SS9208 Rev 48 (Production Acceptance Criteria)

TABLE OF CONTENTS
SECTION TABLE OF CONTENTS SCOPE APPLICABILITY 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 9.0 10.0 11.0 12.0 13.0 14.0 15.0 15.1 15.2 16.0 16.1 17.0 17.1 17.2 ANGULAR TOLERANCE FOR SHEET METAL FLANGES CHAMFER OR RADIUS OF EXTERNAL CORNERS ACCEPTANCE OF SURFACE IMPERFECTIONS REPLACEMENT FASTENERS (SOLIDS, HILOKS, REPLACEMENT FASTENERS (BLIND FASTENERS) RIVETS FOR NUT PLATE INSTALLATION EDGE ACCEPTANCE OF ALUMINUM SHEET METAL DETAILS ACCEPTANCE ASSEMBLY METHODS SHIMMING METALLIC AIRFRAME COMPONENTS TRIMMING METALLIC AIRFRAME SKINS TRIMMING METALLIC AIRFRAME COMPONENTS PILOT HOLES THAT BREAK INTO FINISHED FASTENER HOLES DIMENSIONAL TOLERANCES FOR FORMED SHEET METAL FLANGES ACCEPTANCE CRITERIA TO MEET PROPER GRIP LENGTH OF MECHANICALLY LOCKED FASTENERS. ACCEPTANCE CRITERIA TO MEET PROPER GRIP LENGTH OF 1/4 TURN CAMLOC FASTENER ACCEPTANCE CRITERIA FOR PIN HOLE LOCATIONS INTERCHANGEABLE FASTENERS (STUMP & PULL TYPE LOCKBOLTS) SAFETY WIRING / SAFETY CABLE ACCEPTANCE CRITERIA TO MEET THREAD PROTUSION ACCEPTANCE CRITERIA FOR EDGE AND PITCH DISTANCE COATINGS AND FINISHES ACCEPTANCE CRITERIA FOR CASTINGS / FORGINGS SCREW THREADS SCREW THREADS ON ELECTRICAL CONNECTORS THREADED FASTENERS WITH INCONSISTANT FUNCTIONAL ELEMENT/SIZE CONTROL COMPONENTS PROOF PRESSURE TESTING OF FLUID COMPONENTS AND PROOFTESTING OF CONTROL CABLE ASSEMBLIES ELECTRICAL COMPONENTS GROMMET ALTERNATES WIRE MARKING CRITERIA FOR ALLSIKORSKY AIRCRAFT WIRING. TITLE PAGE 1 2 2 3 3 4 5 11 14 15 15 16 21 23 46 1/31/01 47 10/23/02 48 12/04/02
DATE:
34 35 36 39 40 43 44 45 50 59 61 62 62 62 63 63 64 64 64
SA 5140 REV D 5/97 .
WARNING THIS DOCUMENT, OR AN EMBODIMENT OF IT IN ANY MEDIA, DISCLOSES INFORMATION WHICH contractors Administrative/Operation use. OF SI and their IS PROPRIETARY, IS THE PROPERTYProprietary information as of 19 Nov 99. Other requests shall be referred to the KORSKY AIRCRAFT CORPORATION, IS AN UNPUB Utility Helicopters Project Management Office at: LISHED United States Army Aviation and Missile Command WORK PROTECTED UNDER APPLICABLE Sparkman Center, IS DELIVERED ON COPYRIGHT LAWS, ANDBuilding 5308, 4th Floor THE EX PRESS CONDITION AMSAM-DSA-UH NOT TO BE USED, THAT IT IS Redstone Arsenal, AL 35898-5280 DISCLOSED, OR REPRODUCED, IN WHOLE OR IN WARNING This document contains technical data whose export is PART (INCLUDING REPRODUCTION AS A DERIVA restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et. TIVE the Export Administration Act MANUFACTURE FOR seq.) orWORK), OR USED FOR of 1979, as amended, Title 50, U.S.C., App. 2401 et. seq. Violations of these export laws are subject to ANYONE OTHER THAN SIKORSKY AIRCRAFT WITH severe ITS WRITTEN CONSENT, AND THAT NO RIGHT OUT criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25. IS GRANTED TO DISCLOSE OR SO Sikorsky Aircraft Delivered Under Contract DAAH23-02-C-0006 By USE ANY IN Corporation. FORMATION CONTAINED THEREIN. ALL RIGHTS RESERVED. ANY ACT IN VIOLATION OF APPLICA BLE LAW MAY RESULT IN CIVIL AND CRIMINAL PEN ALTIES.
Distribution C: Distribution authorized to U.S. Government Agencies
6900 MAIN ST STRATFORD, CT 06497-9129
SIKORSKY SPECIFICATION
MATERIAL & PROCESS
PREP. E. JARONCZYK APVD.J. SONICK GOVT J. BONNEY . SUPERSEDES:
PRODUCT DEFINITION ACCEPTANCE CRITERIA
CAGE NUMBER
78286
SS 9208
SHEET ___1___ OF 64___
Verify current revision of this document in WorldView prior to use.
10/27/83
REVISED:
SCOPE:
This specification authorizes product definition/acceptance criteria to be used in conjunction with Sikorsky Aircraft drawings. This specification will define criteria such as tolerances, process criteria and acceptance criteria that is not defined on the drawing. Unless otherwise specified, dimensions are in inches.
APPLICABILITY:
This specification applies when invoked on the Engineering Parts List. When SS9208 is invoked, the practices and standards described herein may be used in fabrication and inspection of the parts unless a drawing note appears on the drawing specifically excluding the practice or standard. REVISION DATE DATE REV 5/17/84 24 8/23/84 25 7/19/85 26 8/14/85 27 6/13/86 28 1/27/87 29 7/23/87 30 1/13/88 31 3/7/88 32 4/20/88 33 6/6/88 34 8/17/88 35 8/18/88 36 VOID 37 2/9/89 38 6/26/89 39 7/21/89 40 8/29/89 41 11/16/89 42 1/4/90 43 4/23/90 44 6/29/90 45 9/10/90 46 47 48
48
SA 5139-1 REV D 5/97 .
WARNING THIS DOCUMENT, OR AN EMBODIMENT OF IT IN ANY MEDIA, DISCLOSES INFORMATION WHICH IS PROPRIETARY, IS THE PROPERTY OF SIKORSKY AIRCRAFT CORPORATION, IS AN UNPUBLISHED WORK PROTECTED UNDER APPLICABLE COPYRIGHT LAWS, AND IS DELIVERED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED, DISCLOSED, OR REPRO DUCED, IN WHOLE OR IN PART (INCLUDING REPRODUCTION AS A DERIVATIVE WORK), OR USED FOR MANUFACTURE FOR ANYONE OTHER THAN SIKORSKY AIRCRAFT CORPORATION WITHOUT ITS WRITTEN CONSENT, AND THAT NO RIGHT IS GRANTED TO DISCLOSE OR SO USE ANY INFORMATION CONTAINED THEREIN. ALL RIGHTS RESERVED. ANY ACT IN VIOLATION OF APPLICABLE LAW MAY RESULT IN CIVIL AND CRIMINAL PENALTIES.
CAGE NUMBER
78286
STRATFORD, CONNECTICUT 06497-9129
SS9208
SHEET 2
DATE
10/27/83
PG# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
INDEX OF SHEETS REV# PG# REV# PG# 48 28 48 55 48 29 48 56 30 30 48 57 47 31 48 58 47 32 48 59 48 33 48 60 48 34 48 61 48 35 48 62 48 36 48 63 48 37 48 64 48 38 48 48 39 48 48 40 48 48 41 48 47 42 48 47 43 48 47 44 48 48 45 48 48 46 48 48 47 48 48 48 48 48 49 48 48 50 48 48 51 48 48 52 48 48 53 48 48 54 48
48
REV# 48 48 48 48 48 48 48 48 48 48
REVISED
REV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
DATE 10/3/90 10/22/90 2/7/91 5/15/92 11/9/92 12/4/92

