Government of India Department of Space

ISRO SATELLITE CENTRE BANGALORE – 560 017

Phone: +91-080-2508 4370, Fax: +91-080-2520 5283 / 84

Ref No: ISAC/PUR/Group F/01 16.05.2016

FASTENERS

INVITATION FOR “EXPRESSION OF INTEREST”

ISRO Satellite Centre [ISAC] of Indian Space Research Organisation [ISRO] under Department of Space, Government of India is the lead centre of ISRO for Design, Development, Fabrication and Testing of all Indian made satellites. As a sequel to its mandate of spacecraft realisation, the Centre is engaged in the development of cutting-edge technologies of relevance to its satellite building activities and setting up of infrastructure for Design, Development, Fabrication and Testing of Spacecraft.

The proposal is to invite Expression of Interest to enter into Rate Contract for supply of Fasteners to ISAC. The important factors for supply of Fasteners [i.e. Titanium Fasteners, Stainless Fasteners, Stainless Steel Wire Thread Insert form an integral part of the Satellite]. Brief Specification is available in the website www.isro.gov.in under ‘Tenders’. Interested Vendors having sufficient know-how, experience and financial background are invited to express their interest to Supply the Fasteners to ISAC, Bangalore. Along with “Expression of Interest” please furnish the following information also in detail: 1 Registered address with Phone, Fax,

Email, Web etc. 8 Capital and Turnover for last Three

years with copy of latest Annual Report

2 Company Status (Proprietary / Partnership / Private Ltd. Etc.) with Name and Address of Proprietor, Partners, Board of Directors etc.

9 Financial Capacity / Credit facilities available

3 Associates : (a) Indian (b) Foreign 10 Name and Address of Bankers 4 List of Major Customers with full

address and their Contact Persons 11 Trade Association to which you

belong to 5 Details of other Contracts, if any now

in hand 12 Establishment / Sales / Service Tax

Registration Number 6 Details of Infrastructure Facilities

owned / available 13 Nature of Business

7 A brief process involved in supply of Fasteners

14 Any other information you consider relevant

Pre-bid Meeting for Expression of Interest: A Pre-bid meeting for Expression of Interest is arranged by ISRO Satellite Centre, Bangalore in order to have a better understanding of our Invitation to EOI document, clarify doubts if any, and other allied technical details of the Fasteners.

Contd... 2/-

: 2 :

The interested Vendor[s] are hereby requested to take part in the Pre-bid meeting for Expression of Interest on the Date, Time and Venue mentioned here below:- Date of Pre-bid Meeting for Expression of Interest : 15th June, 2016 Time : 10.00 Hours IST Focal Point & Venue of Pre-bid Meeting : Shri. P K Poddar for Expression of Interest Project Manager, AIT [M]

Systems Integration Group ISRO Satellite Centre, HAL Airport Road, Vimanapura Post, Bangalore – 560 017. Contact No. 080 25375067 E-mail: poddar@isac.gov.in

Last date for submission of EOI : 07th July, 2016 at 14.00 Hours IST Opening date of EOI : 07th July, 2016 at 15.00 Hours IST Interested Vendor[s] may please provide the details of the representative[s] taking part in the Pre-Bid meeting for Expression of Interest well in advance in order to arrange for Security clearance. Please note that request for “preponement/postponement of Pre-Bid meeting for Expression of Interest” will not be entertained under any circumstances. The Tenderers who do not participate in the Pre-Bid Meeting for Expression of Interest will not be considered and shall be disqualified. In the event if the Vendor(s) are unable to attend the Pre-Bid Meeting for Expression of Interest physically, a Pre-Bid Meeting for Expression of Interest through Video Conference / Skype / Conference Call shall be arranged by ISRO Satellite Centre, Bangalore upon the request from Vendor(s). Data required for Security Clearance:

1. Name of the visitor: 2. Nationality: 3. Date of Birth: 4. Place of Birth: 5. Gender: 6. Passport Number, Validity, Date and Place of Issue [Photocopy of Passport is to be attached]: 7. Business Visa Number and validity [Photocopy of Business Visa is to be attached]: 8. Occupation: 9. Name and Address of Organization/Company:

“Expression of Interest” with all the above information shall reach the undersigned, Quoting above Reference Number on or before July 7, 2016. This proposal is initiated as a Pre-Bid Qualification. ISAC reserves the right to accept or reject all or any such “Expression of Interest”; without assigning any reasons what so ever.

Sd/- HEAD, PURCHASE & STORES

Expression of Interest

Description FASTENERS Quantity: REFER AS PER LIST.

EXPRESSION OF INTEREST(EOI) FOR FASTENER PROCUREMENT

1. Introduction and Scope

ISRO Satellite Center (ISAC), having established itself as an operational space service provider to the nation has also attained self-reliance in the strategic area of remote sensing satellite and communication satellites.

Titanium and Stainless Steel fasteners form an integral part of the sa te l l i te . With the increased sa te l l i te requirements projected in the next five year plan, it is required to enter into long term contract under prime minister's "Make in India" banner with the prospective indigenous fastener manufacturers to have just in time supply of fasteners for the space program.

The scope of this EOI is to enter into Rate Contract for manufacture and supply of Titanium fasteners in heat treated / anodized condition, Stainless Steel fasteners in passivated condition and Stainless Steel wire thread inserts conforming to the ISAC specifications as follows:

1) Titanium fasteners specification as attached- Annexure1 2) Stainless Steel Fastener specification as attached- Annexure2 3) Stainless Steel Wire thread insert specification as attached- Annexure3 4) Tentative yearly requirement of fastener- Annexure4 5) Pre bid evaluation questioner - Annexure 5

2. Manufacture of Fasteners Detailed process and QC plan shall be submitted to ISAC and approval to be obtained from ISAC before the manufacture of the fasteners. The processes used must be standard and part of Annexure-1, 2 and 3. Any new process or change in processes should be discussed and shall be approved by ISAC. Following are the major details regarding manufacturing which requires to be addressed by vendors. Other detail will be provided/ discussed as and when required. If some of the following details do not fit into the manufacturing process (applicable mainly for wire thread insert) of particular item the same may be provided with justification note. 2.1. Raw Material

Raw material shall be procured confirming to the specification requirement. Certificates pertaining to chemical, mechanical, gas level checks, micro, macro and 100% UT as per AMS 2630/ AMS 2631/ AMS 2632 with the acceptance class-A1 has to be obtained from the material supplier and needs to be produced for ISAC clearance. Also confirmatory checks after the receipt of the material for chemical, mechanical including heat treated samples and gas level checks shall be carried out and all inspection reports shall be provided and clearance to be obtained from ISAC before taking up the actual production. All testing to be done in NABL approved labs.

Given below detail applicable only for wire thread insert Raw material (stainless steel wire with round cross-section) shall be procured confirming to the specification requirement. Material Test Certificates from the Raw Material supplier supported by Material Test certificates showing Chemical and Physical properties will be obtained.

2.2. Heat Treatment The headed forged blanks shall be heat treated using applicable heat treatment cycle as per the material specifications to achieve the minimum tensile strength requirements as specified in the standard part drawing. Before heat treatment, calibration of the furnace, thermocouples and controllers shall be ensured as per the calibration procedures approved by AMS 2750D and ISAC. All heat treatment to be carried out in NADCAP approved facility for titanium heat treatment. May not be applicable for wire thread insert

2.3. Fillet and Thread Rolling After heat treatment, the shank and bearing surface of the head of the blanks may be wet ground such that the amount of metal removal shall be minimum and grain flow around the under head is maintained. The head to shank fillet radius shall be cold rolled. The fillet radius profile shall be smooth and blend into the other surfaces. The dies for thread rolling shall be qualified dimensionally for thread profile prior to starting production. Qualification of a trial batch of fasteners shall be done prior to starting production of fasteners with a new thread size. Threads shall be formed by one single rolling process after final heat treatment. Machined threads shall not be permitted. Any attempt to increase the length of an existing thread by either rolling or machining shall be unacceptable. Given below detail applicable only for wire thread insert

Wire drawing – Stainless Steel Wires of round cross-section are formed to achieve the required diamond-shaped cross-section by passing through wire drawing rollers on the wire drawing machine. Coiling - The formed wire thus achieved is coiled on the Coiling Machines to produce Screw Thread Inserts of different sizes. Tail cutting – The extra length of the tail at the end of the insert is sheared off using the tail-cutting tool on the tail-cutting machine. Notching – A V-shaped notch is provided on the wire (on the side with the tang) on the Notching Machine Barreling – Finished screw thread inserts are finally washed with detergent in the Barreling Machine to remove oil and dirt residues.

2.4. Surface Treatment Finished fasteners shall be surface treated as required by the specification. All surface treatment shall be done in a NADCAP certified facility for the specific process. May not be applicable for wire thread insert

2.5. Wire thread insert winding

Detail process along with standard to be provided.

3. Identification and Packaging The identification of the fasteners of size M8 and above shall be marked, on the upper face or side of the head with depressed characters of rounded root form and not greater than 0.25 mm in depth. Property class and manufacturer shall be indicated in the identification. For fasteners of size below M8 and wire thread inserts shall be identified with full identification detail and tags as a batch. The bolts/screws/wire thread inserts shall be packed in such a way so as to prevent any damage or corrosion occurring in the course of handling, transportation and storage. Each batch/lot shall be packed in sealed polythene bag/containers in order to avoid moisture and corrosion. Fasteners of size M8 and above shall be covered with plastic sheath to avoid thread damage. Each individual package of fasteners shall be provided with outside marking ensuring traceability.

Given below detail applicable only for wire thread insert Screw Thread Inserts are packed in plastic pouches with packing labels mentioning size, part no., quantity and Lot No. The packets are subsequently packed in carton boxes during despatch in such a way so as to prevent any damage in the course of handling, transportation and storage.

4. Quality System and Inspection of Fasteners The manufacturer shall have all the major facilities required for inspection and testing of the fasteners. Any subcontracting of inspection if resorted to shall be after thorough evaluation of the party’s capability and approval by ISAC. Inspection, quality control and testing at the subcontractor’s end shall be carried out by the manufacturer or independent reputed third party agencies under the responsibility of the manufacturer. The manufacturer shall have an independent inspection and quality control system within the company. All measuring instruments shall be calibrated periodically. The manufacturer of fastener shall certify the compliance with QA requirements specified by ISAC as per Annexure 1,2 and 3. All processing and testing stages as per Process cum QC plan will be witnessed by ISAC at their discretion. After completing all the inspection requirements as specified in the specification document, fasteners shall be offered by the party for pre-dispatch inspection and clearance by ISAC team. Additional confirmatory mechanical tests on 3 nos. per batch and visual from each batch of fasteners on random sampling basis shall be done before final clearance of the items.

Given below detail applicable only for wire thread insert Screw Thread Inserts to be subjected to stringent quality checks both during in-process and final inspection. Parameters like free outer diameter, number of turns, to be periodically checked during in-process inspection. Inserts to be installed in gauge compliant aluminium test blocks and to be checked for fitment using Go-NoGo Thread Plug Gauge. Outside micrometers, thread plug gauges used during inspection to be calibrated from NABL certified laboratories. The insert

to be checked for locking torque properties after installation.

5. Delivery Terms Fasteners shall be delivered within 6 months from the date of release of individual work orders or supply orders. Fasteners after pre-dispatch inspection and clearance shall be delivered to ISAC.

6. Guarantee

Quality of the products is to be strictly maintained. The items supplied shall be guaranteed for a period of shelf life (defined by manufacturer) from the date of receipt of material at the Purchaser’s stores and the defective items shall be replaced during the guarantee period free of cost. Items supplied shall be stored in a secured location at the buyers end to protect parts from environment corrosion, handling damages and contamination by foreign objects.

7. Evaluation Questioner

Data sheet containing pre bid evaluation questioner as given in Annexure 5 to be filled and submitted by all Indian manufactures along with EOI

8. Additional Information Vendor may provide additional information if any for review and consideration.

9. Vendor Selection and Rate Contract Procedure Followings are the nominal steps will be followed for selection/short listing vendors

1. Publication of EOI in all Indian leading news paper by ISAC. 2. Pre bid Presentation by ISAC. 3. Submission of filled EOI to ISAC by interested Indian manufacturers. 4. Evaluation of all EOI received from various Indian manufacturers. 5. Short listing potential/probable Indian manufacturers for interview. 6. Short listing potential/probable Indian manufacturers for site inspection. 7. Site/factory inspection, verification of information provided, review of facility etc by ISAC team. 8. Short listing potential/probable Indian manufacturers for considering rate contract. 9. Rate contract proposal from short listed Indian manufacturer through purchase procedure. 10. Submission of technical bid and price bid by Indian manufacturers. 11. Finalization of rates of individual items with all Indian manufactures.

