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1 NOTE: has been redesignated as a Test Method Standard. The cover page has been changed for Administrative reasons. There are no other changes to this Document. 15 FEBRUARY 1957 SUPERSEDING NAVSHIPS JANUARY 1955 DEPARTMENT OF DEFENSE TEST METHOD VISUAL INSPECTION GUIDE FOR RUBBER MOLDED ITEMS AMSC N/A FSC 93GP DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
2 OFFICE OF THE ASSISTANT SECRETARY OF DEFENSE, WASHINGTON 25, D. C. 15 FEBRUARY Supply and Logistics VISUAL INSPECTION GUIDE FOR RUBBER MOLDED ITE.MS 1. This standard has been approved by the Department of Defense and is mandatory for use by the Departments of the Army, the Navy, and the Air Force, effective immediately. 2. In accordance with established procedure, the Standardization Division has designated the Ordnance Corps, the Bureau of Ships, and the Air Force, respectively, as Army Navy-Air Force custodians of this standard. 3. Recommended corrections, additions, or deletions should be addressed to the Standardization Division, Office of the Assistant Secretary of Defense (Supply and Logistics), Washington 25, D. C. ii
3 FOREWORD Government material procurement specifications have been primarily concerned with detailing composition, construction and necessary physical requirements. However, little attention has been paid to defining the limits of acceptable quality regarding manufacturing defects other than such generalizations as the workmanship shall be first class. In such a diverse industry as that of rubber manufacturing, individual plants vary considerably in their production and quality control techniques. Defects are likely to occur from many causes such as variation in the quality of the basic materials and variations in manufacturing processes and finishing operations. Therefore, the quality generalizations used in this document must of necessity cover a considerable range which represents the best available judgment. This document is issued as a practical yardstick which Inspectors w-ill use to appraise visually the quality of rubber molded items. iii
4 CONTENTS 1. SCOPE AND PURPOSE SCOPE PURPOSE REFERENCED DOCUMENTS STANDARDS DEFINITIONS DEFECT DESCRIPTIONS AND CLASSIFICATION TABLES Table I Defects Classification iv
5 LIST OF FIGURES Air check location I major; location II minor. Air checks location I major; location II major. Trapped air location I major; location II major, Trapped air location I major; location II major, Trapped air location I major; location II minor. Trapped air location I major; location II minor, Blister location I major; location II major. Blister 1ocation I major; location II major. Blister 1ocation I major; location II major. Blister 1ocation I major; location II minor. Blister 1ocation I major; location II minor. Blister 1ocation I major; location II minor. Bloom, heavy location I major; location II minor. Bloom, heavy-location I major; location II minor. Cavity, damaged location I major; location II minor. Cavity, damaged-location I major; location II minor. Cavity, damaged location I major; location II minor. Cavity, damaged location I major; location II minor. Cavity, damaged location I major; location II minor. Cavity, damaged location I major; location-minor. Cavity, small mold scratch location I not a defect; location II not a defect. Coating, defective location I major; location II major Coating, defective location I major; location II major. Coating, defective-location I major; location II major, Crack location I major; location II major, Crack 1ocation I major; location II major, Crack 1ocation I major; location II major. Crack 1ocation I major; location II minor,. Deformed location I major; location II major. (Upper example is a defective. Lower example is a correct one for comparison. ) Deformed location I major; location II minor. Deformed location I major; location II minor, Deformed location I major; location II minor. Bad fill location I major; location II major. Bad fill location I major; location II major. Bad fill-location I major; location II major. Poor fill-location I major; location II minor. Flash, tion Flash, tion Flow tion Flow tion F1ow tion Flow tion cured-in location I major; loca- II major. cured-in location I major; loca- II minor. mark location I major; loca- II minor. mark location I major: loca- II minor. mark location I major; loca- II minor. mark location I major; loca- II minor. Foreign material location I major; location II major. v