12/15/94
9/15/95
11/27/95
1/20/96 3/19/96 4/15/96 12/13/96 2/13/97 7/21/97 10/20/98 1/28/99 7/26/99 9/3/99 10/8/99 11/09/00 1/17/01 1/31/01 10/23/02 12/04/02
48 12/04/02
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1. 1.1
ANGULAR TOLERANCE FOR SHEET METAL FLANGES. The angular tolerance for sheet metal flanges with a flange height greater than .44 but not more than 1.5 shall be 2. The flange angle as produced shall not vary more than 1 over its entire length. Good shop practice shall be followed and kinks or crimps are not acceptable. The angular tolerance for sheet metal flanges with a flange height of .44 or less shall be 30. The flange angle as produced shall not vary more than 1 over its entire length. Good shop practice shall be followed and kinks or crimps are not acceptable.
1.2
Paragraph 1.1 does not apply when the field of drawing calls out a specified angular tolerance for sheet metal flanges. 2. 2.1 CHAMFER OR RADIUS ON EXTERNAL CORNERS. Extruded parts with a .25 X 45 chamfer or less, or .25 radius or less, specified or drawn on an undimensioned drawing, either a .25 radius or a .25 X 45 chamfer is acceptable and dependent on the process used. .25 X 45 CHAMFER
.25R
Paragraph 2.1 does not apply when the field of drawing calls out a chamfer of .25 X 45 or less, or a .25 radius or less, each having a specified linear tolerance.
XX XX R
.25 XX x 15
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3. 3.1
ACCEPTANCE OF SURFACE IMPERFECTIONS The visual inspection for nicks, dents, scratches, machining tool marks and scuff marks shall be conducted by Quality Assurance personnel. The acceptance of these detected irregularities are determined by engineering drawing requirements and the following: Irregularities, such as nicks, dents, scratches, machining tool marks and scuff marks, on Flight Safety parts with critical characteristics, are acceptable when they are .0005 inch deep or less. For all other parts, irregularities, such as nicks, dents, scratches, machining tool marks and scuff marks, are acceptable when they fall within drawing specified finish requirements. Surface irregularities, which have been shot peened over, will be acceptable if they meet the surface requirements of the engineering drawing and under 10x magnification, exhibit shotpeen coverage throughout the irregularity. REPLACEMENT FASTENERS (Limited Usage) NOTE: These allowances are for occasional replacements, repetitive use in any location requires investigation and possible drawing correction. Complete pattern replacement of Lockbolts or rivets with Hilock fasteners is acceptable without limitation of 4.1 b,c. Solid Rivets, HiLoks, Lock Bolts. In cases where nonblind fastener installation is difficult or impossible for reasons of temporary inaccessibility, unavailability of the fastener, unavailability or inference of the tooling Tables I through IV may be used to provide replacement blind fasteners providing the following are met: (Note: Tables I through IV may also be applied in the reverse condition.) a) The number of replacement blind fasteners shall not exceed 10% (1 in 10, 10 in 100, etc.) of the total number of solid rivets, HiLoks or Lockbolts that are required to join any one detail part or assembly to any other detail part or assembly. For example, where a stringer joins to a skin, a frame joins to a skin panel assembly or skin panel assemblies are joined together. This applies to Tables I through IV. HiLok fasteners (Table III) may be used to replace steel lockbolts where installed space does not permit. The number of replacement HiLoks (Table IV) for aluminum lockbolts shall not exceed 10 percent (1 in 10,10 in 100, etc ) of the original total number of aluminum lockbolt. All hole sizes for replacement fastener shall conform to SS5100. Blind and nonblind fasteners shall not be mixed together in splice joints.
3.1.1
3.1.2
4.
4.1
b) c)
d) e)
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f) g) h) 4.1.1
All blind fasteners shall be wet installed using epoxy primer per MilP23377. Both ends of the rivet must be covered with primer upon completion of the installation. Rivet length shall be determined by Manufacturing Personnel through the use of a grip gage. Minimum sheet thickness must be met where specified. Aluminum Hiloks can replace Aluminum Lockbolts, Aluminum rivets or aluminum sleeved blind fasteners providing the following is met:
a) b) c)
A pattern of 1 to 4: Replace 100% of the pattern. A pattern of 5 to 10: Replace 1 fastener or 100% of the pattern. A pattern of 11 or more : Indivual replacement fastener in a line of fasteners are allowed provided that the next replacement fastener is 9 fasteners or more away; or 100% of the pattern. Steel Hiloks can replace steel rivets or steel sleeved blind fasteners provided the above are met:
4.1.2
SS9208 REV 48
TABLE 1 (SOLID RIVETS) NAS523 CODE DRAWING CALLOUT MS20426AD4 BB MS20426AD5 MS20426AD6 MS20470AD4 BJ MS20470AD5 MS20470AD6 NAS1097AD4 LZ NAS1097AD5 NAS1097AD6 BLIND REPLACEMENTS NAS1739B4 M7885/74 NAS1739B5 M7885/74 NAS1739B6 M7885/74 NAS1738B4 M7885/64 NAS1738B5 M7885/65 NAS1738B6 M7885/66 NAS1739B4 M7885/74 NAS1739B5 M7885/74 NAS1739B6 M7885/74 MIN. SHEET THICKNESS .040 (a) .050 (a) .071 (a) .032 (b) .040 (b) .050 (b) .040 (a) .050 (a). .071 (a)
a) b)
Minimum sheet thickness must be met on the sheet that lies against the manufactured countersunk head to avoid knife edge conditions. For solid universal head rivets to be replaced with blind protruding head rivets, each of the sheets being riveted must meet the minimum sheet thickness requirement.
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TABLE II (HILOKS) NAS523 CODE DRAWING CALLOUT HL20PB5 HL20PB6 HL20PB8 HL20PB10 HL20PB12 HL20PB14 HL20PB16 HL19PB5 HL19PB6 HL19PB8 HL19PB10 HL19PB12 BLIND REPLACEMENT MS9035405 MS9035406 MS9035408 MS9035410 MS9035412 MS9035414 MS9035416 MS9035305 MS9035306 MS9035308 MS9035310 MS9035312 MIN. SHEETTHICKNESS(a) N.A. N.A N.A. N.A N.A. N.A. N.A. .080 .090 .125 .160 .190
. AHT
WY
a)
Minimum sheet thickness must be met where specified, on the sheet that lies against the manufactured countersunk head to avoid knife edge conditions.
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TABLE III (STEEL LOCK BOLTS)

NAS523 CODES DRAWING CALLOUT STANDARD REPLACEMENT COLLARS MIN. SHEET THICKNESS(a) BLIND REPLACEMENT MIN. SHEET THICKNESS(a)
NAS1415 EA JY OP NAS1416 NAS1418 NAS1420 NAS1422 NAS1425 DY JW OS DZ JX OO NAS1426 NAS1428 NAS1430 NAS1432 NAS1436 NAS1438 NAS1440 NAS1442 DX JV OR DV DW NAS1446 NAS1448 NAS1450 NAS1452 NAS1456 NAS1458 NAS1460 NAS1462
HL19PB5 HL19PB6 HL19PB8 HL19PB10 HL19PB12 HL20PB5 HL20PB6 HL20PB8 HL20PB10 HL20PB12 HL19PB6 HL19PB8 HL19PB10 HL19PB12 HL20PB6 HL20PB8 HL20PB10 HL20PB12 HL21PB6 HL21PB8 HL21PB10 HL21PB12
Note (1) Note (1) Note (1) Note (1) Note (1) Note (2) Note (2) Note (2) Note (2) Note (2) Note (1) Note (1) Note (1) Note (1) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2)
.050 .063 .080 .100 .125 N.A. N.A. N.A. N.A. N.A. .063 .080 .100 .125 N.A. N.A. N.A. N.A. .090 .125 .160 .190
MS9035305 .080 MS9035306 .090 MS9035308 .125 MS9035310 .160 MS9035312 .190 MS9035405 N.A. MS9035406 N.A. MS9035408 N.A. MS9035410 N.A. MS9035412 N.A. MS9035306 .090 MS9035308 .125 MS9035310 .160 MS9035312 .190 MS9035406 N.A. MS9035408 N.A. MS9035410 N.A. MS9035412 N.A. MS9035306 .090 MS9035308 .125 MS9035310 .160 MS9035312 .190
Continued on next page. Note (1). HiLok Collars; HL70, HL79, HL82 and HL1094 may be used. Note (2). HiLok Collars; HL75 and HL1087A may be used. (a) Minimum sheet thickness must be met where specified, on the sheet that lies against the manufactured countersunk head to avoid knife edge conditions.
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TABLE III
NAS523 CODES DRAWING CALLOUT
(STEEL LOCK BOLTS) CONTINUED

COLLARS MIN. SHEET THICKNESS(a) BLIND REPLACEMENT MIN. SHEET THICKNESS(a)
STANDARD REPLACEMENT
NAS1465 DS DT NAS1466 NAS1468 NAS1470 NAS1472 RC RD NAS1486 NAS1488 NAS1490 NAS1492 NAS1496 RE RF NAS1497 NAS1498 NAS1500 NAS1502 Note (1). Note (2). (a)
HL20PB5 HL20PB6 HL20PB8 HL20PB10 HL20PB12 HL21PB6 HL21PB8 HL21PB10 HL21PB12 HL20PB6 HL20PB5 HL20PB8 HL20PB10 HL20PB12
Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2)
N.A. N.A. N.A. N.A. N.A. .090 .125 .160 .190 N.A. N.A. N.A. N.A. N.A.
MS9035405 N.A. MS9035406 N.A. MS9035408 N.A. MS9035410 N.A. MS9035412 N.A. MS9035306 .090 MS9035308 .125 MS9035310 .160 MS9035312 .190 MS9035406 N.A. MS9035405 N.A. MS9035408 N.A. MS9035410 N.A. MS9035412 N.A.
HiLok Collars; HL70, HL79, HL82 and HL1094 may be used. HiLok Collars; HL75 and HL1087A may be used.
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TABLE IV (ALUMINUM LOCK BOLTS)