ISRO SPECIFICATION DOCUMENT FOR TITANIUM ALLOY Ti6Al4V

BOLTS AND SCREWS

Contents

Section 1 Scope

Section 2 Applicable & Reference documents

Section 3 Manufacture

Section 4 Dimensional and Metallurgical requirements

Section 5 Mechanical Testing

Section 6 Quality Assurance

Section 7 Quality Requirement Plan

Annexure Specific requirements to be included for procurement of Titanium fasteners

Section 1

Scope

This document specifies the requirements for the manufacturing, inspection and quality control of aerospace quality bolts and screws manufactured from Ti6Al4V alloy. This specification is not meant for use of fasteners for high temperature applications.

Section 2 Applicable & Reference Documents

The following standards form a part of this specification to the extent specified herein (latest version of the standards on date shall be applicable) 2.1 Aerospace Material Specifications

AMS 2427 Aluminium Coating - Ion Vapour Deposition

AMS 2474 Chemical Film treatment for Aluminium Alloys

AMS 2488 Anodic Treatment of Titanium and Titanium Alloys

AMS 2750 Pyrometry

AMS 3084 Lubricant, Solid Film- Minimal Out gassing

AMS 4928 Titanium Alloy, Bars, Wire, Forgings and Rings, 6Al-4V Annealed

AMS 4965 Titanium Alloy, Bars, Wire, Forgings and Rings, Solution heat treated and Aged

AMS 4967 Titanium Alloy Bars, Forgings and Rings, 6Al-4V, Annealed, Heat Treatable

AMS 2630 Inspection, Ultrasonic Product Over 0.5 Inch (12.7 mm) Thick AMS 2632 Inspection, Ultrasonic, of Thin Materials 0.50 Inch (12.7 mm) and Under in Cross-

Sectional Thickness 2.2 NFL standards

NF L05-220 ISO Metric thread profile

NF L05-224 ISO Metric thread tolerances

2.3 National Aerospace Standards

NASM 1312 Military Standard, Fasteners, Test Methods

NASM 1312-8 Fastener Test Methods, Method 8, TensionTest

NASM 1312-13 Fastener Test Methods, Method 13, Double shear test

2.4 ASTM standards

ASTM B 600 De scaling and Cleaning Titanium and Titanium Alloy Surfaces

ASTM E 8M Tension Testing of Metallic Materials

ASTM E 120 Chemical Analysis of Titanium and Titanium base alloys

ASTM E 340 Standard Test Method for Macro etching Metals and Alloys

ASTM E 407 Standard Test Practice for Micro etching Metals and Alloys

ASTM E 1417 Standard practice for Liquid Penetrant Examination

ASTM E 1447 Standard Test Method for determination of Hydrogen in Titanium

ASTM F 606M Standard Test Methods for determining the Mechanical properties of externally and internally threaded fasteners, washers and rivets.

2.5 ISO standards

ISO 1502 ISO general - purpose metric screw threads - Gauges and gauging

ISO 2859/1 Sampling plan indexed by AQL for lot-by-lot inspection

ISO 3353 Aerospace - Lead and run out threads - Part1: Rolled external threads.

ISO 4759 – 1 Tolerances for fasteners - Part 1: Bolts, screws, studs & nuts - Product grades A, B & C

ISO 6157/3 Fasteners - surface discontinuities - Part 3 : Bolts, screws & studs for special requirements.

ISO 8080 Aerospace – Anodic treatment of titanium and titanium alloys – Sulfuric acid process

2.6 MIL standards

MIL PRF 46010 LUBRICANT, SOLID FILM, HEAT CURED, CORROSION INHIBITING

2.7 Reference documents:

1) BS A.101:1969 - General requirements for Titanium Bolts

2) ESA PSS-01-746 Issue 1 - General requirements for threaded fasteners

3) ECSS-Q-70-46A - Requirements for manufacturing & procurement of threaded fasteners

4) SAE AS 7461 - Procurement specification for Bolts and Screws, Titanium Alloy, 6Al 4V

5) NAS 4004 - Fastener, 6Al-4V Titanium Alloy Externally Threaded

6) VSSC/SR/QDMF/GEN/183/2006 - Specification document for Bolts and Screws

7) MSFC-STD-557 - Threaded fasteners, 6Al-4V Titanium Alloy, usage criteria for space

applications

Section 3

Manufacture

3.1 Raw Material

3.1.1 The wires / rods used for the manufacture of fasteners shall be Titanium alloy (Ti6Al4V)

Conforming to AMS 4967.

3.1.2 Chemical composition: determined either by wet chemical methods in accordance with

ASTM E120, by spectrographic methods or by other approved analytical methods shall

Conform to the following. (Spec given as per AMS 4967)

Element Composition (% by weight)

Minimum Maximum

Aluminium 5.50 6.75

Vanadium 3.50 4.50

Iron - 0.30

Carbon - 0.08

Oxygen - 0.20 (2000ppm)

Nitrogen - 0.050 (500ppm)

Hydrogen - 0.0125 (125ppm)

Residual Elements, each - 0.10

Residual Elements, Total - 0.40

Titanium Remainder

Note: 1. Oxygen and hydrogen content shall be controlled at raw material stage so as to meet the above requirements in the product. 2. For products supplied in STA condition (1100 MPa class), the Oxygen content shall be closer to 2000 ppm, so as to meet the specified mechanical properties.

3.1.3 All the rods / wires shall be subjected to normal beam ultrasonic inspection, as per AMS 2630/ AMS 2632, either by contact or immersion technique. Alternatively, ultrasonic inspection may be carried out at a suitable intermediate stage.

3.1.4 The raw material shall conform to ultrasonic class A1. Discontinuities shall not exceed the values given below:

Single discontinuity Multiple discontinuities Linear discontinuity, max.

ф 1.2mm,max ф 0.8mm,max. ф 0.8mm response for 25mm length 3.1.5 Confirmatory check requirements

Party shall identify each coil size, heat number and batch number with manufacturer’s identification tag and correlate with raw material test certificates.

As a confirmatory check one sample coupon from beginning of each coil or one rod per heat from each size shall be taken and tested for

(a) Chemical including gas content (b) Microstructure analysis

3.2 Head forming

3.2.1 The heads of bolt/screws shall be formed by hot or warm forging before heat treatment. The sockets on heads or driving recesses may be machined or forged. Temperature during hot or warm forging shall not exceed 950 °C.

3.2.2 The heating equipment for hot forging shall be approved by ISRO inspection authority and shall be of a type which ensures a consistent temperature throughout the batch of that part of the material being worked. The temperature shall be automatically controlled.

3.3 Cleaning

3.3.1 Blanks shall be cleaned prior to heat treatment in accordance with ASTM B 600.

3.3.2 Blank surfaces shall be free of halogen compounds, such as residue from halogenated solvents, coolants etc and salt from sweaty hands.

3.3.3 Surfaces of parts, fixtures, racks, etc. shall be clean and free of dirt, water, oil, grease, paints, crayon markings, ink, dyes, finger prints and other foreign materials.

3.3.4 After cleaning and prior to heat treatment the blanks shall be handled with white cotton gloves or equivalent.

3.4 Heat Treatment

3.4.1 Headed blanks after cleaning as per Sec. 3.3, shall be heat treated, before finishing the shank and bearing surface of the head, cold working the head-to-shank fillet radius and rolling the threads.

3.4.2 Forged blanks belonging to the same type and diameter, forged from material of the same heat / lot and produced as one continuous run, shall preferably be heat treated in one batch.

3.4.3 Heat treatment shall be carried out in a calibrated electrically heated furnace, ensuring uniform temperature throughout the blanks and shall be equipped with, and operated by, automatic temperature controllers and data recorders conforming to AMS 2750 Class III. Vacuum or inert gas environment shall be employed when removal of surface contamination is not feasible by subsequent operations.

3.4.4 Heat treatment cycle:

Property Class Heat Treatment Details

900 Mpa Annealing

Temperature : 730 ± 10 °C Soaking time : 2 hours Cooling media : Furnace cool up to 565°C and then cool in air.

1100 Mpa

Solution heat treatment

Temperature : 955 ± 10 °C Soaking time : 1 hour Cooling media : Water quench Quench delay : < 8 seconds

Precipitation treatment Temperature : 538 ± 8 °C Soaking time : 6 hours Cooling media : Air cool

3.4.5 Heat treatment Stage Qualification

3.4.5.1 Three test samples shall be heat treated along with each heat treatment batch of bolt/screw blanks. The test samples shall be from material of the same cast and nominal diameter used to manufacture the bolt/screw blanks.

3.4.5.2 Tensile properties evaluated from the heat treated test samples shall meet the respective property requirements, specified in Section 3.5.

3.4.5.3 If one of the heat treated specimens fail to meet the mechanical properties, two specimens, originally heat treated along with the charge shall be re-tested. If the failure is attributed to specimen preparation or testing issues, such samples shall be replaced with another one. During re-testing all specimens shall meet the property requirements. If any of the specimens fail to meet the requirements during re-test, the lot shall be rejected.

3.4.5.4 Retesting is not allowed if more than one specimen fail to meet the property requirements during the first test. In such cases, the manufacturer shall analyze the cause of failure and may re-heat treat the lot on metallurgical evidence that the cause of failure is curable. In such cases, detailed reports regarding the initial test, failure analysis, re-heat treatment etc. shall be submitted to ISRO.

3.4.5.5 Re-heat treatment of a batch is permitted only once.

3.5 Tensile Property requirements

Property Class

Nominal thickness

UTS, Mpa (min)

0.2% YS, Mpa,(min)

%El (min) (GL=50mm / 4D)

% Reduction of area (min)

900 Mpa ≤ 25mm 900 825 10 25 1100MPa 1100 1030 10 20

3.6 Contamination Removal

3.6.1 The heat treated blanks, before cold working the fillet radius and rolling the threads, shall be free from any surface contaminations caused by the heat treatment.

3.6.2 The shank and bearing surface of the head of the heat treated blanks may be wet ground. The removal process shall produce no inter-granular attack or corrosion, or changes of structure of the blanks. The amount of material removal shall be as little as practicable, consistent with the production of a clean smooth surface, maintenance of optimum grain flow around the under-head radii and removal of surface contamination. Material removal shall in no case be as great as to produce more cutting of flow lines in the head-to-shank junction.

3.7 Cold Rolling of Fillet Radius

3.7.1 After removal of contamination, the head-to-shank fillet radius shall be cold rolled sufficiently to remove all visual evidence of grinding or tool marks. The fillet radius, after rolling, shall conform to that specified in the product drawing.

3.7.2 For parts with compound fillet radii between head and shank, cold roll only the radius that blends with the head.

3.7.3 There shall be no machining of the fillet radius after rolling.

3.8 Thread Rolling

3.8.1 Threads shall be formed by rolling process only. Machined threads are not acceptable.

3.8.2 Thread rolling shall be carried out on the heat treated and finished blanks in one single continuous operation. Heat treatment after thread rolling is not permitted.

3.9 Identification marking

3.9.1 Bolts / screws of size M5 and above shall have the identification markings applied on the upper face of the head. Markings shall also identify the manufacturer , property class and Batch number.

3.9.2 The markings shall be by depressed characters, as required by the part drawing. The depressed characters shall not be greater than 0.25mm in depth and shall be of rounded root form. Identification by laser marking is preferable.

3.10 Protective coatings

3.10.1 The fasteners shall be finished by either anodising (or) Aluminium coating (IVD) (or) plain as specified in the purchase order.

3.10.2 Anodizing (Shall be based on the end user requirements)

a) Blue anodizing: Acid based anodizing which give blue coloured conductive coating conforming to ISO 8080. Additional lubrication is preferable when the fasteners are anodized as per ISO8080 to avoid galling.

b) Wherever requirements for non conductive and coating with propellant compatibility are required, anodizing shall be carried out in accordance with AMS 2488. The coating shall be of Type 2. Acceptance and periodic tests as specified in the standard shall be applicable.

