1 Purpose and Scope 2 Table of Contents Welding and Brazing Workmanship Requirements ..... 6 6...

ViaSat, Inc. Process Area: Document Number: Revision:

Quality 070-QA-044 05

Name of Document: Process Category: Page:

Standard for Workmanship and General Practices Quality 1 of 40

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1 Purpose and Scope

To establish procedures and ensure consistency in requirements for general workmanship and standard practices of

electronics hardware.

The documents referenced herein shall represent the minimum workmanship standards for all fabricated printed

circuit boards, electronic sub-assemblies and assemblies, as well as mechanical assemblies, which represent ViaSat

products. The requirements herein are applicable not only to ViaSat and its Divisions but all contracted product for

which this standard would be imposed.

2 Table of Contents

1 Purpose and Scope ................................................................................................................... 1 2 Table of Contents..................................................................................................................... 1 3 General Procedure ................................................................................................................... 1 4 Metal Fabrication Workmanship Requirements ...................................................................... 3

5 Welding and Brazing Workmanship Requirements ................................................................ 6 6 Mechanical Assemblies ........................................................................................................... 7

7 Cleaning of Parts and Assemblies ........................................................................................... 8 8 Wiring/Cable Crimping and Installation Workmanship .......................................................... 9 9 Acceptance Criteria for Circular Coax Crimps ..................................................................... 12

10 Handling of Equipment ...................................................................................................... 16 11 Cosmetic Inspection Criteria.............................................................................................. 16

11.1 Purpose and Scope ..................................................................................................... 16

11.2 Inspection Purpose ..................................................................................................... 16

11.3 Terms and Defect Definitions ..................................................................................... 16

11.4 Preferred Appearance Quality ................................................................................... 33

11.5 Surface Categories ..................................................................................................... 34

11.6 Light Source ................................................................................................................ 34

11.7 Inspection Table Surface ............................................................................................ 34

11.8 Viewing Time .............................................................................................................. 35

11.9 Viewing Orientation ................................................................................................... 35

11.10 Magnification Tools .................................................................................................... 35

11.11 Viewing Distance ........................................................................................................ 35

11.12 Acceptable Defects Matrix .......................................................................................... 36

12 References .......................................................................................................................... 40

3 General Procedure

Verify all workmanship attributes comply with drawing specifications as well as the appropriate reference standard

Workmanship

Name of Document: Document Number: Revision Page:

Standard for Workmanship and General Practices 070-QA-044 05 2 of 40

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All procedures applied in the manufacture of products as referenced in Section 4 are expected to be in accordance

with the best manufacturing practices that will produce the highest quality products. ViaSat, Inc. or any Divisions,

as the Buyer, reserves the right to review all Supplier procedures on workmanship practices during a process audit

under the AS9100 / ISO 9001 Quality Management System or any additional or subsequent systems that ViaSat, Inc.

may deem necessary to impose. Those procedures should detail or reference practices such as:

soldering practices as specified in IPC documents

marking of parts and assemblies

wiring assembly and installation practices

welding and brazing practices

plating practices

riveting practices

surface finishing practices (e.g., faying, sealing, painting, sanding, conformal coating, passivation, etc.)

machining operations practices

screw assembly practices

deburring practices

sharp edges removal practices

proper removal of unwanted contaminates and surface films

The Supplier shall schedule and perform inspections on the contracted product throughout the manufacturing

process to insure compliance with approved procedures for workmanship practices. Examples of areas to be

inspected are:

mounting and installing parts and subassemblies

cleaning of parts and assemblies

installation of threaded fasteners and rivets

installation of gear and bearing assemblies

assembly of wiring

installation of wiring

soldering, welding and brazing

The Supplier should develop inspection checklists so that consistent inspections can be conducted to insure good

workmanship.



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4 Metal Fabrication Workmanship Requirements

SURFACE ROUGHNESS

Unless otherwise specified, surface roughness shall be no greater than a 125 micro inch finish.

BURRS AND SHARP EDGES

Definition

A burr is a rough or irregular piece of material that typically occurs at the edge of a part feature. The burr is usually

the result of the part fabrication process.

Burr Types

Tight Burr – A burr that is strongly attached to the part. The burr cannot be moved or dislodged.

Rolled-over Burr – A burr that is curled over on itself. Concern is that contaminates can be trapped in the

burr.

Embedded Burr – Any burr that has been pressed into the base metal. The burr cannot be moved or

dislodged.

Loose Burr – A burr that is not firmly attached to the part. The burr can be moved or dislodged.

Feather Burr – A very thin or fine burr typically less than .001” thick. The burr can be moved or

dislodged.

Deburring Requirements

Unless otherwise specified, when the drawing specifies that the fabricated item shall be deburred, Table 1 shall be

used to determine the acceptability or non-acceptability of burrs according to the specified part class. The

requirement is applicable to all edges and corners.

Burr removal shall not result in a chamfer or radius that exceeds .015 inches, or one-quarter of the material

thickness, or the maximum edge break radius as specified on the drawing, whichever is smaller.

After the deburring process the parts shall meet the dimensional tolerances specified on the drawing.

Part Classifications

Class 1 - General Service Parts

Non critical parts. Can include commercial parts and special test equipment (STE). Includes applications

where burrs would not impact product functionality or cosmetic requirements.

Class 2 - Dedicated Service Parts

Includes military and commercial parts where high performance and extended life is required.

