Test Requirements for Launch, Upper-Stage, and Space …

1 SMC Standard SMC -S-0 16 5 September 2014 ------------------------ Supersedes: SMC -S-016 (2008) Air Force Space Command Space AND MISSILE SYSTEMS CENTER STANDARD TEST Requirements FOR launch , upper - stage AND Space VEHICLES APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED Downloaded from from i Change History Description of Change Effective Date Inserted clarifications in Chapter 4, General Requirements Revised Tables , - 2, Unit qualification, protoqualification and acceptance test Requirements for units Clarified Evaluation Required (ER) Requirements Revised Tables , - 2, Subsystem qualification, protoqualification and acceptance test Requirements Revised Table , Vehicle acceptance test Requirements Added text in Chapter 4 General Requirements clarifying Requirements for, and use of, the flightproof test method Added criteria for waiver of proof testing on composite structures, Chapter 6 Added random vibration reduction of minimum workmanship guidelines for units weighing >50 lb, Appendix B Clarified criteria for unit shock testing, Chapter 6 Reduced acoustic test spectrum minimums to reflect EELV flight experience, Appendix B Decreased unit thermal cycling requirement on cycles from 27 to 20.

2 Chapter 6 Added Option 1, qualification using engineering qualification models (EQMs) Added Option 2, qualification/protoqualification by similarity (QBS) Added Option 3, alternate test sequence for vehicle level tests Added Option 4, modification of unit level random vibration protoqualification margins and durations Added Option 5, vehicle level flightproof acoustic testing Added Option 6, Conditions for deletion of the vehicle level acoustic test Added Option 7, two phase acoustic/vibration qualification/protoqualification Added Option 8, Unit thermal cycle acceptance credit for pre-conditioning at the board/slice level Added Option 9, two tier unit thermal testing Added allowable notching methodology for vibration tests June 25, 2014 Downloaded from iiContents 1.

3 Scope .. 1 Purpose .. 1 1 Baseline Requirements .. 1 1 Test Categories .. 1 Exclusions for Additional Environments .. 2 2. Reference Documents .. 3 Applicable Documents .. 3 Guidance Documents .. 4 3. Definitions .. 7 Assembly .. 7 Ambient Environment .. 7 Battery .. 7 Burst 7 Computer Program .. 7 Design Burst Pressure .. 7 Design Factor of Safety .. 7 Design Ultimate Load .. 7 Design Yield Load .. 8 Development Test Article .. 8 Electromagnetic Compatibility (EMC) Margin .. 8 Effective Duration for Acoustics and Random Vibration.

4 8 Explosive Ordnance Device .. 8 Firmware .. 8 Flight Vehicle .. 8 Flight Critical Item .. 9 Downloaded from iii Functional Testing .. 9 Hot Operational Soak .. 9 launch System .. 9 launch 9 Limit Load .. 9 Maximum and Minimum Model Temperature Predictions .. 9 Maximum and Minimum Predicted Temperatures .. 9 Maximum Expected Operating Pressure (MEOP) .. 10 Maximum Predicted Acceleration .. 10 Maximum Predicted Environment (MPE) for Acoustics .. 10 Maximum Predicted Environment (MPE) for Random Vibration .. 10 Maximum Predicted Environment (MPE) for Shock .. 10 Maximum Predicted Environment (MPE) for Sinusoidal Vibration.

5 11 Moving Mechanical Assembly (MMA) .. 11 Multipaction .. 11 Multi -Unit Module (MUM) .. 11 On-Orbit 11 Operational Modes .. 11 Part .. 12 Performance Testing .. 12 Pressure Component .. 12 Pressure Vessel .. 12 Pressurized Structure .. 12 Pressurized Subsystem .. 12 Proof Factor .. 13 Proof Test .. 13 Reusable Item .. 13 Service Life .. 13 Significant Shock Event .. 13 Downloaded from iv Simulator .. 13 Software .. 13 Software Item .. 13 Software Unit .. 13 Space Vehicle .. 14 Statistical Estimates of Vibration, Acoustic, and Shock Environments.

6 14 Structural Component .. 14 Subassembly .. 14 Subsystem .. 14 Survival Temperatures .. 14 System .. 15 Temperature Stabilization .. 15 Test Discrepancy .. 15 Test Item Failure .. 15 Thermal Dwell .. 15 Thermal Soak .. 15 Thermal Uncertainty Margin .. 15 Unit .. 15 upper - stage Vehicle .. 16 4. General Requirements .. 17 Baseline Requirements .. 17 Program Requirements .. 17 Testing Philosophy .. 17 Development tests .. 19 Qualification tests .. 19 Protoqualification tests .. 20 Acceptance tests .. 20 Testing Approach.

7 20 Development .. 20 Downloaded from v Qualification .. 21 Protoqualification .. 22 Acceptance .. 24 Special Considerations .. 24 Propulsion Equipment tests .. 24 Thermal Uncertainty Margins .. 25 Software and Firmware tests .. 27 Software Development tests .. 27 Software Qualification tests .. 27 Testing of Commercial Off-the- Shelf (COTS) and Reuse Software .. 27 Software Regression Testing .. 27 Other Software-Related Testing .. 27 Inspections .. 27 Post -Qualification Test Inspections .. 28 Post -Test Flight Hardware Inspection (Including launch Site).

8 28 Test Input Tolerances .. 28 Test Plans and Procedures .. 29 Test Plans .. 29 Test Procedures .. 30 Documentation .. 30 Test Documentation Files .. 30 General Test Data .. 31 Qualification, Protoqualification, and Acceptance .. 31 Test Log .. 31 Test Discrepancy .. 31 Exceptions to General Requirements .. 31 Qualification and Protoqualification by Similarity (QBS) .. 31 Electrical and Electronic Unit Thermal Vacuum Test Exemptions .. 32 Downloaded from vi5. Alternative Strategies .. 35 Spares Strategy .. 35 Flightproof Strategy .. 35 Combination Test Strategies.

9 36 Qualification Using Engineering Qualification Models (EQM) .. 36 6. Unit Test Requirements .. 37 General Requirements .. 37 Development tests .. 37 Subassembly Development tests , In-Process tests , and Inspections .. 37 Unit Development tests .. 37 Development tests for Composite Structures .. 37 Thermal Development tests .. 38 Shock and Vibration Isolator Development tests .. 38 Battery Development tests .. 39 EMI/EMC Development tests .. 39 Test Program for Units .. 39 Unit Wear-In Test .. 39 Unit Performance and Functional Test .. 43 Unit Leakage Test.

10 44 Unit Shock Test .. 44 Unit Vibration Test .. 46 Unit Acoustic Test .. 50 Unit Acceleration Test .. 53 Unit Thermal Cycle Test .. 54 Unit Thermal Vacuum Test .. 63 Unit Climatic tests .. 67 Unit Static Load Test .. 70 Unit Pressure Test .. 72 Unit Electromagnetic Compatibility (EMC) Test .. 74 Downloaded from vii Unit Life Test .. 75 7. Subsystem Test Requirements .. 77 Requirements .. 77 Subsystem Development tests .. 79 Mechanical Fit Development tests .. 79 Mode Survey Development tests .. 79 Structural Development tests .