3.10.2.1 Quality: Anodic coating shall be continuous, smooth, adherent to base metal, uniform in texture and appearance, and free from burnt or powdery areas, loose films, discontinuities, such as breaks or scratches or other damages or imperfections detrimental to usage of the coating.

3.10.2.2 Acceptance tests: Acceptance tests shall be performed on each lot

3.10.2.3 Periodic tests: Periodic tests shall be carried out on cleaning and processing solutions at a frequency to be jointly worked out by ISRO and the manufacturer.

3.10.3 Aluminum Coating (IVD)

Aluminum coating shall be by Ion Vapour deposition in accordance with AMS 2427. The

Thickness of coating shall be 8-15µm or as specified in the applicable drawing.

3.10.3.1 Quality: Coating shall be smooth, continuous, adherent to base metal, uniform in appearance, and essentially free from pin holes, porosity, blisters, nodules, pits, and other

imperfections detrimental to performance of the coating.

3.10.3.2 Acceptance tests: Acceptance tests shall be carried out on each lot for coating thickness and adhesion. Coating thickness shall be measured by micro structural analysis on fasteners.

3.10.3.3 Periodic tests: Corrosion resistance, porosity and verification of process controls are periodic tests and shall be performed at a frequency to be jointly decided by ISRO and the manufacturer.

3.10.4 Supplementary treatments

Supplementary treatments, namely, chromating and MoS2 coating may be given to the

fasteners, if specified in the purchase order.

3.10.5 Chromate treatment

Chromate treatment shall be in accordance with AMS 2474.

3.10.5.1 Quality: The coating shall be continuous, non-powdery, free from scratches and other imperfections detrimental to usage of the coating.

3.10.5.2 Acceptance tests: Acceptance tests for uniform quality shall be carried out on each lot of fasteners.

3.10.5.3 Periodic tests: Periodic tests shall be carried out for corrosion resistance, adhesion, and adequacy of processing solutions at a frequency to be jointly worked out by ISRO and manufacturer.

3.10.6 MoS2 coating

MoS2 coating shall be based on the end user requirements as follows:

MoS2 thin film lubrication by PVD – Sputtering technique

3.10.6.1 Quality: The lubricant shall be homogeneous and shall show no evidence of gelation.

The cured lubricant film, examined macroscopically, shall be smooth and uniform in colour and shall show no evidence of foreign matter, grit, rough particles, separation of ingredients, and other imperfections detrimental to usage of the lubricant film.

3.10.6.2 Acceptance tests: Acceptance tests shall be carried out on each lot for film adhesion, coating thickness, visual inspection in accordance with the relevant ASTM standards specified therein.

3.10.6.3 Periodic tests: Tests such as salt spray tests & humidity exposure tests are periodic test and shall be performed at a frequency to be decided by ISRO and the manufacturer. Humidity exposure test shall be done for MoS2 coating done by PVD – Sputtering technique. The samples subjected to humidity exposure shall be subjected to adhesion test and visual inspection.

3.11 Sampling:

3.11.1 Acceptance tests: Sampling for acceptance tests shall be in accordance with Table - I.

3.11.2 Periodic tests: Sampling for periodic tests shall be decided jointly by ISRO and the manufacturer.

Section 4

Dimensional and Metallurgical requirements

4.1 General

Dimensional and metallurgical controls shall be carried out in accordance with the sampling procedures and acceptance criteria specified in Section 7. Acceptance criteria shall be as given below:

4.2 Nominal dimensions

4.2.1 Nominal dimensions shall be in accordance with the product drawing.

4.2.2 Thread geometry shall conform to relevant ISO / NFL standards specified in product drawing/ purchase order.

4.2.3 Tolerances for fasteners shall be in accordance with ISO 4759-1 “Product Grade A”.

4.3 Shank Straightness

The straightness of shank shall be as specified in the drawing. If not, the permissible deviation of the straightness of shank including the threaded portion, defined as in Figure 1, shall conform to Table A.

FIGURE - 1 : Shank straightness definition

TABLE - A: Geometrical straightness tolerances for bolt shanks

Bolt nominal size (mm) Straightness tolerance (mm)

M3, M4, M5 0.15% of bolt length plus a constant of 0.025

M6, M8 0.12% of bolt length plus a constant of 0.025

M10 0.10% of bolt length plus a constant of 0.025

M12 0.07% of bolt length plus a constant of 0.025

M14, M16, M18, M20 0.05% of bolt length plus a constant of 0.025

4.4 Head-to-shank fillet

4.4.1 Distortion of the head-to-shank fillet due to cold rolling shall not exceed 0.05 mm above or below the profile lines at points indicated at A and B in Figure 2.

4.4.2 The distorted area shall not extend beyond the dimension “C” listed in the Table B.

TABLE - B: Dimensions of Permissible Distortion

Nominal diameter (mm) M5 M6 M8 M10 M12 M14 M16 M18 M20

Dimension ‘C’ max. (mm) 1.7 2.0 2.4 3.0 3.3 3.6 3.8 3.9 4.0

4.5 Thread Run-out

4.5.1 The thread run-out portion shall ensure a progressive and regular junction with the shank avoiding sharp changes in section.

4.5.2 Thread lead and run-out portions shall conform to that specified in ISO 3353.

4.6 Surface Roughness

4.6.1 The values of surface roughness shall not exceed the values specified in Table C.

4.6.2 The surface roughness shall be determined by visual or fingernail comparator method. In case of controversy, a profilometer shall be used, on accessible surface areas.

TABLE - C : Surface Texture

Feature Roughness height rating maximum, Ra (цm) Head-to-shank fillet, Thread run-out 0.4 Thread root, Thread sides Bearing surface of head / Shank 0.8 3.2 Others

4.7 Non-destructive inspection

4.7.1 Fasteners shall be free from surface defects such as flaws and inclusions.

4.7.2 Bolts and screws shall be subjected to fluorescent penetrant inspection as per ASTM E 1417.

4.7.3 Non-destructive inspections shall be carried out only by qualified level II personnel (or) operators approved by ISRO.

4.7.4 No cracks are permitted in any location. Other discontinuities are permitted only to levels

specified in Table D.

4.8 Metallurgical examination

4.8.1 Fasteners selected for metallurgical examination shall be cut and prepared for observation in accordance with good standard laboratory practice. Specimens shall be cut from sample bolt/screws as indicated in Figure 3.

4.8.2 Grain flow at head and at transition of head-to-shank:

4.8.2.1 Longitudinal sections of fasteners, properly etched and visually examined at a

magnification of between 10X and 50X shall exhibit a continuous grain flow in the head

area and head-to-shank transition zone, as shown in Figure 4.

4.8.2.2 Excessive cutting of flow lines in the shank, head-to-shank fillet and bearing surface, as

shown in Figure 5, is not

permissible.

4.8.3 Grain flow at threads: Fasteners visually examined at a magnification of 50X - 100X shall exhibit continuous grain flow following the thread profile with maximum density of flow lines at thread roots, as shown in Figure 6.

4.8.4 Laps and surface irregularities in threads:

4.8.4.1 Laps and surface irregularities as in Fig. 7shall be limited to the extent specified in Table D.

4.8.4.2 Root defects, such as laps, seams, notches, slivers, folds, roughness and oxide scales are not

permissible.

4.8.4.3 Multiple laps on the flanks of threads are not permissible regardless of location. Single laps on

the flanks of threads that extend towards the root are not permissible.

4.8.4.4 No indications are permitted on pressure flanks(or) below the pitch diameter on non pressure Flanks.

4.8.5 Internal defects: Voids, cracks and bursts are not permitted in any location.

4.8.6 Surface contamination: Micro-examination at 200X - 500X, shall not show contamination greater than the limits specified in Table D.

TABLE - D : Discontinuities and surface contamination

Location Permissible condition

Max. depth normal to surface (mm) M3,M4 &M5 M6 M8 M10 M12

M14-M20

Head to shank fillet No discontinuities - - - - - - Root of bolt/screw threads

No surface contamination

- - - - -- -

Shank diameter Bearing surface of head

Bolt/screw thread locations

Laps and surface irregularities 0.13 0.13 0.13 0.15 0.18 0.2 No surface contamination - - - - - -

Non-bearing surface of Laps, seams, nicks or gouges 0.25 0.25 0.25 0.3 0.35 0.4 Head Surface contamination 0.075 0.075 0.07 0.075 0.075 0.075 Recess Surface contamination 0.05 0.05 0.05 0.05 0.05 0.05 Protruding head Overheating 2 2.3 2.9 3.5 4 4.76 Countersunk head Overheating 1.25 1.65 2 2.8 3.3 3.8

4.8.7 Microscopic Examination:

Specimens cut from parts shall be polished and etched in accordance with ASTM E 407 and examined at a magnification not lower than 100X to determine conformance to the following:

4.8.7.1 Microstructure: The micro-structure shall exhibit primary alpha in transformed Beta matrix with no continuous network of alpha at prior beta grain boundaries. It shall be free from gross alloy segregation, alpha casing and from overheating. The material shall be free from indications that it has been heated to a temperature above the ‘ ’ transus without subsequently receiving significant mechanical reduction in the "α- temperature range. Slight overheating on the head non-bearing surface is permissible provided measurement normal to the top surface of the head to the greatest depth of overheating does not exceed the limits given in Table D. A structure showing outlines of equi-axed beta grains and no primary alpha grains is considered to be an overheated structure and shall be cause for rejection.

4.8.7.2 Grinding damage: Altered micro-structure consisting of continuous or intermittent disturbed material or heat affected zone is considered as grinding damage and is rejectable. Grinding burns are not permitted on the shank or head-to-shank fillet. Grinding burns are allowed on the head of the fastener and head bearing surface to a depth of 0.08 mm max.

4.8.8 Micro structural shearing: A section through the thread profile shall be examined for indications of incipient micro-structural shearing (shear banding) at a magnification of not less than 100X. This defect generally manifests as a ‘V’ or ‘U’ shape of rippled grain structure immediately below the thread root, as shown in Figure 8, but may also occur as chevrons within the thread crest. Parts showing micro-structural shearing below the pitch diameter are not acceptable.

[Ref 1]

4.9 Measurement of Hydrogen content

4.9.1 Hydrogen content in fasteners shall be measured by an approved vacuum fusion or vacuum extraction method.

4.9.2 The hydrogen content shall be determined for all inspection batches from material in the head side of the finished bolt/screw, after removal of any surface coating.

4.9.3 Hydrogen content in fully finished fasteners shall not exceed 0.0125% (125 ppm)

4.9.4 Sampling shall be in accordance with Section 7.1.1.

4.10 Control of Oxygen content

4.10.1 Oxygen content shall be determined from a specimen taken from the thread end of a finished fastener. Procedures and equipment used shall be capable of measuring oxygen content to an accuracy of 0.01% (100 ppm).

4.10.2 Oxygen content shall not exceed 0.2% (2000 ppm).

4.10.3 Sampling plan and frequency of test shall be jointly decided by ISRO and manufacturer.

Section 5

Mechanical Testing

5.1 General

5.1.1 Mechanical testing for quality control purposes shall be performed at room temperature.

5.1.2 Tests shall be carried out in accordance with the sampling plan specified in Table K.

5.2 Tensile test

5.2.1 Tensile testing at product stage shall be applicable for fasteners having minimum lengths as given in Table E.

Nominal product Minimum length, diameter, mm Mm

3* 10

4* 12

5 12

6 14

8 20

10 25

12 30

14 35

16 40

20 45

Over 20 2.5D * - for non structural requirements

Countersunk head fasteners with overall length ≥ three times the nominal diameter shall be tensile tested.

5.2.2 Tensile testing shall be in accordance with NASM-1312-8 / ASTM E 8M / ASTM F 606M.

5.2.3 Test jigs shall ensure tensile loading parallel to the fastener main axis and no torsional stress shall be induced by the assembly. The product shall be assembled on the fixture, leaving six complete fastener threads exposed between the grips. A bolt/screw length of at least two pitches shall protrude beyond the threaded part of the jig or the nut.

5.2.4 Speed of testing shall not exceed 25mm/min. and be preferably between 0.5 to 1.0 mm/min.

5.2.5 Failure shall occur only in the shank or thread. For protruding head fasteners, failure at the head-to-shank fillet shall be considered as a non conformance.

5.2.6 For CSK head fastener, it is recommended to us only 90 deg CSK. Minimum length for testing CSK head fasteners is 3D and failure in head to shank is permitted for CSK head fasteners.

