall be approved for the specific copper and
nickel braze process by RAC.
All surfaces of parts to be copper or nickel brazed, including the brazing filler material, must be
mechanically clean, free from scale, rust, oxide, paint, and/or loose particles of any type. The
supplier performing the brazing operation will normally select the cleaning process best suited
for a given part.
Abrasive media blasting for cleaning prior to copper or nickel brazing is permitted only on
carbon and low alloy steels and is limited to steel grit blasting only.
No abrasive blasting is permitted on stainless steel or nickel alloys when performing silver,
copper, or nickel brazing.
Copper or nickel brazed parts normally require some type of assembly prior to brazing. Due to
the high temperatures involved in the brazing process, fixtures are not typically used. In some
cases, sheet metal parts can be tacked by spot welding. Other types of parts can be tacked by
fusion welding. In many cases, the type of joint is self-supporting and does not require any
additional positioning method.
It shall be the responsibility of the supplier to verify proper joint gap for the braze alloy and
braze method employed.
It shall be the responsibility of the supplier to maintain on file all records and certifications
associated with the braze filler material.
Braze alloy shall be properly stored, dated, and otherwise controlled in accordance with
applicable specification requirements.
During the assembling of detail parts, braze filler material in the form of powder, paste, or wire
shall be positioned onto the part. The supplier shall determine the type of filler material most
suitable for the joint and also determine the location and quantity required for an acceptable
joint.
Thermal Processing - After copper brazing, the assembly requires a thermal processing cycle to
decrease the large grain size that was created within the material during the brazing operation.
If the engineering drawing requires a heat treatment, then the heat treat process will refine the
grain structure. If a heat treatment is not specified, the supplier shall provide for a separate
grain refine operation following brazing. Copper braze joints are not adversely affected by
subsequent heat treatment because the braze temperature is sufficiently higher than the heat
treat and grain refinement temperatures.
Stress Relief - Engineering drawings for some parts require a thermal stress relief following
nickel brazing. A stress relief operation shall not be accomplished unless specified on the
engineering drawing.
All required proof load testing shall be performed and verification shall be included with part
certification documents (reference Sub-section 1.3 Limitations).
3.5.4 Chemical Milling
General
Chemical milling of metal is the process of chemically etching away excess material from the surface
of a part by suspending the material in an etchant solution for a given period of time. Material can be
removed from the entire part or in selective areas only, by masking areas that do not require milling.
Chemical milling is well suited for use on irregular shaped parts that would not be easily milled using
conventional mechanical equipment.
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 23 of 68
Title Page Rights Apply
Requirements/Limitations
Suppliers performing chemical milling shall be approved for that process by RAC.
Chemical milling shall be performed in accordance with RAC engineering drawing referenced
specifications.
Edge Trim. Due to the difficulty in preventing peripheral leaks in the mask, edge trim shall be
allowed for all parts as shown in Figure 1.
Tooling holes should be located in tabs outside the part. This applies both to holes used for locating
the masking templates and to holes for jig location of the part. Pilot holes for rivet layouts are to be
drilled after chemical milling to help minimize double masking required for all holes. The final net
trim and any cutouts shall be made after the chemical milling operation.
A taper of 0.020 inch per side per running inch is the maximum degree of taper that can be chemical
milled satisfactorily. Any taper less than one inch in length shall not be chemical milled.
Mask
Depth of Cut
Metal
Depth of Cut
Mask
Excess Trim Material
(Depth of Cut + 1/2 inch)
Allow 1/2 inch excess plus the depth of the cut
on all parts that will mill the edge areas as shown.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 24 of 68
Title Page Rights Apply
Mask
Metal
Edge of Part
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 25 of 68
Title Page Rights Apply
Requirements/Limitations
Suppliers performing chemical film treatment shall be approved for that process by RAC.
Chemical film treatment shall be performed in accordance with RAC engineering drawing
referenced specifications.
Chemical film coatings resulting from treatment of aluminum and aluminum alloy surfaces with
chemical conversion coating materials are specified by Classes as follows:
Class 1A - For maximum protection against corrosion, for surfaces to be painted or left
unpainted. Class 1A chemical conversion coatings are intended to provide corrosion
prevention when left unpainted as well as to improve adhesion of paint finish systems to
aluminum and aluminum alloys.
Class 3 - For protection against corrosion where low electrical resistance is required.
Parts with electrical bond will receive a Class 3 chemfilm at the time of the electrical
bond.
Prior to chemical film treatment, all aluminum material must be thoroughly cleaned and free of
grease, oils, oxides, heat treat scale, paint, welding fluxes, corrosion, or other surface
contamination, which would be detrimental to the formation of a good chemical film. Abrasives
containing iron such as steel wool, iron oxide, rouge, or steel wire are prohibited for all cleaning
operations because ferrous particles may become embedded in the surface and accelerate
corrosion of aluminum and aluminum alloys.
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 26 of 68
Title Page Rights Apply
See section 3.5.14 Anodize for chemfilm process of chromic acid anodized parts.
3.5.6 Primer
General
This process defines the finish requirements of aluminum alloys, both bare and clad, steel and
magnesium alloys requiring basis finish requirements for corrosion control.
Requirements/Limitations
Suppliers performing prime application shall be approved for that process by RAC.
Application of primer coatings shall be performed in accordance with RAC engineering drawing
referenced specifications.
In the absence of specific finish requirements on the engineering drawing, BS361 shall be the
governing document for Models excluding Hawker and Model 400.
MHI specification P2700 provides additional information for the Model 400, such as heat
resistant coating, not found in BS361. Contact RAC Supply Chain Management for additional
information.
Exterior skins and/or parts as defined in BS253303 shall be primed with 10P8-11 Primer,
P/N of AKZO Nobel.
Requirements/Limitations
Suppliers performing chemical etch shall be approved for that process by RAC.
Chemical etching is suitable only for application to raw stock or unassembled detail parts. Parts
and/or assemblies that provide joints and laps that could entrap etch solutions are not suitable
for chemical etching.
Etching prior to penetrant inspection is required on parts in which the surface to be penetrant
inspected has been subjected to machining, grinding, spinning, or any other type of operation
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 27 of 68
Title Page Rights Apply
that might produce smearing or cold work of the part surface. The etch process for penetrant
inspection shall be designed to remove 0.0002 inch of material from the part surfaces. On
parts with close tolerance holes, it is acceptable to plug the holes to prevent oversizing.
3.5.8 Pickle and Passivate
General
Parts made of corrosion resistant ferrous alloys (stainless steels) may be subjected to surface
contamination with traces of other metals occurring during fabrication processes such as machining,
forming, welding, contact with heat treatment fixtures, etc. All surface contamination shall be removed
to minimize the potential for reduced service life of the finished product.
Pickle and passivate are two independent chemical processes that remove foreign metallic
contamination from the surface of the part.
Pickling is a chemical etching process that utilizes a combination of acids for the removal of metal and
scale from the surface of the part.
Passivation is a chemical process using a solution of nitric acid and/or various oxidizing salts to
remove iron particles and other foreign materials that have become imbedded in the surface of a
corrosion resistant ferrous alloy material. Operations such as forming, tumbling, machining, etc., can
potentially smear or imbed impurities into the surface of parts compromising long-term corrosion
resistance. Passivation removes the impurities and imparts a thin transparent oxide film over the
surface to increase corrosion resistance.
Examples of precipitation hardened stainless steels are 17-4PH, 15-5PH, and 17-7PH.
Requirements/Limitations
Suppliers performing pickle and passivation treatments shall be approved for that process by
RAC.
Pickle and passivation treatments shall be performed in accordance with RAC engineering
drawing referenced specifications.
When to Pickle
1. Following operations such as welding, high temperature forming and heat treatments such
as annealing, hardening, etc.
2. Pickle is required following abrasive grit blasting.
3. Following severe forming operations.
4. Pickle may be used for brightening.
5. Pickle is used for pre-weld cleaning if dimensional requirements permit, parts with
tolerances of +/- 0.003 or greater.
When not to Pickle
1. If passivation is sufficient to remove surface contamination.
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 28 of 68
Title Page Rights Apply
Requirements/Limitations
Suppliers performing low temperature stress relief shall be approved for that process by RAC.
Time and temperature baking cycles for all low temperature stress relief operations prior to
electroplating and/or other hydrogen producing chemical treatments are designated in
BS25526.
3.5.10 Embrittlement Relief of Ferrous Parts
General
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 29 of 68
Title Page Rights Apply
Certain chemical processing operations such as electroplating, pickling, acid stripping, and phosphate
coating generate hydrogen as a by-product of the processing operation. When subjected to these
types of operations, ferromagnetic steel alloys that have been heat treated above 150 ksi will begin to
absorb (or diffuse) hydrogen into the microstructure of the material. This type of hydrogen absorption
into the material is known as hydrogen embrittlement. Hydrogen embrittlement may result in failure
when the part is introduced to stresses produced by in-service applications. For materials subjected to
hydrogen embrittlement, a baking operation described as embrittlement relief is performed after the
processing operation to bake out any absorbed hydrogen and eliminate the potential for hydrogen
embrittlement. To minimize the potential for hydrogen embrittlement of ferrous products, adherence to
specified procedure is critically important.
Requirements/Limitations
Suppliers performing hydrogen embrittlement relief shall be approved for that process by RAC.
Time and temperature baking cycles for embrittlement relief following electroplating and/or
chemical treatments are designated in BS25526.