NAS523 CODES DRAWING CALLOUT STANDARD REPLACEMENT COLLARS MIN. SHEET THICKNESS(a) BLIND REPLACEMENT MIN. SHEET THICKNESS(a)
NAS1516 CP NAS1518 NAS1520 NAS1522 NAS1525 NAS1526 CS NAS1528 NAS1530 NAS1532 NAS1535 NAS1536 DJ NAS1538 NAS1540 NAS1542 NAS1546 CW NAS1548 NAS1550 NAS1552 NAS1555 NAS1556 CV NAS1558 NAS1560 NAS1562 NAS6915 NAS6916 NAS6918 NAS6920 NAS6922
HL21PB6 HL21PB8 HL21PB10 HL21PB12 HL20PB5 HL20PB6 HL20PB8 HL20PB10 HL20PB12 HL19PB5 HL19PB6 HL19PB8 HL19PB10 HL19PB12 HL21PB6 HL21PB8 HL21PB10 HL21PB12 HL20PB5 HL20PB6 HL20PB8 HL20PB10 HL20PB12 HL19PB5 HL19PB6 HL19PB8 HL19PB10 HL19PB12
Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (1) Note (1) Note (1) Note (1) Note (1) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (2) Note (1) Note (1) Note (1) Note (1) Note (1)
.090 .125 .160 .190 N.A. N.A. N.A. N.A. N.A. .050 .063 .080 .100 .125 .090 .125 .160 .190 N.A. N.A. N.A. N.A. N.A. .050 .063 .080 .100 .125
MS9035306 .090 MS9035308 .125 MS9035310 .160 MS9035312 .190 MS9035405 N.A. MS9035406 N.A. MS9035408 N.A. MS9035410 N.A. MS9035412 N.A. MS9035305 .080 MS9035306 .090 MS9035308 .125 MS9035310 .160 MS9035312 .190 MS9035306 .090 MS9035308 .125 MS9035310 .160 MS9035312 .190 MS9035405 N.A. MS9035406 N.A. MS9035408 N.A. MS9035410 N.A. MS9035412 N.A. MS9035305 .080 MS9035306 .090 MS9035308 .125 MS9035310 .160 MS9035312 .190
Note (1). HiLok collars; HL70, HL79, HL82 and HL1094 may be used. Note (2). HiLok collars; HL75 and HL1087A may be used. (a) Minimum sheet thickness must be met where specified, on the sheet that lies against the manufactured countersunk head to avoid knife edge conditions.
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5. 5.1
REPLACEMENT FASTENERS (LIMITED USAGE) Tables V thru VII may be used to provide replacement fasteners for the drawing callout providing the following criteria are met : a) b) c) All hole sizes for replacement fasteners shall conform to SS5100. Rivet length shall be determined by Manufacturing Personnel through the use of a grip gage. Minimum sheet thickness must be met where specified.
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TABLE V NAS523 CODE DRAWING CALLOUT MS20600AD4 AA MS20600AD5 MS20600AD6 MS20600B4 AB MS20600B5 MS20600B6 MS20600M4 JS MS20600M5 MS20600M6 MS20601AD4 AC MS20601AD5 MS20601AD6 MS20601B4 AE MS20601B5 MS20601B6 MS20601M4 JT MS20601M5 MS20601M6 (a) REPLACEMENT FASTENER(S) NAS1738B4 M7885/64 NAS1738B5 M7885/65 NAS1738B6 M7885/66 NAS1738B4 M7885/64 NAS1738B5 M7885/65 NAS1738B6 M7885/66 NAS1738MW4 NAS1738MW5 NAS1738MW6 NAS1739B4 M7885/74 NAS1739B5 M7885/75 NAS1739B6 M7885/76 NAS1739B4 M7885/74 NAS1739B5 M7885/75 NAS1739B6 M7885/76 NAS1739MW4 NAS1739MW5 NAS1739MW6 MIN. SHEET THICKNESS(a) N.A. N.A. N.A. N.A. N.A. N.A. N.A. N.A. N.A. .040 .050 .071 .040 .050 .071 .040 .050 .071
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TABLE VII (ALUMINUM LOCKBOLTS) NAS523 CODES CP CS CS CS DJ DJ CW CV CV CV DRAWING CALLOUT NAS1516 NAS1525 NAS1526 NAS1528 NAS1535 NAS1536 NAS1546 NAS1555 NAS1556 NAS1558 NAS6915 NAS6915 NOTE (3) a) STANDARD COLLARS REPLACEMENT HL236 HL225 HL226 HL228 HL235 HL236 HL236 HL225 HL226 HL228 HL235 HL236 NOTE (3) NOTE (3) NOTE (3) NOTE (3) NOTE (3) NOTE (3) NOTE (3) NOTE (3) NOTE (3) NOTE (3) NOTE (3) NOTE (3) MIN. SHEET THICKNESS 0.07 N.A. N.A. N.A. 0.063 0.07 0.07 N.A. N.A. N.A. 0.063 0.07
HILOK COLLARS ; HL77, HL182, HL277, MAY BE USED. Minimum sheet thickness must be met, where specified, on the sheet that lies against the manufactured countersunk head to avoid knife edge conditions
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TABLE VI NAS523 CODE DRAWING CALLOUT NAS1919B04 AFJ NAS1919B05 NAS1919B06 NAS1919C04 WE NAS1919C05 NAS1919C06 NAS1919M04 WD NAS1919M05 NAS1919M06 NAS1921B04 AFH NAS1921B05 NAS1921B06 NAS1921C04 WH NAS1921C05 NAS1921C06 NAS1921M04 WF NAS1921M05 NAS1921M06 (a) REPLACEMENT FASTENER(S) NAS1738B4 M7885/64, NAS1919B04S NAS1738B5 M7885/65, NAS1919B05S NAS1738B6 M7885/66, NAS1919B06S NAS1738CW4, NAS1919C04S NAS1738CW5, NAS1919C05S NAS1738CW6, NAS1919C06S MIN. SHEET THICKNESS(a) N.A. N.A. N.A. N.A. N.A. N.A.
NAS1738MW4, NAS1919M04S N.A. NAS1738MW5, NAS1919M05S N.A. NAS1738MW6, NAS1919M06S N.A. NAS1739B4 M7885/74, NAS1921B04S NAS1739B5 M7885/75, NAS1921B05S NAS1739B6 M7885/76, NAS1921B06S NAS1739CW4, NAS1921C04S NAS1739CW5, NAS1921C05S NAS1739CW6, NAS1921C06S .040 .050 .071 .040 .050 .071
NAS1739MW4, NAS1921M04S .040 NAS1739MW5, NAS1921M05S .050 NAS1739MW6, NAS1921M06S .071
6. 6.1
RIVETS FOR NUT PLATE INSTALLATION Cherry Fastener CCR264SS, (steel, blind rivet), shall be considered optional for nut plate installation in lieu of MS20426 solid rivet.The CCR264SS fastener shall not be used as a replacement for the MS20426 fastener in exterior surfaces.
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6.1.1
Cherry Fastener CR1122 (ALUMINUM blind rivets) shall be considered optional for nut plate installation in lieu of MS20426 aluminum solid rivets for exterior and interior installations. Cherry Fastener CCR244SS (steel, blind rivet), shall be considered optional for nut plate installation in lieu of NAS1097.The CCR244SS fastener shall not be used as replacement for the NAS1097 fastener in exterior surfaces. EDGE ACCEPTANCE OF ALUMINUM SHEET METAL DETAILS The tolerance of .000 .015 is optional in place of the existing break sharp edge requirement of .005 .015 (radius or chamfer) provided: a) b) The process used is capable of this tolerence without producing a knife edge and all details shall remain free of burrs . This applies only to aluminum sheet .012 .125 thick. Paragraph 7.1 shall not apply to: (1.) (2.) Specific Field of Drawing notes pertaining to radius/chamfered edges Fastener holes that have been opened to final size
6.2
7. 7.1
7.1.1
8. 8.1 8.1.1
(3.) SS1038 or SS1040 flanged holes. ACCEPTABLE ASSEMBLY METHODS Shimming aluminum to other Metallic Airframe Components Applicability a. During the assembly of sheet metal or thin walled machined fittings with forgings, castings, other sheet metal members or thin walled machine fittings, gaps may occur that require shimming for proper fit.
8.1.2
Limitations a. The elements of this shimming section do not apply to the assembly of machined, forged or cast parts in such assemblies as rotor heads, transmissions, etc. b. Gaps are not allowed for machined fitting components equal to 0.070in. or greater. Sheet metal components of extrusions with thickness greater than or equal to 0.070 inches are considered to be equivalent to machined fittings. c. Measured gaps up to the limits listed in Table 8.1(see also Figure 8.1) are closed using the fasteners required by the drawing. Gaps greater than those listed in the table, up to a maximum of .063 inches, can be shimmed using solid shims, or 50% laminated shims, flat or tapered, sized to fit the gap without strain or clampup.
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8.1.3
Definitions: a. High Speed Machining(HSM) is defined as a process by which a machined component is cut at high rates of speed and feed such as 16,000rpm at 250 in/min. For the purpose of this document, there is no difference in criteria between conventional machined components and high speed machined components that are 0.070 in. or greater. b. Thin Walled Machining (TWM) is defined as a machined component on which any feature has a final thickness less that 0.070inches. c. Gaps are spaces measured between mating parts. Gaps measured under the head or tail of a fastener are not addressed herein. Reference SS9201 d. In order to determine gap size, finger pressure (thumb and forefinger) is applied to the mating parts during assembly before take up of mechanical fasteners. e. In cases where it is impractical to use finger pressure to determine gap size, the spring type CLECO fasteners may be used in order to determine gap size. Draw type CLECO fasteners shall not be used.
8.1.4
Procedure: a. Measure gap and determine proper shim size. The length of the shim shall be determined by individual circumstances as shown in the figures. Shim width is to approximate the width of the flange or other member to which it will be attached. b. Shim shall be made of 7075T6 unless the same material as the corresponding metal material, heat treatment and finish is available. c. Where appropriate, shim shall be installed making sure it does not ride the radius of the mating part. Chamfer of the shim edge may be necessary to avoid the radius. d. Shims are to pick up existing fasteners, which shall be increased in grip length as required by the added thickness of the stack up. e. In addition , added shims (with the exception of floating frame designs) are to be bonded in place to a metal member using SS8622006 or SS8622007 adhesive per SS8669 Class II B (clean room requirements waived). See Figures 8.11 through 8.15 for shimming examples. f. Insulate per SS8630
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TABLE 8.1 ALLOWABLE GAPS PRIOR TO FASTENER INSTALLATION JOINT COMBINATIONS Sheet Metal or Extrusion less than 0.070 Thk Sheet Metal or Extrusion 0.070 Thk or Greater Machined Fitting Less Than 0.070 Thk Machined Fitting 0.070 Thk or Greater Sheet Metal or Extrusion less than 0.070 Thk 0.020 in. Sheet Metal or Extrusion 0.070 Thk or Greater 0.020 in. Machined Fitting Less Than 0.070 Thk 0.020 in. Machined Fitting 0.070 Thk or Greater 0.020 in.
0.020 in.
0.020 in.
0.010 in.
0.000 in.
0.020 in.
0.010 in
0.010 in
0.010 in
0.020 in.
0.000 in.
0.010 in
0.000 in.
Example: A joint made up of an 0.094 extruded angle and an 0.050 thick machined fitting can have up to a 0.010 gap prior to fastener installation.
POTENTIAL GAP LOCATIONS
Figure 8.1 GAP LOCATIONS
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Added shim is to pick up one additional fastener on both sides of gapped area
Bond
Corner must clear radius Figure 8.11
18
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8.1 Shimming Metallic Airframe Components (cont)
Bond
Added shim to pick up 3 additional fasteners on either side of the gapped area.
Corner must clear radius Figure 8.12
Added tapered shim
Bond Figure 8.13 Added shim Outer skin
Structure
Figure 8.14
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8.1
Shimming Metallic Airframe Components (cont)
