Raytheon - Control of Product Manufacturing Processes For Suppliers and Outside Production

Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.
RLSD NOV 04 2005
Raytheon Aircraft Company

Wichita, Kansas 67201
CAGE Code 70898
Engineering Specification
BS25691 Rev 8
Control of Product Manufacturing Processes
For
Suppliers and Outside Production
DOC153925 R8
Mar. 27, 2003
Written by: Steven Schmitter

Engineer- Engineering Standards
Approved: Michael Granite Approved: Doug Oliver (John Ewing for)

Engineering Standards Process Engineering
Approved: Larry Young Approved: Joe Garst

Engineering Integrity Engineering Liaison
Approved: Greg Lovendahl Approved:

Engineering Project
980-32321 Reference EPP024 Facsimile of G:\Forms\Eng\Specform.dot

Issued 01/99 DOC141941 R01
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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:
Section 2.3 corrected title to MS299 was:

BRONZE. Now: Bronze, Specification for
Bearing.
Included reference to new Sub-section 4.3

Direct Purchase Program for Casting and
Forging in Sub-section 3.1.d.
Removed sub-bullet 6 under bullet 5 in Sub-

section 3.5.25 Fluorescent Penetrant Inspection
to eliminate conflicting data with Sub-section
3.3.1 Non-Ferrous Sheet Material.
Added the following new Sub-sections to

Section 4 QUALITY ASSURANCE PROVISIONS.
4.3 Direct Purchase Programs for Castings and
Forgings
4.4 RAC Engineering Clarification of Part
Manufacturing Criteria.
Added bullet to 3.5.6 to add primer for exterior

skins and parts.
Added SAE Aerospace Material Specifications,

AMS5560, AMS5561, AMS5563, AMS5564,
AMS5565, AMS5566, AMS5567, AMS5569,
AMS5570, AMS5571, AMS5639, and AMS5668
superseding Mil-T-8606. AMS5556, and
AMS5557 superseding Mil-T-8808 as required
for modification of Table 12. Ferrous Alloy Tube
Substitution Table.
Added 303 Alloy to Table 10.
Created Table 16 and added substitution of

AMS4634 for AMS4631. Added reference to
table 16 to Sect 3.1.b
Added the word Casting to table 13 title.
Revised applicability note in section 1.2,

was: Engineering drawing shall take
precedence.
now: more stringent requirement shall be
followed. Deviations to this shall be addressed
to RAC Engineering.
Added BS253303 to applicable documents table

in sect 2.3
Revisions are identified by a Revision Bar in left
margin and highlighted bold.
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Table of Contents
Page
Revision History ...................................................................................................................................................................... 2

Table of Contents.................................................................................................................................................................... 3
List of Figures.......................................................................................................................................................................... 4
List of Tables ........................................................................................................................................................................... 4
1. Scope ........................................................................................................................................................................... 6
1.1 Purpose .................................................................................................................................................................... 6
1.2 Applicability............................................................................................................................................................... 6
1.3 Limitations................................................................................................................................................................. 6
1.4 Abbreviations, Acronyms, Symbols, and Definitions ................................................................................................ 7
2. Applicable documents .................................................................................................................................................. 8
2.1 Government/Military.................................................................................................................................................. 8
2.2 Industry ..................................................................................................................................................................... 9
2.3 Raytheon Aircraft Company ................................................................................................................................... 13
3. 3. Requirements ......................................................................................................................................................... 13
3.1 Raw Material........................................................................................................................................................... 13
3.2 Machining ............................................................................................................................................................... 16
3.2.1 Aluminum Alloys and Other Nonferrous Alloys................................................................................................... 16
3.2.2 Ferrous Alloys ..................................................................................................................................................... 16
3.3 Forming................................................................................................................................................................... 17
3.3.1 Non-Ferrous Sheet Material ............................................................................................................................... 17
3.3.2 Non-Heat Treatable Ferrous Sheet Material....................................................................................................... 17
3.3.3 Heat Treatable Ferrous Sheet Material .............................................................................................................. 17
3.3.4 Extrusion ............................................................................................................................................................. 18
3.4 Edge Conditions ..................................................................................................................................................... 18
3.4.1 Sheet Metal Edge Conditions ............................................................................................................................. 18
3.4.2 Machined Part Edge Conditions ......................................................................................................................... 19
3.5 Special Processes .................................................................................................................................................. 19
3.5.1 Abrasive Blasting ................................................................................................................................................ 20
3.5.2 Silver Brazing...................................................................................................................................................... 20
3.5.3 Copper, Nickel Brazing ....................................................................................................................................... 21
3.5.4 Chemical Milling.................................................................................................................................................. 22
3.5.5 Chemical Film ..................................................................................................................................................... 25
3.5.6 Primer.................................................................................................................................................................. 26
3.5.7 Light Chemical Etching Of Aluminum and Aluminum Alloys .............................................................................. 26
3.5.8 Pickle and Passivate........................................................................................................................................... 27
3.5.9 Low Temperature Stress Relief (Ferrous Parts) ................................................................................................. 28
3.5.10 Embrittlement Relief of Ferrous Parts................................................................................................................. 28
3.5.11 Heat Treatment of Aluminum Alloys ................................................................................................................... 29
3.5.12 Heat Treatment of Ferrous Alloys....................................................................................................................... 30
3.5.13 Shot Peening and Peen Forming........................................................................................................................ 35
3.5.14 Anodize ............................................................................................................................................................... 35
3.5.15 Chromic Dip for Lead Alloys ............................................................................................................................... 37
3.5.16 Dry Film Lubricant / Solid Film Lubricant ............................................................................................................ 37
3.5.17 Cadmium Plating................................................................................................................................................. 38
3.5.18 Copper Plating .................................................................................................................................................... 40
3.5.19 Nickel Plating ...................................................................................................................................................... 41
3.5.20 Electroless Nickel Plating.................................................................................................................................... 42
3.5.21 Chromium Plating ............................................................................................................................................... 43
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3.5.22 Manganese Phosphate Coating (Anti-Seize). .................................................................................................... 44

3.5.23 Fusion Welding. .................................................................................................................................................. 45
3.5.24 Electron Beam Welding. ..................................................................................................................................... 46
3.5.25 Fluorescent Penetrant Inspection ....................................................................................................................... 47
3.5.26 Magnetic Particle Inspection ............................................................................................................................... 48
3.5.27 Hot Forming of Aluminum ................................................................................................................................... 49
3.5.28 Hot Forming and Bending of Ferrous Alloys....................................................................................................... 50
3.5.29 Hot Forming of Magnesium Sheet Material ........................................................................................................ 50
3.5.30 Titanium Sheet Material ...................................................................................................................................... 52
3.5.31 Water Jet Cutting ................................................................................................................................................ 52
3.5.32 Laser Cutting....................................................................................................................................................... 52
3.5.33 Electrical Discharge Machining (EDM) ............................................................................................................... 52
3.5.34 Polishing Operations (Buffing) ............................................................................................................................ 52
4. Quality Assurance Provisions .................................................................................................................................... 67
4.1 RAC Supply Chain Management Responsibilities and Requirements................................................................... 67
4.2 RAC Engineering Requirements ............................................................................................................................ 67
4.3 Direct Purchase Program for Castings and Forgings ...................................................................................... 68
4.4 Engineering Clarification of RAC Controlled Metallic Hardware Parts........................................................... 68
5. Preparation for Delivery.............................................................................................................................................. 68
6. Notes .......................................................................................................................................................................... 68
APPENDIX A........................................................................................................................................................................... 1
List of Figures
Page
Figure 1. Edge Chamfer and Radius Limitations ................................................................................................................. 19

Figure 2. Masking for Chemical Milling ................................................................................................................................ 24
List of Tables
Page
Table 1. Typical RAC Specified Strength Ranges ............................................................................................................... 53

Table 2. Maximum Cross Section Thickness (inches) to Achieve Specified Heat Treat Range ........................................ 53
Table 3. Minimum Thickness of Nickel Plating if not Specified............................................................................................ 53
Table 4. RAC Approved Ferrous Materials for Hot Bending and Forming........................................................................... 54
Table 5. Aluminum Alloy Extruded Wire, Rod, and Shapes Substitution Tables................................................................. 54
Table 6. Aluminum Alloy Rolled or Cold Finished Wire, Rod, and Bar Substitution Table.................................................. 56
Table 7. Aluminum Alloy Bare Plate and Sheet Substitution Table ..................................................................................... 58
Table 8. Aluminum Alloy Alclad Sheet Substitution Table ................................................................................................... 59
Table 9. Aluminum Alloy Drawn Tube Substitution Table.................................................................................................... 59
Table 10. Ferrous Alloy Bar Substitution Table ................................................................................................................... 60
Table 11. Ferrous Alloy Sheet, Plate, and Strip Substitution Table..................................................................................... 61
Table 12. Ferrous Alloy Tube Substitution Table................................................................................................................. 63
Table 13. Copper & Bronze Alloy Casting Substitution Table ............................................................................................. 63
Table 13. Copper & Bronze Alloy Casting Substitution Table ............................................................................................. 64
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Table 14. Aluminum Minimum(Min) Bend Radii (at Room Temperature)............................................................................ 65

Table 15. Copper Recommended(Rec) and Minimum(Min) Bend Radii (at Room Temperature) ...................................... 66
Table 16. Copper & Bronze Alloy Rod & Bar Substitution Table ......................................................................................... 66

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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.