3.5.11 Heat Treatment of Aluminum Alloys
General
Aluminum heat treatment may be defined as an operation or a combination of operations in which
metal in the solid state is processed through cycles of heating and cooling for the purpose of obtaining
certain desired conditions or properties. Common thermal processing cycles designated for aluminum
heat treatment are defined as follows:
Solution Heat Treatment - Soaking parts at an elevated temperature for a sufficient time to put alloying
elements in solution followed by quenching to retain the acquired condition until parts are aged.
Aging - Allowing solution heat treated and quenched parts to naturally age at room temperature and/or
soaking solution heat treated and quenched parts at a moderately elevated temperature, as required to
produce the desired temper designation.
Annealing - A process to soften material for enhanced formability. A full anneal will soften aluminum
alloy material to develop maximum formability and ductility. A partial anneal is used when grain growth
is of concern or when less formability or ductility is required. A full anneal is considered equal to a
solution heat treatment when considering reheat treatment associated with alclad alloys.
Requirements/Limitations
Suppliers performing heat treatment of aluminum alloys shall be approved for that process by
RAC.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 30 of 68
Title Page Rights Apply
All heat treat operations shall be performed in accordance with RAC engineering drawing
referenced specifications.
All preservatives, forming lubricants, and/or other surface contaminates shall be removed prior
to any heat treat related thermal process.
2xxx, 6xxx, and 7xxx series aluminum alloys respond to appropriate thermal processing cycles
to achieve strength requirements designated by temper designations assigned to the alloy.
1xxx, 3xxx, 4xxx, and 5xxx series aluminum alloys can be strengthened by work hardening at
the material producer mill and may be annealed for softening. However, these alloys will not
respond to strengthening by thermal heat treatment. For example, a material in the -H34
temper can be annealed to the -O temper. After annealing to the -O temper, the -H34 temper
cannot be restored by thermal processing.
Alclad sheet is produced at the mill by the rolling of a thin layer of pure aluminum onto the
surface of aluminum alloy sheet. Bare material shall not be substituted for an application that
requires alclad. The pure aluminum coating provides an increased degree of corrosion
protection to the product. The thickness of the alclad layer depends on the overall thickness of
the product but is normally from 2 1/2 to 5 percent of the total thickness on each side. Alclad
sheet shall be handled and processed in a manner to preclude degradation of the alclad
coating through mechanical, chemical, and/or thermal processing.
When alclad aluminum sheet is subjected to an excessive number of heat treatment or full
anneal cycles, alloying elements from the base material diffuse into the alclad layer and destroy
the corrosion protection afforded by the alclad. Alclad sheet products shall be planned so that
fabrication can be accomplished within the restrictions on the total number of heat treat and/or
full anneal cycles allowed. Specification AMS2770 Heat Treatment of Aluminum Alloys limits
the number of solution heat treat cycles and/or full anneal cycles based on the sheet product
thickness as noted below:
1. For alclad sheet products over 0.125 inch in thickness, limitations provide for three heat
treat operations only. This could include one full anneal, one heat treatment and one
reheat treatment, or one heat treatment and two reheat treatments.
2. For parts made from alclad sheet products 0.020 to 0.125 inch in thickness, two heat treat
operations are allowed. This could include one full anneal and one heat treatment or one
heat treatment and one reheat treatment.
3. Alclad Sheet under 0.020 Inch in Thickness. For parts made from alclad sheet products
under 0.020 inch in thickness, one heat treatment is allowed. Full annealing and/or reheat
treatment is prohibited.
4. Alclad material received in the -O (annealed) temper is not considered to have been heat
treated for purposes of control of alclad diffusion. Material received in the T condition is
considered to have been heat treated for purpose of alclad diffusion control.
The temper of aluminum alloys is designated by a system that includes an alphabetical letter
sometimes followed by a number or series of numbers. Definition of the temperature
designations may be found in ANSI H.35.1.
3.5.12 Heat Treatment of Ferrous Alloys
General
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 31 of 68
Title Page Rights Apply
Ferrous alloys are divided into four groups: carbon and low alloy steel; martensitic corrosion resistant
steel; austenitic corrosion resistant steel; and, precipitation hardening corrosion-resistant steel.
Steel heat treating may be defined as an operation or combination of operations in which metal in the
solid state is taken through cycles of heating and cooling for the purposes of obtaining certain desired
conditions or properties. Some examples of the various thermal processing cycles are defined as
below:
Annealing - Heating and holding at a suitable temperature followed by relatively slow cooling. The
primary purpose of annealing is normally to soften the material for an increased degree of formability,
improve machinability, remove stresses, refine the grain structure, and/or obtain other desirable
properties in the material.
Case Hardening or Carburizing - A process in which steel is heated to a prescribed temperature while
in a carbon rich atmosphere. At the proper elevated temperature, carbon from the atmosphere is
absorbed into the outer surface of the material producing a case or carburized surface layer.
The steel can then be heat treated to produce a high degree of hardness and wear resistance in
the surface layer and yet retain a ductile core without brittle characteristics.
Hardening - The process of heating a metal to a temperature above the critical range and then cooling
rapidly by quenching. For most steel alloys, a very hard and brittle structure is produced by
hardening. For most applications the material must be tempered to produce the required strength
range and to increase ductility.
Quenching - Quenching is the term applied to rapid cooling of a steel alloy from the austenitizing
temperature by quickly immersing the metal in a bath of water, oil, or other suitable media.
Tempering (Drawing) - Tempering is the process of reheating steel that has been quench hardened
to some temperature below the critical range followed by air cooling. The object of this treatment
is to lower the hardness and increase ductility.
Stress Relief - Stress relief is the heating process used for reducing internal stresses in metals that
have been induced by casting, quenching, welding, cold working, etc. The metal is soaked at a
suitable temperature for a time sufficient to allow relaxation of stress.
General Requirements/Limitations
Suppliers performing heat treatment of steel alloys shall be approved for that process by RAC.
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 32 of 68
Title Page Rights Apply
All heat treat operation shall be performed in accordance with designated specifications.
Requirements/Limitations for Carbon and Low Alloy Steel (1025, 1035, 1045, 1095, 4130, 4135,
4140, 4330V, 4340, 6150, 8630, 8735, 8740, etc.)
All carbon and low alloy steel used in production of aircraft parts at RAC shall be thermally
processed in a manner that provides for a heat treat tensile strength range with designated
minimum tensile strength properties.
Hardening of carbon and low alloy steel is accomplished by austenitizing (high heat), quenching
(usually in oil), and tempering (draw or drawing) at a temperature that will produce the required
physical strength level. Typical alloy steel strength ranges designated for RAC parts are listed
in Table 1.
Some RAC Engineering drawings specify that parts be manufactured from 4130 bar stock
(Specification MIL-S-6758 or equivalent) in Conditions A, B, C, D, or E without any requirement
for a heat treatment to a designated strength level. Under such circumstances, the material or
parts shall be heat treated to 110 140 ksi with the following size limitations.
o For round bar stock two inches or less in diameter, and square or rectangular bar stock two
inches or less in both cross-section dimensions, heat treatment to the 110-140 ksi range shall
normally be performed on the raw bar stock material prior to machining.
o For round bar stock over two inches in diameter, and square or rectangular bar stock with
either cross-section dimension exceeding two inches, parts/material shall be rough machined
to a cross-section dimension of two inches or less prior to heat treatment to the 110-140 ksi
range.
Carbon and low alloy steels exhibit varying degrees of hardenability based on section thickness
at the time heat treatment is performed. The depth of hardening is closely related to the speed
at which cooling (quenching) of the material can be accomplished. In some instances, a part
may require rough machining prior to hardening to remove material and reduce the section
thickness to a dimension capable of achieving the desired strength range. A general guide for
determining the maximum allowable section thickness at the time of heat treatment to achieve
the designated strength ranges is provided in Table 2.
In most material specifications for 4130 sheet, plate and tubing, the terms Normalize and
Condition N are not synonymous. Normalize is defined as a metallurgical process that
consists of applying designated heating and cooling cycles to achieve desired microstructural
characteristics. The term normalize is usually associated with bar stock material, not sheet,
plate and tubing. Many material specifications do not require designated minimum property
characteristics for material in the normalized condition. Condition N is a term associated with
4130 sheet, plate, and tubing products. Condition N describes a heating and cooling process
that controls metallurgical structure, but also requires designated minimum mechanical property
characteristics. Engineering drawings specify 4130 sheet, plate, and tubing material be
procured in Condition N. An example is Condition N, 4130 sheet/plate produced to Military
Specification, MIL-S-18729. In accordance with this specification, sheet less that 3/16 inch in
thickness shall exhibit a minimum ultimate tensile strength of 95 ksi. For plate between 3/16
inch through 1.5 inches in thickness, the material shall exhibit a minimum ultimate tensile
strength of 90 ksi.
If only one tensile strength value is referenced on a drawing, that value is to be considered as
the minimum with a maximum of 20 ksi above the minimum.
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 33 of 68
Title Page Rights Apply
Once final temper has been achieved, no fabrication process shall be employed that could
potentially affect the final temper or produce a heat affected zone (i.e., electrical discharge
machining, friction saw cutting, laser cutting/machining, uncontrolled grinding, etc.).
