MIL-DTL-83054C
4.5.3.2. Rejection and retest. Failure of any of the test specimens to conform to the process control
requirements specified herein shall require a retest of one additional set of test specimens for the
property that failed from the same test section. In the event of failure of any of the retested specimens,
production shall be halted and no additional baffle material accepted until the reason for failure has been
determined and corrective action taken. The qualifying activity shall be notified of any test failures
encountered.
4.6 Test methods.
4.6.1 Examination of product. Each finished bun of material shall be visually inspected for consistency
of cell structure, color, complete reticulation, obvious voids, or surface imperfections and the
dimensional tolerances specified in 3.8 prior to final packaging. Criteria for rejection of buns shall be
any exterior surface defects that could seriously affect the end function of the product, such as:
a. Excessive cleaves, voids, or splits.
b. Holes larger than 0.5 inch diameter and of 0.5 inch depth, not to exceed four per bun and no
closer than 2 feet.
c. Level of non-reticulation not to exceed 0.43% of the total surface area or 0.07% of the total
volume, based on the standard size bun.
4.6.2 Color test. Testing for color shall be by visual analysis. The baffle material shall be of a uniform
bright color as specified in table I. Any unusual color variations over the foam surface shall be cause for
rejection, especially distinct surface darkening due to dirt, contamination, or surface deterioration.
4.6.3 Density test. One test specimen shall be tested in accordance with ASTM-D3574 (Suffix W).
Specimen size shall be 3x7x10 inches, such that the 3-inch dimension is in the direction of the width (see
6.3.3) and the 7-inch dimension is in the direction of rise (6.3.4) of the test section. The results shall be
reported to the nearest 0.1 pound per cubic foot.
4.6.4 Porosity (air pressure drop) test. The pore size shall be determined by the air pressure drop
technique specified herein. Two specimens for each production and lot sample shall be run. For
qualification, three specimens shall be tested. The cylindrical specimen shall be 10 inches in diameter by
1 +0.02 inch thick, where the 1-inch dimension is in the height direction of the test section. For
production and lot testing, the porosity test specimens shall be taken within the top and bottom three
inches of the test section heist (foaming height). For qualification testing, the three specimens shall be
taken from the same location but from the upper, middle, and lower portions of the bun height.
Pressure drop measurements shall be made using a porosity test jig (see figure 1 for details) which has
been properly calibrated. Calibration shall be conducted on a daily basis using a special pressure drop
screen in order to determine the reference setting for the orifice differential manometer. Prior to sample
testing, both manometers shall be adjusted to zero with no airflow. The specimen shall then be inserted
into the sample holder until it is properly seated into the cutout. The blower shall be started and the
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