5.2.7 Test nuts shall be used only once.

5.2.8 The thread stress area of the fastener used in the interpretation of the tensile test results, expressed in ‘mm2' shall be calculated based on the formula:

As = 0.7854 (D - 0.9382P)2

where, D = nominal diameter of the fastener ; P = Pitch of the fastener

5.2.8 Proof Load Test: The fasteners chosen for tensile test shall initially be proof load tested, in accordance with ASTM F 606M, for 75% of minimum ultimate tensile load given in Table F. The fasteners shall withstand the test without any permanent set.

5.2.9 The finished bolts / screws shall also develop the minimum tensile loads specified in Table F.

TABLE - F: Minimum Tensile load requirements

Size 900 Mpa Class 1100MPa Class

(ф x Pitch)

Tensile Load (kN) Proof Load (kN) Tensile Load (kN) Proof Load (kN) Protruding head

CSK head

Protruding head

CSK head

Protruding head

CSK head

Protruding head

CSK head

M3X0.5 4.5 3.6 3.4 2.7 5.5 4.4 4.1 3.3

M4x0.7 7.9 6.3 5.9 4.7 9.7 7.8 7.3 5.9

M5x0.8 12.8 10.2 9.6 7.7 15.6 12.5 11.7 9.4

M6x1.0 18.1 14.5 13.6 10.9 22.1 17.7 16.6 13.3

M8x1.0 35.3 28.2 26.5 21.2 43.1 34.5 32.3 25.9

M10x1.25 55.4 44.3 41.6 33.2 67.3 53.8 50.5 40.4

M12x1.25 82.9 66.3 62.2 49.7 101.3 81 76 60.8

M16x1.5 150.3 120.2 112.7 90.2 183.9 147.1 137.9 110.3

M20x2.0 232.2 185.8 174.2 139.4 283.8 227 212.9 170.3

5.2.10 Fasteners of smaller diameter and lengths than that specified in Table E, which cannot be subjected to tensile testing, shall be accepted based on the evaluation of mechanical properties on test coupons / wires of equivalent cross section, heat treated along with the fasteners.

5.3 Shear test (to be carried out if specified in the purchase order, based on end use)

5.3.1 The test shall apply to finished fasteners of all sizes M5 and larger.

5.3.2 Shear test shall be in accordance with NASM-1312-13. Shear test shall be carried out in double shear loading configuration. The shear loads to failure shall not be less than the values specified in Table G.

5.3.3 The ultimate double shear breaking loads shall be based on the formula, Ls = 2 x Fs x A,

where, Fs = ultimate shear stress for Ti 6Al 4V alloy

A = shank cross sectional area of bolt/screw

TABLE - G: Shear strength of bolts (Double shear)

Nominal size of fasteners Ultimate double shear, min (kN)

900 Mpa Class 1100MPa class

M5 21.2 25.9

M6 30.5 37.3

M8 54.3 66.4

M10 84.8 103.7

M12 122.2 149.3

M16 217.1 265.4

M20 339.3 414.7

5.4 Acceptance requirement for Tensile and Shear tests

Samples, selected in accordance with Table K, shall be evaluated for tension and shear as follows:

5.4 Acceptance requirement for Tensile and Shear tests

Samples, selected in accordance with Table K, shall be evaluated for tension and shear as

follows:

5.5 Sustained Load verification test:

5.5.1 Five (5) samples representing the lot shall be tightened on a part with a demonstrated hardness of at least 45HRc.

5.5.2 Torque corresponding to 75% of the minimum ultimate tensile strength specified for the material shall be applied on the fasteners. Samples of fastener shall be lubricated with Molybdenum disulfide and tightened on a part with demonstrated hardness at least 45HRC to a torque T = 0.10 X D X F where D is the nominal diameter of fastener, and F = 0.75 X UTS X [/4 X ((d2+d3)/2) 2] where d2 and d3 are the pitch diameter and minor diameters respectively. 5.5.3 The fasteners shall sustain the load for 24 hours.

5.5.4 The fasteners shall be subjected to dye penetrant inspection before and after the test.

5.5.5 The fasteners under evaluation may be considered as acceptable if it successfully withstands the test and also if no indications are observed during the dye penetrant inspections.

5.5.6 The test is also applicable for qualifying fasteners stored for a period greater than 10 years.

Section 6

Quality Assurance

6.1 General

6.1.1 The supplier shall establish and implement adequate quality control stages and inspections to provide evidence of conformity to the product requirements.

6.1.2 Subcontracting of any work / testing shall be after evaluation of sub-contractor’s capability and approval by ISRO.

6.1.3 The fastener manufacturer shall have a recognized quality assurance system in place.

6.2 Quality control of materials

6.2.1 Selection and control of materials for fastener fabrication shall be based on the requirements specified in this document. The supplier shall provide evidence that only materials in accordance with this document are used in the fabrication.

6.2.2 The supplier shall issue a raw material test certificate specifying: material standard designation, form, heat treatment, manufacturer, batch number, chemical analysis, ultrasonic inspection status, tensile test results - 0.2% proof stress, ultimate stress, % elongation and % reduction in area.

6.3 Manufacturing

6.3.1 The manufacturer shall have all the facilities required for the realization, inspection and testing of the fasteners.

6.3.2 Sub-contracting of works, if any, shall be after thorough evaluation of the party’s capability jointly by the supplier and ISRO. Quality control, inspection and testing at the sub-contractors end shall be carried out by the supplier or an independent reputed third party agency approved by ISRO, under the responsibility of the manufacturer.

6.3.3 The manufacturer shall have an independent inspection and quality control system within the company.

6.3.4 Fasteners shall be manufactured as per an approved manufacturing process and quality control plan.

6.3.5 Surveillance shall be provided by ISRO representative during inspection stages identified in the QC plan.

6.3.6 Imported fasteners shall be certified by reputed third party agencies after witnessing testing at manufacturer’s site.

6.3.7 The dies for thread rolling shall be qualified dimensionally for thread profile prior to start of production.

6.3.8 A trial batch of fasteners shall be qualified prior to starting batch production.

6.4 Acceptance of production batches

6.4.1 Batch definition:

A batch shall consist of finished bolts / screws which are of the same type and diameter, fabricated by the same process from material of the same cast, heat treated as one lot, processed and produced as one continuous run, free from any interruptions or changes, such as, in the opinion of the Inspection Authority, might be expected to result in a significant variation in the quality of the finished product.

6.4.2 Sampling

6.4.2.1 Except where 100% inspection is specified, random samples shall be taken from each batch.

6.4.2.2 Sampling for attributes, namely, dimensional inspection, NDE and metallurgical analysis shall be as per ISO standards 2859/1. Applicable AQL and inspection levels are given in Table - I.

6.4.2.3 Destructive tests - Tensile and shear testing, shall be as per variables sampling plan detailed in Table - K.

6.4.2.4 Sampling for H2 analysis shall be as per section 7.1.1.

6.4.3 Fasteners under development shall be inspected under tightened inspection category.

6.4.4 Control of dimensions

All dimensions shall be controlled by a system of gauging approved by ISRO. The accuracy of

each gauge shall be maintained by regular calibration at an approved calibration facility.

6.5 Nonconforming batches

6.5.1 In the case where the number of non conforming units is greater than the acceptance level specified in this document, the batch shall be rejected.

6.5.2 Fasteners rejected for dimensional features may be re-submitted for inspection subject to the approval of the Inspection Authority.

6.5.3 In re-submitted batches, all units in the batch shall be re-examined. Such batches shall be separately identified as a re-submitted batch specifying the cause for previous non-conformance.

6.6 Product conformance report

Each batch of fasteners shall be supplied with a Product Conformance Report, which shall contain the following minimum details: - Purchase Order reference - Raw material test certificate and supplier’s name - Date of manufacturing - Batch identification

- Reference Specification - Hot Forging temperature - Heat treatment cycle - Dimensional inspection report - Mechanical properties - Product NDT status - Microstructure details (with photographs) - Manufacturer Certificate of conformance (COC)

6.7 Packing

6.7.1 The bolts / screws shall be packed in such a way so as to prevent any damage or corrosion in the course of handling, transportation and storage.

6.7.2 The external thread of the fasteners of M8 and above shall be protected by plastic sheath to prevent damage to threads.

6.7.3 Each batch / lot shall be packed in sealed polythene bag / containers in order to prevent moisture and corrosion.

6.7.4 Fasteners of one batch and part number shall be packed in unit packages.

6.7.5 An assortment of unit packages may be packed in large cartons.

6.8 Labeling

6.8.1 Each individual package shall be clearly identified by a durable and legible external marking indicating the product type, size, quantity, batch identification, manufacturer and acceptance status.

6.8.2 The packages shall meet commercial handling requirements.

6.9 Receipt inspection

6.9.1 All fasteners received shall be verified for compliance to the product conformance record by physically verifying the packages / crates for identification. Test results provided in the product conformance report shall be verified for adequacy and compliance to the specification requirements.

6.9.2 Confirmation tests, on sampling basis, shall be repeated for all fasteners realized without direct surveillance by ISRO. Receipt inspection shall include gauging for dimensions, cross verification of identification markings, mechanical property evaluation and visual inspection.

6.9.3 Sampling shall be as that for reduced inspection at same initial AQL level, except for mechanical property evaluation. Normal inspection level S2 with AQL 2.5% shall be used for mechanical property evaluation.

6.9.4 After inward inspection, accepted fasteners shall be packed in separate covers with proper identification tags giving the following details:

– Product size and property class – Batch no. – Quantity supplied – Date of receipt – Receipt Inspection date & Report no.

Section 7

Quality Requirement plan

Details of Qualification / Acceptance tests required

Category

Imported Fasteners

Imported material and Indigenous

manufacture

Indigenous material

and manufactur

e

Ingot stage

Chemical composition & Gas content

Verify Manufacturer’s Test Certificate.

Verify Manufacturer’

s Test Certificate.

Macrostructure --- --

Rod/ wire stage

Chemical composition

Verify Manufacturer’s Test Certificate.

Macrostructure --

Microstructure – Grain size and Inclusion rating --

Ultrasonic test --

Mechanical properties on samples (Tensile)

Fastener stage

Macro of longitudinal section

Verify Manufacturer’s Test Certificate.

Microstructure

Mechanical properties on fastener samples (Tensile / Shear)

FPI

Dimensional inspection

Inward inspection

after receipt – As per

sampling plan

Dimensional

Ensure traceability w.r.t test certificate.

Ensure traceability w.r.t test certificate.

Chemical composition & gas content

Mechanical properties (Tensile)

Microstructure

Macro – Flow lines

Sampling Plan 7.1 Sampling

Except where 100% inspection is specified, random samples shall be taken from each batch in accordance with Table - G, for dimensional, non-destructive and destructive inspection.

7.1.1 Sampling plan for H2 analysis

One part per inspection batch shall be checked; if the hydrogen / oxygen content is below the respective maximum limits, the batch shall be accepted. If the hydrogen / oxygen content is above the maximum limits, a second sample of two (2) for batches under 500 or five (5) for batches of 500 and over shall be taken. When none of the analyses in the second sample exceeds the respective maximum limits, the batch shall be accepted; if any of the analyses in the second sample exceeds the maximum limit, the batch is not acceptable.

ISRO SPECIFICATION DOCUMENT FOR

STAINLESS STEEL

BOLTS AND SCREWS

1.0 INTRODUCTION:

This document defines quality assurance requirements for stainless steel SS 304 fasteners for spacecraft subsystem requirements. It gives information related to all fasteners used in space hardware. It includes screws, bolts, nuts, plain washers, spring washers used for assembly of parts/subsystem in various types of communication, remote sensing, navigation & scientific missions by ISAC-ISRO. These are the baseline requirements for the fastener procurement, receiving inspection, and storage requirements for all space hardware. It contains details such as QA requirements, specifications, and acceptance testing for available precision grade fasteners. These requirements are generated based on space application needs. Standards like ISO / DIN /ASTM are also referred. To ensure fasteners Quality and reliability, its Physical & Chemical properties are required to be ensured. This is done by various inspections & tests. Requirements such as Chemical composition, Tensile strength, Hardness, Breaking torque, Dimensional accuracy, Go, No-Go Inspection, Visual-Workmanship needs to be evaluated. This document specifies details type of fasteners, materials, and test methodology and acceptance criteria. This document gives all physical and chemical properties, dimensional specifications, sample size for inspection and testing for screw, nut and spring & plain washers.

