mil metal removal

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LOCKHEED FPS-3017EFort Worth Company Date: 17 January 1995FSCM 81755 Superseding: FPS-3017D

METAL REMOVAL PROCEDURESAND LIMITATIONS

Contract Number F33657-88-C-O037

Releasability of this material under the Freedom ofInformation Act is subject to the restrictions on release inDoD Regulation 5400.7-R and DoD Directive 5230.25.

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Prepared and Approved By:

.,, . -,, .- . .

/wfk’’tlL/.—— —S. B. Klehl, ChiefStructural and EnvironmentMaterials & Processes

LOCKHEEDFort Worth CompanyFSCM 81755

FPS-3017EDate: 17 January 1995Superseding: FPS-3017D

CHANGE INDEX

Revision “E” incorporates the requirements of amendments 1 through 9. The only new requirement is theaddition of 3.8.5, which defines allowable anodize clamp marks.

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LOCKHEED FPS-3017EFort Worth Company Date: 17 January 1995FSCM 81755 Superseding: FPS-30170

Para

11.11.2

22.12.2

33.13.1.13.1.23.1.33.1.43.23.2.13.2.23.2.33:2.43.2.53.2.63,2.73.2.83.2.93.2.103.2.113.33.3.13.3.23.3.33.43.4.13.4.23.53.5.13.5.23.5.33.63.6.13.6.23.6.33.73.83.8.13;8.23.8.33.8.43.8.53.93.9.13.10

I AtILt Ul_ GUN 1 ENTS

S C O P EREQUIREMENTSLIMITATIONS

APPLICABLE DOCUMENTSMILITARY SPECIFICATIONSLFWC SPECIFICATIONS

REQUIREMENTSRAW STOCK CLEANUP

Removal of Mill DecarburizationRemoval of Mill Skin from Titanium, 10 Nickel, and PH/CRES Alloy ProductsRemoval of Mill Skin from AluminumSkin Milling Parameters

INITIAL CUITING OPERATIONFlame CuttingAbrasive CuttingFriction SawingCircular SawingLaser CuttingElectrical Discharge Machining (EDM)Plasma Arc Machining (PAM)Abrasive Water Jet CuttingAluminum Hand ForgingsMatte Finishing of Aluminum PartsMachining Of Fully Heat Treated Alloy And Carbon Steel Parts

GRINDINGGrinding of Steel PartsGrinding of Chromium Plated Low Alloy Steel PartsGrinding of Titanium Parts

BENCH WORKING OF METAL PARTSDeburring of Metal PartsHand and Power Tools

HOLE PREPARATIONHigh Strength SteelChamfering and Spot FacingClose Tolerance Holes

HOLE DEBURRINGFastener Holes in AluminumFastener Holes in Metals Other Than AluminumNon-fastener Holes

CORNER RADIISURFACE INTEGRITY

I Surfac& lntegrityForNon~FatiguwArrd-Nom-Fracture Critical PartsSurface Integrity For Fatigue And Fracture Critical PartsSurface Integrity For HolesMOO1Anodize Clamp Marks

MATERIALS HANDLINGCorrosion Protection

COOLANTS

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2222222222333333333333444444444555555555556

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88.18.28.38.48.58..6

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TABLE OF CONTENTS

QUALITY REQUIREMENTSPARTQUALITYAND lNTEGRllVSURFACEINTEGRITYDIMENSIONALTOLERANCESEXAMINATION

PREPARATION FOR DELlVERY

ACKNOWLEDGEMENT

REJECTIONS

N O T E SEDGECORNEREDGE BREAKCLOSE TOLERANCE HOLEFASTENER HOLECHIPLOADFORMULA

ENVIRONMENTAL HEALTH AND SAFETY

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LIST OF FIGURES

Figure Page

1 Polishing Requirements Around the Mold Line of Formed Sheet Metal 7

LIST OF TABLES

Table

1A

IB

Ic11A

IIB

[11A

IIIB

Iv

Mill Decarburization Removal Amounts

Titanium Mill Skin Removal Amounts

10 Nickel and CRES Mill Skin Removal Amounts

Minimum Material Removal After .Flame Cutting ,, .