Skin
Frame
Added shim (a single round shim) for floating frame designs, no bonding or pickup of additional fastenners required. Change existing fastener to steel or install a HiLok. Insulate dissimilar metals using epoxy primer per MILP23377or MILP85582
Figure 8.15
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8.2 8.2.1
Trimming Metallic Airframe Skins Applicability a. Trimming metallic skins to eliminate overlap, next assembly interference and/or improve cosmetic appearance.
8.2.2
Limitations a. Metallic skins are defined as:
Aluminum Steel Stainless Steel Titanium Up to and including .125 material thickness. a. No fasteners are to be eliminated or bypassed as the result of trimming. b. The minimum edge distance between the center of the nearest hole and part edges shall be 2D or greater unless otherwise specified by the engineering drawing. D = maximum diameter of the fastener shank being installed. c. After all trimming operations, remove all burrs and sharp edges created by trimming. d. Areas exposed by trimming are to be touched up locally in accordance with the table below: Material Aluminum Steel Stainless Steel Titanium Process Specification SS8693 MILSTD865, Prime, if required per B/P Not required Not required
NOTE: See Figure 8.21 for example of skin trimming.
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8.2 Trimming Metallic Airframe Skins (cont)
2D Min.
Skin
Removed material
Figure 8.21
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8.3 8.3.1
Trimming Metallic Airframe Components Applicability a. End and/or edge of part trim. Trimming of sheet metal and extruded parts to provide clearance between adjacent parts.
8.3.2
Limitations a. Extent of trimming should only be to provide minimum (.003 inch) clearance between adjacent structure and the part being trimmed. b. Metallic components are defined as: Aluminum Sheet Extrusion Steel Stainless Steel Titanium c. No fasteners are to be eliminated or bypassed as the result of trimming. d. This does not apply to composite parts, rotor blades, rotor heads, transmissions, forgings, machined or cast parts. Exceptions: Interference that occurs on forged frame splices may be trimmed as shown in Figure 8.38. e. The minimum edge distance between the center of the nearest hole and part edges shall be 2D or greater unless otherwise specified by the engineering drawing. D = maximum diameter of the fastener shank being installed. f. After trimming operations remove all burrs and sharp edges created by trimming. g. See Figures 8.31 thru 8.310. for trimming examples.
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8.3 Trimming Metallic Airframe Components (cont)
Trim to clear and not violate edge distance 2D Min.
Conditions: Part touches fastener
Figure 8.31
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2D Min Clearance per part drawings Typ
Beam
Sheet metal intercostal Removed material (Maintained original radius)
D = Max. dia of fastener
Figure 8.32
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Extruded cap angles 2D Min. Clearance per part drawings Typ
Beam
Removed material (Maintain original radius)
Intercostal assembly
D = Max. dia of fastener
Figure 8.33
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2D Min
Trim to clear
Figure 8.34
27
SS9208 REV 48
Trim as required to clear radius and not violate edge distance of fasteners.
2D Min. Caution: Part rides radius
Figure 8.35
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FILLERS & SPACERS
Trim Drawing Reqt Filler at this end to obtain condition shown in view below. Filler
2D Min
Filler (after trimming)
Figure 8.36
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2D MIN
Spacer Overlap Trim either or both ends as needed to permit flush seating.
Web
Figure 8.37
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CABIN FRAME SPLICE EXCEPTION Interference that occurs on forged frame slices may be trimmed in accordance with the procedure outlined in Section 8.3.3
Frame
2D MIN
Trim in installation to maintain B/P gap and not violate fastener edge distance requirements
Splice plate Frame
Figure 8.38
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2D MIN
Trim permitted 2D Min.
No trimming permitted
Material removal permitted to clear adjacent fastener. Must maintain 2D Min.
2D MIN 2D MIN
Figure 8.39
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Stringer chafes on frame cutout
Original Distance D Trim to clear. Not to exceed 10% of original distance D. Maintain original radius.
Figure 8.310
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SS9208 REV SS9208 REV 47 48
8.4 8.4.1
Pilot Holes that Break into finished fastener holes Applicability a. This section applies to mislocated pilot holes that break into finished fastener holes in aluminum, steel, titanium, stainless steel sheet metal, aluminum extrusions and thin walled machined components under .070 inch thickness.
8.4.2
Limitations a. This does not apply to composite parts, rotor blades, rotor heads, transmissions, forgings, cast or machined parts .070 inch thick or greater. b. The minimum edge distance between the center of the nearest hole and part edges shall be 2D or greater unless otherwise specified by the engineering drawing. D = maximum diameter of the fastener shank being installed. c. Next larger fastener diameter. Hole size shall be per SS5100. Hole shall completely clean up the mislocated pilot hole. d. Exposed edges shall be cleaned and touched up in accordance with Table 8.41 below: TABLE 8.41 Material Process Specification Aluminum SS8693, primer if required by B/P Steel MILSTD865, prime, if required per drawing Stainless Steel Not required Titanium Not required All materials must be deburred and sharp edges removed prior to assembly.
c)
Install next larger fastener. The same style and type of fastener must be used. Example: BJ4 rivet must be replaced by a BJ5 rivet.
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8.5 8.5.1
DIMENSIONAL TOLERANCE FOR FORMED SHEET METAL FLANGES APPLICABILITY These criteria shall define the acceptable dimensional tolerance on the width of the formed flanges on sheet metal parts. CRITERIA The standard dimensional tolerance on the width of formed sheet metal flanges shall be +/.030, except, if the following conditions are satisfied, a conditional tolerance of +.060 .000 shall apply. CONDITIONS
8.5.2
8.5.3
a) b) c)
The engineering drawing does not specify a dimensional tolerance for the flange width that is tighter than the standard tolerance. The (nonformed) web dimension of the part must satisfy a tolerance of +.000 .030.
.030 WEB FORMED FLANGE .030 WEB
.000 .030 .060 .000
FORMED FLANGE
STANDARD TOLERANCE
CONDITIONAL TOLERANCE
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8.6
ACCEPTANCE CRITERIA TO MEET PROPER GRIP LENGTH OF MECHANICALLY LOCKED FASTENERS Fastener grip length The requirement for proper grip length is necessary to ensure joint integrity. Improper grip length selection may cause fastener looseness or possible head failure. The requirement for proper grip length shall apply to all mechanically locked fasteners. Applicability in the event of conflict between the contents herein and any specifications or standards referenced in the field of drawing, the referenced document on the drawing shall take precedence. Section 8.6 is not applicable for the assembly and/or installation of dynamic components such as rotor systems, transmission and drive systems, engine speed controls or the dynamic portions of flight control systems. Compensation for assembly tolerance stackup Only when the hardware specified on the engineering drawing does not meet the installed fastener requirements may the following length deviations and use of washers be implemented. Acceptable fastener length deviations Assemblies using composite materials When the assembly to be fastened is comprised of at least one composite member the fastener length may be varied +/ 2 consecutive length dash numbers from the length noted on the engineering drawing to meet variations in composite material thickness. Assemblies using metallic Airframe components Fastener length may be varied +/ 1 length dash number from the length noted on the engineering drawing to meet variations in total material thickness. Use of washers washers may be used to adjust grip length only when proper grip cannot be achieved with the fastener alone and only per the following. The list of fasteners approved for the use of washers to adjust grip length is shown in table 8.6l. Washers shall be .016 in., .032 in., or .064 in thickness. For single washer applications the total washer thickness shall not exceed .032 in. The total thickness for multiple washer applications shall not exceed .096 in.
8.6.1
8.6.2
8.6.2.1
8.6.3
8.6.3.1 8.6.3.1.1
8.6.3.1.2
8.6.3.2
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Table 8.61 Fasteners approved for grip length adjustments by the use of washers. NASl4l4 NAS1424 NAS1436 NAS1446 NAS1456 NASl465 NAS1475 NAS1486 NAS1496 NASl5l6 NAS1525 NAS1535 NAS1546 NAS1555 8.6.3.2.1 thru thru thru thru thru thru thru thru thru thru thru thru thru thru NAS1422 NAS1432 NAS1442 NASl452 NAS1462 NAS1472 NAS1482 NAS1492 NAS1502 NAS1522 NAS1532 NAS1542 NAS1552 NAS1562 MS90353 MS90354 NAS1738 NAS 1739 M7885/6 M7885/7 M7885/8 M7885/9 All HL Hiloks
Lockbolt and Hilok type fasteners (NASl4l41562, HL)Protruding head A maximum of two washers may be used to adjust grip length. The preferred washer location is under the collar. If insulating washers are used, or if the collar has an integral washer, only 1 additional washer may be used and the preferred location is under the collar. Flush head one washer may be used under the collar to adjust grip length. Pull through type blind rivets (MS90353, MS90354, NAS1738, NAS1739, M7885/6 thru M7885/9). Protruding head A single washer may be used to adjust the grip length. On installations where the blind side is inaccessible the washer shall be located under the manufactured head. On installations where the blind side is accessible the washer may be located under the formed head or under the manufactured head unless the application is on an exterior surface. On exterior surface applications the washer shall be located under the formed head. Flush head Where the blind side of the fastener is accessible, one washer may be used under the formed head to adjust grip length.