6 Foreign material location I major; location II major. Foreign material location I major; location II minor. Pin hole location I major; location II minor. Pin hole location I major; location II minor. Pin hole location I major; location II minor. Marking not clearly legible minor. Marking not clearly legible minor. Marking not clearly legible minor. Dirty mold Iocation I major; location II minor. Dirty mold location I major: location II minor. Dirty mold location I major; location II minor. Dirty mold location I major: location II minor. Porosity location I major; location II major. Porosity location I major; location II major. Porosity location I major: location II minor. Porosity location I major: location II minor. Off register location I major; location II major. Off register location I major; location II major. Off register location I major; location II minor. Off register location I major; location II minor. Off register location I major; location II minor. Back rind location I major; location II major. Back rind location I major; location II major. Back rind location I major; location II minor. Back rind location I major; location II minor. Sprue mark location I major; location II major Sprue mark location I major; location II not a defect. Sprue mark location I major; location II not a defect. Trim, buff location I major; location II major. Trim, buff location I major; location II minor. Trim, buff location I major; location II minor. Trim, buff location I not a defect; location 2 not a defect. Trim, hand location I major: location II not a defect. Trim, hand location I major; location II not a defect. Trim, hand location I major; location II not a defect. Trim, hand location I major; location II not a defect. Trim, hand location I major; location II not a defect. Trim, machine location I major: location II major. Trim, machine location I major; location II major, Trim, machine location I major; location II major. Trim, machine location I major; location II minor. (Top example is correct for comparison. Bottom example is a defective.) Trim, machine location I major; location II minor. Trim, machine location I major; location II minor. Trim, machine location I major; location II major. (Top example is the defective. Bottom example is a correct one for comparison.) Trim, machine location I major; location II major. Trim, machine location I major; location. II major. Trim, machine location I major; location II major. Trim, tumble location I major; location II major. Trim, tumble location I major; location II not a defect. vi
7 Trim, tumble location I major; location II not a defect. Floating fabric location I major; location II minor. Bad adhesion location I major; location II major. Bad adhesion location I major; location II major. Bad adhesion location I major; location II major. Poor adhesion location I major; location II minor. Poor adhesion location I major; location II minor. Poor adhesion location I major; location II minor. Excessive flash location I major; location II major. Excessive flash location I major; location II major. Excessive flash location I major; location II major. Excessive flash location I minor; location II not a defect, Misplaced (insert) location I major; location II major. Misplaced (insert) location I major; location II major. Missing (insert) location I major; location II major. Missing (insert) location I major; location II major. Rust location I major; location II major. Rust location I major; location II minor. Bad staking location I major; location II major. (Top bolt is the defective. Bottom bolt shows the correct position.) Bad threads major. Bad threads major. Bad threads major. (Top bolt has chafed threads. Bottom bolt is an acceptable example.) Bad threads major; (Threads in the top bolt are missing. Other bolts are acceptable examples.) Poor threads minor. vii
8
9 1. SCOPE AND PURPOSE 1.1 Scope. This document covers the defects for conventional rubber molded items, that is, articles which are made by curing rubber compounds in a forming mold. Cast plastisol items, O rings, pneumatic tires and tubes, molded rubber fuel tanks, ebonite items and items containing cellular rubber are specifically excluded. 1.2 Purpose. The primary objective of this document is to present word descriptions and photographs of possible defects in rubber molded items that may be presented for inspection. In addition it provides a training aid for inspectors In general, this document is not intended to take the place of a particular inspection procedure aid which may be provided for inspectors to verify conformance with a particular specification. The quality requirements specified in the basic specification are governing. 2. REFERENCED DOCUMENTS 2.1 Standards MILITARY ML-STD-105 Sampling Procedures and Tables for Inspection by Attributes. MIL-STD-177 Rubber Products, Terms for Visible Defects of. (Copies of specifications, standards, drawings, and publications required by contractors in connection with specific procurement functions should be obtained from the procuring agency or as directed by the contracting officer.) 3. DEFINITIONS 3.1 The categories, major and minor defects, are as defined in Standard MIL-STD Word descriptions of defects used in this standard are in accordance with Standard MIL-STD Location I defect. The condition where the imperfection occurs on a primary use part of the item surface as regards dimensional tolerances or physical stress in service. 3.4 Location II defect. The condition where the imperfection does not occur on a primary use part of the item surface as regards dimensional tolerances or physical stress in service. 3.5 Fabric, floating. The condition where a reinforcing fabric is not in the correct position. 