Recommended Flame Cutting Speeds

Abrasively Cut Surface Layer Removal

Recommended Abrasive Blades and Cutting Speeds

Maximum Feeds for Grinding Titanium Parts

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LOCKHEEDFortWorthCompanyFSCM 81755

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S C O P E

REQUIREMENTS - This specification establishes the requirementsfree and acceptable surfaces on metallic parts and components from which metal is removed bv anv of the

for metallurgically damage-

common metal removal methods.. .

1.2 LIMITATIONS - This specification does not cover chemical machining methods. Refer to FPS-1051 and M039 for chemical milling requirements.

2 APPLICABLE DOCUMENTS - The following publications shall be applicable to theextent specified herein, or as defined in the contract or purchase order. These publications shall be therevision listed in 16PR711, except in cases where a particular revision is specified in this specification.Compliance with any other issues of these publications requires prior written approval from LOCKHEEDFort Worth Company (LFWC) Materials and Processes Technology (M&PT). If any of the publicationsreferred to herein conflict with the requirements of this specification, this specification shall govern.

2.1 MILITARY SPECIFICATIONS - Available from Commanding Officer, Naval Publications andForms Center, 5801 Tabor Avenue, Philadelphia, PA 19120.

MI L-P-3420 Packaging Materials, Volatile Corrosion Inhibitor, Treated, Opaque

MlL-C-l6173 cOrrOSiOt_I PfWE?ntiVe Compound, Solvent Cutback, ColdApplication

2.2 LFWC SPECIFICATIONS - Available from LFWC Service Library, P. O. Box 748, MZ 1519, FortWorth, TX 76101.

FPS-1051 Chemical Milling of Metals

FPS-1089 Grinding of Steel Parts and Chromium Plated Steel Parts HeatTreated to 180,000 psi and Over

FPS-1 098 Drilling and Reaming of Alloy Steel Parts Heat Treated to 180,000psi and Above

FPS-3014 Heat Treatment of Steels (Aerospace Practice, Process For)

FPS-3018 Forming of Aluminum Alloys

“FPS=3086 ‘“ ‘ ‘ Composite?vtachining Procedures and” Requirements

FQPL-3017 Fort Worth Division Qualified Material List for FPS-3017

NDTS 9111 Nital Etch Inspection

M039 Dynamic Etch Process,Tolerances For

Aluminum Alloy Roughness and Radius

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MOOI Surface Roughness and Tolerances for Machined Surfaces

M333 Installation of Bushings, Interference Fit

16 PR711 F-1 6 Materials Procurement and Processing SpecificationsApplicable Issues

3 REQUIREMENTS

3.1 RAW STOCK CLEANUP - The surface finish after skin milling shall be 125 RMS maximum.

3.1.1 REMOVAL OF MILL DECARBURIZATION - Carbon and alloy steels shall have all hot workedsurfaces machined to remove mill decarburization, unless otherwise specified on the engineeringdrawing. Refer to Table 1A for material removal amounts. This requirement is not applicable to 10 Nickel(HY 180) steels.

3.1.2 REMOVAL OF MILL SKIN FROM TITANIUM, 10 NICKEL, AND PH/CRES ALLOY PRODUCTS -Material not deskinned at the mill shall be machined to remove oxide, scale, or contaminated skin beforethe surface is in a satisfactory condition for use as the surface of a finished part. Titanium products maybechemical milled per FPS-1 051 in lieu of machining. Refer to Table IB for titanium material removal amountsand Table IC for PH/CRES and 10 Nickel removal amounts. A286 and 300 Series stainless steels areexcluded from this requirement.

3.1.3 REMOVAL OF MILL SKIN FROM ALUMINUM - When skin milling aluminum, proper speeds andfeeds shall be maintained in order to achieve a chip load of .006 -.01 O“, with a preferred chip load of .008 -.010”. Refer to paragraph 8.6 for instructions on determining chip load. Cutters used for skin milling musthave a positive axial rake angle and a positive radial rake angle for their cutters/inserts. In addition, the skinmilling operation must be run with coolant or microlube.