8.6.3.2.2
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8.6.3.2.3
Selection of washers To avoid a dissimilar metal condition the material of the washer used to correct grip length shall be the material of any additional washers defined in the field of the engineering drawing. If the engineering drawing does not specify a washer, then the washer material shall be selected according to table 8.62 with regards to the material that the washer contacts. Table 8.6-2 Washer material and callout for grip adjustment Parent Material Aluminum Steel Cres Titanium Graphite Washer Material Aluminum Steel Cres Cres Cres Callout AN960KDx AN960x AN960Cx AN960Cx SS5072CxH
Electrical grounding and bonding per SS7007 shall take precidence over the above section regarding electrical/electronic assemblies. 8.6.3.3 Limitations of hardware use When the fastener length is varied as described in 8.6.3.1 and/or washers are used as described in 8.6.3.2, the assembly shall not violate any clearance requirements.
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8.7
Acceptance criteria to meet proper grip length of 1/4 turn CAMLOC fasteners. Purpose The purpose of this section is to allow grip length adjustment of 1/4 turn fasteners from that on the engineering drawing to compensate for assembly tolerance stackup. Compensation for assembly tolerance stackup Only when the hardware specified on the engineering drawing does not meet the installed fastener requirements may the following length deviations be implemented. Acceptable fastener length deviations Assemblies using composite materials When the assembly to be fastened is comprised of conforming parts, with at least one composite member, and is assembled and gauged with the appropriate installation tools, the fastener length may be varied 2 grip length dash numbers from the length noted on the engineering drawing to meet variations in composite material thickness.
8.7.1
8.7.2
8.7.3 8.7.4
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8.8
ACCEPTANCE CRITERIA FOR PIN HOLE LOCATIONS (Limited Usage) NOTE: These allowances are only for use when the Engineering Drawing does not specify locations. In case of any conflict with this specification, the Engineering Drawing shall govern. PURPOSE: During the manufacture of sheet metal components, the use of pin holes may be required for positioning, alignment and/or assembly operations. This section provides guidelines for acceptable locations for pin holes. LIMITATIONS: This section applies to Aluminum, Steel or Titanium sheet metal Airframe components. This criteria does not apply to Flight Safety or Flight Essential components. The criteria specified herein may only be used to define acceptable locations if not already specified on the Engineering drawing. DEFINITIONS:
8.8.1
8.8.2
8.8.3
8.8.3.1
Pin Holes are defined as .188 diameter holes which are used during the manufacturing process of sheet metal components. These holes are used to hold a sheet metal part in position during routing, blanking, or cutting operations, and to align the part correctly with the forming tool(s) during forming operation(s). Occasionally, pin holes are also used to locate parts during assembly and assembly operations. Edge Distance is defined as the distance from the center of the hole to the edge of the part. External Tabs are defined as a detail of the sheet metal part which is trimmed off as part of the manufacturing operation and does not remain on the final part. Web Area is defined as the portion of a part, such as a frame, which may contain pin holes and/or is not formed (e.g., bent flange) as a step of the manufacturing process. GUIDELINES FOR ACCEPTABLE PIN HOLE LOCATIONS GENERAL(see Figure 8.81 for examples): Pin holes located in external tabs are the preferred method. However, if pin holes must be in the body of the part, they may be located in sheet metal details provided the following guidelines are met.
8.8.3.2
8.8.3.3
8.8.3.4
8.8.4
8.8.4.1
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8.8.4.2
Pin holes which coincide with fastener locations are acceptable and may override the guidelines within section 8.8.5 below. Pin holes coinciding with fastener locations within a pattern shall utilize the center fastener hole location or at least the third fastener from the edge of the pattern where practical. Where practical, pin holes in aluminum parts, which do not coincide with fastener locations, shall be subsequently plugged using MS20470AD6 bucked rivets. In all parts, pin holes may not be left unplugged if environmental sealing requirements exist. Pin holes may not be located in any portion of a part which will be subsequently formed, such as a bent flange or a beaded panel, unless all other requirements of this specification are complied with. Example of exception; pin hole located near flanged hole in web per para 8.8.5.6 Pin holes shall not be located such that they may interfere with subsequent manufacturing and assembly operations. GUIDELINES FOR ACCEPTABLE PIN HOLE LOCATIONS SPECIFIC(see Figures 8.81 & 8.82 for examples) Pin holes at each end of part, for parts that are a minimum of 5 long shall be located a minimum of 1.25 from edge and approximately at center of edge length. General pin hole spacing shall be approximately 15 for parts that are greater than 18 long. Pin holes in long narrow parts (i.e., less than 3 wide) shall have a minimum spacing of 2, along the length of the part. Preferred location for pin holes in an unobstructed web area shall be approximately in the center , unless this is not practical and all other requirements are met. Minimum edge distance of .56 shall be maintained from the edge of part or cut edge of detail (e.g., edge of a cutout, bend relief, hole, etc., or final edge location of part to be subsequently trimmed or cut) to the center of the pin hole. A minimum distance of .35 shall be maintained from the tangent lines of formed details (e.g., joggles, flanged cutouts, bent flanges, etc.) or final tangent line location of detail to be subsequently formed, to the center of the pin hole.
8.8.4.3
8.8.4.4
8.8.4.5
8.8.5
8.8.5.1
8.8.5.2
8.8.5.3
8.8.5.4
8.8.5.5
8.8.5.6
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Pin Hole at center of fastener pattern Minimum distance of .35 to tangency of formed detail (flanged hole)
Center Pin Hole along edge of part Mininum Edge Distance of .56
Minimum distance of .35 to tangency of formed detail (joggle bend radius) Center of web area
Figure 8.81 Formed frame example
Minimum distance of .56 to edge of cut or trim
Minimum 2 spacing
Minimum Edge distance of .56 Figure 8.82 Long narrow part example
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9. 9.1
INTERCHANGEABLE FASTENERS (STUMP & PULL TYPE LOCKBOLTS) Stump and pull type lockbolts may be used in place of each other provided finish, grip, size and collar material are the same (see NAS 1080 for proper collar selection). Substitution may be in either direction for each size fastener in each category in the Table 9.11. TABLE 9.11 PULL TYPE & STUMP STEEL 100 SHEAR PULL TYPE LOCKBOLTS NAS1436 NAS1438 NAS1440 NAS1442 NAS1446 NAS1448 NAS1450 NAS1452 NAS1456 NAS1458 NAS1460 NAS1462 NAS1465 NAS1466 NAS1468 NAS1470 NAS1472 NAS1475 NAS1476 NAS1478 NAS1480 NAS1482 NAS1516 NAS1518 NAS1520 NAS1522 NAS1525 NAS1526 NAS1528 NAS1530 NAS1532 STUMP TYPE LOCKBOLTS NAS1416 NAS1418 NAS1420 NAS1422 NAS1426 NAS1428 NAS1430 NAS1432 NAS1486 NAS1488 NAS1490 NAS1492 NAS1497 NAS1496 NAS1498 NAS1500 NAS1502 NAS6925 NAS6926 NAS6928 NAS6930 NAS6932 NAS1546 NAS1548 NAS1550 NAS1552 NAS1555 NAS1556 NAS1558 NAS1560 NAS1562
SIZE 3/16 1/4 5/16 3/8 STEEL 3/16 PROTRUDING HD 1/4 SHEAR 5/16 3/8 STEEL 3/16 100 HD 1/4 (MS24694) 5/16 TENSION 3/8 STEEL 5/32 PROTRUDING HD 3/16 TENSION 1/4 5/16 3/8 STEEL 5/32 100 HD 3/16 (MS20426) 1/4 TENSION 5/16 3/8 ALUMINUM 3/16 100 HD 1/4 (MS24694) 5/16 TENSION 3/8 ALUMINUM 5/32 PROTRUDING HD 3/16 TENSION 1/4 5/16 3/8
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15
10. 10.1
SAFETY WIRING / SAFETY CABLE Safety Cable per AS 3509, AS 3510, and AS 3511 when used in accordance with AS 4536, installed with calibrated Safety Cable manufacturer recommended tools, may be used as an approved alternate to Safety Wire per MS 20995 installed in accordance with MS33540. The following list indicates the proper alternates: 1. MS20995C alternate is AS3510 of corresponding diameter and length. 2. MS20995N alternate is AS3509 of corresponding diameter and length. 3. MS20995F No alternate is currently available. 4. MS20995NC alternate is AS3510 of corresponding diameter and length . 5. MS20995AB No alternate is currently available. 6. MS20995CY No alternate is currently available.
10.1.1
Safety Cable shall not be used for shear or sealing wire applications or in applications where the ferrule/end fitting could cause an interference. Safety Cable shall not be used where verification of safety wire application per MS33540 is a Critical Characteristic (CC ). Safety Cable shall not be used on H53 aircraft.
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11. 11.1 11.1.1
ACCEPTANCE CRITERIA TO MEET THREAD PROTRUSION Definitions Thread Protrusion is the term defining the requirements for the protrusion of a free running threaded fastener beyond the surface of an engaged nut to ensure complete engagement of the mating threads. Grip Length is the distance from the under head bearing surface to the start of the thread. Justification for Thread Protrusion The requirement for thread protrusion is necessary because the first 2 lead threads of the chamfered end of a threaded fastener are not designed to carry loads, but are present to facilitate assembling the nut to the fastener. Also, the 2 lead threads provide inadequate locking when selflocking nuts are used. Applicability In the event of conflict between the contents herein, and any specifications or standards referenced in the field of drawing, the referenced documents on the drawing shall be considered a superseding requirement. Fasteners The requirement for thread protrusion shall apply to free running bolts, studs, or screws. Nuts The requirement for thread protrusion shall apply to free running and selflocking 6 and 12 point hex nuts, fixed and floating blind nuts, and barrel nuts. Limits of protrusion Unless otherwise specified on the engineering drawing, a bolt, stud, or screw end shall extend beyond the nut at least the length equivalent to 2 pitches, including the chamfer. (Figure11.l1., Table 11.1I.) Maximum thread protrusion shall be limited by any assembly clearance requirements. 2 X PITCH, MIN.