3.6 Staking, bad. The condition where an insert is not in the correct position. 4. DEFECT DESCRIPTIONS AND CLAS- SIFICATION 4.1 Since the classification of certain defects depends on the service requirements of the item, it is imperative that the end use be known before inspection is started. In the majority of cases, the end uses will be apparent or can be readily determined from the procurement document. However, in case of doubt, the cognizant technical bureau or agency (on primes) or the endorsing inspection service (on subs) should be requested to supply this information. 4.2 The classification of defects for molded items is more complex than that for a singleshape, single-application item such as V-belts. Molded items are produced in a nearly infinite variety of sizes and shapes so that there is no common or typical shape for this class of item. Also, these items have several principal end uses or service requirements which are dissimilar in the amount of perfection or quality required. These include the following: (a) Flexing A primary use where the. item undergoes constant or intermittent bending, twisting or deflecting during service such as a vibration isolation mounting. (b) Sealing A primary use where the item serves as an airtight or watertight closure such as a gasket or a boot. (c) Barring (barrier material) A primarỵ use where the item serves as an impervious material to passage of a liquid or gas such as a diaphragm or pneumatic closure., (d) Matching A primary application for dimensional tolerances where the item must be assembled with mating parts such as a stud mounting or a cable connector. (e) Protecting-An intermediate use where the item serves as a covering material and physical stress is non-existent or occurs infrequently, such as a brake pedal. 1
10 (f) Filling Subordinate use where the. item serves merely as an interns] space filler and physical stress is nonexistent or occurs infrequently. A molded item may, and frequently does, have two or more of these service requirements in combination. 4.3 It is recognized that the rejection of an inspection lot of molded items for defects which are not commensurate with the dimensional tolerances or degree of quality required by the user can result in an appreciable increase in the cost of production. Also, in some instances the enforcement of very high standards could result in an appreciable decrease in the volume of production. Accordingly, some of the defects in this standard are classified under three categories (major, minor, or acceptable) depending on the type of service requirement Note the definitions of location I and location II defects under definition of terms 4.4 Illustrations. The illustrations of physical defects, as shown on figures 1 through 116 and listed in table I, have been selected as typical ones, it not being feasible to gather examples of all possible defects. Table I. Defects Classification 2
11 Table I. Defects Classification Continued 3
12 Table I. Defects Classification Continued 4
13 Copies of specifications, standards, drawings, and publications required by contractors in connection. with specific procurement functions should be obtained from the procuring agency or as directed by the constructing officer. Copies of this standard for Military use may be obtained as indicated in the foreword to the Index of Military Specifications and Standards. Copies of this Standard may be obtained for other than official use by individuals, firms, and contractors from the Superintendent of Documents, U. S. Government Printing Office, Washington 25, D. C. Both the title and the identifying symbol number should be stipulated when requesting copies of Military Standards. Notice. When Government drawings, specifications, or other data are used for any purpose other than in connection with a definitely related Government procurement operation, the United States Government thereby incurs no responsibility, nor any obligation whatsoever; and the fact that the Governmfent may have formulated, furnished, or in any way supplied the said drawings, specifications, or other data is not to be regarded by implication or otherwise as in any manner licensing the holder or any other person or corporation, or conveying any rights or permission to manufacturer use or sell any patented invention that may in any way be related thereto. Custodians: Army Ordnance Corps Navy Bureau of Ships Air Force Other interest: Army CEQSigT Navy AOr v. 5
14
15 FIGURE 1. Air check location I major; location II minor. 7
16 FIGURE 2. Air checks location I major; location II major. 8
17 FIGURE 3. Trapped air location I major; location II major. 9
18 FIGURE 4. Trapped air location I major; location II major. 10
19 MIL-STD-4O7 FIGURE 5. Trapped air location I major; location II minor. 11
20 FIGURE 6. Trapped air location I major; location II minor. 12
21 FIGURE 7. Blister location I major; location II major. 13
22 FIGURE 8. Blister location I major; location II major. 14
23 FIGURE 9. Blister location I major; location II major. 15
24 16 FIGURE 10. Blister location I major; location II minor.