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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.
AMS Aerospace Material Specification MRS Minimum Residual Stress

ANSI American National Standards Institute NDI Non-Destructive Inspection
ASTM American Society for Testing and Materials QA Quality Assurance
AWS American Welding Society RAC Raytheon Aircraft Company
EDM Electrical Discharge Machining Registered Trademark
GTAW Gas Tungsten Arc Welding RMS Root mean square
ksi Thousand pounds per square inch SAE Society of Automotive Engineers
MHI Mitsubishi Heavy Industries TIG Tungsten Inert Gas

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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
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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
American National Standards Institute (ANSI)

ANSI H35.1 Alloy and Temper Designation Systems for Aluminum
Aerospace Material Specification (AMS) by Society of Automotive Engineers (SAE)

AMS-2681 Welding, Electron Beam
AMS-2759 Heat Treatment of Steel Parts
AMS-2759/1 Heat Treatment of Carbon and Low-Alloy Steel Parts, Minimum
Tensile Strength Below 220 KSI
AMS-2759/2 Heat Treatment of Carbon and Low-Alloy Steel Parts, Minimum
Tensile Strength Below 220 KSI
AMS-2759/3 Heat Treatment, Precipitation-Hardening Corrosion-Resistant and
Maraging Steel Parts
AMS-2759/4 Heat Treatment, Austenitic Corrosion-Resistant Steel Parts
AMS-2759/5 Heat Treatment, Martensitic Corrosion-Resistant Steel Parts
AMS-2770 Heat Treatment of Wrought Aluminum Parts
AMS-2771 Heat Treatment of Aluminum Alloy Castings
AMS4025 6061-O Aluminum Alloy Sheet & Plate
AMS4026 6061 Aluminum Alloy Sheet & Plate
AMS4040 2024 Alclad Aluminum Alloy Sheet & Plate
AMS4078 7075 Alclad Aluminum Alloy Plate
AMS4080 6061 Aluminum Alloy Drawn Seamless Tubing
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AMS4115 6061 Rolled or Cold-Finished Aluminum Alloy Bars, Rods, & Wire
AMS4123 7075 Rolled or Cold-Finished Aluminum Alloy Bars & Rods
AMS4128 6061 Rolled or Cold-Finished Aluminum Alloy Bars
AMS4150 6061 Aluminum Alloy Extrusions & Rings
AMS4152 2024 Aluminum Alloy Extrusions
AMS4187 7075 Aluminum Alloy Bars & Rods
AMS4339 2024 Aluminum Alloy Bars & Rods
AMS5507 Steel, Corrosion and Heat-Resistant, Sheet, Strip, and Plate
17CR-13NI-2.5MO (SAE 30316L) Solution Heat Treated
AMS5510 321 CRES Steel Sheet, Strip, & Plate
AMS5556 Steel, Corrosion and Heat Resistant, Seamless or Welded
Hydraulic Tubing 18Cr 11Ni 0.70Cb (SAE 30347) Solution
Heat Treated
AMS5557 Steel, Corrosion and Heat-Resistant, Seamless or Welded
Hydraulic Tubing 18.5Cr 10.5Ni 0.40Ti (SAE 30321) Solution
Heat Treated
AMS5560 Steel, Corrosion Resistant, Seamless Tubing
19Cr 10Ni (SAE 30304) Solution Heat treated.
AMS5561 Tubing, Steel, Welded and Drawn, Corrosion and Heat Resistant
9.0MN 20CR -6.5NI 0.28N High Pressure Hydraulic
AMS5563 Steel, Corrosion Resistant, Seamless or Welded Tubing
19Cr 9.5Ni (SAE 30304) Cold Drawn, Hard Temper.
AMS5564 Steel, Corrosion Resistant, Tubing 19Cr 10Ni (SAE30304)
High-Pressure Hydraulic, Welded Plus Ultrasonically Testes or
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Seamless Cold Drawn, One Eighth - Hard Temper.
AMS5565 Steel, Corrosion Resistant, Welded Tubing
19Cr 9.5Ni (SAE30304) Solution Heat Treated.
AMS5566 Steel. Corrosion Resistant, Seamless or Welded Hydraulic Tubing
19Cr 10Ni (SAE30304) High Pressure, Cold Drawn.
AMS5567 Steel, Corrosion Resistant, Seamless or Welded Hydraulic Tubing
19Cr 10Ni (SAE30304) Solution Heat Treated.
AMS5569 Steel, Corrosion and Heat Resistant, Seamless and Welded
Hydraulic Tubing 19Cr 9.5Ni 0.03C max Cold Drawn,
1/8 Hard Temper.
AMS5570 Steel, Corrosion and Heat Resistant, Seamless Tubing
18Cr - 11Ni 0.40Ti (SAE30321) Solution Heat treated.
AMS5571 Steel, Corrosion and Heat Resistant, Seamless Tubing
18Cr 10.5Ni 0.70Cb (SAE30347) Solution Heat Treated
AMS5639 Steel Corrosion-Resistant, Bars, Wire, Forgings, Tubing, and Rings
19Cr 10Ni Solution Heat treated.
AMS5645 321 CRES Steel Bars, Wire, Forgings, Tubing, & Rings
AMS5647 304 CRES Steel Bars, Wire, Forgings, Tubing, & Rings
AMS5668 Nickel Alloy, Corrosion and Heat Resistant, Bars, Forgings, and
Rings 72Ni - 15.5Cr - 7.0Fe 2.5Ti 1.0(Cb+Ta) 0.70Al
2100F (1149 C) Solution and Precipitation Heat Treated.
AMS5907 Steel, Corrosion and Heat Resistant, Sheet, Strip, and Plate 17CR-
12NI-2.5CMO (SAE 30316) Cold Rolled, Hard, 125 KSI (862MPA)
Tensile Strength
AMS6345 4130 Steel Sheet, Strip, & Plate
AMS6350 4130 Steel Sheet, Strip, & Plate
AMS6370 4130 Steel Bars, Forging, & Rings
AMS6415 4340 Steel Bars, Forgings, & Tubing
AMS-C-8837 Cadmium Coating (Vacuum Deposited)
AMS-C-81769 Chemical Milling of Metals
AMS-M-3171 Processes for Pretreatment and Prevention of Corrosion on
Magnesium Alloy
AMS-QQ-A-200 2014 Extruded Aluminum Alloy Bar, Rod, Shapes, Tube, and Wire
AMS-QQ-A-225 2014 Aluminum Alloy Bar, Rod, Wire, and Special Shapes
AMS-QQ-A-250 2024 Aluminum Alloy Plate and Sheet
AMS-QQ-C-320 Chromium Plating (Electrodeposited)
AMS-QQ-N-290 Nickel Plating (Electrodeposited)
AMS-QQ-P-35 Passivation Treatments for Corrosion-Resistant Steel
AMS-QQ-P-416 Plating, Cadmium (Electrodeposited)
AMS-S-5000 Chrome-Nickel-Molybdenum Steel (Bars & Reforging Stock)
AMS-S-6758 Steel, Chrome-Molybdenum (4130) Bars and Reforging Stock
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(Aircraft Quality)
AMS-S-13165 Shot Peening of Metal Parts
AMS-S-7720 Steel, Corrosion, Resistant (18-8) Bar, Wire, and Forging Stock
(Aircraft Quality)
AMS-T-6736 Chrome-Molybdenum Seamless & Welded Steel Tubing
AMS-WW-T-700 Drawn & Seamless Aluminum Alloy Tube
American Society for Testing and Materials (ASTM)

ASTM A276 Standard Specification for Stainless Steel Bars and Shapes.
ASTM A569 Hot Rolled, Sheet & Strip Carbon Steel
ASTM A606 Sheet & Strip, High Strength, Low Alloy, Hot & Cold Rolled CRES Steel
ASTM A659 Hot Rolled, Sheet & Strip Carbon Steel
ASTM B148 Aluminum-Bronze Sand Castings
ASTM B271 Copper-Base Alloy Centrifugal Castings
ASTM B505 Copper Alloy Continuous Castings
ASTM E1417 Fluorescent Penetrant Inspection
ASTM E1444 Magnetic Particle Examination

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2.3 Raytheon Aircraft Company