2.0 ACRONYMS AND DEFINITIONS:

2.1 ACRONYMS

AIA Aerospace Industries Association ANSI American National Standards Institute ASME American Society of Mechanical Engineers ASTM American Society for Testing and Materials COC Certificate of Conformance COTS Commercial Off-the-Shelf CVT Certification Validation Testing DIN Deutsches Institut fur Nornung (German Institute for Standardization) EN Europaische Norn (European Standard) MTR Manufacturer's Test Report MUA Materials Usage Agreement NAS National Aerospace Standard NASA National Aeronautics and Space Administration OES Optical Emission Spectroscopy SI Systeme Internationale or metric system of measurement

STD Standard

2.2 DEFINITIONS

Accredited Laboratory: A laboratory that has been recognized by the national and /or international standard-setting organizations to carry out specific tests competently according to established quality management, administrative and test method accreditation criteria.

Approved Manufacturer: A manufacturer that has passed an audit intended to verify that a company has the manufacturing capability and implemented quality management system with controlled processes that will ensure that products meet the requirements of applicable specifications. Audit: A systematic, independent, and documented process to verify that a company has the capability to manufacture fasteners with documented and controlled processes that meet the requirements of standard. Bolt: All fasteners having external cylindrical screwed bar provided with a head, generally not threaded along its entire length NOTE For example: Shank plus threaded portion. Certificate of Conformance (COC): A document that is signed by the fastener supplier to affirm that the product has met the requirements of the relevant specification(s), contractual requirements, and any other applicable regulations. Certification Validation Test (CVT): Receiving inspection test(s) that are performed to assure conformance to the procurement specification requirements. For fasteners, this includes elemental analysis and mechanical property testing and inspection. Commingled: A storage state where hardware (e.g., fasteners, inserts, etc.) from two or more different lots are co-located or stored in the same bin or other holding container. Complete Traceability: Documentation that demonstrates a solid chain of custody from the original fastener manufacturer through all intermediate distributors down to the buyer. Distributor: An enterprise that stocks the products of various manufacturers for resale and does not engage in manufacturing activity. Connecting part: Structural elements to provide mechanical joint E.g., Bolts, nuts, rivets, inserts and clip Part types: 1] non-critical mechanical part; 2] critical mechanical part Internal defects: Voids, cracks, inclusions, gross alloy segregation and indication of overheating Nut: All fasteners having internal threads metal collar, to fit a bolt NOTE: usually hexagonal in shape and operated by a spanner. Mechanical part: Off-the-shelf commercial and military (CAM) equipment or item designed and produce to feature primarily a distinct mechanical function. Space-proven part: Mechanical item whose properties are known and that is produced by means of stable processes and has been approved for use in previous space applications which are still valid for its intended use. Part classification: 1] space-proven mechanical part; 2] non-space proven mechanical part; 3] space-proven part, with deviation in materials, design or use environment Fastener: An item such as a bolt (could be a tensile or shear bolt, shoulder bolt, screw, nut, nut plate or anchor nut, rivet, shear pin, helical or cylindrical insert, setscrew, washer, safety wire, cotter pin, etc., which joins or retains components or structural elements. Lot: A collection of units or items (e.g., fasteners or inserts) are of the same type and diameter, manufactured from a homogeneous batch of material of the same continuous, uninterrupted production.

Manufacturer’s Test Report (MTR): A document that is produced by the fastener manufacturer that certifies information required by the applicable fastener specification.

Screening: An in-house receiving inspection that verifies that requested procurement documentation has been received and that procurement requirements have been met. This is intended to be done in addition to the CVT required.

Sampling plan: Combination of sample size to be used with associated batch acceptability criteria

Shank: Unthreaded portion of the cylindrical screwed bar of a bolt (Screw) thread: Helical ridge of approximately triangular, square or rounded section, formed on a cylindrical core, the pitch and core diameter being standardized under various systems

Technical Authority: The agency or organization that is responsible for the technical details of a particular design and the resolution of any associated technical issues.

3.0 REFERENCE DOCUMENTS:

ISRO PAS 208: ISRO Design Manual: Vol-1, Section-2, Fasteners VSSC: FPS: 2011:01: FASTENER PROCUREMENT SPECIFICATION

ECSS-Q-ST-70-46C: Requirements for manufacturing and procurement of threaded fasteners NASA-STD-6008: NASA Fastener procurement, receiving inspection, and storage practices for

spaceflight hardware American Society for Mechanical Engineering (ASME)

ASME B1.3 Screw Thread Gaging Systems for Dimensional Acceptability – Inch and Metric Screw Threads, System 22

American Society for Testing and Materials (ASTM) ASTM F 606: Standard Test Methods for Determining the Mechanical Properties of

Externally and Internally Threaded Fasteners, Washers, Direct Tension Indicators, and Rivets

Aerospace Industries Association/National Aerospace Standards (AIA/NAS) NASM1312-6 Fastener Test Methods, Method 6, Hardness

NASM1312-8 Fastener Test Methods, Method 8, Tensile Strength

NAM1312-108 Fastener Test Methods, Metric, Method 108, Tensile Strength 2.1 ISO 3506-1: Mechanical properties of corrosion resistant stainless-steel fasteners - Part 1: Bolts,

screws and studs 4.0 SPECIFICATIONS FOR STAINLESS STEEL SS-304 GRADE SCREWS AND NUTS

4.1 TYPE AND DETAILS OF SCREWS AND NUTS

All Fasteners of following designation of ISO metric precision grade shall conform to the dimensions and tolerances specified in the relevant standard.

1. Hexagon socket head cap screw as per ISO 4762:2004 or DIN 912 2. Slotted cheese head screw as per ISO 1207:1992 or DIN 84 3. Slotted counter-sunk head screw as per ISO 2009:1994 or DIN 963 4. Hexagonal nut as per ISO 4032:1999 or DIN 934 5. Hexagon head screw as per ISO 4017:1999 or DIN 933

Screws & nuts shall be manufactured from materials specified as below;

4.2 CHEMICAL COMPOSITION:

Chemical/elemental analysis shall be performed on the fastener material on a sampling basis using any quantitative or semi-quantitative chemical/ elemental analysis technique.

Stainless steel material of SS304 (SS A2-70 according to ISO 3506 or ASTM F738 or equivalent IS:1367-1984.)

Fastener should have the following chemical compositions:

A quantitative Optical Emission Spectroscopy (OES) analysis is destructive to the fastener but is the preferred test method. Sampling follows TABLE – I.

4.3 MECHANICAL PROPERTIES REQUIREMENTS:

Hardness testing shall be carried out in conformance with ASTM F 606 or NASM1312-6, Fastener Test Methods, Method 6, Hardness. Tensile testing shall be performed for threaded fasteners according to one of the following three standards,

1. ASTM F 606, Standard Test methods for Determining the Mechanical Properties of externally and Internally Threaded Fasteners, Washers, Direct Tension Indicators and Rivets.

2. NASM1312-8, Fastener Test Methods, Method 8, Tensile strength 3. NAM1312-108, Fastener Test Methods, Metric, Method 108, Tensile strength

The location of tensile break and ultimate strength determined shall be recorded. (Mechanical properties of Fasteners shall be conformance with following specifications.

(As Per ISO 3506 or ASTM F738) Sampling inspection as per TABLE – I.

Hardness

SCREWS NUTS

Tensile Strength

N/mm2

Min

Stress at 0.2 percent Permanent Strain

N/mm2

Min

Elongation after fracture

mm

Min

Proof Load

Stress

N/mm2

Min

96 HRB to 33 HRC 700 450 0.4d 700

Sr. No. ELEMENTS SS 304 1. Carbon (C) Maximum 0.08% 2. Manganese (Mn) Maximum 2.00% 3. Silicon (Si) Maximum 1.00% 4. Sulphur (S) Maximum 0.03% 5. Phosphorous (P) Maximum 0.045% 6. Nickel (Ni) 8 to 10.5% 7. Chromium (Cr) 18 to 20% 8. Nitrogen Maximum 0.1%

4.4 DIMENSIONAL INSPECTION:

Dimensional inspection of threads and also head height, fillet radius, thread length and shank length shall be according to IS standard.

Sampling inspection follows TABLE – II.

4.5 BREAKING TORQUE REQUIREMENTS:

Screws are required to meet the following breaking torque requirements. (As Per ISO 3506-1 or equivalent Standard IS: 1367-1984)

Thread Size Course Series Breaking Torque in N.m (Min.) M 1.6 0.2 M 2.0 0.4 M 2.5 0.9 M 3.0 1.6 M 4.0 3.8 M 5.0 7.8 M 6.0 13 M 8.0 32 M 10 65

Sampling inspection as per TABLE – I

4.6 GO, NO-GO INSPECTION:

The screw thread profile, wherever applicable shall conform to ISO metric thread form. The fasteners should confirm to Go, No-Go attribute checking requirement for thread tolerances. Screws shall be checked with threaded ring gauge of 6g tolerance and nuts shall be checked with threaded plug gauge of 6H tolerance.

Fasteners shall undergo Go, No-Go inspection of all the batches as per Table-II. If COC is not supplied along with batch definition Go, No-Go inspection shall be carried out on 100% basis.

4.7 VISUAL INSPECTION FOR WORKMANSHIP AND FINISH REQUIREMENTS:

All fasteners shall undergo 100% Visual inspection to assure lot uniformity at 1X magnification (unaided eye) on every fastener in a given lot. Visual inspection for surface finish and other characteristics shall be performed at 10X minimum magnification on a sampling basis that is specified in Table-II. All fasteners shall be free from workmanship defect like injurious burrs, cracks, laps, irregular surface seams, voids, tool marks, nicks or gouge, folds and other defects which affects the serviceability. Surface should be bright and clean. Ref Standard ASTM F 788 & F 812.

Item Feature Roughness Height Rating

Ra max (µm)

Bolts Shank head bearing face and fillet radius

Close tolerance shank other than close tolerance

shank

0.8

1.6 Thread flank and root-

radius Rolled thread

Cut thread 0.8 1.6

Other surface 3.2

Nuts Bearing faces Circular lay 3.2 Other faces -- 3.2

4.8 TRACEABILITY / CERTIFICATION & PACKING:

Supplier shall maintain traceability from raw material procurement to finish product, and the certificate of Traceability should be submitted along with the consignment. However acceptance of Lot will be decided based on sampling plan. Ref. Table-I & II.

Each packet of ordered fasteners shall bear a tag of plainly marked with the following. ASTM designation number and alloy number, size and brand or trademark of manufacturer, number of pieces and purchase order number.

4.9 CERTIFICATE OF CONFORMANCE:

Dispatch of material to ISAC must be made along with material test certificates, Certificate of Conformance (COC). A COC document that is signed by the fastener supplier to affirm that the product has met the requirements of the relevant specifications, contract, and any other applicable regulations

It attests that the fasteners are of the quality specified in the acceptance document and conform in all respects with contractual requirements, including specifications, drawings, preservation, packaging, and packing, marking requirements, applicable heat/lot number and physical item identification.

A COC to the applicable fastener specification is required for every fastener lot and shall be obtained from the manufacturer or distributor selling the fastener.

4.10 RECEIVING INSPECTING: SCREENING & CVT: All fasteners shall be subjected to a receiving inspection that includes a documentation screening and

Certification validation Test to check conformity with specification requirements refer to sampling basis that indicate that every fastener does not need to be tested.

Failure in meeting the specifications during testing or defective component are found at our end will result in rejection of the entire lot.

Manufacturer should carry out all mechanical and chemical tests specified in this document in Govt. Laboratory or NABL certified Laboratory. Manufacturer’s Test Report (MTR) is a document produced by fastener manufacturer to certify information required by the applicable fastener specification. The information typically includes fastener lot number, manufacturing date, lot quantity, raw material heat number, chemical composition and mechanical and metallurgical test results.

4.11 STORAGE: Pack of fasteners of the same batch shall be in unit packages. Each individual package shall be univocally identified by a durable and legible external marking indicating

the product denomination, quantity, batch identification, manufacturer, product conformance report and date of packing.

4.12 OTHER REQUIREMENTS: 4.12.1 Fastener shall be non magnetic. Sampling inspection as per table –I

4.12.2 The supplier must be an authorized agent or dealer of Stainless Steel fastener's

manufacturer. Supplier should provide a copy of certificate of the same.