11.1.2
11.2
11.3
11.3.1
11.3.2
11.4
FIGURE 11.11
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Table 11.1I. Minimum Acceptable Protrusion UNC size 440 632 832 1024 1/420 5/1618 3/816 7/1614 1/213 5/81l 3/410 7/89 18 11.5 min protrusion, in. size .050 .063 .063 .083 .100 .111 .125 .143 .154 .182 .200 .222 .250 448 640 636 1032 1/428 5/1624 3/824 7/1620 1/220 5/818 3/416 7/814 112 UNF min protrusion, in. .042 .050 .055 .063 .071 .083 .083 .100 .100 .111 .125 .143 .167
Compensation for assembly tolerance stackup Section 11.5 is not applicable for the assembly and/or installation of dynamic components such as rotor systems, transmission and drive systems, engine speed controls, and the dynamic portions of flight control systems. NOTE: Only when the hardware specified on the engineering drawing does not meet the thread protrusion requirements specified herein may the following length deviations and addition of washers be implemented.
11.5.1 11.5.1.1
Acceptable bolt, or screw length deviation Assemblies using composite materials. Due to variations in total composite material thickness, and fastener length variations, the bolt, or screw length may be varied +/2 consecutive length dash numbers from the length noted on the engineering drawing. Assemblies not using composite materials. Due to variations in total material thickness, and fastener length variations, the bolt, or screw length may be increased one consecutive length dash number from the length noted on the engineering drawing. Paragraph 11.5.1.2 shall not apply to electrical/electronic assemblies. Electrical/electronic assembly requirements shall be as specified in SS7500.
11.5.1.2
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11.5.2
Use of washers. In all cases, except as noted below, a maximum total of 3 washers, in any combination of thickness, may be used to insure proper grip length. Assemblies in General. The number of washers specified on the engineering drawing plus any washers added to insure proper grip length shall be a total of two (2) under the nut, and one (l) under the head. (Figure 11.12). Assemblies using nut plates or barrel nuts. The number of washers specified on the engineering drawing plus any washers added to insure proper grip length shall be a total of two (2) under the head. (Figure 11.12). Assemblies using studs or fasteners with countersunk heads. The number of washers specified on the engineering drawing plus any washers added to insure proper grip length shall be a total of two (2) under the nut. (Figure 11.1 2). Protection against electrolytic corrosion. To avoid a dissimilar metal condition, the material of any additional washer(s) used under the nut to insure proper grip length shall be the material of the washer defined on the engineering drawing for use under the nut . If the engineering drawing does not specify a washer under the nut, then the washer material shall be selected according to MIL STD 889 (DISSIMILAR METALS). Similarly, the material of any additional washer(s) used under the head to insure proper grip length shall be the material of the washer defined on the engineering drawing for use under the head If the engineering drawing does not specify a washer under the head, then the washer material shall be selected according to MIL STD 889 (DISSIMILAR METALS). Paragraph 11.5.2.4 shall not apply to electrical/electronic assemblies. Protection against electrolytic corrosion for electrical/electronic assemblies shall be per the requirements of SS7007. Selection of washers Washers shall be selected from the following standards: AN960 WASHER, FLAT
11.5.2.1
11.5.2.2
11.5.2.3
11.5.2.4
11.5.2.5
MS20002 WASHER, COUNTERSUNK AND PLAIN, HIGH STRENGTH MS21206 WASHER, COUNTERSUNK AND PLAIN, FOR USE WITH BOLTS AND NUT UP TO AND INCLUDING 220 FTU SS4409 S5S5072 WASHERMETALLIC, SPECIAL WASHER (FOR COMPOSITE APPLICATIONS)
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11.5.3
Limitations of hardware variations When the bolt, or screw length is varied as described in 11.5.1, and/or washers are used as described in 11.5.2, the assembly shall not violate any clearance requirements, the nut shall not bottom out on the imperfect threads, and the load transferred by the assembled parts to the bolt, stud, or screw shall not be carried by the threaded portion of the bolt, stud, or screw. Production engineering shall be notified when the bolt, or screw length is varied as described in 11.5.1 and/or washers are used as described in 11.5.2. Any assembly that requires repetitive corrective action to ensure thread protrusion as described herein requires investigation and possible drawing correction.
11.5.3.1
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1ST & 2ND 2 MAX UNDER NUT (PLAIN)
3RD 1 MAX UNDER HEAD (PLAIN OR C SUNK WHERE REQUIRED)*
HEX BOLT OR SCREW TO HEX NUT
2 MAX UNDER NUT (PLAIN) 2 MAX UNDER HEAD (PLAIN OR C SUNK WHERE REQUIRED)*
CSUNK OR STUD
BARREL NUT OR NUT PLATE
* INSURE THAT WASHER UNDER BOLT HEAD IS COMPATIBLE WITH HEAD TO SHANK RADIUS (CSUNK WHERE REQD). FIGURE 11.12
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12. 12.1
,ACCEPTANCE CRITERIA FOR EDGE AND PITCH DISTANCE PURPOSE The purpose of this section is to define the minimum acceptable edge and pitch distance requirements for fasteners installed through sheet metal assemblies and thin walled machined components under .070 inch thickness.
12.2
SCOPE This section provides acceptance criteria for minor product characteristics not defined on the engineering drawings.
12.3 12.3.1
LIMITATIONS This section does not apply to fastener through forgings, castings or machined fittings .070 inch thick or greater. Included tables do not apply to composite structure, which shall be reworked to meet dwg. requirements. DEFINITIONS Edge distance (ED) is the distance between a fastener centerline and the edge of a part (see Figure 121). Pitch distance is the distance between the centerline of adjacent fasteners (see Figure 121). A row of rivets is defined as a line of rivets extending between two frames, stringers, intercostals or other members as shown in Figure 121A. Edge distance shall be acceptable when any one of the following or combination of the following conditions are met: a) The edge distance is greater than or equal to two times the nominal shank diameter. (COMANCHE RAH66 REQUIREMENTS: The edge distance is greater than or equal to 1.5 times the nominal shank diameter except that the edge distance for radius blocks shall be greater than or equal to 1.0 times the nominal shank diameter). The edge distance is defined on the drawing in the form of a note, dimension or scaled from the EMD (Engineering Master Drawing). As defined in Tables 121 for protruding head fastener in aluminum structure or Table 122 for countersunk fasteners in aluminum structure. A maximum of three fasteners (in a row of fasteners) with edge distances greater than or equal to 1.5 times the fastener shank diameter (limitations defined in Table 123)( NOT APPLICABLE TO COMANCHE RAH66). The End Fastener (in a row of five or more fasteners) with edge distance greater than or equal to 1.5 times the fastener shank diameter, provided all other fasteners conform to Conditions a, b or c above (limitations defined in Table 124)( NOT APPLICABLE TO COMANCHE RAH66).
12.4 12.4.1 12.4.2 12.4.3 12.4.4
b) c) d)
e)
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SS9208 REV 48
PITCH DISTANCE
FASTENER CENTERLINE EDGE DISTANCE EDGE OF PART SHANK DIAMETER
FIGURE 121
FRAMES STRINGER
ROW OF FASTENERS, TYP.
STRINGER
ROW OF FASTENERS, TYP. FIGURE 121A
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TABLE 121 MINIMUM ACCEPTANCE EDGE DISTANCES FOR PROTRUDING HEAD FASTENERS THESE VALUES APPLICABLE TO FASTENER INSTALLATION INTO 2014,2024,2219,AND 7075 ALLOYS IN ANY FULLY HARDENED TEMPER Thickness .025 .032 .040 .050 .063 .071 .080 .090 .100 .125 .160 .190 A . 16 .14 .14 .14 .14 .14 .14 .14 .14 .14 .14 .14 B .25 .22 .19 .19 .19 .19 .19 .19 .19 .19 .19 .19 C .31 .31 .27 .23 .23 .23 .23 .23 .23 .23 .23 .23 D .31 .31 .31 .27 .23 .23 .23 .23 .23 .23 .23 .23 E .37 .37 .36 .34 .28 .28 .28 .28 .28 .28 .28 .28 F .37 .37 .37 .37 .33 .31 .28 . 28 .28 .28 .28 .28 G .37 .37 .37 .37 .37 .33 .30 .28 .28 .28 .28 .28 H .37 .37 .37 .37 .37 .37 .37 .37 .37 .35 .30 .28
A = MS20470AD3 B = MS20470AD4 C = MS20470AD5 D = MS20470DD5 E = MS20470AD6 F = MS20470DD6 G = NAS1526 H = NAS1446, NAS1466, NAS1496, NAS1426, NAS2006, NAS2206, NAS2606
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TABLE 122 MINIMUM ACCEPTANCE EDGE DISTANCES FOR FLUSH (COUNTERSINK) HEAD FASTENERS THESE VALUES APPLICABLE TO FASTENER INSTALLATION INTO 2014,2024,2219,AND 7075 ALLOYS IN ANY FULLY HARDENED TEMPER Thickness .025 .032 .040 .050 .063 .071 .080 .090 .100 .125 .160 .190 A .19 .17 .16 .16 .16 .15 .15 .15 .14 .14 .14 .14 B .25 .25 .22 .21 .21 .21 .20 .20 .19 .19 .19 .19 C .31 .31 .27 .26 .26 .25 .25 .25 .25 .24 .23 .23 D .31 .31 .31 .30 .26 .25 .25 .25 .25 .24 .23 .23 E .37 .37 .37 .37 .33 .32 .32 .31 .31 .30 .30 .28 F .37 .37 .37 .37 .37 .36 .32 .31 .31 .30 .30 .28 G .37 .37 .37 .37 .37 .37 .34 .31 .31 .30 .30 .28 H .37 .37 .37 .37 .37 .37 .37 .37 .37 .37 .32 .28
A = MS20426AD3 or NAS1097AD3 B = MS20426AD4 or NAS1097AD4 C = MS20426AD5 or NAS1097AD5 D = MS20426DD5 or NAS1097DD5 E = MS20426AD6 or NAS1097AD6 F = MS20426DD6 or NAS1097DD6 G = NAS1536 H = NAS2506V, NAS2706V, NAS1416, NAS1436
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TABLE 123 ACCEPTANCE CRITERIA FOR SINGLE AND DOUBLE ROW FASTENERS WITH ED GREATER THAN OR EQUAL TO 1.5 X NOMINAL SHANK DIAMETER Number of Fasteners Along Edge of Part Single Row of Fas- Double Row of Fasteners Along Edge teners Along Edge of Part* of Part** Number of fasteners allowed down to1.5 x nominal shank diameter ED. 12 34 59 1014 >14 UH60A EH60A SH60B SH60F HH60H HH60J 0 0 1 2 3 0 1 2 3 3 S70C2 S70C5 S70A14 S70B2 CH53E PRC BRUNEI 1 BRUNEI 2 RAN