High Temperature Stress Relief - All weld assemblies and/or welded structures that do not
receive subsequent heat treatment shall be furnace stress relieved. This requirement also
applies to electron beam welded parts. Most weld assemblies and/or welded structures should
be stress relieved at a temperature between 800F and 1000F. Detailed guidance on
allowable stress relief methods, together with appropriate stress relief temperatures is found in
BS249.
Annealing - Annealing is an operation that is normally used to soften material and increase
ductility to facilitate forming operations. In accordance with RAC specified practice, all
annealed low alloy steel shall receive a subsequent heat treat operation to provide minimum
tensile strength properties. If the engineering drawing or the material specification does not
require a specific minimum strength level, sheet material will be heat treated to a minimum
tensile strength level of 95 ksi and bar stock material (or parts made from bar stock material)
under two inches in diameter will be heat treated to within a range of 110 - 140 ksi.
Annealing - Anneal of carbon and low alloy steels to facilitate forming operations must be used
with discretion. Some product forms (especially thin sheet) may warp significantly during
subsequent heat treatment to restore the material to the specified strength level.
Normalizing - Normalizing is a metallurgical process used to refine grain structure, provide for
more uniform metallurgical microstructure, and/or to relieve internal stress.
Normalizing - Welded Parts/Assemblies that have been welded shall be normalized prior to
hardening, if hardening is required.
Parts and/or material to be hardened or tempered to 200 ksi and above shall be normalized
prior to hardening.
Requirements/Limitations for Martensitic Corrosion Resistant Steel (403, 410, 416, 420,
440C, etc.)
All martensitic corrosion resistant steel used in production of aircraft parts at RAC shall be
thermally processed in a manner that provides for a heat treat tensile strength range with
designated minimum tensile strength properties.
Hardening of Martensitic Corrosion Resistant Steel - Martensitic corrosion resistant steel
responds to thermal heat treatments in a manner similar to carbon and low alloy steel.
Hardening is accomplished by austenitizing (high heat), quenching (usually in oil), and
tempering (draw or drawing) at a temperature that will produce the required physical strength
level. Process planning shall show the strength level required by the drawing on the operation
sheet.
Annealing - Not applicable to RAC use of martensitic corrosion-resistant steel.
Normalizing - Not applicable to martensitic corrosion-resistant steel.
Once final temper has been achieved, no fabrication process shall be employed that could
potentially affect the final temper or produce a heat affected zone (i.e., electrical discharge
machining, friction saw cutting, laser cutting/machining, uncontrolled grinding, etc.).
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 34 of 68
Title Page Rights Apply
Requirements/Limitations for Austenitic Corrosion Resistant Steel (201, 202, 301, 302, 303, 304,
304L, 308, 309, 310, 316, 316L, 321, 347, 348, etc.).
Hardening - Hardening procedures for precipitation hardening steels are dependent on the
condition in which the material is procured, and vary considerably from one alloy to another. As
an example, some alloys such as 17-7PH require an austenite conditioning treatment, followed
by cooling, then refrigeration at -100F to facilitate transformation, and finally a precipitation
treatment to establish the required strength level. Other alloys such as 17-4PH require only a
precipitation hardening cycle to establish the required strength level.
Alloy Specific Procedure - Engineering drawings designate the specific precipitation hardening
alloy required for the application. Referenced specifications for control of the material
designate strength requirements for the noted precipitation treatment.
Once final temper has been achieved, no fabrication process shall be employed that could
potentially affect the final temper or produce a heat affected zone (i.e., electrical discharge
machining, friction saw cutting, laser cutting/machining, uncontrolled grinding, etc.).
Normalizing - Not applicable to precipitation hardening corrosion resistant steels.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 35 of 68
Title Page Rights Apply
Requirements/Limitations.
Shot peen and shot peen forming suppliers shall be approved for the process by RAC.
Areas of parts to be shot peened shall be within dimensional and surface finish requirements
prior to peening.
Shot peening shall not be used for the straightening of parts when not specified.
All heat treatments, machining, and grinding shall be completed prior to shot peening, except
as may be specified by the drawing.
All fillets shall be formed, all burrs shall be removed, and all sharp edges and corners to be
peened shall be provided with sufficient radii to result in complete coverage without distortion
prior to peening.
Except as otherwise specified on the drawing, magnetic particle or fluorescent penetrant
inspections shall be accomplished prior to shot peening.
All steel parts requiring stress relief to facilitate subsequent operations such as plating shall
have stress relief accomplished prior to peening.
Shot peening does not preclude requirements for hydrogen embrittlement relief and magnetic
particle inspection following electroplating.
3.5.14 Anodize
General
Anodize coating of aluminum and aluminum alloys is the process of converting the exposed aluminum
surface to aluminum oxide while the part is immersed in an acid bath, and electrically charged as the
anode of an electrolytic cell. Anodize coatings can be applied to most wrought and cast forms of
aluminum to: (a) improve corrosion resistance characteristics, (b) provide a base to increase adhesion
in subsequent paint operations, (c) to improve the decorative appearance of the product, (d) to provide
anti-seize properties for aluminum, and (e) through the use of hardcoat anodize, provide for abrasion
resistance. The four principal types of anodize coatings are sulfuric acid anodize, chromic acid
anodize, hardcoat anodize and phosphoric acid anodize.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 36 of 68
Title Page Rights Apply
General Requirements/Limitations.
Anodize suppliers shall be approved for the process by RAC.
Anodize coatings shall be applied in accordance with RAC engineering drawing referenced
specifications.
AMS-A-8625 Anodize surface coatings are categorized into Types and Classes.
1. Type I - Type I specifies conventional chromic acid anodize. Coating thickness can range
from 0.00002 - 0.0003 inch. Conventional chromic acid anodize can be applied to
common aluminum and aluminum alloys with the exception of the 7xxx series. A special
low voltage application (Type IB) of chromic acid anodize shall be employed for the
coating of 7050 and 7075 in any variation of the T73 temper series alloys. Type 1B
anodize must meet the same requirements per AMS-A-8625 for coating weight and
corrosion resistance. An initial set of test panels of the same material type and temper for
each alloy anodized must be ran to show conformance to MIL-A-8625. Type I anodize
does not affect dimensions of the part.
2. Type II - Type II specifies sulfuric acid anodize. Coating thickness can range from
0.00007-0.0010 inch. Conventional sulfuric acid anodize can be applied to all common
aluminum and aluminum alloys, but shall not be used where solution can be entrapped.
Type II is sometimes specified as clear anodize and is used for decorative applications.
Clear anodize as called out on engineering or as Finish Code P46 is sulfuric acid anodized
for only 5 minutes +/- 1 minute once the final voltage is reached.
3. Type III - Type III specifies hardcoat anodize. Hardcoatings may vary in thickness from
0.0005 - 0.0045 inch. The thickness for hardcoat should be specified on the engineering
drawing. If thickness is not specified, a coating of 0.002 inch shall be applied. Type III
anodize will penetrate into the surface of the part to a depth of 50% of the coating
thickness (i.e., a coating surface of 0.002 will add 0.001 inch to the surface). Because
Type III anodize will dimensionally alter the part, dimensions should be provided for both
before and after hard coat application. Threads shall not be hardcoat (Type III) anodized
unless required by the engineering drawing.
4. Class 1 - Class 1 is not dyed or pigmented (remains the natural color). This class is also
used for clear anodize.
5. Class 2 - Class 2 is dyed or colored. The color shall be specified on the engineering
drawing.
The Type and Class for all MIL-A-8625 anodize surface coating requirements shall be specified
on the RAC Engineering drawing.
Sealing - The oxide coating produced as a result of the anodize process is porous and shall be
sealed to provide for maximum corrosion protection. For Type I and Type II anodize coatings, a
sealing treatment shall be specified and performed. Type III hardcoat anodize is normally not
sealed when applied for abrasion resistance applications. Sealing treatments are as follows:
1. Hot water seal - Used for all Class 1, unless otherwise specified.
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 37 of 68
Title Page Rights Apply
BS24554 shall be the governing document for phosphoric acid anodize for metal bond applications.
3.5.15 Chromic Dip for Lead Alloys
General
The purpose of this process is to provide a procedure for applying chromate coating on lead and its
alloys to obtain maximum paint adhesion. This process is applicable to lead alloys which contain no
more than 20% alloying elements. It is also applicable to chromadizing lead balance weights.
Requirements/Limitations
Suppliers performing chromic dip for lead alloys shall be approved for that process by RAC.
Prior to chromic dip, all machining, forming, grinding, etc., shall be completed.
Dissimilar metal inserts that are not compatible with the chromadizing solution should be
installed after the chromic dip. If it is not possible to install inserts after chromic dip, then the
metal inserts shall be masked prior to chromadizing to prevent contact with the solution.
Prior to chromic dip, parts shall be cleaned to remove grease, oil, and other contaminants as
required.
Whenever PS23210 is invoked by an engineering drawing, refer to BS182011 for applying
conversion coat to lead alloys.
Requirements/Limitations
Suppliers performing dry film lubricant application shall be approved by RAC.
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 38 of 68
Title Page Rights Apply
Application of dry film lubricant shall be in accordance with RAC engineering drawing
referenced specifications.
Prior to application of the dry film lubricant, surface preparation shall be in accordance with
applicable specification requirements.
Coated parts should be thermal cured at the specified time and temperature as listed in the
product manufactures recommendations. Aluminum parts shall not be cured at temperatures
exceeding 275F. Contact RAC for alternate methods for curing.
3.5.17 Cadmium Plating
General
Cadmium plating is the process of depositing a thin layer of cadmium metal on the surface of a part.