Class 3 - High Reliability Parts

Includes space, military, and commercial parts where continued performance or performance on demand is

critical. Equipment failures or downtime cannot be tolerated and must function when required.

Table 1. Burr Acceptability Criteria

Criteria

Part Classification

Class 1 Class 2 Class 3

Inspection Magnification None 10X 30X

Allowable Burr Type

(unless specified on

drawing)

Tight Burr, Embedded

Burr


Burr


Burr

Part Dimensions Burr does not violate

overall part dimensional

Burr does not violate


Burr does not violate




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Criteria

Part Classification

Class 1 Class 2 Class 3

requirements requirements

requirements

Part Function Does not affect part form

or function as determined

by engineering.

Does not affect part form


by engineering.



by engineering.

Acceptable Burr Locations Non-critical areas of part

as determined by

engineering.

Non-critical areas of part

as determined by

engineering.

Non-critical areas of part

as determined by

engineering.

Burr Attachment

Condition

Not removable by hand or

tweezers.


tweezers.


tweezers.

Post Burr Removal

Condition

Does not violate overall

part dimensional

requirements


or function

Exposed base metal must

be approved by

engineering.


part dimensional

requirements


or function


be covered by an

engineering approved

coating.


part dimensional

requirements


or function


be covered by an

engineering approved

coating.

Post Burr Removal Base Metal Repair

If exposed base metal is left as the result of burr removal, the vendor shall notify the buyer listed on the PO and

provide the location and size of the exposed base metal. The buyer will then contact the cognizant engineer who

shall determine whether the base metal can be left as is or shall specify the coating and application method for

covering the base metal.

INSIDE SHARP CORNERS

Inside sharp corners shown, but not specified as such on the drawing, may have a .015 inch maximum radius, or

.015 inch maximum chamfer.

THREAD RELIEF

Unless otherwise noted on the drawing, thread reliefs shall be as follows:

External: The relief diameter shall be equal to:

Minimum minor diameter +.000/-.010 inches for threads .25 inch diameter and under.

Minimum minor diameter +.000/-.020 inches for threads over .25 inch diameter

Internal: The relief diameter shall be equal to:

Maximum major diameter +.020"/-.000 inches for threads .25 inch diameter and under.

Maximum major diameter +.040"/-.000 inches for threads over .25 inch diameter

Length of the thread relief shall not exceed 2-1/2 threads.

CONCENTRICITY

Unless otherwise specified, all diameters shown concentric to each other shall be concentric within .010 total

indicator runout.



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PERPENDICULARITY OF HOLES

Unless otherwise specified, clearance holes shown perpendicular to a surface shall be perpendicular within 0.5

degrees. Unless otherwise specified, tapped holes shown perpendicular to a surface shall be perpendicular within 1.0

degree.

PARALLELISM OF PLANE SURFACES

Unless otherwise specified, all machined or sheared surfaces shown parallel shall be so within the tolerance zone for

given length of the surface shown by Figure 1 and Table 1.

Figure 1. Parallelism for Plane Surfaces

Table 1. Parallelism Length/Tolerance

Length (inches) Tolerance (inches)

0.00 – 1.00 .003

1.00 – 3.00 .005

3.00 – 5.00 .010

5.00 – 25.00 .015

25.0 – 60.0 .050

If tolerance exceeds tolerance on the drawing, the drawing tolerance shall take precedence.

FLATNESS

Machined surfaces shall be flat within .002 inch/inch.

SQUARENESS OF 90 DEGREE BENDS

Sheet metal bends shown as 90 on drawing shall be 90 +/- 1.0 degree. All formed parts shall have minimum bend

reliefs where required.

GRAIN DIRECTION

Unless otherwise specified, grain direction in formed metal parts may run in any direction convenient to

manufacturing, provided these parts do not fracture at bends.

COUNTERBORE AND SPOTFACE FILLET RADII

Counterbore and spotface fillet radii shown as sharp shall be sharp to:

.010 maximum radius for bore sizes between 0.00 and 1.00 inches

.030 maximum radius for bore sizes between 1.00 and 2.00 inches

TANGENCY OF FILLETS AND ROUNDS

Fillets and rounds shown tangent to adjacent surfaces shall fair smoothly with tangent surfaces +/- .005 inches.



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5 Welding and Brazing Workmanship Requirements

Aluminum Brazing

ViaSat brazing procedure specifications

When the class of braze is not specified on the ViaSat drawing, or other applicable document, Class A

requirements shall apply per AWS 3.7M/C3.7:2011.

Filler material shall be compatible to the material being brazed.

Brazing filler material will be AWS A5.8m/A5.8 approved foil or paste as specified on the drawing.

Fluxes shall conform to AWS A5.3M/A5.31and shall be compatible to filler material and shall remove oxides to

prevent their reformation during the braze process.

Controlled Atmosphere Brazing (CAB)

Assemblies will be cleaned and assembled following a documented procedure with traceability to each braze run

and will include.

Thermocouple placement and quantity

Thermal Profiles

Cooling time

Welding

When not specified on the drawing ViaSat welded assemblies will be based on the best practices identified in AWS

D17.1/D17.1M:2010-AMD1.

Parts must be checked and verified that they are to print, before welding. Once welding begins selective welding

techniques must be exercised, so that surface distortion is held to a minimum.

BUTT WELDS

Unless otherwise specified, all butt weld joints shall have complete penetration.