3.1.4 SKIN MILLING PARAMETERS - If only one side of a billet is required to be skin milled, theamount of material removed shall not exceed 0.249. If the amount of material to be removed is 0.250” orgreater, equal amounts are to be machined from both sides. When only one side is to be skin milled butthe material size has been substituted with a thicker material, equal amounts shall be removed from bothsides until the final thickness is achieved.

3.2 INITIAL CUTTING OPERATION - Initial cutting operations such as flame cutting, abrasivecutting, bandsawing, friction sawing, circular sawing, laser cutting, plasma arc machining (PAM), electricaldischarge machining (EDM), and abrasive water jet cutting are permitted provided that either a damagefree surface is maintained or the damaged surface layer is subsequently removed, unless otherwisestated on the engineering drawing.

3.2.1 FLAME CUTTING - Steel with carbon content greater than .30% and all low alloy steels maybepreheated at 500 ‘F* 25 ‘F prior to flame cutting to reduce cracking. After flame cutting, these materialsshall be stress relieved per FPS-3014 at 1175 ‘F* 25 “F for a minimum of 2 hours. When flame cutting 10Nickel steel in section thicknesses greater than 2 inches, the material shall be preheated to 250 “F*50“Fprior to cutting. Refer to Table IIB for recommended cutting speeds. Do not flame cut aluminum. Afterflame cutting, the damaged surface layer must be removed per Table II IA.

3.2.2 ABRASIVE -CU?77NG - Materia+-whict?is abrasively-cut must tiavethe damaged surface layerremoved per Table II 1A. Alloy steels which are subsequently hardened and tempered may be stressrelieved per FPS-3014 at 1175 “F * 25 “F for a minimum of 2 hours after abrasive cutting in lieu of thesurface removal requirements. Refer to Table IIIB for recommended blades and cutting speeds.

3.2.3 FRICTION SAWING - Friction sawing is not recommended for aluminum due to its high thermalconductivity. Friction sawing is also not recommended for material greater than 1/2” in thickness due toinadequate softening of the workpiece during the cutting operation.

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LOCKHEED FPS-3017EFortWorthCompany Date: 17 January 1995FSCM 81755 Superseding: FPS-3017D

3.2.4 CIRCULAR SAWING - Circular sawing is not recommended for steel or titanium products due tothe slow cutting speeds which are required.

3.2.5 LASER CUTTING - Laser cutting is permitted for all alloys. A minimum of 0.01 O“ shall beremoved from all laser cut surfaces to ensure removal of the recast zone, the heat affected zone, and themicrocracks caused by the laser cutting. If the laser cut surfaces are to be subsequently welded, metalremoval after laser cutting is not required. Company specific deviations to the minimum metal removal afterlaser cutting may be allowed as follows

(a)

(b)

Manufacture specimens from (1) 2024-T3, T62, or T81, (2) titanium representativeof any titanium cut, (3) carbon steel representative of any carbon steel cut, and (4)stainless steel representative of any stainless steel cut. Two specimens from eachmaterial must be used. One specimen must be a cut edge, the other must be a cuthole. After cutting, NO additional work may be preformed, i.e., deburring, polishing,buffing. The specimens can be any convenient size or thickness, as long as theycan be sectioned and analyzed.

The specimens must be submitted to an independent laboratory to determine thethickness of the recast zone and the heat affected zone. A report, including originalphotographs at 100X minimum, must be submitted to LFWC M&PT for analysis.

3.2.6 ELECTRICAL DISCHARGE MACHINING (EDM) - EDM is permitted for all alloys. A minimum of0.01 0!’ shall be removed from all EDM cut surfaces to ensure removal of the recast zone, the heat affectedzone, and the microcracks caused by the EDM.

3.2.7 PLASMA ARC MACHINING (PAM) - PAM is permitted for all alloys. A minimum of 0.010” shall beremoved from all PAM cut surfaces to ensure removal of the recast zone, the heat affected zone, and themicrocracks caused by PAM.

3.2.8 ABRASIVE WATER JET CUTTING - Abrasive water jet cutting shall not cause any materialdegradation.

3.2.9 ALUMINUM HAND FORGINGS - When machining fully heat treated/aged aluminum handforgings, care must be taken to minimize warpage. Parts shall not be finish machined on one side beforestarting on the other.

