SAE-AS-1896A-1991-R2007.pdf

AEROSPACE STANDARD AS1896 REV. A Issued1984-09 Revised1991-12 Reaffirmed2007-08 Coupling Assembly, Self-Sealing, One Side Only, Hydraulic 1.SCOPE: This document establishes the requirements for aircraft, hydraulic couplings, self-sealing one side only, for use in Type II hydraulic systems (-65 to +275 °F temperature range) as defined by MIL-H-5440. The purpose being to connect a hose or tube to a standard MS33656, MS33514 or MIL-F-85421, or MIL-F-85720 fitting and to provide the self-sealing feature on the hose or tube side of the connection. 1.1Product Classification: Hydraulic self-sealing couplings shall be of the following classes a.Class 1000: 1000 lbf/in2 (gage) b.Class 3000: 3000 lbf/in2 (gage) c.Class 4000: 4000 lbf/in2 (gage) d.Class 5000: 5000 lbf/in2 (gage) 2.REFERENCES: 2.1Applicable Documents: 2.1.1SAE Publications: Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. ARP24Hydraulic Pressure, Determination Of ARP603Impulse Testing of Hydraulic Hose Assemblies, Tubing, and Fittings AS604Hose Assemblies, Teflon, 400 °F, 3000 psi, Hydraulic, Heavy Braid AS614Hose Assemblies, Aircraft and Missiles, High Temperature (450 °F), High Pressure (4000 psig) ARP868Pressure Drop Test for Fuel System Components ARP908Hose Fitting, Installation and Qualification Test Torque Requirements AIR1047A Guide for the Selection of Quick Disconnect Couplings for Fluid Systems RATIONALE This document has been reaffirmed to comply with the SAE 5-Year Review policy. SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright © 2007 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org Copyright SAE International Provided by IHS under license with SAELicensee=Defense Supply Ctr/5913977001 Not for Resale, 12/04/2007 20:50:24 MSTNo reproduction or networking permitted without license from IHS -,-,- SAE AS1896 Revision A - 2 - 2.1.2U.S. Government Publications: Available from Standardization Documents Order Desk, Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094. MIL-F-85421Fitting, Tube, Fluid Systems, Separable, Dynamic Beam Seal, General Requirements For MIL-F-85720Fitting, Tube, Fluid Systems, Separable, High Pressure, Dynamic Beam Seal, General Requirements For MIL-H-25579Hose Assembly, Tetrafluoroethylene, High Temperature, Medium Pressure, General Requirements For MIL-H-5440Hydraulic Systems: Design, Installation and Test of Aircraft (General Specification For) MIL-H-5606Hydraulic Fluid, Petroleum Base, Aircraft and Ordnance MIL-H-83282Hydraulic Fluid, Fire Resistant Synthetic Hydrocarbon Base, Aircraft MIL-H-85800Hose Assemblies, Polytetrafluoroethylene, Aramid Fiber Reinforced, 5000 and 8000 psi, General Specification For MIl-H-8775Hydraulic System Components, Aircraft and Missile, General Specifications For MIL-P-83461Packing, Preformed, Petroleum Hydraulic Fluid Resistant, Improved Performance at 275 °F MIL-R-8791Retainer, Packing, Hydraulic and Pneumatic, Tetrafluoroethylene Resin MIL-STD-129Marking for Shipment and Storage MIL-STD-130Identification Markings of U.S. Military Property MIL-STD-810Environmental Test Methods MS33656Fitting End, Standard Dimensions for Flared Tube Connection and Gasket Seal MS33514Fitting End, Standard Dimensions for Flareless Tube Connection and Gasket Seal 3.TECHNICAL REQUIREMENTS: 3.1Qualification: The couplings furnished under this document shall be a product which has been tested, and has passed the qualification tests specified herein, and has been approved by the Procuring Agency or Prime Contractor. 3.1.1General Specification: The requirements of MIL-H-8775 apply to this document except as specified herein. 3.2Materials: The coupling shall be constructed of materials that will not change the composition of or be adversely affected by hydraulic fluid conforming to MIL-H-5606 or MIL-H-83282. Other materials and fluids can be utilized for similar applications based on Procuring Agency requirements. Copyright SAE International Provided by IHS under license with SAELicensee=Defense Supply Ctr/5913977001 Not for Resale, 12/04/2007 20:50:24 MSTNo reproduction or networking permitted without license from IHS -,-,- SAE AS1896 Revision A - 3 - 3.3Design and Construction: The configuration, dimensions, and other details of design of the couplings shall conform to applicable Specification Control Drawings. This shall include mating with MS33656, MS33514, MIL- F-85421, or MIL-H-85720 end fittings as may be specified. The design objective shall be to obtain the smallest size and lightest weight commensurate with meeting performance requirements herein. 