WELD SIZES

Fillet weld sizes shall be at least 140% of the thickness of the thinner material unless specified otherwise.

JOINT APPEARANCE

Welds shall be free from harmful defects (e.g., cracks, porosity, undercuts, voids, and gaps). All welds and brazes

shall show no burn-through. Weld bead appearance, cross-section and ripples shall be uniform and smooth.

GRINDING

Grinding shall affect the minimum area possible to satisfy the drawing requirements. Welds shall not be ground

unless required by drawing.



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6 Mechanical Assemblies

6.1 When mounting and installing parts and/or subassemblies, the following practices will be adhered to wherever

applicable:

Assembled parts and hardware should be secured or mounted in a manner that satisfactorily accomplishes

the intended purpose without degrading or becoming damaged in the environment in which they are to be

used.

Electronic equipment comprised of missing, inoperative, defective, bent, broken, or otherwise damaged

parts will be deemed unacceptable.

Parts (e.g., hinges, catches, handles, knobs, etc.) installation should avoid damaging adjacent hardware or

the mounting surface.

Rework to damaged finishes will be considered successfully performed when the surfaces are touched-up

with a continuous protective coating of identical composition as the original coating material.

The touch-up color should match the original finish such that the blended colors are not visually noticeable.

6.2 Installation of Threaded Fasteners and Rivets

Threaded fasteners and rivets should be carefully selected and applied so as to produce a safe, non-corroding,

functional and long-lived joining of materials. Commonly practiced procedures, guidelines and requirements

are:

Screws, nuts and bolts should show no evidence of cross threading, mutilation, or detrimental or

hazardous burrs.

The mixing of fasteners composed of different metals should be strictly controlled (e.g., steel nuts against

aluminum flat washers) because dissimilar metals encourage corrosion and unequal resistance to

mechanical stresses. Exceptions would include breakaway applications.

Uneven/over stresses between soft and hard materials should be avoided because such stresses cause

unwanted fatigue or early failure (e.g., steel screws fastening plastic pieces, aluminum screws to stainless

steel nuts, etc.).

All screw-type fasteners should be tight. Tight is defined as the screw or rivet being firmly secured with

no noticeable movement between the attached parts before or after applying maximum force by hand

without tools. It should be noted that tight may not guarantee unloosening, over time, due to vibration and

movement between joined metals.

In critical applications or whenever tightening of fasteners is insufficient, the Supplier manufacturing

processes should specify the proper torque requirements for threaded fasteners.

Self-locking fasteners and lock-wiring will be acceptable when specified on the engineering drawing.

Split-ring lock washers may be used if buffered by flat washers when specified on the engineering

drawing.

Star lock washers will not be allowed.

Anti-seizing chemical locking agents (e.g., Loctite) may be used and only sparingly, with the exception of

instances when grounding bonds of less than 0.10 Ohm are required as specified on the engineering

drawing.

The riveting operation should be carefully performed such that the rivets are tight and satisfactorily

headed with the rivet heads tightly seated against their bearing surface.



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7 Cleaning of Parts and Assemblies

The proper methods for cleaning parts and assemblies during the fabrication of product are essential in assuring the

expected performance and long operational life. The subsequent procedures are offered as examples of acceptable

cleanliness practices.

Product shall be cleaned of:

loose, spattered or excess solder

weld metal

metal chips

mold release agents

smudges

any other foreign material which might detract from the intended operation, function, or acceptable

appearance of the product

unwanted particles that could loosen or become dislodged during the normal expected life of the product

all corrosive material prior to parts assembly into the product

contaminants (e.g., lubricating oils, mold release agents, waxes, sand, corrosion products, solder fluxes,

finger prints, dust, etc.)

all contaminants without incurring damage or change of electrical and mechanical properties of the product

by using the safest and most appropriate agent and methods

After cleaning, the product should be allowed to dry. Any remaining loose contaminants should be blown or

vacuumed away, and all moving parts and assemblies should be relubricated according to design requirements. In

addition, post inspection should reveal no damage, unusual wear or presence of contamination on the product.



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8 Wiring/Cable Crimping and Installation Workmanship

Requirements

ViaSat and all ViaSat Subcontractors or Suppliers performing wiring/cable crimping operations shall implement the

following steps to ensure proper tooling is used and maintained, resulting in acceptable connector contact crimps:

1. Tooling and assembly procedures for wiring shall be per Manufacturers' instructions unless otherwise specified

herein.

2. ViaSat Manufacturing Engineering & Quality Engineering shall review the cable assembly drawings with the

Supplier and discuss the assembly materials, tooling and processes to be utilized to manufacture acceptable

wiring/cable assemblies.

3. All BOM items shall be reviewed. Extra contact pins shall be required to develop the wiring or cable assembly

process and perform the necessary tooling verification tests prior to assembly of production units.

4. Each contact or pin to be crimped shall require specific tooling and this shall be reviewed with the cable

manufacturer.

5. All crimp tooling shall be uniquely and permanently identified with a part number and serial number (e.g., S/N

1, 2, 3) and shall be under the calibration control program of the cable manufacturer. As such, a sticker shall be

added to each tool stating the calibration interval. Note: In the case of crimpers that use exchangeable die sets,

the handles and dies shall each individually be serialized and controlled.

6. The proper wiring/cable preparation and crimping process shall be contained in adequate instructions and

referenced in assembly drawings or other appropriate assembly documentation.