RAC Standard Drawings/Specifications
111503 Ring Silver Solder Brazing
111524 Strip Silver Solder Brazing
BS182011 Corrosion and Paint Adhesion Coatings for Lead Alloys
BS249 Stress Relief of Steel Parts after Welding or Brazing
BS361 Standard Finish Specification
BS510 Design of Welded Joints with Aluminum Alloys
BS511 Design of Welded Joints with Steels and Corrosion and Heat
Resisting Alloys
BS4692 Passivation of Corrosion-Resistant Steel Alloys
BS4896 Electron Beam Welding - General
BS20706 Bonding, Electrical, Electronic, and Avionics for Aircraft
BS24058 Fabrication of Parts from Commercially Pure Titanium and Titanium
Alloy 6Al-4V, Annealed Sheet
BS24554 Phosphoric Acid Anodizing of Aluminum Alloys for Structural
Bonding
BS24757 Finish Codes for Corrosion Protection prior to Top Coating
BS25032 Corrosion Resistant Fuel Cell Epoxy Primer
BS25272 Fusion Welding of Titanium and Titanium Alloys
BS25276 Approved Sources and Procedures for Shot Peen Forming Wing
Skins for the Model 390
BS25339 Hot Bending or Forming of Aluminum Alloys
BS25359 Minimum Residual Stress (MRS) Quality Sheet Material
BS25457 High Temperature Epoxy
BS25526 Stress and Embrittlement Relief Requirements for Chemical
Processes
BS25554 Polishing Metal Surfaces (Buffing)
BS25707 Fluorescent Penetrant and Magnetic Particle Inspection Part
Exemption List
BS253303 Exterior Part List
MS299 Bronze, Specification for bearing
SAS03-003 Sheet Metal Edge Conditions
SAS10-004 Machining Corner Radii
Mitsubishi Heavy Industries (MHI) Specifications
P2306 Phosphate Coating
P2700 Finishes and Coatings
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

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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.
1. Aluminum and Copper Alloy Material
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)
2. Carbon Ferrous Alloy Material

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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.
3. Corrosion Resistant Steel Ferrous Alloys
Size substitutions for CRES ferrous alloys (i.e. 300 and 400 series stainless steels) are not allowed
without written approval from RAC Engineering.
c. Special Requirement for 4130 Steel Bar Stock

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.
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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
3.2.1 Aluminum Alloys and Other Nonferrous Alloys.

Acceptable/Unacceptable Practices
Aluminum and other nonferrous alloys may be machined by conventional and high-speed machine tool
equipment. Cutter condition, speeds, feeds, and coolants shall be controlled to preclude heating the
material to a temperature that will result in machined dimensional tolerance errors due to thermal
expansion and/or affect material property characteristics. Aluminum exposed to temperatures of 300
400 F causes the material to anneal.
Aluminum and other nonferrous alloys shall not be machined utilizing laser, electrical discharge
machining (EDM), or any other non-conventional method without the written approval of RAC.
Grain Direction
If grain direction is specified on the drawing, raw material grain direction shall be verified and oriented
to align with drawing requirements for the finished part.
Penetrant Inspection
Following machining, penetrant inspection shall be performed in accordance with ASTM E1417. Parts
shall be properly prepared for penetrant inspection by etching in accordance with ASTM E1417.
Acceptance criteria for penetrant inspection shall be MIL-STD-1907, grade A. Penetrant inspection
shall be performed in the proper sequence within the overall manufacturing process. A section
addressing additional fluorescent penetrant inspection considerations and requirements is included in
this document.
Hardness and/or electrical conductivity testing
Parts manufactured from aluminum and other nonferrous alloys shall be hardness and/or electrical
conductivity tested (as applicable) to verify material heat treat condition conformance to engineering
requirements. Acceptance criteria for hardness and conductivity testing of aluminum shall be in
accordance with AMS 2658.
3.2.2 Ferrous Alloys
Acceptable/Unacceptable Practice
Ferrous alloys may be machined by conventional machine tool equipment. Cutter condition, speeds,
feeds, and coolants shall be controlled to preclude excessive heating of the part surface.
Ferrous alloys shall not be machined or profiled utilizing laser, electrical discharge machining (EDM),
or any other non-conventional method without the written approval of RAC.
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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
3.3.1 Non-Ferrous Sheet Material

Non-ferrous sheet material (i.e., 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, etc. The forming process shall be controlled to preclude excessive
thinning (not to exceed 10% reduction in thickness). Localized heating to facilitate forming is not
allowed without written approval of RAC. Visual examination for forming cracks and other forming
anomalies is required. Except as other wise specified on the engineering drawing, fluorescent
penetrant inspection shall be performed. Parts listed in BS25707 are exempt from fluorescent
penetrant inspection.
3.3.2 Non-Heat Treatable Ferrous Sheet Material
Non-heat treatable ferrous sheet material (300 series stainless steel alloys, etc.) may be formed at
room temperature by conventional methods such as hydroform, stretch form, brake form, roll form,
hand form, etc. The forming process shall be controlled to preclude excessive thinning (not to
exceed 10% reduction). Localized heating to facilitate forming is not permissible without written
approval of RAC. Visual examination for forming cracks and other forming anomalies is required.
Except as other wise specified on the engineering drawing, fluorescent penetrant inspection shall be
performed. Parts listed in BS25707 are exempt from fluorescent penetrant inspection.
3.3.3 Heat Treatable Ferrous Sheet Material
Heat treatable ferrous sheet material (10xx, 4130, 1095, precipitation hardening corrosion resistant
steel, etc.) may be formed at room temperature by conventional methods such as hydro form, stretch
form, brake form, roll form, hand form, etc. The forming process shall be controlled to preclude
excessive thinning (not to exceed 10% reduction). Localized heating to facilitate forming is
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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
3.4.1 Sheet Metal Edge Conditions

The following limitations are to be met when the Engineering drawing does not specify edge conditions
for sheet metal.
General Requirements/Limitations
Sharp edges are not allowed.
Inspection of sheet metal edge conditions shall be in accordance with approved RAC methods.
When the Engineering drawing does not specify Break Edge, Break Sharp Edge, or similar
statement and the drawing does not specify an edge radius or chamfer, the following limitations
are acceptable to use on all sheet metal part edges. Refer to Figure 1.
Radius Minimum: R = 0.003 inch.

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.
Chamfer Minimum: X = 0.002 inch.

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.
When the Engineering drawing specifies Break Edge, Break Sharp Edge, or similar
statement and the drawing does not note a specific edge radius or chamfer, the following
limitations shall apply. Refer to Figure 1.
Requirements/Limitations Non-Machined Sheet Metal Parts (not routed or milled)
Radius Minimum: R = 0.003 inch.
0.015 inch.
Chamfer Minimum: X = 0.002 inch.

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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
0.015 inch.
Chamfer Minimum: X = 0.007

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
Figure 1. Edge Chamfer and Radius Limitations
3.4.2 Machined Part Edge Conditions

Refer to SAS10-004 for information pertaining to edge conditions of machined parts not noted on the
Engineering drawing.
3.5 Special Processes
A supplier performing Non-Destructive Inspection (NDI) tests, special processes, and certain forming
processes, shall be approved specifically for that special process by RAC. A listing of processes
requiring approval can be found at RAC, Supply Chain Management web page.

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3.5.1 Abrasive Blasting

General
Abrasive blasting is typically utilized for removal of heavy scale, oxides and similar surface
contaminates. Several blast media are available, including aluminum oxide, glass bead, steel, etc.
Without proper control, abrasive blasting can result in excessive erosion of material, produce
undesirable surface conditions, and sensitize surfaces for susceptibility to in-service cracking.
Requirements/Limitations
The process of abrasive blasting shall not be applied to any nonferrous material without written
approval from RAC.
Abrasive blasting may be utilized for the removal of scale, oxides, and other similar
contaminates from ferrous alloys. Written RAC approval is not required for this application.
Abrasive blasting of ferrous alloys shall be accomplished only with finer grades of aluminum
oxide, glass beads, or steel blast media. Silica sand shall not be utilized for abrasive blasting.
Nozzle air pressure, exposure times, and other application parameters shall be controlled to
preclude excessive erosion of material and/or development of undesirable surface conditions.
Immediately subsequent to abrasive blasting, ferrous parts shall be treated and/or stored in a
manner to preclude oxidation (rusting).
Abrasive media blasting for cleaning prior to silver, 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.
3.5.2 Silver Brazing
General
Silver alloy brazing is a process in which parts are joined together utilizing torch or induction heating
and a silver alloy braze filler material. The joint to be brazed is cleaned, fluxed to facilitate oxidation
control, and then heated by either a hand held torch or by an induction heating device. After achieving
the required temperature, the braze alloy is flowed in the joint. Different grades of silver braze alloy
melt at different temperatures. Engineering drawings typically specify the braze alloy class to be
utilized. Brazing temperatures range from about 700F up to 1200F. Normally, silver brazing as a
method of assembly is limited to ferrous parts. Procedures to accomplish silver alloy brazing of non-
ferrous metals (i.e., copper alloys such as certain types of brass and bronze) require specific RAC
approval for the brazed alloy.
Applicable and Associated Documents
AWS C3.4 Torch Brazing
AWS C3.5 Induction Brazing
AWS A5.8 Filler Metals for Brazing
O-F-499 Flux, Brazing, (Silver Brazing Filler Metal, Low Melting Point)
RAC Std. 111503 Ring Silver Solder Brazing
RAC Std. 111524 Strip Silver Solder Brazing
Suppliers performing silver brazing shall be approved for the specific silver braze process by
RAC.
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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).
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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
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.
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AMS-C-81769 Chemical Milling of Metals
BS25359 Minimum Residual Stress (MRS) Quality Sheet Material
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.