4.12.3 Supplier should provide original catalogue containing all technical details to support the product.

4.12.4 Supplier must provide manufacturer’s commitment certificate at the time of offering the quotation, that fasteners will be tested in accordance with and will meet all the requirements mentioned in document.

4.12.5 Supplier must provide manufacturer’s compliance certificate along with consignment, that fasteners are tested in accordance with and meets all the requirements mentioned in document.

4.13 TABLE-I

SAMPLE SIZE FOR TENSILE/HARDNESS TESTING, AND CHEMICAL COMPOSITION TESTING:

TYPE OF TEST OR INSPECTION

NUMBER OF SAMPLES PER LOT OR METHOD

ACCEPTANCE NO. (No. of samples fail for

acceptance of lot)

REJECTION NO. (No. of samples fail for

rejection of lot) CHEMICAL

COMPOSITION 1 0 1

TENSILE/HARDNESS TESTING 1 0 1

4.14 TABLE-II

SAMPLE SIZE & ACCEPTANCE CRITRIA FOR VISUAL INSPECTION FOR FINISH, DIMENSIONAL INSPECTION & GO, NO-GO CHECKING:

LOT SIZE SAMPLE SIZE ACCEPTANCE NO. (No. of

samples fail for acceptance of lot)

REJECTION NO. (No. of samples fail for rejection of lot)

2 TO 15 2 0 1 16 TO 25 3 0 1 26 TO 90 5 0 1

91 TO 150 8 0 1 151 TO 280 13 0 1 281 TO 500 20 0 1 501 TO 1200 32 0 1

1201 TO 3200 50 0 1 3201 TO 10000 80 0 1

10001 TO 35000 125 0 1 35001 TO 150000 200 0 1

150001 TO 500000 315 0 1 500001 and Over 500 0 1

5.0 SPECIFICATIONS OF SS 304 GRADE PLAIN WASHERS

5.1 TYPE AND DETAILS OF PLAIN WASHERS:

1. Punched washers, TYPE A. For hexagonal bolts & screws as per IS: 2016-1967 OR DIN 125

2. Punched washers, TYPE B. For round & cheese head screws as per IS: 2016-1967 OR DIN 433

5.2 CHEMICAL COMPOSITION:

Chemical/elemental analysis shall be performed on the fastener material on a sample procedure and acceptance criteria specified in Table-I, using any quantitative or semi-quantitative chemical/ elemental analysis technique.

Stainless steel material of SS304 (SS A2-70 according to ISO 3506 or ASTM F738 or equivalent IS:1367-

1984.)

Sampling follows as per TABLE –I.

5.3 MECHANICAL PROPERTIES REQUIREMENTS:

Hardness testing shall carry out in conformance with ASTM F 606. Its Hardness should be greater than 140 HV. Sampling follows as per TABLE –I. 5.4 DIMENSIONAL INSPECTION:

Plain washer will be designed / manufactured / supplied by Nominal diameter and dimensional accuracy shall be as per IS: 2016-1967 or DIN 125 & DIN 433. As per Annexure-1.

Surface roughness has to be (▼▼) or better.

Sampling inspection as per TABLE – II.

Sr. No. ELEMENTS SS 304 1. Carbon (C) Maximum 0.1% 2. Manganese (Mn) Maximum 2.00% 3. Silicon (Si) Maximum 1.00% 4. Sulphur (S) Maximum 0.03% 5. Phosphorous (P) Maximum 0.05% 6. Nickel (Ni) 8 to 19% 7. Chromium (Cr) 15 to 20% 8. Nitrogen Maximum 0.1%

5.5 TRACEABILITY / CERTIFICATION & PACKING:

Supplier shall maintain traceability from raw material procurement to finish product, and the certificate of Traceability should be submitted along with the consignment. However acceptance of Lot will be decided based on sampling plan. Ref. Table-I & II.

Each packet of ordered washers shall bear a tag of plainly marked with the following. ASTM designation number and alloy number, size and brand or trademark of manufacturer, number of pieces and purchase order number.

5.6 CERTIFICATE OF CONFORMANCE:

Dispatch of material to ISAC must be made along with material test certificates Certificate of Conformance (COC). A COC document that is signed by the washer supplier to affirm that the product has met the requirements of the relevant specifications, contract and any other applicable regulations.

It attests that the washers are of the quality specified in the acceptance document and conform in all respects with contractual requirements, including specifications, drawings, preservation, packaging, packing, marking requirements, applicable heat/lot number and physical item identification.

A COC to the applicable washer specification is required for every washer lot and shall be obtained from the manufacturer or distributor selling the washers.

5.7 RECEIVING INSPECTING: SCREENING & CVT:

All washers shall be subjected to a receiving inspection that includes a documentation screening and Certification validation Test to check conformity with specification requirements.

Failure in meeting the specifications during testing at our end shall result in rejection of the ordered material.

Manufacturer should carry out all mechanical and chemical tests specified in this document in Govt. Laboratory or NABL certified Laboratory. Manufacturer’s Test Report (MTR) is a document produced by washer manufacturer to certify information required by the applicable washer specification. The information typically includes lot number, manufacturing date, lot quantity, raw material heat number, chemical composition and mechanical and metallurgical test results.

5.8 STORAGE:

Pack of fasteners of the same batch shall be in unit packages.

Each individual package shall be univocally identified by a durable and legible external marking indicating the product denomination, quantity, batch identification, manufacturer, product conformance report and date of packing.

5.9 OTHER REQUIREMENTS: 5.9.1 Plain washer shall not have residual magnetism developed during cold working or otherwise.

The extent of residual magnetism within washer after keeping it in magnetic field of 25 gauss for 15 minutes shall not be more than 1 gamma.

Sampling inspection as per table –I 5.9.2 The supplier must be an authorized agent or dealer of Stainless Steel fastener's manufacturer. Supplier should provide a copy of certificate of the same.

5.9.3 Supplier should provide original catalogue containing all technical details to support the product.

5.9.4 Supplier must provide manufacturer’s commitment certificate at the time of offering the quotation, that washers will be tested in accordance with and will meet all the requirements mentioned in document.

5.9.5 Supplier must provide manufacturer’s compliance certificate along with consignment, that washers are tested in accordance with and meets all the requirements mentioned in document.

6.0 SPECIFICATIONS OF SS 304 GRADE SPRING WASHAERS

6.1 TYPE AND DETAILS OF SPRING WASHERS:

Single coil rectangular section spring washer with flat ends for bolts, nuts and screw as per IS: 3063-1994 or DIN 127

6.2 CHEMICAL COMPOSITION:

Chemical/elemental analysis shall be performed on the fastener material on a sample procedure and acceptance criteria specified in Table-I, using any quantitative or semi-quantitative chemical/ elemental analysis technique.

Stainless steel material of SS304 (SS A2-70 according to ISO 3506 or ASTM F738 or equivalent IS:1367- 1984.)

Sampling for this chemical testing at supplier’s end as per TABLE-I.

6.3 MECHANICAL PROPERTIES REQUIREMENTS: Hardness testing shall carry out in conformance with ASTM F 606. (As Per ASTM F738 / ISO 3506 or Indian Standard IS:1367-1984) Hardness ≥ 95 HRB

Minimum % Elongation ≥ 15% After coiling and suitable heat treatment, the washer should have hardness in the range of 43 HRC to 50 HRC.

Sampling inspection as per TABLE - I. 6.4 DIMENSIONAL INSPECTION:

Single coil rectangular section spring washer shall meet dimensional accuracy as per IS: 3063-1972 or DIN 127. As per Annexure-1.

Sr. No. ELEMENTS SS 304 1. Carbon (C) Maximum 0.1% 2. Manganese (Mn) Maximum 2.00% 3. Silicon (Si) Maximum 1.00% 4. Sulphur (S) Maximum 0.03% 5. Phosphorous (P) Maximum 0.05% 6. Nickel (Ni) 8 to 19% 7. Chromium (Cr) 15 to 20% 8. Nitrogen Maximum 0.1%

Sampling inspection as per TABLE – II. 6.5 TRACEABILITY / CERTIFICATION & PACKING:

Complete traceability is required for all fasteners, inserts and nuts from raw material procurement to finish product. Complete traceability is the documentation that demonstrates a solid chain of custody from the original fastener manufacturer through all intermediate distributors down to the buyer. The original manufacturer shall have lot traceability back through the manufacturing process to the raw material test certifications. However acceptance of Lot will be decided based on sampling plan. Ref. Table-I & II. Each packet of ordered washers shall bear a tag of plainly marked with the following. ASTM designation number and alloy number, size and brand or trademark of manufacturer, number of pieces and purchase order number.

6.6 CERTIFICATE OF CONFORMANCE: Dispatch of material to ISAC must be made along with material test certificates Certificate of

Conformance (COC). A COC document that is signed by the washer supplier to affirm that the product has met the requirements of the relevant specifications, contract, and any other applicable regulations. It attests that the washers are of the quality specified in the acceptance document and conform in all respects with contractual requirements, including specifications, drawings, preservation, packaging, packing, marking requirements, applicable heat/lot number and physical item identification.

A COC to the applicable washer specification is required for every washer lot and shall be obtained from the manufacturer or distributor selling the washers.

6.7 RECEIVING INSPECTING: SCREENING & CVT: All washers shall be subjected to a receiving inspection that includes a documentation screening and

Certification validation Test to check conformity with specification requirements. Failure in meeting the specifications during testing at our end shall result in rejection of the ordered

material. Manufacturer should carry out all mechanical and chemical tests specified in this document in Govt.

Laboratory or NABL certified Laboratory. Manufacturer’s Test Report (MTR) is a document produced by washer manufacturer to certify information required by the applicable washer specification. The information typically includes lot number, manufacturing date, lot quantity, raw material heat number, chemical composition and mechanical and metallurgical test results.

6.8 STORAGE: Pack of fasteners of the same batch shall be in unit packages. Each individual package shall be univocally identified by a durable and legible external marking indicating

the product denomination, quantity, batch identification, manufacturer, product conformance report and date of packing.

6.9 OTHER REQUIREMENTS:

6.9.1 Spring washer shall not have residual magnetism developed during cold working or otherwise. The extent of residual magnetism within washer after keeping it in magnetic field of 25 gauze for 15 minutes shall not be more than 1 gamma.

Sampling inspection as per table –I

6.9.2 The flat faces of washers and the inner and outer peripheries shall be smooth and free from knurling, serration, die-marks, deep scratches, etc, although slight feed roll marks shall be permissible.

6.9.3 Washers shall also be free from burrs, rust, pit marks, loose scale and defects that might affect

their serviceability. 6.9.4 The clearances and angles of the cut ends shall be in such degree so that the washers do not

cause lapping when they are completely compressed and shall not be liable to tangle or link together when in the free condition.

6.9.5 The supplier must be an authorized agent or dealer of Stainless Steel fastener's

manufacturer. Supplier should provide a copy of certificate of the same. 6.9.6 Supplier should provide original catalogue containing all technical details to support the

product. 6.9.7 Supplier must provide manufacturer’s commitment certificate at the time of offering the

quotation, that washers will be tested in accordance with and will meet all the requirements mentioned in document.

6.9.8 Supplier must provide manufacturer’s compliance certificate along with consignment, that

washers are tested in accordance with and meets all the requirements mentioned in document.

7.0 RECOMMENDATIONS: All fasteners to be used shall meet requirements given in this document.

8.0 ANNEXURE-1 DIMENSIONS FOR HEXAGON SOCKET HEAD CAP SCREWS

AS PER IS: 2269-1967

ALL DIMENSIONS ARE IN MILLIMETRES

Nominal Size M3 M4 M5 M6 M8 M8 x 1

M10 M10 x 1.25

b * 12 14 16 18 22 26 + - - - - 28 32

d

Nom 3 4 5 6 8 10 Max 3.00 4.00 5.00 6.00 8.00 10.00 Min 2.86 3.82 4.82 5.82 7.78 9.78

D

Nom 5.5 7 8.5 10 13 16 Max 5.50 7.00 8.50 10.00 13.00 16.00 Min 5.32 6.78 8.28 9.78 12.73 15.73

k

Nom 3 4 5 6 8 10 Max 3.00 4.00 5.00 6.00 8.00 10.00 Min 2.86 3.82 4.82 5.82 7.78 9.78

s

Nom 2.5 3 4 5 6 8 Max 2.61 3.11 4.15 5.15 6.15 8.19 Min 2.52 3.02 4.03 5.03 6.03 8.04

t Max 1.70 2.40 3.10 3.78 4.78 6.25 Min 1.30 2.00 2.70 3.30 4.30 5.50

r Min 0.1 0.2 0.2 0.25 0.4 0.4 da Max 3.6 4.7 5.7 6.8 9.2 11.2

* For lengths up to 130 mm.