3.2.10 MATTE FINISHING OF ALUMINUM PARTS - Machined aluminum parts which are not fracturecritical may be matte finished by the wet abrasive blasthlurry method. Wet abrasive blasthlurry systemsshall not cause any material degradation.

3.2.11 MACHINING OF FULLY HEAT TREATED ALLOY AND CARBON STEEL PARTS - Alloy andcarbon steels heat treated to Ftu = 180 ksi and over which are machined in the fully heat treated condition,shall be nital etch inspected for burns per NDTS 9111 and baked at 50”F below the temperingtemperature for a minimum of two hours perFPS-3014.

3.3 GRINDING

3.3.1 GRINDING OF STEEL PARTS - Alloy or carbon steels heat treated to Ftu = 180 ksi and overshall be ground per the procedures of FPS-1 089. If the material is in the fully heat treated condition, Ftu =180 ksi and above, it shall be nital etch inspected for~rinder burns per NDTS 9111. 10 Nickel, PH Steels,maraging steels, and alloy or carbon steel heat treated to less than 180 ksi are excluded from thisrequirement.

3.3.2 GRINDING OF CHROMIUM PLATED LOW ALLOY STEEL PARTS - Grinding of chrome platedlow alloy steel parts heat treated to 180 ksi and above shall be performed per FPS-1 089.

3.3.3 GRINDING OF TITANIUM PARTS - Low stress grinding shall be performed on the last 0.010” ofmaterial on exterior surfaces and the last 0.005” of material on internal cylindrical surfaces (0.01 O“ on theinternal diameter). Maximum feeds shall be per Table IV. All parts shall be visually checked for overheating

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LOCKHEED FPS-3017E ~

Fort Worth Company Date: 17 Januaty 1995FSCM 81755 Superseding: FPS-3017D

after grinding. Parts which are bright silver, gold, or light blue are acceptable. All other colors shall because for rejection.

3.4 BENCH WORKING OF METAL PARTS

3.4.1 DEBURRING OF METAL PARTS - Parts shall be deburred to eliminate sharp edges andprojections. It is unnecessary to deburr for cosmetic purposes only. Surface integrity shall be perparagraph 3.8.

3.4.1.1 Parts which utilize an automatic sheet deburrer do not require the edges broken if they will bebroken in subsequent operations. However, if the sheet deburrer is used as the final operation, theedges must meet the requirements of paragraph 3.4.1.

3.4.1.2 When planning specifies the use of vibratory deburr, hand deburring may be substituted. Ifthe planning specifies hand deburring, vibratory deburring may be substituted provided that the partmeets engineering drawing requirements. Special care must be exercised when vibratoty deburring partsunder .050” thick, parts in the annealed condition, or long, thin parts without stiffeners due to the risk ofdeformation. It is recommended that parts not be run in the vibratoty deburring/finishing media longerthan 45 minutes due to work hardening effects. After removal, the parts shall be thoroughly rinsed anddryed.

3.4.1.3 Sheet metal which is punched, blanked, or pierced shall be polished to remove smearedmetal where the mold line intersects a net edge of the part, see Figure 1. The polished area shall extendto approximately 1/2” of either side of the mold line.

3.4.2 HAND AND POWER TOOLS - Hand and power tools may be used in the removal of minor flaws,over tolerance areas, and surface marks which have been machined, ground, or them milled to drawingdimensions. Scraping, filing, or grinding should be accomplished using gentle passes all in the samedirection, preferably the direction of grain flow. It is not necessary to blend two intersecting surfacesunless the intersecting radius is less than 0.060”. Do not use scrapers on high strength steel parts. Donot hand grind using stone grinding wheels or arbor mounted stones. Planned excess metal removalduring installation shall be accomplished by course grinding or sanding, tool routing, sawing, or using ahand held shear. A 120 or coarser grit shall be used to avoid overheating. The part must remain withinblueprint tolerances after metal removal.

3.5 HOLE PREPARATION - Holes may be prepared by using methods such as reaming, boring,honing, burnishing, and grinding. If drawing requirements can be met, the drilling of holes maybe used asa finish machining operation. Regardless of tool type, the tool shall be kept rotating during withdrawal. Awithdrawal rate of less than one inch/second is preferred. When machining through both metal andcomposites, refer to FPS-3086 for composites machining procedures and requirements.