This table applies to the following models only: BLACK HAWK S70A9 RAAF QUICK FIX S70A16 WESTLAND SEAHAWK S70A11 JORDAN CVHELO S70C1A TAIWAN HCS S80M MRR MH53E
*Example of Single Row Fasteners, see Figure 123A. **Example of Double Row Fasteners, see Figure 123B. NOTE: This table does not apply to composite structure.
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E.D. GREATER THAN OR EQUAL TO 1.5 X NOM. SHANK DIA. (SEE TABLE 123)
FIGURE 123A SINGLE ROW OF FASTENERS
FIGURE 123B DOUBLE ROW OF FASTENERS
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TABLE 124 ACCEPTANCE CRITERIA FOR SINGLE AND DOUBLE ROW FASTENERS WITH ED GREATER THAN OR EQUAL TO 1.5 X NOMINAL SHANK DIAMETER Number of Fasteners Along Edge of Part 1 1 UH60A EH60A SH60B SH60F HH60H HH60J Number of Fasteners in a row Number of Fasteners allowed down to 1.5 x nominal shank diameter. 0 1 S70C2 S70C5 S70A14 S70B2 CH53E PRC BRUNEI 1 BRUNEI 2 RAN
14 5 or greater
This table applies to the following models only: BLACK HAWK S70A9 RAAF QUICK FIX S70A16 WESTLAND SEAHAWK S70A11 JORDAN CVHELO S70C1A TAIWAN HCS S80M MRR MH53E
NOTE: This table does not apply to composite structure. For Example of end fasteners, see Figure 124A TYP. END FASTENER
FIGURE 124A
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12.4.5
Pitch distance shall be acceptable when one of the following or combination of the following conditions are met: a) Minimum pitch This distance shall be as required by engineering drawing, 4 times nominal fastener shank diameter (4D), or as defined in Table 125 for protruding head fasteners in aluminum structure, Table 126 for countersunk fasteners in aluminum structure or Table 127 for dimpled holed fasteners in aluminum structure. Maximum Pitch Protruding Head and Flush Head Fasteners Maximum allowable pitch is the nominal pitch distance as required on the engineering drawing +1D (nominal fastener shank diameter) . Exceptions to Para. 12.4.5 a) Hard tooled holes must meet drawing tolerances, (spray dot tools are not considered hard tools). TABLE 125 MINIMUM ACCEPTABLE PITCH DISTANCE FOR PROTRUDING HEAD FASTENERS THESE VALUES APPLICABLE TO FASTENER INSTALLATION INTO 2014, 2024,2219, 7075 AND 7079 ALLOYS IN ANY FULLY HARDENED TEMPER Fastener Type MS20470 Rivets All Others
b)
12.4.5.1
Three times nominal shank diameter of fastener (3D) Four times nominal shank diameter of fastener (4D)
TABLE 126 MINIMUM ACCEPTABLE PITCH DISTANCE FOR COUNTERSUNK FASTENERS THESE VALUES APPLICABLE TO FASTENER INSTALLATION INTO 2014, 2024,2219, 7075 AND 7079 ALLOYS IN ANY FULLY HARDENED TEMPER Fastener Type MS20426, NAS 1097 Three times nominal shank diameter of fastener (3D) Rivets All Others Four times nominal shank diameter of fastener (4D)
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TABLE 127 MINIMUM ACCEPTABLE PITCH DISTANCE FOR DIMPLE HOLE FASTENERS THESE VALUES APPLICABLE TO FASTENER INSTALLATION INTO 2014, 2024,2219, 7075 AND 7079 ALLOYS IN ANY FULLY HARDENED TEMPER Fastener Type MS20426 Rivets
Three times nominal shank diameter of fastener (3D)
12.5 12.5.1
GENERAL NOTES When determining the minimum edge distance requirements for replacement with the next larger size fasteners, the diameter of the larger fastener shall be used. When determining the minimum pitch distance requirements for any two adjacent fasteners of different diameters, the nominal shank diameter of the larger fastener shall be used.
12.5.2
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13. 13.1 13.1.1
COATINGS AND FINISHES SHOT PEENED SURFACES Metal detail parts requiring shot peening may be touch up shot peening per SS8769, as required, to meet engineering drawing requirements. PLATED SURFACES Metal detail parts requiring plating (example: Cadmium plate per QQP416) may be touchup plated per MILSTD865 at assembly, as required, to meet engineering drawing requirements. (See SS 8407 for baking requirements which may restrict touchup of parts on assembly). NOTE: Not intended to correct misplated parts.
13.2 13.2.1
13.2.2 13.2.2.1
TOUCHUP FOR ION VAPOR DEPOSITED (IVD) ALUMINUM ALSEAL 505, Coatings for Industry, Inc., Souderton, PA. 18964
13.2.2.1.1 Metal parts coated with IVD Aluminum, that may be exposed to inservice temperature of 950_F maximum, requiring touchup may be repaired by spraying or local brush application of Alseal 505. After application and air drying for one hour minimum, Alseal 505 can be burnished to match the surrounding areas. 13.3 TOUCHUP FOR CADMIUM PLATED ELECTRICAL CONNECTORS AND CONNECTOR ACCESSORY PLATING ABRASIONS Cadmium plated Olive drab connectors, backshells and cable clamps which are determined to be rejectable for scratches which expose or are suspected of exposing bare metal, during electrical harness fabrication, assembly, or installation shall be touchedup as follows. a) b) Corrosion protection shall be provided by treatment of a chemical conversion coating per MilC5541. Top coat sealing of the treated area with flat lacquer, per TTL20 olive drab x34087, or polyurethane per MilC46168, olive drab 34088.
13.3.1
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13.4 13.4.1
PAINTING OF CLOSE TOLERANCE MACHINED SURFACES Unless otherwise specified, machined surfaces with a total tolerance of less than .003 inch, shall not be painted. For example, gears or splined teeth, bearing surfaces, keyways, threads, reamed or honed holes, and super finished surfaces (16 RMS or better). All other surfaces shall be painted as required by the engineering drawing. DIMENSIONAL TOLERANCE LIMITS Unless otherwise specified, dimensional limits and surface roughness designations are prior to shotpeen, plating, painting or other surface treatments. Dimensional limits for threads are after plating and/or other surface treatments.
13.5 13.5.1
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14. 14.1
ACCEPTANCE CRITERIA FOR CASTINGS / FORGINGS The following machining operations may be performed by the supplier on cast or forged parts: 1. It is allowable to machine any casting/forging tooling points to required drawing dimensions. 2. It is allowable to machine any surface of a casting/forging up to 0.060 to meet drawing dimensional requirements. 3. The only allowable machining methods for titanium castings/forgings are turning or milling.
14.1.1
The supplier must retain records of machining operations, on internal operation sheets, by lot number, indicating the castings/forgings that have been machined and the amount of stock removed. Forgings that are subsequenty machined over 90% of their surface are acceptable up to .060 per diameter, .030 per surface, over the drawing maximum material condition, provided that tooling points are not affected.
14.1.2
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15. 15.1 15.1.1
SCREW THREADS SCREW THREADS ON ELECTRICAL CONNECTORS The thread gaging note on Spec or Source Control Drawings, does not apply to military, (AN, MS or Mil ), or vendor electrical connectors. (These connectors meet the requirements of their applicable procurement specifications). THREADED FASTENERS WITH INCONSISTENT FUNCTIONAL ELEMENT/ SIZE INSPECTIONS Threaded fasteners, with method B, system 22 or other inspection requirements per MilS8879, ASME B 1.3M or AS8879 respectively, meeting all geometric features but with inconsistent functional element/size indications during inspection, shall be referee inspected for acceptance using the unbiased calibrated ring std. 13000.003000.
15.2
15.2.1
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16. 16.1
CONTROL COMPONENTS Proof pressure testing of fluid components and proof testing of control cable assemblies and push rods. Unless specifically defined on the engineering drawing, the following tolerances for proof load/pressure, burst pressure and times apply: a) A. Control Cable Assemblies; Proof load; + 5 0 percent Time at load; From 45 to 75 seconds B. Fluid System Components,Lines, Fittings, and Hoses: Proof pressure; +10 percent / 0 percent Burst pressure; +10 percent / 0 percent Time at pressure; +30 / 5 seconds C. Pushrods: Proof Load; Ultimate load;* Time at load; +20 / 0 pounds (lbs.) +20 / 0 pounds (lbs.) From 3 to 60 Seconds
16.1.1
b)
c)
*NOTE:Ultimate load test is a one-time test requirement.
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17. 17.1
Electrical Components Grommet Alternates Grommets per MILDTL22529 may be used as an approved alternate to MS 21266 grommets installed in accordance to SS8640 with exceptions noted herein. The MILDTL22529 grommets do not require adhesive bonding per SS8640. The following table indicates the proper alternates: Table 17 GROMMET ALTERNATES
MS21266 Dash# MS212661 MS212662 MS212663 MS212664 MS212665 17.1.1
Sheet Thickness .015 / .052 .052 / .085 .085 / .128 .128 / .192 .192 / .255
M22529 Range .036 / .063 .070 / .093 .105 / .134 .178 / .198 .240 / .260
M22529 Dash # M22529/22C0085 M22529/24C0085 M22529/26C0085 M22529/27C0085 M22529/28C0085
NOTES / EXCEPTIONS: 1. Where clips intrude into the hole, castles on the M22529 grommets shall be trimmed to .03 max height without sharp edges, allowing fit between the clips without damage to the cushion. The first two castles on each end of the grommet shall not be removed. The gap/seam (.08 max) shall be at the top of the hole or orientated to remove minimal castles around clips. The castles shall be trimmed only as necessary to prevent interference. 2. M22529 grommets may be used on 7/8 (.875) inch diameter holes and larger and shall not be used on lightening holes. 3. M22529 grommet material shall only be used on flanges or straight edges where the minimum flat edge distance exceeds .18 inches, allowing the edge to fully bottom into the grommet. WIRE MARKING CRITERIA FOR ALL SIKORSKY AIRCRAFT WIRING (including electro/mechanical components). Wiring shall be marked in accordance with SS7333 or SS7334. SS 7333 marking processes are preferred. Wiring may be marked per SS7334 using Hot Impression Stamping provided all initial qualification and continual acceptance testing is performed.
17.2
17.2.1
17.2.2
64