7. The visual acceptance criteria for circular coaxial connector contact crimps (which is not covered by IPC

documentation) shall be discussed, and reviewed against the ViaSat acceptance criteria procedure (see

Reference Documents section.)

8. First Articles of contact crimps, and a detailed first article inspection (FAI) report shall be provided to ViaSat

by the wiring/cable manufacturer as required by contract. The First Articles shall be presented to ViaSat for

approval such that the cable crimps can be reviewed and inspected without any cable disassembly.

9. In the case of coaxial crimps, a set of go/no-go gauge tools shall be provided by the wiring/cable manufacturer

and used to ensure the dimensions of the coaxial crimp tooling is acceptable for the contacts specified on the

drawing. An optional method to be measurement of completed crimps to specifications by the crimp contact

manufacturer.

10. Operator and Inspector training shall be provided by the wiring/cable manufacturer (both visual and gauge

tooling checks) for acceptable crimps per requirements. It shall record names, dates and type of training

performed. The Manufacturer, in their training, shall instruct each Operator performing any contact crimps that

it is their responsibility to ensure these crimps are acceptable per the specification applicable before handing the

cable assemblies to the next operation.

11. A Crimp Tooling Logbook shall be created for crimp tooling, and shall accommodate logging of results of daily

a) inspection results of crimp tooling, b) gauge tool checks and c) visual inspection results obtained on the first

three (3) production contact crimps produced with the tooling.

12. At the start of each day’s production of assembly wiring/cables, Manufacturing or Quality personnel shall

inspect the following and log in the Crimp Tooling Logbook:

a. The condition of the crimp tooling. The wear conditions shall be noted, along with any other visual

abnormalities noted.

b. Results of the gauge tool check or measurement in the case of coaxial crimp tooling.

c. The first three (3) production crimps produced with a tool shall be inspected for acceptance per specified

criteria, and results noted.

If acceptable, the tooling shall be released for use for the day for production crimping.

If, however, any contact crimps fail inspection, then production use with this tool shall be withheld until

a failure investigation is completed. The Manufacturer may swap out another qualified and released

tool/die set for production use, provided the successful daily check of that replacement tool is noted in

the Crimp Tooling Logbook. The cause of the rejects shall be identified, and logged in the crimp-

tooling logbook.



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If the failed crimps are determined to be the result of operator error it shall be recorded in the

logbook. The tooling shall then be closely inspected under magnification to ensure the operator did

not damage it during the crimping of the previous 3 units. In the case of coaxial crimps, an

additional check shall be done with either the go/no-go gauge of the tool or measurement of the

final crimped contact to verify acceptable dimensions. Results of these checks shall be logged. To

verify that it was indeed operator error, the operator shall repeat the crimping operation on another

three (3) production crimps. If there are no visual failures, then the tooling can be released for

daily production use.

If the failure analysis determines the crimp failures to be due to crimp tooling wear or malfunction,

then the tooling shall not be released for production use. Again, this shall be noted in the tooling

logbook.

Any tooling that fails inspection, or gauge tool or measurement checks, must be repaired or

replaced prior to use in production. Sufficient evidence of repair or replacement shall be available.

13. During production, each Operator shall be responsible for the quality of the contact crimps they produce.

Verification of tooling to the Contact Manufacturer specification shall be completed prior to use. ViaSat

encourages use of a “buddy system” whereby an Assembler performs a crimp, then performs a self-check to

ensure the crimp is satisfactory before moving material to the next operation. The next Assembler in the

process flow would then perform a quick check to ensure contacts are crimped properly and may now be

processed through the next assembly sequence.

14. In-process Inspection shall be performed on contact crimps prior to any higher-level or subsequent assembly

steps that may obscure full view of the crimps. Final Inspection shall be performed on the completed cable

assemblies. All results shall be recorded and maintained per the manufacturer’s Quality Management System

documentation as appropriate.

15. All assembly, tooling logbook entries and production/inspection data shall be subject to ViaSat (or ViaSat’s

Subcontractor) review and acceptance.

When installing wiring within an enclosure, the following practices shall be adhered to wherever applicable:

a. Insulated wire running between equipment or subassemblies within one piece of equipment (e.g., between

drawers or chassis and module subassemblies) should be formed into cables or ducted wherever possible.

b. Wire and wire bundles routed through holes in paneling or enclosure walls should be protected with

suitable insulated material (e.g., hole grommets).

c. Wires and cables should be positioned or protected to avoid contact with rough or irregular surfaces and

sharp edges.

d. Wire dress or bundling of wires should not result in improper electrical operation or interference with

mechanical operation that could lead to subsequent damage of the wire or cable.

e. Wiring/wire bundles should be securely supported and carefully routed to minimize chafing and abrasion,

small bend radii (no less than three times the wire or bundle diameter) riding against sharp edges and hard

surfaces, loosing of wire bundles, and occurrence of hotspots at the middle of wire bundles.

f. Riding conditions between wire/wire bundles on hard, sharp edges or surfaces shall be deemed

unacceptable.

g. Cold-flowing characteristics of installed wiring should always be known, understood and be taken into

account when implementing wire routing and bundling schemes.

h. Lacing of cabling should be applied firmly, yet not with excessive pressure such that it could cut into

conductor insulation (e.g., plastic cable ties and “stitch-lock” type lacing tape are acceptable materials for

lacing), as well as be neat and orderly in appearance.

i. Cable or wiring harnesses should be anchored to avoid damage to conductors or adjacent parts.

j. Wire bundles and cables should always be fixed such that there is minimum or no mechanical stresses

(radial, torsional or lateral stresses) at the terminated ends (no wire movement at wire termination points,

e.g., connectors/backshells, contacts, solder and crimp joints, splices, etc.-minimizes the mechanical

stresses).

k. Wire routing should be a safe distance from hot components to eliminate wire insulation deterioration.

l. Generous use of lacing tape, plastic tie-wraps or other non-metallic cable clamps to properly dress and stow

wire bundles will be deemed acceptable practice.