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Mask
Metal
Edge of Part
Minimum Excess: 1/4 inch
Allow 1/4 inch excess on all edges that do not mill.

This is in addition to any extra material allowed for tooling tabs as shown.
Figure 2. Masking for Chemical Milling
3.5.4.1 Chemical Milling of Aluminum

Chemical milling is applicable to all wrought and forged aluminum alloys. Chemical milling of cast
aluminum shall not be performed.
There are two types of chemical milling solutions used on aluminum substrates. Type I will produce a
surface finish of approximately 125 - 150 RMS. Type II will produce a surface finish between 40 - 63
RMS.
Chem-mill parts designed for fabrication from -O temper sheet stock do not require the use of special
chem-mill quality material. Parts in this category may be fabricated from normal coil stock material.
Parts fabricated from -T sheet stock material (except 6013, see below) require the use of special
chem-mill quality material with reduced residual internal stresses. Typically, this material is
designated as MRS quality by the producing mill. Mill certifications from the producing mill shall
show qualification of the material as MRS.
6013 material to be chemical milled in the -T conditions does not require the use of chem-mill quality.

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3.5.4.2 Chemical Milling of Steel

Chemical milling of ferrous alloys is applicable to all wrought and forged ferrous base alloys.
Chemical milling of cast ferrous alloys shall not be performed.
Chemical Milling of Titanium Chemical milling of titanium alloys is applicable to all cast, wrought, and
forged titanium base alloys.
3.5.5 Chemical Film

General
Chemical film coating is a process in which aluminum and aluminum alloy products are subjected to a
chemical treatment that forms a thin layer of a chemical compound on the treated surface. The
chemical film provides for: (a) significant increase in corrosion resistance when used under organic
finishes, (b) improved adhesion for organic finishes, and (c) increased corrosion protection for surfaces
that receive no additional finishing. Chemical solutions that provide for chemical film may be applied
by immersion, spraying, brushing, wiping, or other wetting methods.

MIL-C-5541 Chemical Conversion Coatings for Aluminum and Aluminum Alloys
MIL-DTL-81706 Chemical Conversion Materials for Coating Aluminum and
Aluminum Alloys
Weapons Systems
BS20706 Bonding, Electrical, Electronic, and Avionics for Aircraft
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.
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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.

MIL-PRF-23377 Primer Coatings, Epoxy, High Solids
MIL-C-8514 Coating Compounds, Metal Pretreatment, Resin-Acid
BS25032 Corrosion Resistant Fuel Cell Epoxy Prime
BS25457 High Temperature Epoxy
BS24757 Finish Codes for Corrosion Protection prior to Top Coating
P2700 Finishes and Coatings
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
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.
3.5.7 Light Chemical Etching Of Aluminum and Aluminum Alloys

General
Light chemical etching is the process of chemically removing material from the surface of aluminum
and aluminum alloy parts through the use of a chemical bath. Chemical etching is commonly used to:
(a) remove light oxides formed during heat treatment, (b) clean surfaces in preparation for spot
welding, fusion welding, etc. (c) remove surface smearing to facilitate penetrant inspection, and (d)
provide a more even and uniform surface where appearance is a factor.
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
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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.

AMS-QQ-P-35 Passivation Treatments for Corrosion-Resistant Steels
MIL-S-5002 Surface Treatments and (Inorganic) Coatings for Metal
Surfaces of Weapons Systems
BS4692 Passivation of Corrosion-Resistant Steel Alloys
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.
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2. Do not pickle 400 series or PH stainless steels.

3. If parts have close dimensional tolerances, +/- 0.002 or less.
4. Parts that have been brazed or soldered.
5. Stainless steel parts buffed to a mirror finish for decorative purposes.
When to Passivate
1. Passivation is required before welding and heat treat such as annealing, stress relief and
hardening.
2. Passivation is required after final pickling.
3. Passivation is required after final machining, forming or welding.
When not to Passivate
1. On parts which have been subjected to carbonizing (case harden) and/or nitriting.
2. Passivation is not required for corrosion resistant steels which are to be organically coated
or abrasive cleaned for the purpose of painting.
3. Not required after intermediate pickling operations. Passivation is required however after
the final pickling operation with no exceptions.
4. Parts that have been brazed or soldered.
5. Machined or ground surfaces that are to be plated. Iron and other surface contaminates
will be removed by the cleaning steps of the plating operation.
3.5.9 Low Temperature Stress Relief (Ferrous Parts)
General
As a steel mill product progresses from the producing steel mill though various manufacturing
processes, residual stresses typically develop within the material from multiple sources. Many
fabrication operations such as machining, grinding, cold forming, cold straightening, etc., contribute to
the creation of residual internal stress. The presence of residual internal stresses increase
susceptibility of higher strength ferrous products to the absorption of molecular hydrogen during certain
types of plating and/or chemical treatment processes. Absorption of hydrogen results in hydrogen
damage, commonly known as hydrogen embrittlement. By heating the steel to a prescribed
temperature for a controlled period of time, residual internal stresses can be relieved and the
susceptibility for hydrogen embrittlement during subsequent processing operations is significantly
reduced.

BS 25526 Stress and Embrittlement Relief Requirements from Chemical
Processes
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
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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.

Processes
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.
Applicable and Associated Documents.

ANSI H35.1 Alloy and Temper Designation Systems for Aluminum
AMS 2770 Heat Treatment of Wrought Aluminum Parts
AMS 2771 Heat Treatment of Aluminum Alloy Castings
Suppliers performing heat treatment of aluminum alloys shall be approved for that process by
RAC.

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All heat treat operations shall be performed in accordance with RAC engineering drawing
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

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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.

AMS 2759 Heat Treatment, Steel Parts, General Requirements
AMS 2759/1 Heat Treatment of Carbon and Low-Alloy Steel Parts, Minimum
Tensile Strength Below 220 ksi
AMS 2759/2 Heat Treatment of Low-Alloy Steel Parts, Minimum Tensile
Strength 220 ksi and higher
AMS 2759/3 Heat Treatment, Precipitation-Hardening Corrosion-Resistant
and Maraging Steel Parts
AMS 2759/4 Heat Treatment, Austenitic Corrosion-Resistant Steel Parts
AMS 2759/5 Heat Treatment, Martensitic Corrosion-Resistant Steel Parts
BS249 Stress Relief of Steel Parts After Welding or Brazing
Processes
General Requirements/Limitations
Suppliers performing heat treatment of steel alloys shall be approved for that process by RAC.
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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.
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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.
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Requirements/Limitations for Austenitic Corrosion Resistant Steel (201, 202, 301, 302, 303, 304,
304L, 308, 309, 310, 316, 316L, 321, 347, 348, etc.).
Austenitic corrosion resistant steels do not respond to hardening by thermal processing

operations. Strength of the material can be increased at the producing mill by certain types of
rolling operations which induce work hardening and increase strength. Mill work hardened
conditions are typically classified as one-quarter hard, one-half hard, full hard, etc.
Annealing - End Use Condition. Many austenitic corrosion resistant steels are designated for
end use in the annealed condition by engineering drawing.
Intermediate Anneal Cycles - Most austenitic corrosion resistant steel materials will work
harden at a fairly rapid rate during forming operations. For parts that require severe forming, it
may be necessary to progressively incorporate intermediate anneal cycles between
increasingly more severe stages of forming.
Anneal of a Mill Work Hardened Condition - A mill designated work hardened condition cannot
be restored by the user after an anneal operation has been performed. As an example, if one-
quarter hard material is annealed to facilitate forming, the one-quarter hard condition can not be
restored and the final product is considered to be in the annealed condition.
Terminology - Some specifications refer to solution heat treatment of austenitic corrosion
resistant steel. This term is synonymous with anneal with regard to austenitic corrosion
resistant steel.
Normalizing - Not applicable to austenitic corrosion resistant steel.
Requirements/Limitations for Precipitation Hardening Stainless Steel (17-4PH, PH 13-8Mo, 15-

5PH, 17-7PH, PH 15-7Mo, PH14-8Mo 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.
Normalizing - Not applicable to precipitation hardening corrosion resistant steels.