SS9208 Rev 48 (Production Acceptance Criteria)

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TABLE OF CONTENTS

SA 5140 REV D 5/97 .

6900 MAIN ST STRATFORD, CT 06497-9129

PREP. E. JARONCZYK APVD.J. SONICK GOVT J. BONNEY . SUPERSEDES:

PRODUCT DEFINITION ACCEPTANCE CRITERIA

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SA 5139-1 REV D 5/97 .

STRATFORD, CONNECTICUT 06497-9129

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DATE 10/3/90 10/22/90 2/7/91 5/15/92 11/9/92 12/4/92

SS9208 REV SS9208 REV 30 48

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SS9208 REV SS9208 REV 47 48

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SS9208 REV SS9208 REV 47 48

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TABLE III (STEEL LOCK BOLTS)

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(STEEL LOCK BOLTS) CONTINUED

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TABLE IV (ALUMINUM LOCK BOLTS)

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NAS1739MW4, NAS1921M04S .040 NAS1739MW5, NAS1921M05S .050 NAS1739MW6, NAS1921M06S .071

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SS9208 REV 48 SS9208 REV 47

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SS9208 REV 48 SS9208 REV 47

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SS9208 REV 48 SS9208 REV 47

POTENTIAL GAP LOCATIONS

Figure 8.1 GAP LOCATIONS

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Corner must clear radius Figure 8.11

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8.1 Shimming Metallic Airframe Components (cont)

Corner must clear radius Figure 8.12

Added tapered shim

Bond Figure 8.13 Added shim Outer skin

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Shimming Metallic Airframe Components (cont)

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Limitations a. Metallic skins are defined as:

NOTE: See Figure 8.21 for example of skin trimming.

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8.2 Trimming Metallic Airframe Skins (cont)

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8.3 Trimming Metallic Airframe Components (cont)

Trim to clear and not violate edge distance 2D Min.

Conditions: Part touches fastener

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8.3 Trimming Metallic Airframe Components (cont)

2D Min Clearance per part drawings Typ

Sheet metal intercostal Removed material (Maintained original radius)

D = Max. dia of fastener

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8.3 Trimming Metallic Airframe Components (cont)

Extruded cap angles 2D Min. Clearance per part drawings Typ