3.3.1Temperature Range: The couplings shall be designed to operate throughout the temperature range of -65 to +275 °F (see 4.4.3). 3.3.2Sealing, Fluid Loss, and Air Inclusion: The couplings shall, when uncoupled, seal the end of the disconnected line at the point of disconnection. Fluid loss (spillage) as specified in Table 1 and as determined by 4.4.11 is not considered to be external leakage. The coupling containing the valving shall seal under both low and high pressures (see 4.4.4). TABLE 1 - Air Inclusion and Fluid Loss (see 4.4.11) 3.3.3Seals: Only MIL-P-83461 packing material and MIL-R-8791 retainer material shall be used with MIL-H-5606 hydraulic fluid. Packing and retainer material for other fluids shall be specified by the Procuring Agency. 3.3.4Operation: The coupling shall be so designed that it can be uncoupled without special tools (but using standard wrenches), while the fitting is held in a fixed mounting. It shall be possible to couple and uncouple with a static pressure, as shown in Table 2, applied to the coupling assembly. The installation torque, shall not exceed the values shown in Table 2, when completely coupled. 3.3.5Interchangeability: Couplings of the same part number shall be interchangeable. It shall be impossible to interconnect different tube size fitting ends. Copyright SAE International Provided by IHS under license with SAELicensee=Defense Supply Ctr/5913977001 Not for Resale, 12/04/2007 20:50:24 MSTNo reproduction or networking permitted without license from IHS -,-,- SAE AS1896 Revision A - 4 - TABLE 2 - Coupling Torque with the Indicated Pressure and Fitting Ends Shown Copyright SAE International Provided by IHS under license with SAELicensee=Defense Supply Ctr/5913977001 Not for Resale, 12/04/2007 20:50:24 MSTNo reproduction or networking permitted without license from IHS -,-,- SAE AS1896 Revision A - 5 - 3.4Performance: The self-sealing couplings furnished under this document shall perform satisfactorily when conforming to the following performance requirements. 3.4.1Envelope, Weight, Materials: Each coupling half shall conform to the applicable purchaser and supplier envelope dimensions, weight control, materials, and finishes. 3.4.2Proof Pressure: Each coupling half must meet operational and leakage requirements after being subjected to proof pressure of 150% operating pressure for a period of 1 min (see 4.4.2). 3.4.3Extreme Temperature Functioning: Each coupling half shall show no malfunction during or after being subjected to extreme temperature testing from -65 to +275 °F (see 4.4.3). 3.4.4Leakage: Coupling halves shall meet specified leakage requirements at 30 in static head of hydraulic fluid and at operating pressure (see 4.4.4). 3.4.5Vacuum: The uncoupled coupling shall be subjected to a vacuum equivalent of 10 in of Hg internally. The vacuum line shall be closed for 5 min. The coupling assembly shall not exhibit a decrease in vacuum level exceeding 0.5 in Hg within a period of 5 min (see 4.4.5). 3.4.6Surge Flow: Coupling shall meet leakage, operational, and pressure drop requirements after being subjected to five times (three times for -16, two times for -20, -24, and -32) the rated flow in each direction (see 4.4.6). The surge flow pattern shall be repeated 100 times. 3.4.7Vibration: Each coupling shall be capable of withstanding the vibration environment specified without experiencing any malfunction or degradation. Couplings shall be pressurized with 15 lbf/ in2 (gage) pressure (see 4.4.7). 3.4.8Impulse: Coupling halves shall be capable of withstanding the impulse testing specified per ARP603 without any indication of malfunction. Pressures, rate of rise, and impulse form shall be per Table 3 and Figure 3 (see 4.4.8). 3.4.9Endurance: Coupling shall be capable of withstanding 200 endurance cycles without any evidence of malfunction or serious degradation with 15 lbf/in2 (gage) pressure applied to the self-sealing half. Size -32 shall have 10 lbf/in2 (gage) pressure (see 4.4.9). 3.4.10 Manual Operation: The couplings shall be coupled and uncoupled five times for this test. Couplings shall be installed in systems capable of accommodating some fluid displacement without pressure rise. The coupling force/torque and applied pressures shall be per Table 2 (see 4.4.10). 