+ For lengths over 130 mm and up to 200 mm.

Note - For dimensions of “x” see table-III

PREFERRED LENGTH DIAMETER COMBINATIONS FOR HEXAGON SOCKET HEAD CAP SCREWS

L (in MM) M3 M4 M5 M6 M8 M10 Nom Max Min M8 x 1 M10x1.25

4 4.24 3.76 5 5.24 4.76 6 6.24 5.76

(7) 7.29 6.71 8 8.29 7.71

(9) 9.29 8.71 10 10.29 9.71

(11) 11.35 10.65 12 12.35 11.65 14 14.35 13.65 16 16.35 15.65

(18) 18.35 17.65 20 20.42 19.58

(22) 22.42 21.58 25 25.42 24.58

(28) 28.42 27.58 30 30.42 29.58 35 35.50 34.50 40 40.50 39.50 45 45.50 44.50 50 50.50 49.50 55 55.60 54.40

60 60.60 59.40 65 65.60 64.40 70 70.60 69.40 75 75.60 74.40 80 80.60 79.40 85 85.70 84.30 90 90.70 89.30 100 100.70 99.30 110 110.70 109.30 120 120.70 119.30

Note 1: Preferred length diameter combinations are between the stepped lines. Note 2: Where ‘L’ is less than b, the screw shall be considered as fully threaded. Note 3: Second preference lengths are given in brackets.

DIMENSIONS FOR SLOTTED CHEESE HEAD SCREWS AS PER IS: 1366-1968

ALL DIMENSIONS ARE IN MILLIMETRES

Nominal Size M1.6 M2 (M2.2) M2.5 M3 (M3.5) M4 (M4.5) M5 M6

M8 M8 x

1

M10 M10 x 1.25

d

Nom 1.6 2 2.2 2.5 3 3.5 4 4.5 5 6 8 10 Max 1.60 2.00 2.20 2.50 3.00 3.50 4.00 4.50 5.0 6.00 8.00 10.00 Min 1.46 1.86 2.06 2.36 2.86 3.32 3.82 4.32 4.82 5.82 7.78 9.78

D

Nom 3 3.8 4 4.5 5.5 6 7 8 8.5 10 13 16 Max 3.00 3.80 4.00 4.50 5.50 6.00 7.00 8.00 8.50 10.00 13.00 16.00 Min 2.60 3.32 3.52 4.02 5.02 5.52 6.42 7.42 7.92 9.42 12.30 15.30

k

Nom 1 1.3 1.5 1.6 2 2.4 2.6 3.1 3.3 3.9 5 6 Max 1.00 1.30 1.50 1.60 2.00 2.40 2.60 3.10 3.30 3.90 5.00 6.00 Min 0.86 1.05 1.25 1.35 1.75 2.15 2.35 2.80 3.00 3.60 4.70 5.70

n

Nom 0.4 0.5 0.6 0.6 0.8 0.8 1 1 1.2 1.6 2 2.5 Max 0.60 0.70 0.80 0.80 1.00 1.00 1.20 1.20 1.51 1.91 2.31 2.81 Min 0.46 0.56 0.66 0.66 0.86 0.86 1.06 1.06 1.26 1.66 2.06 2.56

t Max 0.65 0.85 1.0 1.0 1.3 1.4 1.6 1.8 2 2.3 2.8 3.2 Min 0.45 0.6 0.7 0.7 0.9 1.0 1.2 1.4 1.5 1.8 2.3 2.7

r Min 0.1 0.1 0.1 0.1 0.1 0.1 0.2 0.2 0.2 0.25 0.4 0.4 da Max 2.0 2.6 2.8 3.1 3.6 4.1 4.7 5.2 5.7 6.8 9.2 11.2 a Max 0.7 0.8 0.8 0.9 1 1.2 1.4 1.5 1.6 2 2.5 3 b Min 15 16 17 18 19 20 22 24 25 28 34 40 Note - For dimensions of “x” see table-III

PREFERRED LENGTH DIAMETER COMBINATIONS FOR SLOTTED CHEESE HEAD SCREWS

L (in MM) M1.6 M2 (M2.2) M2.5 M3 (M3.5) M4 (M4.5) M5 M6 M8 M10

M8 X 1 M10 X 1.25 3 4 5 6

(7) 8

(9) 10

(11) 12

14

16

(18) 20

(22) 25

(28) 30

(32) 35

(38) 40 45 50 55 60 65 70 75

80 85 90

(95) 100

Note 1: Sizes shown in brackets are of second preference. Note 2: Preferred lengths are given between the bold lines. Note 3: Lengths above the dotted line are fully threaded.

DIMENSIONS FOR SLOTTED COUNTERSUNK HEAD SCREWS AS PER IS: 1365-1978

ALL DIMENSIONS ARE IN MILLIMETRES

Nominal Size d1

M1

M1.2

(M1.4) M1.6 M2 M2.5 M3 (M3.5) M4 M5 M6 M8

M10

d2

Nom 1.9 2.3 2.6 3 3.8 4.7 5.6 6.5 7.5 9.2 11 14.5 18 Max 1.90 2.30 2.60 3.00 3.80 4.70 5.60 6.50 7.50 9.20 11.00 14.50 18.00 Min 1.76 2.16 2.46 2.75 3.50 4.40 5.30 6.14 7.19 8.84 10.57 14.07 17.57

k Max 0.6 0.72 0.84 0.96 1.2 1.5 1.65 1.93 2.2 2.5 3 4 5 n

Nom 0.25 0.3 0.3 0.4 0.5 0.6 0.8 0.8 1 1.2 1.6 2 2.5 Max 0.45 0.5 0.5 0.6 0.7 0.8 1 1 1.2 1.51 1.91 2.31 2.81 Min 0.31 0.36 0.36 0.46 0.56 0.66 0.86 0.86 1.06 1.26 1.66 2.06 2.56

t Max 0.3 0.35 0.4 0.5 0.6 0.73 0.85 1 1.1 1.35 1.6 2.1 2.6 Min 0.2 0.24 0.28 0.32 0.4 0.5 0.6 0.7 0.8 1 1.2 1.6 2

r Min 0.1 0.12 0.14 0.16 0.2 0.25 0.3 0.35 0.4 0.5 0.6 0.8 1 b Min * * * 15 16 18 19 20 22 25 28 34 40

* Threaded up to the head.

Note - For dimensions of ”a” and “x” see table-III

PREFERRED LENGTH SIZE COMBINATIONS FOR SLOTTED COUNTERSUNK HEAD SCREWS L

(in MM) M1 M1.2 (M1.4) M1.6 (M1.8) M2 M2.5 M3 (M3.5) M4 M5 M6 M8 M10

2 2.5 3 4 5 6

(7) 8

(9) 10

(11) 12 14 16

(18) 20 22 25

(28) 30

(32) 35

(38) 40 45 50 55 60

(65) 70

(75) 80

(85) 90

(95) 100

Note 1: Sizes and lengths shown in brackets are of second preference. Note 2: Screws with nominal lengths above the broken stepped line are threaded up to the head.

8.1 TABLE-III DIMENSIONS FOR SCREW THREAD RUNOUTS

a AND x ACCORDING TO IS :1369-1982

Pitch P

Thread Runout x

Max

Runout Distance a

Max Normal

(see Note 1) Short

(see Note 2) Normal

(see Note 3) Short

(see Note 4) Long

(see Note 5) 0.2 0.5 0.25 0.6 0.4 0.8 0.25 0.6 0.3 0.75 0.5 1 0.3 0.75 0.4 0.9 0.6 1.2 0.35 0.9 0.45 1.05 0.7 1.4 0.4 1 0.5 1.2 0.8 1.6 0.45 1.1 0.6 1.35 0.9 1.8 0.5 1.25 0.7 1.5 1 2 0.6 1.5 0.75 1.8 1.2 2.4 0.7 1.75 0.9 2.1 1.4 2.8 0.75 1.9 1 2.25 1.5 3 0.8 2 1 2.4 1.6 3.2 1 2.5 1.25 3 2 4

1.25 3.2 1.6 4 2.5 5 1.5 3.8 1.9 4.5 3 6 1.75 4.3 2.2 5.3 3.5 7

2 5 2.5 6 4 8 2.5 6.3 3.2 7.5 5 10 3 7.5 3.8 9 6 12

3.5 9 4.5 10.5 7 14 4 10 5 12 8 16

4.5 11 5.5 13.5 9 18 5 12.5 6.3 15 10 20

5.5 14 7 16.5 11 22 6 15 7.5 18 12 24

Note 1 : Runout “x” normal for all types of screws in product Grades A,B and C.

Note 2 : Runout “x” short only in cases where a short runout is required for technical reasons.

Note 3 : Distance “a” normal for all types of screws in product Grade A.

Note 4 : Distance “a” short for special cases in which for technical reasons a short distance is

necessary.

Note 5 : Distance “a” long for all types of screws in product Grades B and C.

DIMENSIONS FOR HEXAGONAL NUTS AS PER DIN 934

ALL DIMENSIONS ARE IN MILLIMETRES

Thread size

d M1 M1.2 M1.4 M1.6 M2 M2.5 M3 (M3.5) M4 M5 M6 M8

M 8x1

M10 M 10X1

M10X1.25 P Nom 0.25 0.25 0.3 0.35 0.4 0.45 0.5 0.6 0.7 0.8 1 1.25 1.5

da Min 1 1.2 1.4 1.6 2 2.5 3 3.5 4 5 6 8 10 Max 1.15 1.4 1.6 1.84 2.3 2.9 3.45 4 4.6 5.75 6.75 8.75 10.8

dw Min 2 2.1 2.1 2.4 3.2 4.1 4.5 5 5.8 6.8 8.8 11.3 15.3 e Min 2.71 3.28 3.28 3.41 4.32 5.45 6.01 6.58 7.66 8.79 11.05 14.38 18.9

m Max 0.8 1 1.2 1.3 1.6 2 2.4 2.8 3.2 4 5 6.5 8 Min 0.55 0.75 0.95 1.05 1.35 1.75 2.15 2.55 2.9 3.7 4.7 6.14 7.64

m’ Min 0.44 0.6 0.76 0.84 1.08 1.4 1.72 2.04 2.32 2.96 3.76 4.91 6.11

s Max 2.5 3 3 3.2 4 5 5.5 6 7 8 10 13 17 Min 2.4 2.9 2.9 3.02 3.82 4.82 5.32 5.82 6.78 7.78 9.78 12.73 16.73

DIMENSIONS FOR HEXAGON HEAD SCREWS AS PER DIN 933

ALL DIMENSIONS ARE IN MILLIMETRES

Thread size d M1.6 M2 M2.5 M3 (M3.5) M4 M5 M6 M8 M10

P Nom 0.35 0.4 0.45 0.5 0.6 0.7 0.8 1 1.25 1.5 a Max 1.05 1.2 1.35 1.5 1.8 2.1 2.4 3 3.75 4.5

c Min 0.1 0.1 0.1 0.15 0.15 0.15 0.15 0.15 0.15 0.15 Max 0.25 0.25 0.25 0.4 0.4 0.4 0.5 0.5 0.6 0.6

da Max 2 2.6 3.1 3.6 4.1 4.7 5.7 6.8 9.2 11.2 dw Min 2.4 3.2 4.1 4.6 5.1 5.9 6.9 8.9 11.6 15.6 e Min 3.41 4.32 5.45 6.01 6.58 7.66 8.79 11.05 14.38 18.9

k Nominal size 1.1 1.4 1.7 2 2.4 2.8 3.5 4 5.3 6.4

Min 0.98 1.28 1.58 1.88 2.28 2.68 3.35 3.85 5.15 6.22 Max 1.22 1.52 1.82 2.12 2.52 2.92 3.65 4.15 5.45 6.56

k’ Min 0.7 0.9 1.1 1.3 1.6 1.9 2.28 2.63 3.54 4.28 r Min 0.1 0.1 0.1 0.1 0.1 0.2 0.2 0.25 0.4 0.4

s Max=Nominal

size 3.2 4 5 5.5 6 7 8 10 13 17

Min 3.02 3.82 4.82 5.32 5.82 6.78 7.78 9.78 12.73 16.73

Note 1 : P = Pitch of thread

Note 2 : a min. ≥ 1 P

Table for dimension ‘L’ for Table for dimension ‘L’ for

Thread size M 1.6 to M 6 Thread size M 8 & M 10

L Nominal

Min. Max.