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3.5.13 Shot Peening and Peen Forming.

General
Shot peening of metal parts is a process to induce residual compressive stresses in specified surfaces,
for the purpose of improving resistance to fatigue, stress corrosion, and/or galling. Peen forming
utilizes the shot peen process to induce residual stresses of a degree that will create distortion of the
part. By controlling the location and magnitude of induced residual stresses, a part can be contoured to
a desired shape.

AMS-S-13165 Shot Peening of Metal Parts
BS25276 Approved Sources and Procedures for Shot Peen Forming Wing
Skins for the Model 390
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.

Weapons Systems
MIL-A-8625 Anodic Coatings for Aluminum and Aluminum Alloys
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BS24554 Phosphoric Acid Anodizing of Aluminum Alloys for Structural

Bonding
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.
Requirements/Limitations for MIL-A-8625 Anodizing Surface Coating.
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.
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2. Dichromate seal - Use when specified by engineering drawing.

3. Nickel acetate seal - Use for all Class 2 anodize coatings.
A chemically clean surface is essential for successful anodize coating.
When chemfilm has been called out by engineering after chromic acid anodize use the following
process:
1. Chromic acid anodize per the requirements of AMS-A-8625 Type I or IB depending on alloy.
2. Apply chemfilm over the sealed anodized surface. Do not alkaline clean or deoxidize, as this
may change the anodized surface.
Requirements/Limitations for Phosphoric Acid Anodizing
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.
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.
3.5.16 Dry Film Lubricant / Solid Film Lubricant

General
Dry film lubricants, also called solid film lubricants, are coating systems with fine lubricant powders
dispersed in special formulated thermosetting resins with a solvent system carrier that reduces friction,
wear, and corrosion on metal surfaces.

MIL-L-23398 Lubricant, Solid Film, Air Cured, Corrosion Inhibiting
MIL-L-46010D Lubricant, Solid Film, Heat Cured, Corrosion Inhibiting
Suppliers performing dry film lubricant application shall be approved by RAC.
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Application of dry film lubricant shall be in accordance with RAC engineering drawing
Prior to application of the dry film lubricant, surface preparation shall be in accordance with
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.

MIL-STD-1500 Cadmium-Titanium Plating, Low Embrittlement,
Electodeposition
AMS-C-8837 Cadmium Coating (Vacuum Deposited)
AMS-QQ-P-416 Plating, Cadmium (Electrodeposited)
BS24757 Finish Codes for Corrosion Protection and Topcoating
Processes
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.
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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:
1. Fastener hardware shall have Class 3 thickness plating.

2. For articles other than fastener hardware, the cadmium plating shall be Class 2 thickness.
3. Articles with external threads shall have a minimum of Class 3 thickness on the
threaded area.
Plating Type Requirements - The requirements for supplemental treatment of cadmium should
be defined on the engineering drawing. If requirements are not defined, Type II supplemental
treatment shall be applied.
Unless otherwise specified, cadmium plating shall be applied after base metal heat treatments,
after manufacturing operations, such as machining, brazing, welding, soldering, and forming,
and after plating operations, such as nickel, copper and chromium.
Parts shall be routed through suitable cleaning operations to provide for a chemically clean
surface prior to plating. In most cases, the cleaning performed as part of the plating process
will be sufficient and no additional pre-cleaning operations will be required. Parts that have
been heat treated, but do not have subsequent machining operations affecting the entire
surface of the part may require abrasive blast cleaning for scale removal. Abrasive blasting
shall be performed in a manner that precludes alteration of dimensional or surface finish
requirements for the part.
Coated Parts (Paint, Primer, Dry Film Lube, etc.) - Cadmium plated parts that subsequently
receive an organic surface finish shall have a Type II or a Type III supplemental treatment.
Stress Relief - Carbon and low alloy steels, and corrosion resistant steels heat treated to a
strength range of 150 ksi and above, that have been machined, ground, cold formed, or cold
straightened shall be subject to low temperature stress relief to relax residual stresses prior to
cadmium plating in accordance with BS25526.
Embrittlement Relief - Carbon steels, low alloy steels, and corrosion resistant steels heat
treated to a strength range of 150 ksi and above, 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 cadmium plating process has been
completed.
Parts heat treated to strength levels of 240 ksi and above shall not be cadmium plated using
electrodeposited methods. Parts heat treated to 240 ksi and above shall be vacuum cadmium
plated per AMS-C-8837.
Nonplated Areas - Cadmium plated parts that have bare areas shall be treated with protective
oil to prevent corrosion during subsequent operations.

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3.5.18 Copper Plating

General
Copper plating is the process of depositing a thin layer of copper utilizing an appropriate chemical
plating bath and electric current. Copper plating is primarily used as an undercoat for nickel and
decorative chromium plating as the copper plated surface can be buffed to a mirror finish with minimal
effort providing a base for other plated on metals. Another common application for copper plating is as
a stop off to prevent carburizing or decarburization during treatment. In this application, the plated on
copper protects the surface from the furnace atmosphere during heat treatment.
MIL-C-14550 Copper Plating (Electrodeposited)
Processes
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,
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
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.

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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.

AMS-QQ-N-290 Nickel Plating (Electrodeposited)
Processes
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:
6. Grade A - Minimum plating thickness shall be 0.0016 inch.

7. Grade B - Minimum plating thickness shall be 0.0012 inch.
8. Grade C - Minimum plating thickness shall be 0.0010 inch.
9. Grade D - Minimum plating thickness shall be 0.0008 inch.
10. Grade E - Minimum plating thickness shall be 0.0006 inch.
11. Grade F - Minimum plating thickness shall be 0.0004 inch.
12. Grade G - Minimum plating thickness shall be 0.0002 inch.
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.
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with the time/temperature schedule listed in BS25526, within four hours after the nickel plating
process has been completed.
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.

AMS-2404 Electroless Nickel Plating
Processes
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
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.
Stress Relief Steel products heat treated to a strength range of 150 ksi and above that have
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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
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.
3.5.21 Chromium Plating

General
Chromium plating is the process of depositing a thin layer of chromium utilizing an appropriate
chemical plating bath and electric current. There are two types of chromium plating in general use:
Decorative and Engineering. Decorative chromium plating is applied to enhance appearance and
improve corrosion protection. Decorative chromium plating is normally applied over a base of copper
and nickel plate. In some instances, the nickel plate may be applied directly to the base metal;
however, a copper undercoat is the preferred application. Engineering chromium plating (sometimes
referred to as hard chromium plating) is utilized to improve wear characteristics of the surface to which
it is applied.

Processes
AMS-QQ-C-320 Chromium Plating (Electrodeposited)
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:
1. Type I - Bright finish.

2. Type II - Satin finish.
3. Class 1 - Corrosion Protection Plating (Decorative). Minimum plating thickness 0.0001
inch unless otherwise specified.
4. Class 2 - Engineering Chromium Plating. Parts Plated for Class 2 deposition shall be
plated to specific dimensions unless otherwise specified. Minimum plating thickness
0.002 inches after final grinding and other metal finishing operations unless otherwise
specified.

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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.
with the time/temperature schedule listed in BS25526, within four hours after the chromium
plating process has been completed.
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.

MIL-DTL-16232 Phosphate Coating, Heavy, Manganese or Zinc Base (For
Ferrous Metals)
MIL-PRF-3150 Lubricating Oil, Preservative, Medium
Processes
P2306 Phosphate Coating
Suppliers performing manganese phosphate coating shall be approved for that process by
RAC.
Manganese phosphate coating shall be performed in accordance with RAC engineering
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.
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with the time/temperature schedule listed in BS25526, within four hours after the manganese
phosphate coating process has been completed.
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.
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
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.

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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.

AMS 2681 Welding, Electron-Beam
BS4896 Electron Beam Welding - General
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
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.

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3.5.25 Fluorescent Penetrant Inspection

General
Fluorescent penetrant inspection is a Non-Destructive Inspection (NDI) test method for locating
surface connected discontinuities in nonferrous metal and non-magnetic materials.
MIL-STD-1907 Inspection, Liquid Penetrant and Magnetic Particle, Soundness

Requirements for Materials, Parts and Weldments
ASTM E1417 Inspection, Fluorescent Penetrant
Exemption List
Suppliers performing fluorescent penetrant inspection shall be approved for that process by
RAC.
Fluorescent penetrant inspection shall be performed in accordance with RAC engineering
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.

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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).

MIL-STD-1907 Inspection, Liquid Penetrant and Magnetic Particle, Soundness
Requirements for Materials, Parts and Weldments
ASTM E1444 Magnetic Particle Examination
Exemption List
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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
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.