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m. Insulation should show no evidence of burns, abrading, or pinch marks that could cause short circuits or

current leakage. In addition, any condition or stress that exceeds the voltage withstanding or insulation

resistance characteristics should be eliminated.

n. Wires in a continuous run between two terminals should not be spliced during the assembly of the product,

except where a stranded conductor is spliced to a solid conductor and the two are supported at the splice as

allowed by the engineering drawing.

o. Clearance between wires/cables and heat generating parts (e.g., power semiconductors and resistors) should

be such as to avoid deterioration of the wires or cables from the heat dissipated by these parts under the

specified service conditions of the product.

p. Shielding on wires and cables should be secured in a manner that prevents contact or shorting of exposed

current-carrying parts.

q. Shielding should terminate at sufficient distance from the exposed conductors of the cable to prevent

shorting or arcing between the cable conductor and the shielding. The ends of the shielding or braid should

be secured against fraying.



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9 Acceptance Criteria for Circular Coax Crimps

Circular ferrule crimps are not covered in IPC/WHMA-A-620 and therefore have no acceptance criteria associated

with them. It is the purpose of this document to provide the acceptance and rejection criteria for those circular

ferrule crimps to assist with proper assembly and inspection. Standard inspection methods per IPC/WHMA-A-620

shall be applied for circular ferrule crimps. When applicable, this procedure should be cited on the engineering

drawing as the acceptance criteria. Inspections cited herein are accomplished using a high-powered inspection

scope with at least 10X magnification. Substitute inspection scopes should be used to provide the necessary detail to

detect the assembly defects cited herein.

Note: for coaxial and twin-axial assemblies to function properly, it is critical that all assembly instructions provided

by the manufacturer be followed.

Defects/Rejectable Conditions

Defect: Axial Misalignment (See Figure 1) Deformation (banana) of the contact/terminal that affects form, fit,

function or reliability. This type of deformation may interfere with proper insertion or extraction from connector

assembly.

Figure 1. Axial Misalignment (Banana) of the Crimped Contact

Defect: Ferrule Fractures and Cracks - Contact has visible fractures (See Figure 2) or cracks (See Figure 3) in the

formed ferrule.



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Figure 2. Fractured Ferrule

Figure 3. Cracked Ferrule



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Defect: Dislocated Crimp - Crimp extends past crimp barrel out over the cable.

Defect: Lose Crimp - Ferrule and / or connector turns/moves on cable after crimping. This defect indicates the

shield and/or inner contact is not secured which may result in conditions such as disconnected inner contact and/or

unacceptable RF emissions.

Acceptable Conditions

Acceptable: Slight Deformation (See Figure 4) - Slight deformation or irregularity of the metal in crimp ridge area

due to wear and tear of tool. (Considered to be a process indicator.) Tool should be serviced/repaired as soon as this

condition appears in the crimps. No evidence of cracks or fractures under a minimum of 10X magnification.

Figure 4. Slight Deformation in Crimp Ridge Area

Acceptable: Small Gap (See Figure 4) - Very small gap between outer and inner ferrules with no evidence crimp is

loose or will rotate/move in any way.

Acceptable: Uncentered Crimp - Crimp is not centered on crimp area of terminal but does not cause damage to

terminal or fail to hold.



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Target Condition

Target: No Deformations (See Figure 5 and 6) - Smooth straight crimp with no rough edges or evidence of

cracking or gaps. Part cannot be rotated or moved after crimping,

Figure 5. Smooth Crimp with No Evidence of Gaps or Cracks

Figure 6. Smooth and Straight Crimp



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10 Handling of Equipment

Proper handling of parts and equipment must be exercised to preclude physical and/or electrical damage such as

cracks, scratches, twists, fractures, etc. and the possibility of hidden damage such as that produced by flexure of

component leads, stressing of solder joints, over tightening of fasteners, electrostatic discharge (ESD), etc. In

process work is often particularly susceptible to such damage and, as such, special precautions that may include

special fixtures, stowage totes, etc. should be considered.

11 Cosmetic Inspection Criteria

11.1 Purpose and Scope

The purpose of this standard is to define and establish acceptance and rejection criteria for surface finish for

incoming and outgoing inspections applicable at Customer, approved Supplier or Subcontractor and ViaSat. The

company uses similar inspection criteria as today’s technology and market leader. ViaSat can meet any surface

finish on request; our finishing standard is common industrial finish described in Surface Categories Section.

Each finishing class stands for special manufacturing and handling processes, which are proportional to the related

costs. Every customer has to decide if a special cosmetic finish is a requirement or “nice to have”. Manufacturing

processes of bare material (e.g. cold rolled steel, pre galvanized steel, extruded parts) as well from machining

processes (e.g. punching, forming, and welding) may leave visible marks at the finished products, which are not

avoidable. Anodized material is more scratch resistant than Alodine material.