25 FIGURE 11. Blister location I major; location II minor. 17
26 FIGURE 12. Blister location I major; location II minor. 18
27 FIGURE 13. Bloom, heavy location I major; location II minor. 19
28 MIL-STD-4O7 FIGURE 14. Bloom t heavy location I major; location II minor. 20
29 15 F ebruary 1957 FIGURE 15. Cavity, damaged location I major; location II minor. 21
30 22 F IGURE 16. Cavity damaged location I major; location II minor.
31 FIGURE 17. Cavity, damaged location I major; location II minor. 23
32 F IGURE 18. Cavity, damaged location I major; location II minor 24
33 F IGURE 19. Cavity, damaged location I major; location II minor
34 MIL-STD-4O7 F IGURE 20. Cavity, damaged location I major; location minor. 26
35 FIGURE 21. Cavity, small mold scratch location I not a defect (usually); location II not a defect. 27
36 FIGURE 22. Coating, defective location I major; location II major. 23
37 FIGURE 23. Coating, defective location I major; location II major. 29
38 FIGURE 24. Coating, defective location I major; location II major. 30
39 FIGURE 25. Crack location I major; location II major. 31
40 FIGURE 26. Crack location I major; location II major. 32
41 FIGURE 27. Crack location I major; location II major. 33
42 FIGURE 28. Crack location I major; location II minor. 34
43 FIGURE 29. Deformed location I major; location II major. Upper example is a defective. Lower example is a correct one for comparison. 35
44 FIGURE 30. Deformed location I major. location II minor. 36
45 FIGURE 31. Deformed location I major; location II minor. 37
46 MEL-STD-407 FIGURE 32. Deformed location I major; location II minor. 38
47 FIGURE 33. Bad fill location I major; location II major. 39
48 FIGURE 34. Bad fill location I major; location II major. 40
49 FIGURE 35. Bad fill location I major; location II major
50 FIGURE 36. Poor fill location I major; location II minor. 42
51 F IGURE 37. Flash, cured-in location I major; location II major. 43
52 FIGURE 38. Flash, cured-in location I major; location II minor. 44
53 FIGURE 39. Flow mark location I major; location II minor. With internal delamination this is a major defect in all cases. 45
54 FIGURE 40. Flow mark location I major; location II minor. With internal delamination this is a major defect in all cases. 46
55 FIGURE 41. Flow mark location I major; location II minor. in all cases. With internal delamination this is a major defect 47
56 FIGURE 42. Flow mark location I major; location II minor. With internal delamination this is a major defect 48 in all cases.
57 FIGURE 43. Foreign material location I major; location II major. 49
58 50 FIGURE 44. Foreign material location I major; location II major.
59 FIGURE 45. Foreign material location I major; location II minor. 51
60 F IGURE 46. Pin hole location I major; location II minor. 52
61 17 February 1957 FIGURE 47. Pin hole location I major; location II minor. 53
62 FIGURE 48. Pin hole location I major; location II minor. 54
63 FIGURE 49. Marking not clearly legible minor. 55
64 FIGURE 50. Marking not clearly legible minor. 56
65 FIGURE 51. Marking not clearly legible minor
66 FIGURE 52. Dirty mold location l major; location II minor. 58
67 FIGURE 53. Dirty mold location I major; location II minor. 59
68 FIGURE 54. Dirty mold location I major; location II minor. 60
69 FIGURE 55. Dirty mold location I major; location II minor. 61
70 FIGURE 56. Porosity location I major; location II major. 62
71 FIGURE 57. Porosity location I major; location II major. 63
72 FIGURE 58. Porosity location I major; location II minor. 64
73 FIGURE 59. Porosity location I major; location II minor. 65
74 FIGURE 60. Off register location I major; location II major. 66
75 FIGURE 61. Off register location I major; location II major. 67
76 FIGURE 62. Off register location I major; location II minor. 68
77 FIGURE 63. Off register location I major; location II minor. 69
78 FIGURE 64. Off register location I major; Iocation II minor. 70
79 FIGURE 65. Back rind location I major; location II major. 71