Cadmium plating can be applied by electrodeposition utilizing an appropriate chemical plating bath and
electric current or by vacuum deposition where vaporized cadmium is condensed on the surface of a
part in a vacuum chamber. Cadmium plating is used extensively to provide for a high degree of
corrosion protection on ferrous (steel) and some nonferrous metals. Additionally, a cadmium plated
surface is often used to insulate dissimilar metals from direct contact and thus provide a degree of
compatibility in terms of galvanic potential. Use of vacuum cadmium plating is normally reserved for
steel alloys heat treated to high strength levels (above 220 ksi) to eliminate the potential for hydrogen
embrittlement associated with chemical plating baths. Frequently, a supplemental treatment is
specified for cadmium plated surface. A supplemental treatment is a chemical type treatment that
increases the corrosion resistance of cadmium and increases paint adhesion.
Requirements/Limitations
Suppliers performing cadmium plating shall be approved for that process by RAC.
Cadmium plating shall be performed in accordance with RAC engineering drawing referenced
specifications.
Brighteners shall not be used in cadmium plating baths. RAC does not allow their use.
Types and Classes - The surface treatment and thickness of cadmium plating deposited on the
surface of a part is categorized by Type and Class as follows:
1. Type I - Type I cadmium plated surfaces are as plated without any supplemental treatment
applied.
2. Type II - Type II provides a supplemental chromate treatment applied after cadmium
plating and embrittlement relief.
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 39 of 68
Title Page Rights Apply
3. Type III - Type III provides a supplemental phosphate treatment applied after cadmium
plating and embrittlement relief.
4. Class 1 - Provides a minimum plating thickness of 0.0005 inch.
5. Class 2 - Provides a minimum plating thickness of 0.0003 inch
(range of 0.0003 - 0.00049 inch).
6. Class 3 - Provides a minimum plating thickness of 0.0002 inch
(range of 0.0002 - 0.00029 inch).
Plating Class Requirements - The requirements for cadmium plating class should be defined on
the engineering drawing. If the requirements are not specified on the drawing, cadmium plated
coatings shall be applied with the following guidelines:
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 40 of 68
Title Page Rights Apply
Requirements/Limitations
Suppliers performing copper plating shall be approved for that process by RAC.
Copper plating shall be performed in accordance with RAC engineering drawing referenced
specifications.
The thickness of copper plating deposited on the surface of a part is categorized by classes as
follows:
1. Class 0 - For heat treatment stop-off. Unless otherwise specified, plating thickness shall
be 0.001 - 0.0005 inch.
2. Class 1 - For carburizing and decarburizing protection. Unless otherwise specified,
minimum plating thickness shall be 0.001 inch.
3. Class 2 - Used as an undercoat for nickel and other plating. Unless otherwise specified,
minimum plating thickness shall be 0.0005 inch.
4. Class 3 - For protective coating to prevent metal migration into tin substrates during
soldering. Unless otherwise specified, minimum plating thickness shall be 0.0002 inch.
5. Class 4 - Additional applications requiring thin coatings. Unless otherwise specified
minimum plating thickness shall be 0.0001 inch.
Unless otherwise specified, copper plating shall be applied after base metal heat treatments
(except for heat treat control) and mechanical operations such as machining, brazing, welding,
and forming.
Parts shall be suitably cleaned to provide a chemically clean surface prior to plating.
Embrittlement Relief - Steel products heat treated above a strength level of 150 ksi and all
carburized steel products shall receive a hydrogen embrittlement relief operation in accordance
with the time/temperature schedule listed in BS25526, within four hours after the copper plating
process has been completed.
Stress Relief - Steel products heat treated to a strength range of 150 ksi and above that have
been machined, ground, cold formed, or cold straightened shall be processed through low
temperature stress relief to relax residual stresses prior to copper plating as required by
BS25526.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 41 of 68
Title Page Rights Apply
Parts Heat Treated to 240 ksi and above. Parts heat treated to strength levels of 240 ksi and
above shall not be copper plated. For additional information, contact RAC Supply Chain
Management.
3.5.19 Nickel Plating
General
Nickel plating is the process of depositing a thin layer of nickel utilizing an appropriate chemical plating
bath and electric current. Depending on the process used and conditions employed, nickel can be
deposited as either a decorative or hard plating, with either a dull or a bright appearance. Decorative
nickel plating is primarily used as an underplate to provide a base for decorative chromium plating and
to provide corrosion protection. Hard nickel plate is normally called engineering plating and is used
to improve wear characteristics of metals.
Requirements/Limitations
Suppliers performing nickel plating shall be approved for that process by RAC.
Nickel plating shall be performed in accordance with RAC engineering drawing referenced
specifications.
The type and thickness of nickel plating deposited on the surface of a part is categorized by
class and grade as follows:
Class 1 - Class 1 plating is used for corrosion protection and underplate applications. Plating
thickness is specified by grade as follows:
Class 2 - Class 2 plating (engineering plating) is specified for wear applications. Parts plated
for Class 2 deposition shall be plated to specific dimensions.
Plating Requirements - The requirements for nickel plating should be defined on the
engineering drawing. If the requirements are not specified on the drawing, nickel plating
coatings shall be applied in accordance with Table 3.
Unless otherwise specified, nickel plating shall be applied after base metal heat treatments and
mechanical operations such as machining, brazing, welding, and forming.
Parts shall be suitably cleaned to provide a chemically clean surface prior to plating.
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 42 of 68
Title Page Rights Apply
Embrittlement Relief - Steel products heat treated above a strength level of 150 ksi and all
carburized steel products shall receive a hydrogen embrittlement relief operation in accordance
with the time/temperature schedule listed in BS25526, within four hours after the nickel plating
process has been completed.
Stress Relief - Steel products heat treated to a strength range of 150 ksi and above that have
been machined, ground, cold formed, or cold straightened shall be processed through low
temperature stress relief to relax residual stresses prior to nickel plating as required by
BS25526.
Parts heat treated to strength levels of 240 ksi and above shall not be nickel plated. For
additional information, contact RAC Supply Chain Management.
3.5.20 Electroless Nickel Plating
General
Electroless nickel plating is the process of depositing a thin layer of nickel utilizing an appropriate
chemical plating bath without the use of an electric current. The deposit from electroless nickel plating
is generally used to improve wear and/or corrosion resistance.
Requirements/Limitations
Suppliers performing electroless nickel plating shall be approved for that process by RAC.
Electroless nickel plating shall be performed in accordance with RAC Engineering drawing
referenced specifications.
The type and thickness of nickel plating deposited on the surface of a part is categorized by
class as follows:
1. Class 1 Except for hydrogen embrittlement relief, no post plating thermal treatment.
2. Class 2 Thermal treatment at 450F (232C) or above to harden the deposit.
3. Class 3 Thermal treatment at 375F (191C) to improve adhesion for non-heatable
aluminum alloys and beryllium alloys.
4. Class 4 Thermal treatment at 250F (121C) to improve adhesion for heat treatable
aluminum alloys.
Plating Requirements - The thickness requirements for electroless nickel plating shall be
defined on the RAC Engineering drawing.
Unless otherwise specified, electroless nickel plating shall be applied after base metal heat
treatments and mechanical operations such as machining, brazing, welding, and forming.
Parts shall be suitably cleaned to provide a chemically clean surface prior to plating.
Stress Relief Steel products heat treated to a strength range of 150 ksi and above that have
been machined, ground, cold formed, or cold straightened shall be processed through low
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 43 of 68
Title Page Rights Apply
temperature stress relief to relax residual stresses prior to electroless nickel plating in
accordance with or as required by BS25526.
Embrittlement Relief Steel products heat treated above a strength level of 150 ksi and all
carburized steel products shall receive a hydrogen embrittlement relief operation in accordance
with the time & temperature schedule listed in BS25526, within four hours after the electroless
nickel plating process has been completed.
Parts heat treated to strength levels of 240 ksi and above shall not be electroless nickel plated.
For additional information, contact RAC Supply Chain Management.
Requirements/Limitations.
Suppliers performing chromium plating shall be approved for that process by RAC.
Chromium plating shall be performed in accordance with RAC engineering drawing referenced
specifications.
Chromium plating deposited on the surface of a part is categorized by type and class as
follows:
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 44 of 68
Title Page Rights Apply
Unless otherwise specified, chromium plating shall be applied after base metal heat treatments
and mechanical operations such as machining, brazing, welding, and forming.
Parts shall be suitably cleaned and mechanically smoothed to provide a proper surface for
plating.
Embrittlement Relief - Steel products heat treated above a strength level of 150 ksi and all
carburized steel products shall receive a hydrogen embrittlement relief operation in accordance
with the time/temperature schedule listed in BS25526, within four hours after the chromium
plating process has been completed.
Stress Relief - Steel products heat treated to a strength range of 150 ksi and above that have
been machined, ground, cold formed, or cold straightened shall be processed through low
temperature stress relief to relax residual stresses prior to chromium plating as required by
BS25526.
Parts heat treated to strength levels of 240 ksi and above shall not be chromium plated. For
additional information, contact RAC Supply Chain Management.
3.5.22 Manganese Phosphate Coating (Anti-Seize).
General
Manganese phosphate coating is the treatment of a steel alloy with a diluted solution of phosphoric
acid and other chemicals. The process imparts wear resistance and anti-seize characteristics. It also
provides good corrosion resistance to the part when given an appropriate supplementary treatment.