3.5.1 HIGH STRENGTH STEEL - Preparation of fastener holes in steel heat treated to 180 ksi andabove shall be per FPS-1 098. Precipitation hardening steel and 10 Nickel are excluded from thisrequirement.

3.5.2 CHAMFERING AND SPOT FACING - Oversize drills shall not be used for chamfering with handpower tools. Adequate tooling shall be used for chamfering and spot facing.

3.5.3 CLOSE TOLERANCE HOLES - Metal removal for close tolerance holes used for bearing andbushing applications shall follow the provisions of this specification and M333.. , . ,,

3.6 HOLE DEBURRING - When deburring non-bonded stacks of metal, the stacks shall bedisassembled for hole deburring unless otherwise specified on the engineering drawing. Peel shim shallnot be deburred prior to assembly.

3.6.1 FASTENER HOLES IN ALUMINUM - Fastener holes in aluminum do not require deburringunless specified on the engineering drawing, when required for fit or function, or if sharp burrs orprotrusions exist.

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3.6.2 FASTENER HOLES IN METALS OTHER THAN ALUMINUM - Holes shall bedeburredto0.015“chamfer maximum, unless otherwise specified on the engineering drawing. A radiusing tool may be usedwhen entrance and exit surfaces are normal within 2° to the hole. Otherwise, deburring shall beaccomplished by hand.

3.6.3 NON-FASTENER HOLES - All hole edges shall be chamfered or radius deburred, unlessotherwise specified on the engineering drawing.

3.7 CORNER RADII - Undimensioned corners, both internal and external, on air surface skins shallbe square. On internal skins, the radii for undimensioned external corners for both hand routed andmachine routed aluminum sheet metal parts shall be .25” maximum. For parts produced on blanking dies,permissible radii on external corners is 0.12“ maximum and on internal corners is 0.15“ maximum. Adimensioned corner is a corner having a specified radius.

3.8 SURFACE INTEGRITY

3.8.1 SURFACE lNTEGRllY FOR NON-FATIGUE AND NON-FRACTURE CRITICAL PARTS- Surfacemarks do not need to be removed unless they are greater in depth than 10% of the material thickness,.004” maximum.

3.8.2 SURFACE INTEGRITY FOR FATIGUE AND FRACTURE CRITICAL PARTS- Surface markswhich are discernible by touch shall be rejected. A fingernail or a plastic indicator shall be used todetermine the presence of a rejectable surface mark. A surface mark which is visible but cannot bephysically felt is acceptable.

3.8.3 SURFACE INTEGRITY FOR HOLES - Unless otherwise specified on the drawing, hole integrityin parts and assemblies shall be verified as follows:

(1)

(2)

(3)

Visually examine for processing flaws such as axial and spiral tool marks.

Any visible flaw which cannot be physically felt is acceptable.

Axial flaws which can be felt shall be rejected. Spiral or circumferential flawswhich can be felt shall be compared to a surface roughness comparator.Spiral or circumferential flaws which compare to a surface finish of 125 RMS orsmoother are acceptable.

3.8.4 MOOI - MOOI defines the limits to which machined sutface roughness and mismatches may bepermitted in order to minimize hand finishing on machined parts, and is applicable when specifically calledout on engineering drawings.

I3.8.5 ANODIZE CLAMP MARKS - Anodize clamp marks are excluded from the requirements ofParagraph 3.8. For machined parts, anodize clamp marks shall meet the requirements of MOOI, with amaximum depth per side of .004”. For formed parts, anodize clamp marks shall meet the thinningrequirements of FPS-3018.

3.9 MATERIALS HANDLING - Care shall be taken to avoid damage to materials and parts duringstorage, work, and transportation. Parts shall not be left on machines covered with residual coolant whennot running for longer than 2.days without being removed-and cleaned. In addition, all parts shall becleaned after machining. Cleaning shall be accomplished by a parts washer, alkaline cleaning, or causticetch.