80 FIGURE 66. Back rind location I major; location II major. 72
81 FIGURE 67. Back rind location I major; location II minor
82 FIGURE 68. Back rind location I major; location II minor. 74
83 FIGURE 69. Sprue mark location I major; location II major. 75
84 FIGURE 70. Sprue mark location I major; location II not a defect. 76
85 FIGURE 71. Sprue mark location I major; location II not a defect. 77
86 FIGURE 72. Trim, buff location I major; location II major. 78
87 FIGURE 73. Trim, buff location I major; location II minor. 79
88 FIGURE 74. Trim, buff location I major; location II minor. 80
89 FIGURE 75. Trim, buff location I not a defect (generally); location II not a defect. 81
90 FIGURE 76. Trim, hand location I major; location II not a defect. 82
91 FIGURE 77. Trim, hand location I major; location II not a defect. 83
92 FIGURE 78. Trim, hand location I major; location II not a defect. 84
93 FIGURE 79. Trim, hand location I major; location II not a defect. 85
94 FIGURE 80. Trim, hand location I major; location II not a defect. 86
95 FIGURE 81. Trim, machine location I major; location II major. 87
96 FIGURE 82. Trim, machine location I major; location II major. 88
97 FIGURE 83. Trim, machine location I major; location II major
98 FIGURE 84. Trim, machine location I major; location II minor. Top example is correct for comparison. Bottom example is a defective. 90
99 FIGURE 85. Trim, machine location I major; location II minor. 91
100 FIGURE 86. Trim, machine location I major; location II minor. 92
101 FIGURE 87. Trim, machine location I major; location II major. Top example is the defective. Bottom example is a correct one for comparison. 93
102 FIGURE 88. Trim, machine location I major; location II major. 94
103 FIGURE 89. Trim, machine location I major; location II major. 95
104 FIGURE 90. Trim, machine location I major; location II major. 96
105 FIGURE 91. Trim, tumble location I major; location II major. 97
106 FIGURE 92. Trim, tumble location I major; location II not a defect. 98
107 FIGURE 93. Trim, tumble location I major; location II not a defect. 99
108 100 FIGURE 94. Floating fabric location I major; location II minor.
109 FIGURE 95. Bad adhesion location I major; location II major. 101
110 FIGURE 96. Bad adhesion location I major; location II major. 102
111 FIGURE 97. Bad adhesion location I major; location II major. 103
112 FIGURE 98. Poor adhesion location I major; location II minor. 104
113 FIGURE 99. Poor adhesion location I major; location II minor. 105
114 F IGURE 100. Poor adhesion location I major; location II minor. 106
115 F IGURE 101. Excessive flash location I major; location II major. 107
116 l5 February F IGURE 102. Excessive flash location I major; location II major.
117 F IGURE 103. Excessive flash location I major; location II major. 109
118 FIGURE 104. Excessive flash location I minor; location II not a defect. 110
119 FIGURE 105. Misplaced (insert) location I major; location II major. 111
120 FIGURE 106. Misplaced (insert) location I major; location II major. 112
121 FIGURE 107. Missing (insert) location I major; location II major. 113
122 114 FIGURE 108. Missing (insert) location I major; location II major.
123 FIGURE 109. Rust location I major; location II major. 115
124 FIGURE 110. Rust location I major; location II minor. 116
125 FIGURE 111. Bad staking location I major; location II major. correct position. Top bolt is the defective. Bottom bolt shows the 117
126 FIGURE 112. Bad threads major. 118
127 F IGURE 113. Bad threads major. 119
128 120 FIGURE 114. Bad threads major. Top bolt has chafed threads. Bottom bolt is an acceptable example.
129 FIGURE 115. Bad threads major Threads in the top bolt are missing. Other bolts are acceptable examples. 121
130 FIGURE 116. Poor threads minor. 122 *U.S. GOVERNMENT PRINTING OFFICE: /14134
131
DEPARTMENT OF DEFENSE TEST METHOD VISUAL INSPECTION GUIDE FOR RUBBER ELASTROMERIC O-RINGS AMSC N/A FSC 5330
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