This standard applies to Surface Finishes such as Paint, Chemical Conversion Coating (Alodine, Anodize), Plating,

Molding and silk-screening.

11.2 Inspection Purpose

The inspection purpose is to determine any conditions for which the part or system will be rejected. The intent of

inspection is

To ship a part or system that meets the finish standard of this specification.

It is NOT the intent of inspection to find all imperfections on a part or system.

11.3 Terms and Defect Definitions

Accept per approved engineering drawing

Some cosmetic imperfections are not avoidable in certain process and design circumstances. Approved

engineering documents will point this out.

Abrasion

Surface imperfection that doesn’t remove or displace material appears as a scuff or changes to the surface

finish.

Bare Metal

A metal surface that has an intact protective coating but no cosmetic finish.

Base Metal

A bare metal surface on which the protective coating has been compromised.

Bleed Out

A Substance that runs out of seams. Color can vary from brown, dark brown to gray white at plating.



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Bleeding

Rough and not densely packed dull gray lines at plated material.

Blister

A bubbling in the surface of the finish. Non-adhesion or lack of proper sticking of the coating to the surface

caused by trapped air, gas or moisture.

Blush

Discoloration or change in gloss.

Break-out

Tearing of metal, or other material away from a casted or molded edge as a result of a

cutting/trimming process. This is likely to occur at flash points, or parting lines due to undersized, or

dull die cutting/trimming tools.

Burns

Brown marks or streaks on a surface of the part caused by trapped gases burning the surface of the plastic

during molding operation.



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Bubble

A bubbling in the surface of the finish. Non-adhesion or lack of proper sticking of the coating to the surface

caused by trapped air, gas or moisture.

Bump

Protrusions caused by trapped air / gas or moisture usually seen in finished parts.

Burnish Marks

Marks or lines that cannot be felt usually caused by tooling dies most common on flattened cold rolled

material e.g. Steel or aluminum sheets

Burrs

Sharp edges around part features caused by manufacturing process like punching, shearing, milling or

drilling.

Caution: Sheet metal edges that are compliant to UL 1439 can still cut through protective gloves and/or

human hands.

Chipping

Areas in which the adhesion between the paint and the surface is poor, causing the paint to come off with

light rubbing.



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Cloudiness

A haziness or lack of clarity in otherwise transparent part.

Contamination

Rough and not densely packed dull gray lines at plated material. Colored specks of foreign material

embedded in or on the surface part.

Corrosion

Areas of corrosion on any metal surfaces.

Caution: Small areas of rust are acceptable where plating is removed by a standard manufacturing or

welding process, e.g. sheared (cut) edges.

Cracking

Crackled appearance due to poor adhesion usually from surface contamination before plating.

Hairline cracks of anodized material caused by bending, high temperature curing after silk screening of the

aluminum or tool mark hair cracks on the opposite site of the aluminum.

Fine damages which may extend in a pattern on or beneath the surface or through a layer of material.



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Crazing

A fine mesh of minute cracks on the surface of some plastics due mainly to the effects of UV light.

Delaminating

Separation, peeling of thin layer of material

Dent

A surface depression caused by an impact.

Caution: Tooling marks are not dents.

Die marks

Marks made on the metal’s surface when it is formed, usually consist of long straight lines.



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Ding

Roughly funnel shaped dent caused by an impact.

Dirt

Any particle of foreign material.



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Discoloration

Any change from the original color or shade in the finish.

Distortion

A deformation of a diecasted part



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Dust

Small particles.

Fill In

An excess of ink that alters the form of a screened feature not affecting legibility.

Fingerprints

An impression left on the surface due to operator handling.

Finish

An area of smoother finish of molded plastic parts.



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Flaking


light rubbing.

Flash

Thin, excess material usually around the area of the mold parting line or internal shutoff areas.

Flow Marks

Waviness of edge or excess linear surface texture of silk-screened areas.

Fracture

Material splitting usually on the outside bend radius.

Gates

Point at which plastic is injected in cavity, usually on parting line.

Gloss

A uniform appearance of a painted or molded area. E.g. Shiny, matt

Glossiness

An area of either excessive or deficient gloss.

Gouge

A groove or scratch that extends through the finish and into the metal caused by a sharp object. A depth is

measurable.



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Grease

Any lubricant transferred to the part’s surface, shiny or glossy patches on the surface of the part.

Haze

Cloudiness on an otherwise transparent part.

Inconsistency

Variation of gloss, thickness of line or surface texture.

Inclusions

Small craters on surface caused by dust or dirt.

Lint

Any unintended foreign substance in the coating or on the surface.

Marbling

Colored streaks on a surface caused by improper mixing of molten plastic.

Marks

Pits, sanding, or other marks on base material that remains visible after coating.

Matt Finish

A less glossy finish of a surface area.

Metal Fuzz

Fine grit metal shavings that are clumped together may also be magnetic.



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Nicks

Like gouges but short of length caused by impact.

Non-adhesion

Lack of proper sticking of the coating or a glued material to the surface.

Non-uniform Coverage

Areas that have an insufficient or excessive coating.

Oils

Oily material on the surface due to materials used in manufacturing processes. Oily looking spots caused by

Loctite locking feature.

Orange Peel

Paint defect, rippled or mottled appearance viewable as concentric lines caused by under pressurizing not

dried paint surfaces.

Orange Skin

Paint defect, rippled or mottled appearance.