Requirements/Limitations.
Suppliers performing manganese phosphate coating shall be approved for that process by
RAC.
Manganese phosphate coating shall be performed in accordance with RAC engineering
drawing referenced specifications.
Manganese phosphate coatings and supplementary treatments are defined by following type
and classes:
1. Type M - All manganese phosphate coatings are Type M.
2. Class 1 - Supplementary preservative treatment or coating as specified.
3. Class 2 - Supplementary treatment with lubricating oil conforming to MIL-PRF-3150.
4. Class 3 - No supplementary treatment.
Embrittlement Relief - Steel products heat treated above a strength level of 150 ksi and all
carburized steel products shall receive a hydrogen embrittlement relief operation in accordance
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 45 of 68
Title Page Rights Apply
with the time/temperature schedule listed in BS25526, within four hours after the manganese
phosphate coating process has been completed.
Stress Relief - Steel products heat treated to a strength range of 150 ksi and above that have
been machined, ground, cold formed, or cold straightened shall be processed through low
temperature stress relief to relax residual stresses prior to manganese phosphate coating as
required by BS25526.
Parts heat treated to strength levels of 240 ksi and above shall not be manganese phosphate
coated. For additional information, contact RAC Supply Chain Management.
MHI Parts - For MHI parts requiring manganese phosphate coating to specification P2306,
contact RAC Supply Chain Management.
3.5.23 Fusion Welding.
General
The process of melting a base metal and sometimes a filler metal with heat and without pressure to
form a one-piece weldment after cooling is called fusion welding. Fusion welding of steel, aluminum,
and titanium alloys for RAC is accomplished by the Gas Tungsten Arc Welding (GTAW) process.
Other names commonly associated with this method of welding include Tungsten Inert Gas (TIG) and
Heli-Arc.
Applicable and Associated Documents.
AWS D17.1 Fusion Welding for Aerospace Applications
BS 510 Design of Welded Joints with Aluminum Alloys
BS 511 Design of Welded Joints in Steels and Corrosion and Heat
Resisting Alloys
BS 25272 Fusion Welding of Titanium and Titanium Alloys
Requirements/Limitations.
Suppliers performing fusion welding shall be approved for the specific fusion weld process by
RAC.
Fusion welding shall be performed in accordance with RAC engineering drawing referenced
specifications.
Prior to fusion welding, detail parts must be thoroughly cleaned to preclude contamination of the
weld fusion zone. The supplier shall determine the most appropriate method to accomplish
cleaning requirements within allowable options.
Weld assembly detail parts made from stainless steel or nickel base alloy material that have
been formed on Kirksite (zinc base) dies shall be passivated prior to welding.
Pickling is generally used as a preweld cleaning operation for corrosion resistant steel in the
annealed or solution heat treated condition. Precipitation hardened and 400 series corrosion
resistant steels shall not be cleaned by pickling.
Stress Relief - Low alloy steel weld assemblies and structures that do not receive subsequent
heat treatment shall be furnace stress relieved at 1000 F unless otherwise specified on the
engineering drawing. Stress relief of welded corrosion resistant, nickel base, and heat resistant
alloys is required only when specified on the engineering drawing. Stress relief temperatures
for corrosion resistant, nickel base, and heat resistant alloys shall be as designated in the
applicable material and/or heat treat specification.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 46 of 68
Title Page Rights Apply
A magnetic particle inspection shall be performed on all ferromagnetic steel weld assemblies
prior to heat treatment or stress relief.
Penetrant inspection of nonferrous material (with the exception of nonferrous welded parts)
shall be performed only when specified on the engineering drawing (refer to Sub-section 3.4.25
Fluorescent Penetrant Inspection).
Carbon and low alloy steel parts that have been welded shall be normalized prior to hardening
as part of the heat treat operation.
All plating operations shall be performed after completion of the welding operations.
3.5.24 Electron Beam Welding.
General
Electron beam welding is a fusion welding process that utilizes a tightly focused beam of electrons to
bombard the surfaces of metals to be welded. The impact of the electrons generates sufficient heat to
melt the metal and fuse the joining surfaces together. Electron beam welding is used to weld most
metals that can be electric arc welded. Aerospace quality electron beam welding is accomplished
within a chamber evacuated to a hard vacuum.
Requirements/Limitations
Suppliers performing electron beam welding shall be approved for the process by RAC.
Electron beam welding shall be performed in accordance with RAC engineering drawing
referenced specifications.
Prior to electron beam welding, detail parts must be thoroughly cleaned to preclude
contamination of the weld fusion zone and to prevent unnecessary contamination of the
electron beam welding chamber. Cleaning requirements are specified in BS4896. The supplier
shall determine the most appropriate method to accomplish cleaning requirements.
Joint Fit-Up - Electron beam welding requires special consideration for joint fit-up and joint
tolerance. Control for joint fit-up is specified on the engineering drawing and shall be in
accordance with BS4896.
Stress Relief - All carbon and low alloy steel electron beam weld assemblies that do not receive
subsequent heat treatment shall be by furnace stress relief. Some stress relief temperatures
are designated on the engineering drawing. However, if stress relief temperatures are not
designated on the drawing, weld assemblies shall be furnace stress relieved at a temperature
of 1000F unless other characteristics of the part preclude exposure to 1000F.
Magnetic Particle Inspection - To identify and allow for repair of weld defects prior to heat
treatment or stress relief, a magnetic particle inspection operation shall be performed on all
ferromagnetic steel weld assemblies following electron beam welding.
Proof Load - Engineering drawings on many parts require a proof load test to ensure integrity of
the weld joint. When specified on the drawing, a proof load operation shall be performed.
Verification of proof load testing shall be included with the part certification documents.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 47 of 68
Title Page Rights Apply
Requirements/Limitations
Suppliers performing fluorescent penetrant inspection shall be approved for that process by
RAC.
Fluorescent penetrant inspection shall be performed in accordance with RAC engineering
drawing referenced specifications.
Only Type I, Sensitivity Level 3, penetrant materials shall be used.
Acceptance criteria shall be MIL-STD-1907, Grade A, with no laps or seams allowed.
A final penetrant inspection shall be performed following all operations that could cause surface
connected discontinuities. Such operations include, but are not limited to, grinding, welding,
straightening, machining, forming, and heat treating with the following exceptions:
Final penetrant inspections shall not be performed on welds unless specified on the
engineering drawing.
Final penetrant inspections are not required on sheet material sheared or cut by a router.
Non-ferrous castings and forgings that have had a fluorescent penetrant inspection
performed prior to machining require an additional fluorescent penetrant inspection after
machining to detect only machine induced anomalies. This inspection process should be
concentrated on the machined surfaces.
Final penetrant inspections are not required on parts with machined normally drilled holes or
bores unless fracture critical or specified on the engineering drawing.
Final penetrant inspections are not required on tubing unless it is swaged, fracture critical, or
specified on the engineering drawing.
Final penetrant inspections shall not be performed on hot formed parts unless specified on
the engineering drawing.
Final penetrant inspections are not required for sawing, shearing, deburring, or blending
processes.
Penetrant inspections shall be performed after bending operations, but before grinding, buffing,
and/or sanding operations, except parts made from sheet material .249 inch and under.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 48 of 68
Title Page Rights Apply
A final penetrant inspection may be performed prior to treatments that can smear the surface,
but do not cause surface discontinuities. Such treatments include, but are not limited to, vapor
blasting, sanding, buffing, sandblasting, lapping, and peening. Performing final penetrant
inspection after such treatments requires that etching be included in the precleaning operation.
A final penetrant inspection shall be performed before surface coatings such as paint, primer,
anodize, plating, and thermal barrier are applied. All bar, rod, and extruded shapes subjected
to either cold forming, cold straightening, or hot forming, shall be penetrant inspected in the
formed and/or straightened areas.
All surfaces to be inspected shall be clean, dry, and free of soils, oil, grease, paint (and other
coatings), corrosion products, scale, smeared metal, weld flux, chemical residues, or any other
material that could prevent the penetrant from entering discontinuities. Cleaning methods,
including etching, shall not be detrimental to the component or the intended function of the
component. A degrease operation is not a sufficient cleaning operation prior to fluorescent
penetrant inspection.
Etching, unless otherwise specified, shall be performed when evidence exists that previous
cleaning, surface treatments, or other influence has produced a surface condition that degrades
the effectiveness of the penetrant inspection.
Close tolerance holes may be masked prior to etching for control of close tolerance diameters.
Components shall be cleaned after inspection to remove inspection material residues. Surface
treatment operations that typically follow penetrant inspection, that contain a cleaning operation,
are anodize and chemical film. For parts that require a surface treatment described above, an
additional cleaning operation after fluorescent penetrant inspection is not required. Care should
be taken to avoid redundant cleaning.
When fluorescent penetrant inspection is not specified on the engineering drawing, fluorescent
penetrant inspection shall be performed in accordance with the requirements of the MIL-STD-
1907 and ASTM E1417.
The application of fluorescent penetrant inspection to non-ferrous sheet material is not required
unless machine tool cutting has been performed (i.e. machining of pockets, etc.).
Parts made from aluminum plate or bar stock that have material left as raw stock after
machining require fluorescent penetrant inspection after machining to detect only machine
induced anomalies. The fluorescent penetrant inspection shall be concentrated on the
machined surfaces.
Parts listed in BS25707 do not require Fluoresent Penetrant Inspection.