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3.9.1 CORROSION PROTECTION - After machining, and during transportation and storage, partsshall be protected from atmospheric corrosion. Paper or plastic may be used to cover the parts. Inaddition, MIL-P-3420 vapor phase inhibiting (VPI) paper maybe used on aluminum and either MIL-P-3420VPI paper or Ml L-C-l 6173, Grades 2 or 3 Oil may be used on non-corrosion resistant steel. Do not useMIL-P-3420 to protect cadmium plated surfaces.

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3.10 COOLANTS - Coolants shall be used during all machining operations on steel and titaniumproducts and when necessary to prevent overheating when machining aluminum. Coolant isrecommended for machining aluminum. Coolants shall not cause pitting, corrosion, or staining ofmachined parts. Coolants shall be cleaned from parts per 3.9. Water soluble cutting fluids shall bemaintained at a ratio of 1 part concentrate to 30 parts or less water. Deionized water or distilled water maybe used. Clean tap water is permissible when machining steel or aluminum.

4 QUALITY REQUIREMENTS

4.1 PART QUALITY AND INTEGRITY- Machining practices shall not induce metallurgicaldegradation to the metal surface. Surfaces shall not exhibit visual evidence of overheating, shall not besmeared or galled, and shall be visually free from contamination and defects.

4.2 SURFACE INTEGRITY - Surface roughness shall be in accordance with the drawing callout.When surface roughness is not specified on the drawing, machined parts roughness shall be 250 AAmaximum. The length of the surface roughness measurement taken shall be 0.03 minimum, unlessotherwise specified on the face of the drawing. Surface marks and edges shall meet the requirements ofparagraph 3.8.

4.3 D I M E N S I O N A L T O L E R A N C E S - Parts shall meet the dimensional tolerances of theengineering drawing.

4.4 EXAMINATION - One of the first five parts produced when establishing a new, fixed set ofmachining parameters shall be checked and meet the requirements of paragraphs 4.1, 4.2, and 4.3. Thisexamination shall be repeated after significant changes in machining parameters.

5 PREPARATION FOR DELlVERY - This section is not applicable to this specification.

6 ACKNOWLEDGEMENT - A vendor shall mention this specification number and itsrevision letter in all quotations and when acknowledging purchase orders.

7 REJECTIONS - Product not conforming to this specification, or to modifications authorizedby the purchaser, will be subject to rejection.

8 NOTES

8.1 EDGE - The edge is the intersection of two surfaces.

8.2 CORNER - The corner is the intersection of three or more surfaces.

8.3 EDGE BREAK - An edge break is the amount of material removed from the theoreticalintersection of two surfaces. This may be chamfered or radiused. The chamfer shall be burr free.

8.4 CLOSE TOLERANCE HOLE - A close tolerance hole is one with tolerances equal to or lessthan A .002”. . ..:- .>

8.5 FASTENER HOLE - A fastener hole is a hole which any type of fastener goes in including, butnot limited to, bolts, screws, rivets, and blind rivets.

8.6 CHIPLOAD FORMULA - The formula for computing the chipload is as follows:

(1) Chipload = Inch Per Inserl

(2) Number Of Inserts= Number Of Inserts In Face Mill Or Number Of Flutes Per Endmill

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(3) Table Feed Rate = Inches Per Minute

(4) Inch Per Insert X Number Of Inserts X RPM= Table Feed Rate

(5) RPM = Spindle Speed

9 ENVIRONMENTAL HEALTH AND SAFETY - Appropriate persona] protectiveequipment is required when melting, forging, machining, forming, or otherwise processing metals. Thenature of the processing activity will determine what equipment is necessary, i.e., glasses, respirator,protective clothing, and/or ear protection. Contact an occupational health professional to make theappropriate determination.