Oxidation

Has a rough feel of appearance. Dull gray, dark gray, black, brown, dark cinnamon or possibly white

colored substance.

Peeling


light rubbing.



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Pitting

Small craters on surface.

Punch mark

Mark on the surface of a material due to punch process.

Runs

Drips, bleeding, visible lines or raised areas of excessive paint or chemical coating similar to non-uniform

coverage.



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Rust

Areas of corrosion on any metal surfaces

.

Caution: Small areas of rust are acceptable where plating is removed by a standard manufacturing or

welding process, e.g. sheared (cut) edges.

Scratch

A shallow groove that can be seen but not felt.

Scuff marks

A series of very light, concentrated scratches that can be seen but not felt.

Short-Shot

Incomplete molded feature.



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Sink

Depression or dimple caused by non-uniform material shrinkage.

Slug Mark

A surface deformity caused by the punching process.

Smearing

The presence of ink on areas not called out in the master artwork.



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Smudge

Any dirt particle of foreign material.

Specks

Small particles.



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Spot Weld Mark

Dish shaped surface caused by spot welding process.



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Tooling Marks

Very shallow lines which are parallel to bends in part.

Unwanted impact of a tool during punch process.

Caution: Some tooling marks are not avoidable in some process steps. E.g. punching, forming, and bending.

Texture

An area of rougher finish of plastic molded parts.

A rougher but uniform finish of painted parts.

Visible Surface

Surfaces those are visible when the enclosure or part is installed in a completed assembly.

Void

The failure of ink to define a graphic feature.

Warpage

Dimensional distortion in a part after molding, pressing or laminating. Twist or bows in the part.

Water Spots

Rough and not densely packed dull gray lines at plated material.



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Weld lines

Line where molten plastic or metal joins form a part. A weld line usually appears as a noticeable line or

gloss variation across the surface of the part.

11.4 Preferred Appearance Quality

PAINT

Preferred

o Painted surfaces should be defect free and the texture and color should be uniform throughout the

entire surface.

o The finish on a continuous surface shall exhibit no gross imperfections such as gouges, large chips,

runs, blisters, oil spots, flaking, or any defects that will affect the functional properties of the finish.

o Paint touch-up is acceptable.

o A touch-up is not acceptable if visible at the viewing distance for that class of surface.

SILK-SCREENING

Preferred

o Silk-screened logos or symbols should be defect free, and should withstand cleaning with mild solvents

and the tape pull test.

PLATING

Preferred

o Visible outside surfaces should be defect free, and die and slug marks should not be visible.

o The coating surface shall have a uniform, metallic appearance without visible defects such as blisters,

pits, pimples, and cracks.

o Imperfections that arise from surface conditions of the substrate and persist in the coating shall not be

cause for rejection.

o Scratches and surface imperfections that occur after plating shall not penetrate the plating and expose

base metal or under-plating and are subject to further review.

CHEMICAL CONVERSION COATING (Alodine)

Preferred

o The finish shall have uniform appearance; be semi-bright, smooth, and clear to slightly yellow or

iridescent in color. Visual appearance will vary between different alloys and between machined,

milled, cast, and grained surfaces.

o Outside surface shall be free from scratches, dents, or gouges.

INSPECTION REQUIREMENTS

Viewing Conditions

o The inspector shall scan the surface in a continuous manner. All judgments shall be made from the

specified lighting, viewing distance, angle and material classes as described below.



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11.5 Surface Categories

Class A

o Is a critical cosmetic surface usually front exterior surface which is most often closely viewed by the

user / customer.

o Panels

o Instrument cases

o Desktop cases

o Customer specified

Class B

o Is a semi-critical cosmetic surface usually exterior surface which is adjacent to Class A, not viewed as

often but easily seen.

Class C

o Is a non-critical cosmetic surface either exterior surface rarely viewed by the user / customer, such as

back surface; or an internal surface that is visible but not normally viewed by the user / customer.

11.6 Light Source

Light Specification

o White, cool artificial office lighting (e.g. fluorescent light)

o Do not use direct sunlight.

Light Intensity

o Uniform intensity between 70 and 120 foot-candles. (750 and 1250 Lux)

Caution: At levels of greater light intensity caution should be used to not over inspect the parts in

order of accentuate surface flaws.

Light position

o Reflection free, non-directional from the top.

Caution: No direct overhead light above inspection table.

11.7 Inspection Table Surface

The table surface should be made of a non-reflective dark color to avoid twilight conditions.

Preferred: Black rubber mat Acceptable: Dark blue or dark green rubber mat



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Unacceptable: Light color table surfaces e.g. white, gray, yellow, metallic etc.

Caution: Reflective light-colored surfaces eliminate or accentuate surface flaws.

11.8 Viewing Time

Class A

o Systems: Ten (10) seconds per 200 square inches per part

o Front Panels: Five (5) seconds per 50 square inches per part

Class B

o Seven (7) seconds per 200 square inches per part

Class C

o Five (5) seconds per 200 square inches per part

11.9 Viewing Orientation

During inspection, view objects in an orientation perpendicular to each surface. During assembly, view

objects in normal orientation of manufacturing process. In some cases inspection should be held prior to

assembly. Any visible surface flaw has to be verified against the acceptable defect matrix.

Caution: Parts shall not be manipulated to reflect a single light source in order to accentuate surface flaws.

11.10 Magnification Tools

Magnification tools may be used to find root causes for defects or to verify correctness of special areas.

