MIL-DTL-16232G
4.4. Preproduction inspection. The preproduction inspection shall consist of obtaining
approval as specified in 3.1 of procedure, chemicals, and equipment proposed to be used during
production and when specified (see 6.2), the test and examinations specified in TABLE III.
4.5 Quality conformance inspection. The quality conformance inspection shall consist of the
tests and examinations specified in TABLE III. The stress and hydrogen embrittlement test shall
be performed for each lot only when specified by the procuring activity (see 6.2). Records of bath
controls and history shall be maintained by the contractor and made available to the Government
upon request as specified in 3.2.1 e and g.
4.6 Examinations.
4.6.1 Process examination. The phosphate coating process shall be subject to examination at
the discretion of the procuring activity to verify conformance with 3.2.
4.6.2 Coated item examination. Samples selected in accordance with 4.3 shall be examined
for compliance with the requirements of 3.8, 3.9 and 3.10. Dimensional and surface roughness
measurements after application of the coating need be made only when specified (see 6.2).
4.7 Test specimens. Test specimens shall be in accordance with the following:
a. If the size, shape or cost of the coated item is such that tests cannot reasonably
be performed on the item, separate representative test specimens may be utilized. These test
specimens shall be supplied by the contractor. Such test specimens shall be cut from scrap items
or made from the same alloy, heat treated in the same manner, and surface finished by the same
process as the items they represent. The specimens shall have an external surface area of from
10 to 100 square centimeters (cm2) except as noted in 4.6.2.
b. The test specimens shall be distributed randomly and processed concurrently
with the items.
c. The test specimens shall be used only once and then discarded.
4.7.1 Process control tests. Process control tests shall be performed at the frequency
established in accordance with 4.3.4 to verify conformance with 3.2.1 through 3.2.5. The
contractor's procedures shall be used as approved per 3.1.
4.7.2 Hydrogen embrittlement testing. Unless otherwise specified, testing to determine the
adequacy of the hydrogen embrittlement relief treatment shall be performed in accordance with the
following:
a. For parts that are surface or through hardened at Rockwell C 39 and above, testing shall be
performed in accordance with ASTM F519 using Type 1a cylindrical specimens to represent the
parts. Phosphated specimens shall be subjected to a sustained tensile load equal to 75 percent of
the ultimate notched tensile strength of the material. Loading of the specimen shall be
accomplished within one hour after completing the hydrogen embrittlement relief treatment stated
in the approved procedure. The steel, 4340 at Rockwell C51-54, is acceptable for worse case
situations unless otherwise specified on the drawing or in the contract.
b. Unless otherwise specified (see 6.2) the specimens shall be held under the load for a
minimum of 200 hours and then examined visually under lox magnification and an illumination of
1100 lux (lx) for cracks. The production parts covered by the test period shall be rejected if any
coated specimen develops any crack or breaks as a result of the test.
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