3.5.26 Magnetic Particle Inspection
General
Magnetic particle inspection is a Non-Destructive Inspection (NDI) test method for locating surface and
subsurface discontinuities in ferromagnetic materials (materials capable of being magnetized).
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 49 of 68
Title Page Rights Apply
Requirements/Limitations
Suppliers performing magnetic particle inspection shall be approved for that process by RAC.
Magnetic particle inspection shall be performed in accordance with RAC engineering drawing
referenced specifications.
Only the wet continuous method of magnetic particle inspection shall be used.
Acceptance criteria shall be MIL-STD-1907, Grade A, with no laps or seams allowed on
machined surfaces ONLY.
Magnetic particle inspection is required when ferromagnetic steel parts that have been
hardened by heat treatment, regardless of whether heat treatment was performed on the raw
stock (bar, tube, forging, etc.), a rough machined part, a finished machine part, or a weld
assembly.
Magnetic particle inspection shall follow processing and embrittlement relief operations to
detect any hydrogen embrittlement cracking or other damage that may have occurred.
All ferromagnetic steel parts heat treated above 150 ksi that have been electroplated, pickled,
acid stripped, or phosphate coated shall be magnetic particle inspected following the noted
process.
When magnetic particle inspection is not specified on the engineering drawing, magnetic
particle inspection shall be performed in accordance with the requirements of MIL-STD-1907
and ASTM E1444 with the following exceptions.
Magnetic particle Inspection is not required on rough machined areas of parts that will be
finished at the next assembly.
Final magnetic particle inspections are not required on parts with machined normally drilled
holes or bores unless fracture critical or specified on the engineering drawing.
Ferrous castings and forgings that have a magnetic particle inspection performed prior to
machining require an additional magnetic particle inspection after machining to detect only
machine induced anomalies. The additional magnetic particle inspection shall be concentrated
on the machined surfaces.
Parts made from ferrous plate or bar stock that have material left as raw stock after machining
require magnetic particle inspection after machining to detect only machine induced anomalies.
The magnetic particle inspection shall be concentrated on the machined surfaces.
Parts listed in BS25707 do not require Magnetic Particle Inspection.
3.5.27 Hot Forming of Aluminum
General
Certain product forms of both annealed and heat treated aluminum alloys require special process
controls for forming conducted within temperature ranges above room temperature. Generally, these
are product forms of the 2xxx and 7xxx series alloys. Hot forming of aluminum encompasses any
elevated temperature forming process to include bending, stretching, joggling, etc.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 50 of 68
Title Page Rights Apply
Requirement/Limitations
Suppliers performing hot forming of aluminum alloy product forms shall be approved for that
process by RAC.
Hot forming of aluminum product forms shall be performed in accordance with RAC
Engineering drawing referenced specifications.
Hot forming may be designated on the engineering drawing as a forming requirement. On other
parts, the part design may imply a necessity to hot form in order to achieve the required
geometrical shape. All options should be considered when evaluating manufacturing methods.
When possible, severe forming operations, including joggling, should be accomplished with the
material in the -O or the -W temper to possibly avoid hot forming. The ability to form in
the -O or -W temper is limited by multiple factors:
1. The material must be of size and configuration suitable for heat treatment without
producing significant warpage or distortions that would adversely affect the part. For
example, an extrusion heat treated to facilitate joggling should not exceed approximately
three feet in length unless a stretch operation is employed as part of the joggle operation to
remove warpage created by the heat treat process.
2. The final temper of the material shall be as designated on the engineering drawing. If the
final temper requirement does not allow for annealing or heat treatment, the material shall
be formed in the heat treated condition. As an example, if the drawing specified 2024 with
-T351 as a final temper, annealing and/or solution heat treating for increased formability in
the -O or -W temper is not allowed because of the resultant -T42 final temper.
3.5.28 Hot Forming and Bending of Ferrous Alloys
General
Many ferrous alloys can be heated to facilitate forming. Hot forming is normally utilized for more
severe forming and bending operations where the product is difficult to shape and/or would be likely to
crack during cold bending or forming. The process consists of heating the areas to be formed with
oxy-acetylene torches then hammer forming or hand bending the parts into the required shape over
simple form blocks.
Requirements/Limitations.
Suppliers performing hot forming of ferrous alloys shall be approved for that process by RAC.
Bending or forming of ferrous alloys is limited by RAC to the materials shown in Table 4.
Bending and forming operations that require heating shall be accomplished prior to hardening
by heat treatment, if hardening is required.
3.5.29 Hot Forming of Magnesium Sheet Material
General
The primary magnesium alloy sheet material in use for RAC part fabrication is AZ31B. Engineering
drawings normally specify that parts be made from annealed material (-O temper) or material in a work
hardened condition (usually -H24 temper). Magnesium alloy AZ31B material will not respond to
thermal heat treatment. If the mill work hardened temper is altered or lost as a result of manufacturing,
the temper cannot be restored by heat treatment.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 51 of 68
Title Page Rights Apply
Requirements/Limitations
Suppliers performing hot forming of magnesium sheet shall be approved for that process by
RAC.
Hot forming of magnesium alloy sheet requires prior approval by RAC.
Raw Material - Magnesium alloy shall be procured with a chrome pickle surface treatment
applied for corrosion protection. It is not uncommon for magnesium sheet material to exhibit
residual graphite from the mill rolling process. It is required that any graphite residue be
mechanically removed prior to forming and/or processing.
AZ31B - AZ31B can be formed at room temperature. If required for more severe forming
applications, forming can be conducted at elevated temperatures. Considerations for forming
temperatures are relative to the material temper as designated below:
Corrosion Protection - All magnesium materials shall have a Type III (Dow No. 7) chemical film
applied in accordance with AMS-M-3171 to provide for corrosion protection.
Stress Relief For AZ31B as follows:
1. AZ31B cold formed in the -O temper shall be stress relieved at 375 25F for
60 minutes after forming. Prior to stress relief, it is required that chrome pickle be
removed.
2. AZ31B cold formed in the -H24 temper shall be stress relieved at 300 25F for
45 minutes. Prior to stress relief, it is required that chrome pickle be removed.
Magnesium material having the chrome pickle film removed during manufacturing operations
(such as mechanical removal of residual graphite, drilling, filing, mechanical deburring, sawing,
milling, hot forming, stress relief, etc.) shall not be without a corrosion protection for more than
eight hours. If scheduling requires that corrosion protection be removed for more than (8)
hours, It shall be the responsibility of the supplier to apply a protective oil to prevent corrosion
attack. The protective oil film shall be removed by a degrease operation, prior to hot form,
stress relief, dichromate treatment or any operation requiring the removal of the protective oil
film.
Primer Coating - When primer coating is required, parts shall be primer coated within 24 hours
of the final Type III (Dow No. 7) chemical film treatment. Primer coating shall be in accordance
with MIL-PRF-23377. Application of two primer coats shall be required as noted in BS361.
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 52 of 68
Title Page Rights Apply
Requirements/Limitations
Suppliers performing titanium forming shall be approved for that process by RAC.
Titanium forming shall be accomplished in accordance with RAC engineering drawing
referenced specifications.
BS24058 establishes requirements for the fabrication and processing of parts manufactured
from titanium materials commonly specified by RAC design.
Stress Relief - Most parts fabricated from titanium sheet material require a stress relief
operation after completion of forming. BS24058 contains information and flow charts that
identify requirements for stress relief.
The forming of titanium materials, utilizing either room temperature or elevated temperature
methods, requires special considerations and practice. In some areas, terminology applied to
forming differs from that of other materials. Forming/processing that includes such operations
as cold forming, elevated temperature forming, hot forming, restrike, soak time, dwell time, and
stress relief; require special controls as designated in BS24058.
3.5.31 Water Jet Cutting
Suppliers performing water jet cutting shall be approved for that process by RAC.
3.5.32 Laser Cutting
Suppliers performing laser cutting shall be approved for that process by RAC.
3.5.33 Electrical Discharge Machining (EDM)
Suppliers performing electrical discharge machining shall be approved for that process by RAC.
3.5.34 Polishing Operations (Buffing)
General
Polished/buffed surfaces are achieved by mechanical or hand-buffing systems in conjunction with a
buffing compound, which will produce a bright luster to the metal surface.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 53 of 68
Title Page Rights Apply
Requirements/Limitations
Polishing operations (buffing) performed by suppliers on metal surfaces shall be in accordance
with BS25554.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 54 of 68
Title Page Rights Apply
Table 5. Aluminum Alloy Extruded Wire, Rod, and Shapes Substitution Tables
Material Specified on Authorized and Approved
RAC Engineering Drawing Material Substitution
Temper Applicable Temper Applicable
Alloy Alloy Comments/Limitations
Condition Specification Condition Specification
T4 AMS QQ-A-200/2 T451x AMS QQ-A-200/2
AMS QQ-A-200/2 AMS4153
T6
AMS4153 AMS QQ-A-200/2
T6
AMS QQ-A-200/2
T6510 or T6511 AMS QQ-A-200/2
or AMS4153
T42 AMS QQ-A-200/2 T4 or T451x AMS QQ-A-200/2
2014 AMS QQ-A-200/2 2014 AMS4153
T62
AMS4153 AMS QQ-A-200/2
T62
AMS QQ-A-200/2 or AMS QQ-A-200/2 or
T6
AMS4153 AMS4153
T6510 AMS QQ-A-200/2 T6511 AMS QQ-A-200/2
Age Harden to T6511 per
T6511 AMS QQ-A-200/2 T4511 AMS QQ-A-200/2
AMS2770
2024 AMS QQ-A-200/3 2024 T3 AMS4152
AMS4152 AMS QQ-A-200/3
T3 AMS QQ-A-200/3
T3510
AMS QQ-A-200/3 or or AMS4164
AMS4152 AMS QQ-A-200/3
T3511
or AMS4165
AMS QQ-A-200/3
T3
or AMS4152
T4 or T42 AMS QQ-A-200/3 AMS QQ-A-200/3
T3510
or AMS4164
AMS QQ-A-200/3
T3511
or AMS4165
T3, T3510, or Age Harden to T81, T8510, or
T81 AMS QQ-A-200/3 AMS QQ-A-200/3
T3511 T8511 per AMS2770.