Caution: Magnification is not to be used when inspecting for cosmetic defects.

11.11 Viewing Distance

Viewing Distances from the surface being inspected

Class A

o 24 Inch (610 mm)

Class B

o 30 Inch (760 mm)

Class C

o 36 Inch (760 mm)



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11.12 Acceptable Defects Matrix

Acceptable Defects for Class “A” Surfaces

Viewing Time Viewing Distance

Ten (10) seconds per 200 square inches per part, five (5)

seconds per 50 square inches for front panels

24 inch (610 mm)

DEFECT ACCEPT REJECT

Bleed Out Up to 5/16” away from seam.

Touch up allowed.

Any greater than 5/16”

Blister None Any

Blush Accept per approved engineering

document.

Bubble None Any

Burns Accept per approved engineering

document.

Burrs Reference Table 1. Reference Table 1.

Cloudiness None Any

Contamination None Any

Corrosion/Rust/Oxidation None Any

Cracks None Any

Dent/Ding/Pitting None Any

Discoloration Color Consistency Accept per approved engineering

document for 100% uniformity of

surface

Partial discoloration

Dirt/Lint/Specks/Smudge Less than or equal to 0.02” Any greater than 0.02”

Flash Accept per approved engineering

document.

Flow Marks None Any

Fingerprints None Any

Flaking/Chipping/Peeling None Any

Metal Fuzz None Any

Paint Non-Adhesion/Non-

Uniformity/Inconsistency

None Any

Paint Runs None Any

Scratches/Gouges Qty. 3, less than or equal to 0.01” x

0.03”

More than qty. 3. Any bare metal or

base metal on a painted surface.

Scuff Marks Accept per approved engineering

document.

Short-Shots None Any

Sink Less than or equal to 0.003” deep Any greater than 0.003”



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Smearing None Any

Spot Weld, Welding Lines Accept per approved engineering

document.

Texture/Gloss/Finish 100% uniformity of surface, Accept

per approved engineering document.

Partial variation.

Tooling Marks/Die Marks/Slug

Mark/Punch Mark/Burnish Marks

Accept per approved engineering

document.

Voids Less than or equal to 0.01” Any greater than 0.01”

Water Spots None Any

Acceptable Defects for Class “B” Surfaces


Seven (7) seconds per 200 square inches per part. 30 inch (760 mm)


Bleed Out Up to 3/8” away from seam. Touch

up allowed.


Blister None Any


document.

Bubble None Any


document.


Cloudiness None Any



Cracks None Any


Discoloration Color Consistency 90% uniformity of surface More than 10% surface discoloration

or consistency.

Dirt/Lint/Specks/Smudge Qty. 3, Less than or equal to 0.03” More than qty. 3 per surface or any

greater than 0.03”

Flash Less than or equal to 0.005” in

height

Any greater than 0.005” in height

Flow Marks None Any


Flaking/Chipping/Peeling Less than or equal to 0.03” Any bare metal greater than 0.03” or

any exposed base metal



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Metal Fuzz None Any



None Any

Paint Runs None Any


0.09”; Qty. 1; Less than or equal to

0.01” x 0.25”

More than limit qty. per surface.

Any exposed base metal on painted

surfaces.


document.


Sink Less than or equal to 0.005” deep Any greater than 0.005”

Smearing None Any

Spot Weld, Welding Lines Less than or equal to 0.005” in

height or depth

Any greater than 0.005” in height or

depth

Texture/Gloss/Finish Less than or equal to 0.02” x 0.25” Any greater than 0.02” x 0.25”




document.



Acceptable Defects for Class “C” Surfaces


Five (5) seconds per 200 square inches per part. 36 inch (460 mm)


Bleed Out Up to 3/8” away from seam. Touch

up allowed.


Blister None Any


document.

Bubble None Any


document.


Cloudiness None Any



Cracks None Any



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Discoloration Color Consistency 80% uniformity of surface More than 20% surface discoloration

or consistency.

Dirt/Lint/Specks/Smudge Qty. 3, Less than or equal to 0.06” More than qty. 3 per surface or any

greater than 0.06”

Flash Less than or equal to 0.005” in

height

Any greater than 0.005” in height

Flow Marks None Any


Flaking/Chipping/Peeling Less than or equal to 0.09” Any bare metal greater than 0.09” or

any exposed base metal

Metal Fuzz None Any



None Any

Paint Runs None Any


0.25”; Qty. 1; Less than or equal to

0.01” x 0. 5”

More than limit qty. per surface.

Any exposed base metal on painted

surfaces.


document.


Sink Qty. 1, Less than or equal to 0.015”

deep

Any greater than 0.015”

Smearing None Any

Spot Weld, Welding Lines Less than or equal to 0.005” in

height or depth

Any greater than 0.005” in height or

depth

Texture/Gloss/Finish Less than or equal to 0.02” x 0.09” Any greater than 0.02” x 0.09”




document.





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12 References

Documents

IPC-A-600 – Workmanship Standards for printed circuit boards

IPC-A-610 – Workmanship Standards for electronic sub-assemblies

IPC/WHMA-A-620 – Requirements and Acceptance for Cable and Wire Harness Assemblies

1 Purpose and Scope 2 Table of Contents Welding and Brazing Workmanship Requirements ..... 6 6...

Documents

Transcript of 1 Purpose and Scope 2 Table of Contents Welding and Brazing Workmanship Requirements ..... 6 6...