2 1.8 2.2 3 2.8 3.2 4 3.76 4.24 5 4.76 5.24 6 5.76 6.24

(7) 6.71 7.29 8 7.71 8.29

10 9.71 10.29 12 11.65 12.35

(14) 13.65 14.35 16 15.65 16.35

(18) 17.65 18.35 20 19.58 20.42

(22) 21.58 22.42 25 24.58 25.42

(28) 27.58 28.42 30 29.58 30.42 35 34.5 35.5 40 39.5 40.5 45 44.5 45.5 50 49.5 50.5 55 54.4 55.6 60 59.4 60.6 65 64.4 65.6 70 69.4 70.6

(75) 74.5 75.6 80 79.4 80.6

L Nominal

Min. Max.

(7) 6.71 7.29 8 7.71 8.29

10 9.71 10.29 12 11.65 12.35

(14) 13.65 14.35 16 15.65 16.35

(18) 17.65 18.35 20 19.58 20.42

(22) 21.58 22.42 25 24.58 25.42

(28) 27.58 28.42 30 29.58 30.42 35 34.5 35.5 40 39.5 40.5 45 44.5 45.5 50 49.5 50.5 55 54.4 55.6 60 59.4 60.6 65 64.4 65.6 70 69.4 70.6

(75) 74.4 75.6 80 79.4 80.6

(85) 84.3 85.7 90 89.3 90.7

(95) 94.3 95.7 100 99.3 100.7 110 109.3 110.7 120 119.3 120.7 130 129.2 130.8 140 139.2 140.8 150 149.2 150.8

DIMENSIONS FOR PLAIN WASHERS, TYPE A, FOR HEXAGONAL BOLTS & SCREWS AS PER IS: 2016-1967 OR DIN 125A

ALL DIMENSIONS ARE IN MILLIMETRES

DIMENSIONS FOR PLAIN WASHER, TYPE B, FOR ROUND & CHEESE HEAD SCREWS AS PER IS: 2016-1967 OR DIN 433

ALL DIMENSIONS ARE IN MILLIMETRES

For Bolt or Screw Size

d (ID)

D (OD)

s Nom

M1.6 1.8 4.0 0.4 (M1.8) (2.1) 5.0 0.4

M2 2.4 5.0 0.4 (M2.2) (2.6) 6.0 0.5 M2.5 2.9 6.5 0.5 M3 3.4 7.0 0.5

(M3.5) (4.0) 8.0 0.8 M4 4.5 9.0 0.8

(M4.5) (5.0) 10 1.0 M5 5.5 10 1.0 M6 6.6 12.5 1.6

(M7) 7.6 14 1.6 M8 9.0 17 1.6

M10 11 21 2.0

For Screw Size

d (ID)

D (OD)

s Nom

M1.6 1.8 3.5 0.4 (M1.8) (2.1) 3.5 0.4

M2 2.4 4.5 0.4 (M2.2) (2.6) 4.5 0.5 M2.5 2.9 5.0 0.5 M3 3.4 6.0 0.5

(M3.5) (4.0) 7.0 0.5 M4 4.5 8.0 0.8

(M4.5) (5.0) 9.0 0.8 M5 5.5 9.5 1.0 M6 6.6 11 1.6

(M7) 7.6 13 1.6 M8 9.0 14 1.6

M10 11 18 2.0

DIMENSIONS FOR SINGLE COIL RECTANGULAR SECTION SPRING WASHER WITH FLAT END

AS PER IS: 3063-1994 OR DIN 127

ALL DIMENSIONS ARE IN MILLIMETRES

Nominal Size

Inside Dia d1 Outside

Dia (Max.) d2

Width b

Thickness s r

Nom

h

Basic Tol + Basic Tol

± Basic Tol ± Min Max

M2 2.1 0.3 4.4 0.9 0.1 0.5 0.1 0.1 1 1.2 M2.2 2.3 0.3 4.8 1 0.1 0.6 0.1 0.1 1.2 1.4 M2.5 2.6 0.3 5.1 1 0.1 0.6 0.1 0.1 1.2 1.4 M3 3.1 0.3 6.2 1.3 0.1 0.8 0.1 0.2 1.6 1.9 M4 4.1 0.3 7.6 1.5 0.1 0.9 0.1 0.2 1.8 2.1 M5 5.1 0.3 9.2 1.8 0.1 1.2 0.1 0.2 2.4 2.8 M6 6.1 0.4 11.8 2.5 0.15 1.6 0.1 0.3 3.2 3.8 M8 8.1 0.4 14.8 3 0.15 2 0.1 0.5 4 4.7 M10 10.2 0.5 18.1 3.5 0.2 2.2 0.15 0.5 4.4 5.2

ISRO SPECIFICATION DOCUMENT FOR

STAINLESS STEEL

WIRE THREAD INSERTS

SPECIFICATION FOR WIRE THREAD INSERTS: METRIC, SCREW LOCK

Applicable Standard: SAE MA 3329 and MA 1565 Rev.A Designation: M_____x______(L) (Length to be given in multiples of diameters, For shear strength of parent material, 200MPa (Al) and Bolt Ultimate tensile strength: 1100MPa(Ti) the length of helicoil recommended is 2D.) Material: SS 304 as per AS 7245 Hardness: 43 to 50 RC Mechanical properties: Ultimate tensile strength>=1375 MPa Bending: Wire shall withstand, without cracking, bending when tested in accordance with AS7245 Threads: The inserts, when installed in threaded holes conforming to MA1567, shall form threads conforming to ISO metric screw thread-M profile. Locking torque: As per table 16.1, given below Surface roughness: 0.2 to 0.4µm Acceptance inspection: AS per SAE MA 1565 Rev. A, Surface coating: No coating Sampling procedure: AS per SAE MA 1565 Rev A, Table : Locking torque

Nominal Thread Size

Maximum Locking Torque

Minimum Breakaway Torque, 15th Cycle

N-m N-m M2X0.4 0.12 0.003

M2.2X0.45 0.14 0.02 M2.5X0.45 0.22 0.06

M3X0.5 0.44 0.10 M3.5X0.6 0.68 0.12 M4X0.7 0.90 0.16 M5X0.8 1.60 0.30 M6X1 3.00 0.40 M7X1 4.4 0.60

M8X1.25 6.00 0.80 M10X1.5 10.50 1.40

Annexure 4 YEARLY FASTENERS REQUIREMENT FOR ISAC

(AIT,SMG, STR AND CEFF) Requirement of Screw/Bolt

SL. NO. SIZE LENGTH Ti. FAS. SS FAS.

QTY Head QTY Head 1 M2 4L-20L 400 Socket 40000 Socket,Chess,CSK 2 M2.2. 8L-12L 0 NA 31000 Socket,Chess,CSK 3 M2.5 4L-25L 0 NA 55000 Socket,Chess,CSK 4 M3 6L-50L 3800 Socket 316000 Socket,Chess,CSK 5 M4 6L-40L 85000 Socket 63000 Socket,Chess,CSK 6 M5 6L-50L 5100 Socket 32000 Socket,Chess,CSK 7 M6 12L-60L 32000 Socket 14000 Socket,Chess,CSK 8 M8 20L-50L 1900 Socket 1000 Socket,Chess,CSK 9 M10 25L 1000 Socket 0 Socket,Chess,CSK

Note: Quantity requirement includes all lenghts and head type together Requirement of Washer

SL. NO. SIZE Ti Washer Qty SS Washer Qty Remarks

Plain Spring Plain Spring 1 M2 0 0 25000 0 2 M2.2. 0 0 25000 0 3 M2,5 0 0 37000 0 4 M3 2500 500 288000 2000 5 M4 28000 4000 106000 2000 6 M5 3000 500 32000 2000 7 M6 31000 500 56000 2000 8 M8 1000 500 4000 2000 9 M10 2000 0 1000 1000

Note: All washers are of standard dimension Requirement of Nuts

SL. NO. SIZE Ti Nut Qty SS Nut Qty

Plain Lock Plain Lock Plate 1 M2 0 0 26000 0 0 2 M2.2. 0 0 26000 0 0 3 M2.5 0 0 26000 0 0 4 M3 NA 3000 10000 144000 3000 5 M4 NA 9000 5000 10000 3000 6 M5 NA 2000 10000 16000 3000 7 M6 NA 3000 5000 6000 3000 8 M8 NA 500 3000 1000 3000 9 M10 NA 500 3000 1000 3000

Requirement of SS Wire Thread Inserts

SL No SIZE

Qty Requirement Remarks

1D FR 1D SL 1.5D FR 1.5D SL 1 M2 5000 10000 5000 10000 Nil 2 M2.2 5000 10000 5000 10000 Nil 3 M2.5 5000 10000 5000 10000 Nil 4 M3 2000 15000 2000 30000 Nil 5 M4 2500 25000 2500 150000 Nil 6 M5 2000 3000 2000 7000 Nil 7 M6 2000 10000 2000 20000 Nil 8 M8 500 1000 500 1500 Nil 9 M10 500 1000 500 1500 Nil 10 M12 500 500 500 1000 Nil

EOI EVALUATION QUESTIONARE ANNEXURE 5

Query Answer

1 Company Profile

1.1) Total employee strength

a) Engineers

b) Diploma

c) ITI

d) Other

1.2)Total Manufacturing Area

1.3)Turn Over in last 3 years

2 Details of Quality/Process certification:

2.1)AS 9001 Certification

2.2)ISO Certification

2.3)NADCAP Certification

2.4)NABL Certification

2.5) OEM qualifications

2.6) Any other Certification

3 Competency for manufacturing aerospace fasteners

4 Is the manufacturing facility dedicated for aerospace fasteners

Provide details of other manufacturing units if any.

5 Previous experience of manufacturing and supply of fasteners to ISRO made from

1. Titanium fasteners

2. Stainless Steel Fasteners

3. Wire thread Inserts

6 Details of Raw Material:

6.1) Source of Raw Material & melting route

6.2) Whether material will confirm to UT(Class A1) as per AMS 2630/AMS2632

6.3) Details of the lab where confirmatory checks for chemistry , gas content and inclusion rating will be carried out

6.4) What is the available traceability procedure for fasteners currently used

6.5) Any other Information

7 Details of Processing route for screws/bolts:

7.1) Hot or cold forging process

7.2) Manual forging in press or automated forging

7.3) If hot forging details of the heating system along with pyrometer calibration certificate is furnished

7.4) Any other Process as applicable

7.4) Provide details of the proposed manufacturing flow for

1. Titanium fasteners

2. Stainless Steel fasteners

3. Wire thread Inserts

8 Details of heat treatment facilities:

8.1) Furnace details: Type, capacity, Heating Systems etc.,

8.2) Calibration certificate of the furnace and thermocouples to be provided

8.3) Any other process as applicable

9 Details of fillet radius and thread forming facilities:

9.1) Machine and tolling details: Type & Capacity

9.2) Profile projector and Thread Gauges available & calibration certificates to be provided

9.3) Anodizing facility and qualification details

9.4) MOS2 Coating Facility

9.5) Any other Process as applicable

10 Details of the following qualification facilities to be provided: 10.1 UTS and proof loading facilities for screw/bolts

10.2 Sustain load test facility

10.3 Hardness test facility

10.4 Macrostructure examination facility

10.5 Microstructure examination facility

10.6 FPI/MPI/DP test facility

10.7 Gas content testing facility

10.8 Details of availability of calibrated gauges for thread with tolerance & certificates to be provided

10.9 Facility for measurement of dimensional & geometric features such as thread size, shank diameter, shank length, overall length , head angle, bearing surface, thread chamfer, head to shank fillet, thread run out, roughness, head dimensions, squareness of bearing surface, concentricity, straightness etc.,

10.10 Residual magnetic field check

10.11 Surface Treatment inspections: i) Coating thickness measurement

ii) Salt spray test

10.12.Any other Facility as applicable

11 Details of Quality assurance systems for: 11.1) Receipt, storage & distribution of fasteners

11.2) Identification & traceability of fasteners in processing

11.3) Calibration of instruments, machines and tools

11.4) Control of process and documents

11.5) Non conformance control

11.6) Any other Information as applicable

12 Packaging System Provide details of the packaging system used