BS25339 Hot Bending or Forming of Aluminum Alloys

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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.
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.

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MIL-PRF-23377 Primer Coatings, Epoxy, High Solids

AMS-M-3171 Magnesium Alloy, Processes for Pretreatment and Prevention of
Corrosion on
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:
1. AZ31B-O may be formed at a temperature of 500 25F for a maximum cumulative

exposure time of 60 minutes. Stress relief is not required if the material is hot formed
above 325F.
2. AZ31B-H24 may be formed at a temperature of 300 25F for a maximum cumulative
exposure time of 60 minutes. Stress relief is not required if the material is hot formed
above 275F.
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.
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3.5.30 Titanium Sheet Material

General
Limited forming of titanium sheet can be accomplished at room temperature using a variety of standard
fabrication techniques and procedures. For more severe forming operations, titanium material and
tooling require heating to an elevated temperature under closely controlled conditions to facilitate
forming.
BS24058 Fabrication of Parts from Commercially Pure Titanium and

Titanium Alloy 6Al4V, Annealed Sheet
Suppliers performing titanium forming shall be approved for that process by RAC.
Titanium forming shall be accomplished in accordance with RAC engineering drawing
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.
BS25554 Polishing Metal Surfaces (Buffing)

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Polishing operations (buffing) performed by suppliers on metal surfaces shall be in accordance
with BS25554.
Table 1. Typical RAC Specified

Strength Ranges
95-135 ksi
110-140 ksi
125-145 ksi
125-150 ksi
125-155 ksi
150-180 ksi
(See NOTE)
180-210 ksi
220-240 ksi
Spring Temper
Note: Steels heat treated to these strength ranges require low
temperature stress relief prior to plating, and hydrogen
embrittlement relief after plating is required in accordance with
BS25526.
Table 2. Maximum Cross Section Thickness (inches)

to Achieve Specified Heat Treat Range
Material Heat Treat Range
110-140 125-150 150-180 180-210 210 +
4130 Round Bar 2.0 1.0 0.75 0.5 Do Not Use
4130 Sq/Rec Bar 2.0 1.0 0.75 0.5 Do Not Use
4130 Plate 1.5 0.75 0.5 0.5 Do Not Use
4140 All Products N/A 2.5 2.5 1.5 1.0
4340 All Products N/A N/A 2.5 2.5 1.5
Table 3. Minimum Thickness of Nickel Plating if not Specified

Class 1 Nickel Plating (unless otherwise specified)
The minimum thickness for ferrous materials (exterior only) shall be
0.0012 inch
The minimum thickness for ferrous (interior only), zinc, and zinc based
materials shall be 0.001 inch
The minimum thickness for copper and copper alloys shall be 0.0008
inch

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Class 2 Nickel Plating (unless otherwise specified)

The minimum thickness of Class 2 nickel plating shall be 0.003 inch.
The thickness requirement for Class 2 plating shall apply after all
metal finishing and post-plate grinding.
Table 4. RAC Approved Ferrous Materials for

Hot Bending and Forming
Types of Steel Series Examples
Annealed Carbon Steels 10xx
4130
Annealed or Normalized 4140
Low Alloy Steels 4330V
4340
Annealed Stabilized 321
Corrosion-Resistant Steels (CRES) 347
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
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
T3 AMS QQ-A-200/3
T3510
AMS QQ-A-200/3 or or AMS4164
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
Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
Page 55 of 68

AMS QQ-A-200/3 or AMS QQ-A-200/3
T3511
AMS4164 or AMS4165
Table 5. Aluminum Alloy Extruded Wire, Rod, and Shapes Substitution Tables (Contd)
Alloy
Condition Alloy Comments/Limitations
Specification Condition Specification
T3511 AMS QQ-A-200/3 T3511 AMS4165
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.
T8511 AMS QQ-A-200/3 T3511 AMS QQ-A-200/3
AMS2770.
O AMS QQ-A-200/8 O AMS4160
T4
T4 T4510 AMS QQ-A-200/8
AMS QQ-A-200/8
or AMS4161 AMS QQ-A-200/8 or
T4511
AMS4172
T6
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
T4511 T4511
T4511 AMS QQ-A-200/8
AMS2770.
T6510 AMS QQ-A-200/8
AMS QQ-A-200/8 or
T6511
AMS4173
T6511
T6511 AMS4173 AMS QQ-A-200/8
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
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
Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
Page 56 of 68
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
Alloy Alloy Limitations/Comments
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.
T4
T4 T3 or T351 Same as original
Any AMS QQ-A-225/6
T42
or AMS4120
T6
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
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
T351
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.

Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
Page 57 of 68
Table 6. Aluminum Alloy Rolled or Cold Finished Wire, Rod, & Bar Substitution Table (Contd)
T4
T4 AMS QQ-A-225/8
T42
Any or AMS4116
T451 Same as original
T6
T6 AMS QQ-A-225/8
T62 or T651
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
T62
T62 AMS QQ-A-225/8
T6 or T651
or AMS4117 Age Harden to T6 or T62
T4 or T42 AMS QQ-A-225/8
per AMS2770.
T451 T451
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.
T6
T6 AMS QQ-A-225/9
T62
or AMS4124 AMS QQ-A-225/9
T651
or AMS4123
T6
T62 AMS4122 AMS QQ-A-225/9
7075 7075
T651
T651 T651
Any AMS QQ-A-225/9
T73 T7351
T7351
T7351 AMS4124 AMS QQ-A-225/9
AMS QQ-A-225/9 T651 AMS QQ-A-225/9
AMS2770.

Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
Page 58 of 68
Table 7. Aluminum Alloy Bare Plate and Sheet Substitution Table

2024 Bare
T4 AMS QQ-A-250/4 2024 T4 AMS QQ-A-250/4
T-Form
AMS QQ-A-250/4 T3 AMS4037
T3 AMS4037 AMS QQ-A-250/4
T351
T351 T351
2024 2024
AMS QQ-A-250/4
T4 or T42 AMS QQ-A-250/4 T3 or T351
or AMS4037
Age Harden to T81 or T851
T81 AMS QQ-A-250/4 T3 or T351 AMS QQ-A-250/4
per AMS2770.
T851 AMS QQ-A-250/4 T351 AMS QQ-A-250/4
AMS2770.
AMS4025 AMS QQ-A-250/11
AMS QQ-A-250/11 AMS4026
T4 T4
AMS4026 AMS QQ-A-250/11
AMS QQ-A-250/11 AMS4026
T451 T451
AMS4026 AMS QQ-A-250/11
AMS QQ-A-250/11 AMS4027
T6
6061 AMS4027 6061 AMS QQ-A-250/11
AMS QQ-A-250/11
T6 T62 or T651
or AMS4027 AMS QQ-A-250/11 Age Harden to T6 per
T4
or AMS4026 AMS2770.
AMS QQ-A-250/11 AMS4027
T651
T651 AMS4027 AMS QQ-A-250/11
T451
AMS4044 AMS QQ-A-250/12
AMS QQ-A-250/12 AMS4045
T6
T6 AMS4045 AMS QQ-A-250/12
AMS QQ-A-250/12 AMS QQ-A-250/12
T651
7075 AMS QQ-A-250/12 7075 AMS4045
T651 T651
AMS4045 AMS QQ-A-250/12
T73 AMS QQ-A-250/12 T6 or T62 AMS QQ-A-250/12
AMS2770.
AMS QQ-A-250/12 AMS4078
T7351
T7351 AMS4078 AMS QQ-A-250/12
T651

Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
Page 59 of 68
Table 8. Aluminum Alloy Alclad Sheet Substitution Table

2024 Alclad
T4 AMS QQ-A-250/5 2024 T4 AMS4279
T-Form
T3
T3 AMS4041 AMS QQ-A-250/5
AMS QQ-A-250/5 Use when part is listed in
T42 AMS QQ-A-250/5
or AMS4041 BS24765.
2024 2024
AMS QQ-A-250/5
T4 AMS QQ-A-250/5 T3
or AMS4041
AMS QQ-A-250/5
T42 AMS QQ-A-250/5 T3
or AMS4041
T81 AMS QQ-A-250/5 T3
or AMS4041 AMS2770.
AMS4048 AMS QQ-A-250/13
7075 AMS QQ-A-250/13 7075 AMS4049
T6 T6
AMS4049 AMS QQ-A-250/13
T73 AMS QQ-A-250/13 T6
or AMS4049 AMS2770.
Table 9. Aluminum Alloy Drawn Tube Substitution Table

O AMS WW-T-700/3 O AMS4087
AMS4087 AMS WW-T-700/3
2024 2024
AMS WW-T-700/3 AMS4088
T3 T3
O AMS WW-T-700/6 O AMS4080
AMS WW-T-700/6 AMS4082
T6
6061 T6 AMS4082 6061 AMS WW-T-700/6
AMS WW-T-700/6
T62 AMS WW-T-700/6
or AMS4082
AMS WW-T-700/6
T62 AMS WW-T-700/6 T6
or AMS4082
T6 AMS WW-T-700/7 T62 AMS WW-T-700/7
7075 T62 AMS WW-T-700/7 7075 T6 AMS WW-T-700/7
T73 AMS WW-T-700/7 T6 AMS WW-T-700/7
AMS2770.

Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
Page 60 of 68
Table 10. Ferrous Alloy Bar Substitution Table

Conditions Conditions Any of the listed conditions and
MIL-S-6758 A, B, C, D, E, and AMS-S-6758
A, B, C, D, or E finishes may be substituted as
and F long as the substituted material
Finishes and meets the requirements of
AMS-S-6758 Finishes MIL-S-6758
1, 2, 3, 4, or 5 Notes a, c, d, & e.
1, 2, 3, 4, or 5
MIL-S-6758 Condition F AMS-S-6758 Condition F material and any
and finish may be substituted as long
Finishes as the substituted material meets
AMS-S-6758 MIL-S-6758
4130 1, 2, 3, 4, or 5 the requirements of Notes d & e.
Condition F Condition F Condition F material may be
4130 and substituted as long as the
and AMS6346
Finishes Finishes substituted material meets the
1, 2, 3, 4, or 5 1, 2, 3, 4, or 5 requirements of Notes d & e.
MIL-S-6758 or AMS-
S-6758 Conditions Any of the listed conditions and
A, B, C, D, or E finishes may be substituted as
MIL-S-6758 or
and long as the substituted material
AMS-S-6758
Finishes meets the requirements of
1, 2, 3, 4, or 5 Notes b, d, & e.
When used in the manufacture of
MIL-S-6758 or AMS- 4130 Bushings ONLY.
Any S-6758
Condition N AMS-T-6738
Substituted material shall meet
(Tube)
the requirements of Note f.
AMS6415 AMS-S-5000
4340 Any 4340 Same as original
AMS-S-5000 AMS6415
301 AMS5901
ASTM A276
AMS-S-7720 or 304 AMS5513
A Same as original
ASTM A276 ASTM A276
AMS5507
316
ASTM A276
302 301 Hard AMS5517 Plate sawed to bar dimensions.
Same as Original ASTM A276
AMS-S-7720 or 304 Hard AMS5910
B
ASTM A276 Same as Original ASTM A276
Hard AMS5907
316
Annealed Any 304 Annealed ASTM A276
MIL-S-7720 or
303 A AMS-S-7720
303 A ASTM-A-582
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
AMS-S-7720 or Hard AMS5903
304 B ASTM A276
302 Plate sawed to bar dimensions.
Hard AMS5907
316

Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
Page 61 of 68
Table 10. Ferrous Alloy Bar Substitution Table

304 Annealed AMS QQ-S-763 304 Annealed AMS5639
304L Annealed AMS QQ-S-763 304L Annealed ASM5647
Annealed 321 Annealed AMS5645
321 AMS QQ-S-763
Any 347 Same as Original AMS QQ-S-763
347 Any AMS QQ-S-763 321 Same as Original AMS QQ-S-763
Note a: Substituted material shall be heat treated to the requirements of the applicable RAC Engineering drawing in accordance
with AMS2759.
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
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

Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
Page 62 of 68
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
1/4 H 1/4 H
301 304
or AMS5910
MIL-S-5059
302
1/2 H 1/2 H
304
or AMS5911
MIL-S-5059
302
Full Full
304
or AMS5913
MIL-S-5059 302 AMS5516
AMS5516 MIL-S-5059
301
304
or AMS5513
MIL-S-5059
301
1/4 H 1/4 H
302 304
or AMS5910
MIL-S-5059
301
1/2 H 1/2 H
304
or AMS5911
MIL-S-5059
301
Full Full
304
or AMS5913
MIL-S-5059 304 AMS5513
AMS5513 MIL-S-5059
301
302
or AMS5516
MIL-S-5059
301
1/4 H 1/4 H
304 302
or AMS5903
MIL-S-5059
301
1/2 H 1/2 H
302
or AMS5904
MIL-S-5059
301
Full Full
302
or AMS5906

Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
Page 63 of 68
MIL-S-6721 321 AMS5510
AMS5510 MIL-S-6721
321 Annealed Annealed
MIL-S-6721 MIL-S-6721
347
MIL-S-6721 347 AMS5512
AMS5512 MIL-S-6721
347 Annealed Annealed
MIL-S-6721 MIL-S-6721
321
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.
Note b: Substituted material shall be annealed in accordance with AMS2759.
Table 12. Ferrous Alloy Tube Substitution Table

AMS-T-6736 AMS6371
4130 Condition N 4130 Condition N
AMS6371 AMS-T-6736
MIL-T-8808 Type 1 Same as
321 ANY 347 MIL-T-8808 Type 1 or
MIL-T-86066 original
Same as
347 Any MIL-T-8808 Type 1 321 MIL-T-8808 Type 1
Original
Table 13. Copper & Bronze Alloy Casting Substitution Table

Casting, Temper, Casting, Temper,
Applicable Applicable
Alloy & Condition Alloy & Condition Limitations/Comments
Specification Specification
(See Note a) (See Note a)
ASTM B271
MS299
SAE 64 Any
or Any
C93700 Same as original or
ASTM B505
ASTM B271
MS299
SAE 660 Any
or Any
C93200 Same as original or
ASTM B505

Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
Page 64 of 68
Table 13. Copper & Bronze Alloy Casting Substitution Table

Casting, Temper, Casting, Temper,
Applicable Applicable
Alloy & Condition Alloy & Condition Limitations/Comments
Specification Specification
(See Note a) (See Note a)
Type I Casting Type I, II, or III ASTM B148 (Type I), Heat Treated C95300,
As Cast condition Casting ASTM B271 (Type II), C95400, C95410, or
Type II Casting As Cast condition or C95500 Type I, II, or III
As Cast condition ASTM B505 (Type III) castings may be substituted
C95300, for any As Cast condition
C95300 Type III Casting
C95400,
Type III Casting
C95300 Type I, II, or III
ASTM B505 (Type III)
(May also be As Cast condition QQ-C-390 As Cast condition
C95410, castings.
listed as or Any
Type I Casting or Heat Treated C95400,
C953 or 953)
Heat Treated C95500 ASTM B148 (Type I), C95410, or C95500 Type I,
Type I, II, or III
Type II Casting ASTM B271 (Type II), II, or III castings may be
Casting
Heat Treated or substituted for any Heat
Heat Treated
Type III Casting ASTM B505 (Type III) Treated C95300 Type I, II,
Heat Treated or III castings.
Type I Casting Type I, II or III ASTM B148 (Type I), Heat Treated C95400,
As Cast condition Casting ASTM B271 (Type II), C95410, or C95500 Type I,
Type II Casting As Cast condition or II, or III castings may be
C95400 As Cast condition ASTM B505 (Type III) substituted for any As Cast
condition C95400 or
(May also be Type III Casting C95400, Type III Casting
ASTM B505 (Type III) C95410 Type I, II, or III
listed as A Cast condition QQ-C-390 C95410, As Cast condition
castings.
C954 or 954) or Any or
Type I Casting C95500 ASTM B148 (Type I),
Type I, II or III Heat Treated C95500 Type
Heat Treated ASTM B271 (Type II),
or C95410 Casting
or
I, II, or III castings may be
Type II Casting Heat Treated substituted for any Heat
Heat Treated ASTM B505 (Type III)
Treated C95400 or C95410
Type III Casting Type III Casting
ASTM B505 (Type III) Type I, II, or III castings.
Heat Treated Heat Treated
Type I Casting Type I, II or III ASTM B148 (Type I), Heat Treated C95500 Type
As Cast condition Casting ASTM B271 (Type II), I, II, or III castings may be
Type II Casting As Cast condition or substituted for any As Cast
As Cast condition ASTM B505 (Type III) condition C95500 Type I, II,
C95500 Type III Casting Type III Casting or III castings.
ASTM B505 (Type III) (See Notes b & c)
(May also be As Cast condition QQ-C-390 As Cast condition
C95500
listed as Type I Casting or Any
C955 or 955) Heat Treated ASTM B148 (Type I),
Type I, II or III
Type II Casting ASTM B271 (Type II),
Casting
Heat Treated or
Heat Treated
Type III Casting ASTM B505 (Type III)
Heat Treated
Note a: Type I castings identify Static castings, Type II castings identify Centrifugal castings, and Type III castings identify Continuous
castings.
Note b: Heat treated C95400 & C95410 Type I or II castings may also be substituted for any As Cast condition C95500 Type I or II castings.
Note c: Heat treated C95400 & C95410 Type III castings may also be substituted for any As Cast condition C95500 Type III casting.

Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
Page 65 of 68
Table 14. Aluminum Minimum(Min) Bend Radii

(at Room Temperature)
Material Material
Thickness
1100-O 2014-O 2024-W 2219-T81 2024-T3 2014-T6 2219-T851 2024 T-
2219-O 2024-O 2219-T3 6061-T6 2024-T4 2024-T361 2219-T87 Form
3003-O 2524T3 2219-T31 6063-T6 7075-T6 (AMS 4279A
5052-O 3003-H14 2219-T37 7075-T73 &
5052-H32 5052-H34 7075-W 7075-T76 AMS 4297)
6061-O 6061-T4 7178-T6
7075-O
7178-O
Min Min Min Min Min Min Min Min
.012 .03 .03 .03 .06 .06 .09 .25
.016 .03 .03 .03 .06 .09 .09 .25
NA
.020 .03 .03 .03 .06 .09 .09 .25
.025 .03 .06 .06 .09 .12 .12 .31
.032 .03 .06 .06 .12 .12 .16 .44 .06
.040 .06 .06 .09 .16 .16 .20 .56 .08
.050 .06 .09 .12 .20 .20 .25 .63 .10
.063 .06 .12 .16 .25 .25 .31 .63 .13
.071 .09 .12 .16 .28 .31 .38 .75 NA
.080 .09 .16 .20 .31 .38 .44 .88 .16
.090 .09 .20 .25 .38 .38 .50 1.12 NA
.100 .12 .25 .31 .44 .44 .63 1.25 .20
.125 .12 .25 .50 .56 .63 .88 .25
.160 .16 .38 .63 .75 .81 1.12
NA
.190 .20 .50 .75 .88 1.00 1.25 NA
.250 .31 .75 1.00 1.16 1.25 1.50

Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
Page 66 of 68
Table 15. Copper Recommended(Rec) and Minimum(Min) Bend Radii

(at Room Temperature)
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
Stress Stress
C64200 relieved
AMS 4631 4130
Relieved
AMS 4634

Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
Page 67 of 68
4. QUALITY ASSURANCE PROVISIONS
4.1 RAC Supply Chain Management Responsibilities and Requirements

RAC Supply Chain Management shall be responsible for the following:
Ensuring that all RAC Suppliers and Outside Manufacturers have in their possession the most
recent revision of this Specification.
Ensuring that the latest revision of all applicable RAC documents (i.e. RAC Engineering drawings,
RAC Specifications, etc.) that are required by the RAC Supplier and Outside Manufacturer are
provided to them.
The fielding of all questions from suppliers and outside manufacturers and seeing that these
questions are given to the applicable parties for disposition (i.e. RAC Engineering, RAC Quality
Control, etc.).
4.2 RAC Engineering Requirements
Procedures and processes not authorized by this specification shall not be performed without written
authorization from RAC Engineering.

Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
Page 68 of 68
4.3 Direct Purchase Program for Castings and Forgings

Direct Purchase
Castings that have x-ray requirements and are bought directly by the procuring machine shops
must have the required documentation. For x-ray quality castings, if the casting house is
approved by RAC for the process of handling the inspection and retention of x-ray film, x-ray
castings may be shipped directly to the procuring machine shop. RAC internal Work Instructions
04-04-014 will be provided as a reference for the x-ray casting houses, as requested. The x-ray
casting house must be on the Special Process Supplier Approved supplier list with code XRI.
The approved Special Process Supplier list can be found on the RAYTHEON AIRCRAFT
COMPANY website: http://www.raytheonaircraft.com/about_us/scm_quality_assurance.shtml
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.
4.4 Engineering Clarification of RAC Controlled Metallic Hardware Parts

Metallic hardware parts controlled by RAC engineering shall meet the following criteria.
Industry Standard Certification is acceptable for parts which RAC has substituted the RAC
P/N in place of the Industry standard. (This is only true when no additional machine
operations or extra levels of NDI were completed on the parts).
RAC Standards like 130909s that have the additional magnetic particle inspection
requirement that shall be performed by an RAC approved laboratory.
RAC Standard parts that take an industry standard product and machine it for RAC
application shall have all subsequent special processing and required Nondestructive
Testing be performed by RAC approved suppliers).
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.
5. PREPARATION FOR DELIVERY

Preparation for delivery and delivery shall be in accordance with instructions provided by RAC.
6. NOTES
Not Applicable
Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
APPENDIX A
Page 1 of 2
APPENDIX A
Request for Raw Material Modification Form Number: DOC183938
Date: Company: Part
PO# Raytheon Internal Order # Qty.
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 Required (Material Code Description):
Narrative Description of Material Recommended for Substitute (Alloy, Heat Treat Condition,
Dimensional Configuration, etc.):
Amount of Material to be Modified:
Specification Certification for the Substitute Material:
Reason for Substitution:
Modification Required:
Who will Perform the Modification:
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
Approval, Disapproval, Comments:
********************************************************************************************
2. This Section to be Completed by RAC Manufacturing Engineering
Approval, Disapproval, Comments:

Issued 01/99 DOC141941 R01
Rev 08/02
BS25691 Rev 8
APPENDIX A
Page 2 of 2
Request for Raw Material Modification Form Number: DOC183938

RAC Internal Form number
Date: XX/XX/200X Company: XYZ Part Number: XX-XXX-XXXXXX-XXX

(Date of Request) (Company requesting the material
modification request)
PO# Raytheon Internal Order # Qty.
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 Required (Material Code Description):
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.
Amount of Material to be Modified:

The amount of material that is going to be modified. For example: 125 feet, or 35 sheets.
Specification Certification for the Substitute Material:

Material Specification for the substitute material. For example: QQ-A-250/5
Reason for Substitution:

For example: Shortage of material from supplier, or material (alloy) no longer available.
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.
Who will Perform the Modification:

For example: Ground by Company XYZ. Heat treated by Company ABC
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.

Issued 01/99 DOC141941 R01
Rev 08/02

Raytheon - Control of Product Manufacturing Processes For Suppliers and Outside Production

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Printed copies of this document should be re-validated or destroyed 14 days from Friday, 04 November 2005 in accordance with EPP070.

RLSD NOV 04 2005

Raytheon Aircraft Company

CAGE Code 70898

Mar. 27, 2003

Written by: Steven Schmitter

Approved: Michael Granite Approved: Doug Oliver (John Ewing for)

Approved: Larry Young Approved: Joe Garst

Approved: Greg Lovendahl Approved:

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Section 2.3 corrected title to MS299 was:

Included reference to new Sub-section 4.3

Removed sub-bullet 6 under bullet 5 in Sub-

Added the following new Sub-sections to

Added bullet to 3.5.6 to add primer for exterior

Added SAE Aerospace Material Specifications,

Added 303 Alloy to Table 10.

Created Table 16 and added substitution of

Added the word Casting to table 13 title.

Revised applicability note in section 1.2,

Added BS253303 to applicable documents table

Revision History ...................................................................................................................................................................... 2

3.5.22 Manganese Phosphate Coating (Anti-Seize). .................................................................................................... 44

Figure 1. Edge Chamfer and Radius Limitations ................................................................................................................. 19

Table 1. Typical RAC Specified Strength Ranges ............................................................................................................... 53

Table 14. Aluminum Minimum(Min) Bend Radii (at Room Temperature)............................................................................ 65

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AMS Aerospace Material Specification MRS Minimum Residual Stress

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American National Standards Institute (ANSI)

Aerospace Material Specification (AMS) by Society of Automotive Engineers (SAE)

Aerospace Material Specification (AMS) by Society of Automotive Engineers (SAE)

Aerospace Material Specification (AMS) by Society of Automotive Engineers (SAE)

Aerospace Material Specification (AMS) by Society of Automotive Engineers (SAE)

American Society for Testing and Materials (ASTM)

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2.3 Raytheon Aircraft Company

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1. Aluminum and Copper Alloy Material

2. Carbon Ferrous Alloy Material

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3. Corrosion Resistant Steel Ferrous Alloys

c. Special Requirement for 4130 Steel Bar Stock

3.2.1 Aluminum Alloys and Other Nonferrous Alloys.

3.3.1 Non-Ferrous Sheet Material

3.4.1 Sheet Metal Edge Conditions

Radius Minimum: R = 0.003 inch.

Chamfer Minimum: X = 0.002 inch.

Chamfer Minimum: X = 0.002 inch.

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Chamfer Minimum: X = 0.007

Figure 1. Edge Chamfer and Radius Limitations

3.4.2 Machined Part Edge Conditions

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3.5.1 Abrasive Blasting

Applicable and Associated Documents

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Minimum Excess: 1/4 inch

Allow 1/4 inch excess on all edges that do not mill.

3.5.4.1 Chemical Milling of Aluminum

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3.5.4.2 Chemical Milling of Steel