3.4.11 Air Inclusion/Fluid Loss: The air inclusion and fluid loss for the coupling shall be within specified limits per Table 1 (see 4.4.11). Copyright SAE International Provided by IHS under license with SAELicensee=Defense Supply Ctr/5913977001 Not for Resale, 12/04/2007 20:50:24 MSTNo reproduction or networking permitted without license from IHS -,-,- SAE AS1896 Revision A - 6 - NOTE: During impulse testing, this end shall be fixed to allow equivalent length and bend radius shown on Table 5 by clamping either the end fitting or the hose as required. During vibration, both ends are to be mounted to the shaker table. FIGURE 1 - Setup for Impulse and Vibration Test Copyright SAE International Provided by IHS under license with SAELicensee=Defense Supply Ctr/5913977001 Not for Resale, 12/04/2007 20:50:24 MSTNo reproduction or networking permitted without license from IHS -,-,- SAE AS1896 Revision A - 7 - TABLE 3 - Impulse Test 3.4.12 Impact: Connected couplings and coupling halves (disconnected coupling halves with caps and plugs, if required) shall withstand a 20 G impact test without evidence of disconnection. Evidence of leakage or malfunction after the test is not permitted (see 4.4.12). This can be accomplished by 20 G acceleration during the vibration testing per 4.4.7. 3.4.13 Pressure Drop: Each coupling subjected to this test shall have a pressure drop not to exceed those limits specified in Table 4. The fluid temperature shall be 100 °F ± 10 and test setup shall be as shown in Figure 4 (see 4.4.13). TABLE 4 - Rated Flow and Pressure Drop 3.4.14 Burst Test: Coupling shall be capable of withstanding 250% of operating pressure without fluid loss or rupture (see 4.4.14). The connected couplings shall be tested at 275 °F and disconnected couplings shall be tested at the room ambient condition only. Copyright SAE International Provided by IHS under license with SAELicensee=Defense Supply Ctr/5913977001 Not for Resale, 12/04/2007 20:50:24 MSTNo reproduction or networking permitted without license from IHS -,-,- SAE AS1896 Revision A - 8 - FIGURE 2 - Composite Vibration Test Curve for Equipment Mounted on Helicopters or Airplane Engines 3.5Identification of Product: The coupling shall be marked for identification in accordance with MIL-STD-130. In addition, each coupling shall be permanently marked with the customer (NSN, MS, Purchaser Assigned) part number, manufacturer's part number, and the manufacturer's name or code identification number. Class number (or operating pressure) shall be part of product identification. When available surface area precludes complete identification, a tag may be attached. Copyright SAE International Provided by IHS under license with SAELicensee=Defense Supply Ctr/5913977001 Not for Resale, 12/04/2007 20:50:24 MSTNo reproduction or networking permitted without license from IHS -,-,- SAE AS1896 Revision A - 9 - 3.6Workmanship: Workmanship shall be of the quality necessary to produce couplings free from all defects, which would affect proper functioning in service and be equal to or better than qualification test units. 4.QUALITY ASSURANCE PROVISIONS: 4.1Inspection Responsibility: The supplier is responsible for the performance of all inspection requirements as specified herein. Except as otherwise specified, the supplier may utilize his/her own or any other inspection facilities and services acceptable to the Procuring Agency. Inspection record of the examination and test shall be kept complete and available to the Procuring Agency as specified in the contract or order. The government and/or Procuring Agency reserve the right to perform any of the inspections set forth in the document where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements. 4.2Classification of Tests: The tests shall consist of qualification tests and acceptance tests. 4.2.1Qualification Tests: The qualification tests shall consist of the following tests and shall be conducted in the following order. All tests are described under 4.4. Unless otherwise specified, one test sample of each size shall be subjected to all indicated tests. Test samples shall be typical production units. a.Examination of product: 4.4.1 b.Immersion: 4.4.1.1 c.Proof pressure: 4.4.2 d.Extreme temperature functioning: 4.4.3 e.Leakage: 4.4.4 f.Vacuum: 4.4.5 g.Surge flow: 4.4.6 h.Vibration: 4.4.7 i.Impulse: 4.4.8 j.Endurance: 4.4.9 k.Manual operation: 4.4.10 l.Air inclusion and fluid loss: 4.4.11 m. Impact: 4.4.12 n.Pressure drop: 4.4.13 o.Burst pressure: 4.4.14 Copyright SAE International Provided by IHS under license with SAELicensee=Defense Supply Ctr/5913977001 Not for Resale, 12/04/2007 20:50:24 MSTNo reproduction or networking permitted without license from IHS -,-,- SAE AS1896 Revision A - 10 -