Deburred Area

I 1/2” I 1/2” IFIGURE 1: Polishing Requirements Around the Mold Line of Formed Sheet Metal

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TABLE 1A: Mill Decarburization Removal Amounts

NOMINAL DIAMETER OR MAXIMUM MINIMUM AMOUNT OF STOCKDISTANCE BETWEEN OPPOSITE FACES REMOVAL FROM EACH SURFACE

t c .188” None

.188” 5 t c .250” .010”

.250” s t < .375” .015”

.375” s t < .500” ,020”

.500” < t c .625” .025”

.625” < t < 1,00” .030”

1.00” < t c 2.00” .055”

2.00” s t < 3.00” .070”

I 3.00” s t c 4.00” I .085” I4.00” s t < 5.00” .115”

t > 5.()()” .150”

TABLE IB: Titanium Mill Skin Removal Amounts

PRODUCT

Forged Bar and Billet

Hot Rolled Bar

Condition “A” Piate

Condition “RA” Plate

Condition “Beta Annealed” Plate

Extrusions

Die and Hand Forgings

No. 2D Surface Finish Sheet &-Plate

MINIMUM AMOUNT OF STOCKREMOVAL FROM SURFACE

.040”

.030” I

.020” I

.025”

.025”

.015”

.040”

Not Required

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LOCKHEED FPS-3017EFortWorth Company Date: 17 January 1995FSCM 81755 Superseding: FPS-3017D

TABLE IC: 10 Nickel and CRES Mill Skin Removal Amounts

MINIMUM AMOUNT OF STOCKPRODUCT REMOVAL FROM SURFACE

Forged Bar, Billet, and Hand Forgings .040”

I Hot Rolled Bar and Plate I .030” IExtrusions Per Engineering Drawing

Die Forgings Per Engineering Drawing

I No. 2D Surface Finish Sheet & Plate I No Removal Required

TABLE 11A: Minimum Material Removal After Flame Cutting

MATERIAL MINIMUM CLEANUP A~ER FLAME CUTTING

THICKNESS 10 NICKEL STEEL TITANIUM

t c 1.00” .15” .15” .15”

1.00” < t < 2.00” .20” .20” .20”

2.00” <t s 7.00” .40” .25” .30”

TABLE IIB: Recommended Flame Cutting Speeds

MATERIAL MATERIAL CUITING SPEEDTHICKNESS (lN./MlN.)

3 “ 33 - 36

4 “ 30 - 33Titanium

5 “ 27 - 30

6“ - 7“ 20 - 27

3 “ 6 - 6.5

10 Nickel

~, ,, 14 - 202 “ 10 - 14

Steel4 “ 7 - 1 2

6,, - 7,, 5 - 8

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TABLE IIIA: Abrasively Cut Surface Layer Removal


I MINIMUM CLEANUP AHER

MAXIMUM MATERIALTHICKNESS

l%??=

t < 1.00” .10” .15”

1.00” s t c 2.00” .15” .20”

I 2.00” s t < 3.00” I .20” I .30” I

I 3.00” < t s 7.00” I .25” I .30”I

TABLE IIIB: Recommended Abrasive Blades and Cutting Speeds

WHEEL SPEEDMATERIAL BIADE TYPE (RPM)

Steel Aluminum Oxide 5500 - 6500Titanium Silicon Carbide 3000 - 6000

TABLE IV: Maximum Feeds for Grinding Titanium Parts

PASSEXTERIOR INTERIOR CYLINDRICALSURFACES SURFACES I

I Initial Low I .001” per Pass to Within .0005” per Pass to Within IStress Passes .002” of Finish Surface .002” of Finish Surface

3 Passes @! .0004”Finishing Low 4 Passes @ .0002” 10 Passes @ .0002”Stress Passes Final Pass with No Feed Final Pass with No Feed

I I I I

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LOCKHEED MARTIN Amendment 1 to FPS-3017ETactical Aircraft Systems Date: 9 September 1999FSCM 81755

AMENDMENT 1 TOFPS 3017E


Releasability of this material under the Freedom of Information Act is subject to the restrictionson release in DoD Regulation 5400.7R and DoD Directive 5230.25.


1

This amendment incorporates and supersedes all previous amendments. This amendment forms a partof and shall be attached to Lockheed Martin Tactical Aircraft Systems Specification FPS-3017, MetalRemoval Procedures and Limitations, dated 17 January, 1995. This amendment is effectiveimmediately upon issuance.

Paragraph

1.3 Change: Add the following new paragraph 1.3:

1.3 ALUMINUM-LITHIUM ALLOYSAluminum-Lithium (Al-Li) alloys are aluminum-based alloys such as FMS-4097which contain intentional additions of lithium above 0.15% by weight.Requirements for metal removal of Al-Li alloys are identical to those forconventional aluminum alloys, EXCEPT WHERE OTHERWISE NOTEDHEREIN.