T3510 AMS4164 T3510 AMS QQ-A-200/3
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 55 of 68
Title Page Rights Apply
Table 5. Aluminum Alloy Extruded Wire, Rod, and Shapes Substitution Tables (Contd)
Material Specified on Authorized and Approved
RAC Engineering Drawing Material Substitution
Temper Applicable Temper Applicable
Alloy
Condition Alloy Comments/Limitations
Specification Condition Specification
T3511 AMS QQ-A-200/3 T3511 AMS4165
AMS4165 AMS QQ-A-200/3
2024 2024 Age Harden to T8510 or T8511
(Contd) T8510 AMS QQ-A-200/3 (Contd) T3510 or T3511 AMS QQ-A-200/3
per AMS2770.
Age Harden to T8511 per
T8511 AMS QQ-A-200/3 T3511 AMS QQ-A-200/3
AMS2770.
O AMS QQ-A-200/8 O AMS4160
AMS4160 AMS QQ-A-200/8
AMS QQ-A-200/8 AMS4161
T4
AMS4161 AMS QQ-A-200/8
T4 T4510 AMS QQ-A-200/8
AMS QQ-A-200/8
or AMS4161 AMS QQ-A-200/8 or
T4511
AMS4172
AMS QQ-A-200/8 AMS4150
T6
AMS4150 AMS QQ-A-200/8
Age Harden to T6 per
T4 AMS QQ-A-200/8
T6 AMS2770.
AMS QQ-A-200/8 or Age Harden to T6511 per
T4511 AMS QQ-A-200/8
AMS4150 AMS2770.
6061 6061 AMS QQ-A-200/8 or
T6511
AMS4173
AMS QQ-A-200/8 or
T4510 AMS QQ-A-200/8 T4511
AMS4172
AMS QQ-A-200/8 AMS4172
T4511 T4511
AMS4172 AMS QQ-A-200/8
Age Harden to T6511 per
T4511 AMS QQ-A-200/8
AMS2770.
T6510 AMS QQ-A-200/8
AMS QQ-A-200/8 or
T6511
AMS4173
AMS QQ-A-200/8 AMS4173
T6511
T6511 AMS4173 AMS QQ-A-200/8
AMS QQ-A-200/8 or Age Harden to T6511 per
T4511 AMS QQ-A-200/8
AMS4173 AMS2770.
7075 AMS QQ-A-200/11 7075 T6 AMS4154
AMS4154 AMS QQ-A-200/11
T62 AMS QQ-A-200/11
T6 AMS QQ-A-200/11 or
AMS QQ-A-200/11 or T6510
AMS4168
AMS4154
AMS QQ-A-200/11 or
T6511
AMS4169
AMS QQ-A-200/11 AMS4166
T73
T73 AMS4166 AMS QQ-A-200/11
AMS QQ-A-200/11 or Age Harden to T73 per
T6 AMS QQ-A-200/11
AMS4166 AMS2770.
AMS QQ-A-200/11 or
AMS QQ-A-200/11 or T73511
T73510 AMS4167
AMS4164
T6511 AMS QQ-A-200/11 Age Harden to T73511 per
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 56 of 68
Title Page Rights Apply
AMS2770.
AMS QQ-A-200/11 or
T73511
AMS QQ-A-200/11 or AMS4167
T73511
AMS4167 Age Harden to T73511 per
T6511 AMS QQ-A-200/11
AMS2770.
Table 6. Aluminum Alloy Rolled or Cold Finished Wire, Rod, and Bar Substitution Table
Material Specified on Authorized and Approved
RAC Engineering Drawing Material Substitution
Temper Applicable Temper Applicable
Alloy Alloy Limitations/Comments
Condition Specification Condition Specification
T4 Any T42 or T451 Same as original
Age Harden to T6 or T651
T4 or T451
T6 Any Same as original per AMS2770.
T62 or T651
2014 2014
T42 Any T4 or T451 Same as original
Age Harden to T6, T62 or
T4, T42, or T451
T62 Any Same as original T651 per AMS2770.
T6 or T651
Limited to round and flat bar
T3 AMS QQ-A-225/6 T4 or T351 AMS QQ-A-225/6 that is 0.5 inch or greater in
diameter or thickness.
AMS QQ-A-225/6 AMS4120
T4
AMS4120 AMS QQ-A-225/6
T4 T3 or T351 Same as original
Any AMS QQ-A-225/6
T42
or AMS4120
AMS QQ-A-225/6 AMS4339
T6
AMS4339 AMS QQ-A-225/6
T6
AMS QQ-A-225/6 AMS QQ-A-225/6
T851
or AMS4339 or AMS4339
2024 AMS QQ-A-225/6 2024 AMS4120
T42
AMS4120 AMS QQ-A-225/6
Limited to round and flat bar
T42 T3 or T351 Same as original that is 0.5 inch or greater in
Any diameter or thickness.
AMS QQ-A-225/6
T4
or AMS4120
AMS QQ-A-225/6 AMS4120
T351
AMS4120 AMS QQ-A-225/6
T351 Limited to round and flat bar
AMS QQ-A-225/6 T4 AMS QQ-A-225/6 that is less than 0.5 inch in
diameter or thickness.
AMS QQ-A-225/6 AMS QQ-A-225/6 Age Harden to T851 per
T851 T351
or AMS4339 or AMS4120 AMS2770.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 57 of 68
Title Page Rights Apply
Table 6. Aluminum Alloy Rolled or Cold Finished Wire, Rod, & Bar Substitution Table (Contd)
Material Specified on Authorized and Approved
RAC Engineering Drawing Material Substitution
Temper Applicable Temper Applicable
Alloy Alloy Limitations/Comments
Condition Specification Condition Specification
O AMS QQ-A-225/8 O AMS4415
AMS4115 AMS QQ-A-225/8
AMS QQ-A-225/8 AMS4116
T4
AMS4116 AMS QQ-A-225/8
T4 AMS QQ-A-225/8
T42
Any or AMS4116
T451 Same as original
AMS QQ-A-225/8 AMS4117
T6
AMS4117 AMS QQ-A-225/8
T6 AMS QQ-A-225/8
T62 or T651
AMS QQ-A-225/8 or AMS4117
or AMS4117 Age Harden to T6 or T651
T4 or T451 AMS QQ-A-225/8
per AMS2770.
6061 AMS QQ-A-225/8 6061 AMS4116
T42 T4
AMS4116 AMS QQ-A-225/8
AMS QQ-A-225/8 AMS4117
T62
AMS4117 AMS QQ-A-225/8
T62 AMS QQ-A-225/8
T6 or T651
AMS QQ-A-225/8 or AMS4117
or AMS4117 Age Harden to T6 or T62
T4 or T42 AMS QQ-A-225/8
per AMS2770.
AMS QQ-A-225/8 AMS4128
T451 T451
AMS4128 AMS QQ-A-225/8
AMS QQ-A-225/8 AMS4117
T651
T651 AMS4117 AMS QQ-A-225/8
AMS QQ-A-225/8 Age Harden to T651 per
T451 AMS QQ-A-225/8
or AMS4117 AMS2770.
O AMS QQ-A-225/9 O AMS4187
AMS4187 AMS QQ-A-225/9
AMS QQ-A-225/9 AMS4122
T6
AMS4122 AMS QQ-A-225/9
T6 AMS QQ-A-225/9
T62
AMS QQ-A-225/9 or AMS4122
or AMS4124 AMS QQ-A-225/9
T651
or AMS4123
AMS QQ-A-225/9 AMS4122
T6
T62 AMS4122 AMS QQ-A-225/9
7075 7075
AMS QQ-A-225/9 AMS QQ-A-225/9
T651
or AMS4124 or AMS4123
AMS QQ-A-225/9 AMS4123
T651 T651
AMS4123 AMS QQ-A-225/9
Any AMS QQ-A-225/9
T73 T7351
AMS QQ-A-225/9 AMS4124
AMS QQ-A-225/9 AMS4124
T7351
T7351 AMS4124 AMS QQ-A-225/9
Age Harden to T7351 per
AMS QQ-A-225/9 T651 AMS QQ-A-225/9
AMS2770.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 58 of 68
Title Page Rights Apply
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 59 of 68
Title Page Rights Apply
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 60 of 68
Title Page Rights Apply
AMS5901
301 Same as Original
ASTM A276
AMS-S-7720 or AMS5516
304 A ASTM A276
302 Same as Original Plate sawed to bar dimensions.
ASTM A276
AMS5507
316 Same as Original
ASTM A276
Hard AMS 5517
301
Same as Original ASTM A276
AMS-S-7720 or Hard AMS5903
304 B ASTM A276
302 Plate sawed to bar dimensions.
Same as Original ASTM A276
Hard AMS5907
316
Same as Original ASTM A276
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 61 of 68
Title Page Rights Apply
Note b: Substituted material shall be heat treated to 125 145 ksi in accordance with AMS2759.