Reason: To define Al-Li alloys as used in this document.

3.1.3 Change: Add the following new sentence to the end of paragraph 3.1.3:

Scrap segregation requirements for Al-Li alloys are detailed in Section 3.9,Materials Handling.

Reason: To highlight the requirements for scrap segregation of Al-Li alloys.

3.2 Change: Add the following new sentence to the end of paragraph 3.2:



3.2.1 Change: Add the word “alloys” to the next-to-the-last sentence of paragraph 3.2.1, so thatthe sentence reads:

Do not flame cut aluminum alloys.

Reason: To affirm that no aluminum alloys shall be flame cut.

3.2.3 Change: Add the following new sentence immediately after the first sentence ofparagraph 3.2.1:

Friction sawing shall not be performed on Al-Li alloys.

Reason: To disallow friction sawing of Al-Li alloys.

3.2.5 Change: Add the words “except Al-Li alloys” to the first sentence of paragraph 3.2.5, sothat the sentence reads:

Laser cutting is permitted for all alloys except Al-Li alloys.

Reason: To disallow laser cutting of Al-Li alloys.

3.2.7 Change: Add the words “except Al-Li alloys” to the first sentence of paragraph 3.2.7, sothat the sentence reads:

PAM is permitted for all alloys except Al-Li alloys.

Reason: To disallow plasma arc machining of Al-Li alloys.


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3.4.1 Change: Add the highlighted clause to the end of the first sentence of paragraph 3.4.1:

Parts shall be deburred to eliminate sharp edges and projections so that injury topersonnel and damage to equipment are prevented.

Reason: To clarify the intent of sharp edge/projection elimination.

3.4.1 Change: Add the following new sentence to the end of paragraph 3.4.1:



3.5 Change: Add the following new sentence to the end of paragraph 3.5:



3.6.1 Change: Add the word “alloys” after “aluminum” in the first sentence of paragraph 3.6.1,so that the sentence reads:

Fastener holes in aluminum alloys do not require deburring unless specified onthe engineering drawing, when required for fit or function, or if sharp burrs orprotrusions exist.

Reason: To clarify deburring requirements.

3.8.2 Change: Add the clause “typically greater than 0.001” deep on the bare metal” after“touch” and add 3.8.2.1 so that the paragraph(s) read:

3.8.2 SURFACE INTEGRITY FOR FATIGUE AND FRACTURE CRITICALPARTSSurface marks which are discernible by touch (typically greater than 0.001”deep) on the bare metal shall be rejected. A fingernail or a plastic indicator shallbe used to determine the presence of a rejectable surface mark. A surface markwhich is visible but cannot be physically felt is acceptable.

3.8.2.1 Surface Integrity for Painted Fatigue and Fracture Critical PartsWhen it is questionable on a painted surface whether a surface mark extendsinto the metal, the paint and prime shall be removed from the area with fineabrasive (e.g., "scotch-brite") by hand. A rejectable condition exists, if thesurface mark is discernible by touch on the bare metal. If the surface markextends only into the paint, a non-conformance does not exist. Touch-up and re-apply prime and paint per the appropriate finish code elements.

Reason: To clarify how “surface marks” should be handled.

3.9.2 Change: Add the following new paragraph 3.9.2:

3.9.2 SCRAP SEGREGATION OF AL-LI ALLOYSScrap classified as solids, turnings, and borings where large amounts of scrapmaterial are generated shall be segregated from conventional aluminum alloyscrap. Scrap classified as floor sweepings from bench working, drilling, orassembly where scrap contamination typically occurs, does not requiresegregation from conventional aluminum alloys.


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PREPARED BY: APPROVED BY:

_M. L. Polley____________ L. K. Austin________________

M. L. Polley L. K. AustinF-16 Systems Engineering F-16 Systems EngineeringMaterials and Processes Materials and Processes

mil metal removal

Documents

nital etch inspected

anodize clamp marks

heat affected zone

damaged surface layer

plasma arc machining

fracture critical parts

laser cut surfaces

metal removal procedures