Note c: If the RAC Engineering drawing does not specify a heat treat strength level, the material shall be heat treated to
110 140 ksi in accordance with AMS2759. Refer to Sub-section 3.1.c Special Requirement for 4130 Steel Bar Stock
of this specification for further clarification.
Note d: Any raw material Procured finish can be substituted for any RAC Engineering drawing raw material Specified finish
provided the Mill Finish Surface finish of the substituted material is completely removed during machining with the
following exception: If the finish of the substituted material is the same as that specified on the RAC Engineering
drawing, then the finish does not need to be removed.
Note e: Larger material stock may be required in order to meet specified mill finish requirements.
Note f: If the RAC Engineering drawing does not specify a heat treat strength level, the material shall be heat treated to
95 ksi minimum for material with wall thickness that is 0.187 inch or less and to 90 ksi minimum for material with wall
thickness greater than 0.187 inch. Heat treat in accordance with AMS2759.
Table 11. Ferrous Alloy Sheet, Plate, and Strip Substitution Table
Material Specified on Authorized and Approved
RAC Engineering Drawing Material Substitution
Temper Applicable Temper Applicable
Alloy Alloy Limitations/Comments
Condition Specification Condition Specification
Condition N AMS6345
MIL-S-18729 MIL-S-18729
Condition A See Note a.
or AMS6350
Condition N
Condition N MIL-S-18729
AMS6345 MIL-S-18729
Condition A See Note a.
or AMS6350
4130 4130
Condition A AMS6350
MIL-S-18729 MIL-S-18729
Condition N See Note b.
or AMS6345
Condition A
Condition A MIL-S-18729
AMS6350 MIL-S-18729
Condition N See Note b.
or AMS6345
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 62 of 68
Title Page Rights Apply
Table 11. Ferrous Alloy Sheet, Plate, and Strip Substitution Table
Material Specified on Authorized and Approved
RAC Engineering Drawing Material Substitution
Temper Applicable Temper Applicable
Alloy Alloy Limitations/Comments
Condition Specification Condition Specification
MIL-S-5059 301 AMS5901
AMS5901 MIL-S-5059
Annealed Annealed MIL-S-5059
302
MIL-S-5059 or AMS5516
or AMS5901 MIL-S-5059
304
or AMS5513
MIL-S-5059
302
MIL-S-5059 or AMS5903
1/4 H 1/4 H
or AMS5517 MIL-S-5059
301 304
or AMS5910
MIL-S-5059
302
MIL-S-5059 or AMS5904
1/2 H 1/2 H
or AMS5518 MIL-S-5059
304
or AMS5911
MIL-S-5059
302
MIL-S-5059 or AMS5906
Full Full
or AMS5519 MIL-S-5059
304
or AMS5913
MIL-S-5059 302 AMS5516
AMS5516 MIL-S-5059
Annealed Annealed MIL-S-5059
301
MIL-S-5059 or AMS5901
or AMS5516 MIL-S-5059
304
or AMS5513
MIL-S-5059
301
MIL-S-5059 or AMS5517
1/4 H 1/4 H
or AMS5903 MIL-S-5059
302 304
or AMS5910
MIL-S-5059
301
MIL-S-5059 or AMS5518
1/2 H 1/2 H
or AMS5904 MIL-S-5059
304
or AMS5911
MIL-S-5059
301
MIL-S-5059 or AMS5519
Full Full
or AMS5906 MIL-S-5059
304
or AMS5913
MIL-S-5059 304 AMS5513
AMS5513 MIL-S-5059
Annealed Annealed MIL-S-5059
301
MIL-S-5059 or AMS5901
or AMS5513 MIL-S-5059
302
or AMS5516
MIL-S-5059
301
MIL-S-5059 or AMS5517
1/4 H 1/4 H
or AMS5910 MIL-S-5059
304 302
or AMS5903
MIL-S-5059
301
MIL-S-5059 or AMS5518
1/2 H 1/2 H
or AMS5911 MIL-S-5059
302
or AMS5904
MIL-S-5059
301
MIL-S-5059 or AMS5519
Full Full
or AMS5913 MIL-S-5059
302
or AMS5906
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 63 of 68
Title Page Rights Apply
Table 11. Ferrous Alloy Sheet, Plate, and Strip Substitution Table
Material Specified on Authorized and Approved
RAC Engineering Drawing Material Substitution
Temper Applicable Temper Applicable
Alloy Alloy Limitations/Comments
Condition Specification Condition Specification
MIL-S-6721 321 AMS5510
AMS5510 MIL-S-6721
321 Annealed Annealed
MIL-S-6721 MIL-S-6721
347
or AMS5510 or AMS5512
MIL-S-6721 347 AMS5512
AMS5512 MIL-S-6721
347 Annealed Annealed
MIL-S-6721 MIL-S-6721
321
or AMS5512 or AMS5510
MIL-S-7952,
Cold or Hot
1020-1025 ASTM A659, 1020-1025 Cold Finish ASTM A606
Finish
or ASTM A569
Note a: Substituted material that is 0.187 inch or less shall be heat treated to 95 135 ksi in accordance with AMS2759.
Substituted material that is greater than 0.187 inch shall be heat treated to 90 135 ksi in accordance with AMS2759.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 64 of 68
Title Page Rights Apply
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 65 of 68
Title Page Rights Apply
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 66 of 68
Title Page Rights Apply
Material Material
Thickness Berylium Copper Copper
(QQ-C-533) (QQ-C-576)
H H Annealed H H
Min Min Min Min Min
.012 .06 .20 .03 .06 .12
.016 .06 .25 .03 .09 .16
.020 .09 .31 .03 .09 .19
.025 .12 .38 .03 .12 .25
.028 NA .06 .12 .28
.032 .12 .50 .06 .12 .38
.036 NA .06 .16 .44
.040 .16 .63 .09 .16 .50
.045 NA .09 .20 .50
.050 .25 .75 .12 .25 .56
.056 NA .12 .25 .63
.063 .25 1.00 .12 .25 .70
.071 .31 1.13
.080 .31 1.25
NA
.090 .38 1.38
.100 .44 1.50
Table 16. Copper & Bronze Alloy Rod & Bar Substitution Table
Material Specified on Authorized and Approved
RAC Engineering Drawing Material Substitution
Temper Applicable Temper Applicable
Alloy Alloy Limitations/Comments
Condition Specification Condition Specification
Stress Stress
C64200 relieved
AMS 4631 4130
Relieved
AMS 4634
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 67 of 68
Title Page Rights Apply
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
Page 68 of 68
Title Page Rights Apply
If any casting or forging tooling is reworked or modified, or a first time production run, the
procuring machine shop is responsible for First Article Inspection of that casting or forging. For
parts manufactured to RAC drawings/specifications, the FAI on the casting or forging is to be
included in the certification package coming into RAC from the machine shop.
NOTE
If a cadmium plating operation is called out
after the part is machined and the part has a
hardness of 150 ksi or greater, then Magnetic
Particle Inspection per ASTM E1444 is
required.
6. NOTES
Not Applicable
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot
Issued 01/99 DOC141941 R01
Rev 08/02
Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
APPENDIX A
Page 1 of 2
Title Page Rights Apply
APPENDIX A
Check One:
Is this part: machined to final dimension by (from the Company field).
or
machined to final dimension internally at Raytheon Aircraft.
Narrative Description of Material Recommended for Substitute (Alloy, Heat Treat Condition,
Dimensional Configuration, etc.):
Modification Required:
This section is for Cost Analysis/Material Forecast Information for raw material to be
manufactured at Raytheon Aircraft (to be filled out by the raw material supplier):
********************************************************************************************
1. This Section to be Completed by RAC Process Engineering
********************************************************************************************
2. This Section to be Completed by RAC Manufacturing Engineering
BS25691 Rev 8
ENGINEERING SPECIFICATION DOC153925 R8
APPENDIX A
Page 2 of 2
Title Page Rights Apply
Check One:
Is this part: machined to final dimension by (from the Company field).
or
machined to final dimension internally at Raytheon Aircraft.
Narrative Description of Material Recommended for Substitute (Alloy, Heat Treat Condition, Dimensional
Configuration, etc.):
Dimensional configuration (size and form), material alloy designation, heat treat condition and material
specification. For example: thick x 2 wide x 3 length sheet, alclad 2024-T3 per QQ-A-250/5.
Modification Required:
What is required to get the material to the configuration of the part or raw material that is being
substituted for. For example: Grind thickness to meet the thickness material requirement per the
RAC drawing.
This section is for Cost Analysis/Material Forecast Information for raw material to be manufactured at
Raytheon Aircraft (to be filled out by the raw material supplier):
Information for Raytheon Aircraft Manufacturing Engineering To base a decision if the raw material being
received will be a temporary or permanent change.
********************************************************************************************
1. This Section to be Completed by RAC Process Engineering
Approval, Disapproval, Comments: This area will be completed by an RAC authorized department.
********************************************************************************************
2. This Section to be Completed by RAC Manufacturing Engineering
Approval, Disapproval, Comments: This area will be completed by an RAC authorized department.