Jamie Hamilton

Immersion MIL-STD-810 Method 512 is used to evaluate the ingress protection capabilities of products against water intrusion.  This is normally used for military equipment where immersion in water is a probable event in that product’s life cycle, including logistical and tactical transport.  Performance of this testing does not necessarily preclude a requirement for Blowing Rain testing, as this environmental stressor presents different challenges for gasket design.

Procedures for Immersion 

There are two test procedures available for Immersion testing.  Procedure I (Immersion) evaluates the ability of enclosed equipment to withstand water immersion.  Procedure II (Fording) evaluates vehicles traversing a body of water or material secured to such vehicles.  As in other MIL-STD-810 test methods, operational testing is required when indicated by requirements or the Life Cycle Environmental Profile (LCEP).

Typical complete immersion duration is 30 minutes for both procedures.  For Procedure I, a standard depth of 3.28 ft (1 m) is used.  This depth is measured from the surface of the water to the top of the test item.  For Procedure II test depth is determined by the class of vehicle the equipment is designed for. 

When testing to depths greater than 1 meter is required, a pressure vessel may be used with the test item completely submerged.

Pretest Temperature Conditioning 

Temperature differentials between the test item and water are known to increase the likelihood of ingress.  This is caused by pressure differentials created as enclosure interiors cool.  Therefore, it is required to preheat the test item before immersion. 

For items that are subject to heating due to solar radiation, the prescribed temperature is 49 °F (27 °C) above the measured water temperature.  For other items the Unit Under Test (UUT) should be preheated to 18 °F (10 °C) above water temperature.  It is important to ensure that the item has been heated such that the item interior temperature meets requirements.  Where the interior temperature is unknown, the item should be heated for two hours.

When the item being tested is too large for a test facility’s environmental chambers, testing can be performed without preheating if the immersion depth is compensated for the calculated pressure differential that would be caused by heating.

IEC 60529 Ingress Protection

IEC 60529 Ingress Protection is a commercial standard for evaluation.  This method includes dust and penetration tests, water splash, immersion, water jet spray, and high pressure and temperature water jet spray testing.  This standard is typically applied to commercial products and their ability to keep the environment from interfering with the operation of a product.

The standard includes equipment ingress classifications (IP code) defined by the letters IP followed by two digits and an optional letter. As defined in international standard IEC 60529, it classifies the degrees of protection provided against the intrusion of solid objects (including body parts like hands and fingers), dust, accidental contact, and water in electrical enclosures.

Detailed Environmental Test Plan Templates

CVG Strategy offers EZ-Test Plan Templates for MIL-STD environmental (climatic/dynamic) and EMI/EMC testing documentation.  Our Detailed Environmental Test Plans (DETP)s are written as specified in MIL-STD-810 Task 405.  They are available for specific applications such as Ground Mobile, Ground Stationary, and Shipboard Controlled, Shipboard Uncontrolled, and Aircraft Military.

These DETPs include appropriate test methods, (such as Immersion MIL-STD-810 Method 512) addendums for product specific information, test labels for photo identification and data sheets for collection of required data. Profile (LCEP). 

Our Electromagnetic Interference Test Plans are written as specified by the Department of Defense.  They contain the test methodology, addendums for product specific information, test labels for photo identification and data sheets.  These plans are available for procedures listed in MIL-STD-461 and are also available for MIL-STD-1275, MIL-STD-704, and MIL-STD-1399-300. 

Custom Test Plans are also available for applications not covered in the EZ-Test Plan offerings.  These plans can be written for any number of applications and their relevant standards.

MIL-STD-810 Training Classes

CVG Strategy MIL-STD-810 classes will provide you with the ability to develop and conduct an environmental test program.  Our two day course not only provides you with valuable information about climatic and dynamic test methods but also includes training in the methodology to correctly apply test tailoring. 

This course is available online or onsite.  Ample time is available for questions and comments so that participants are encouraged to keep engaged.  Check here for our online Training Registration Schedule.

Put CVG Strategy’s Experience to Work for You

Companies of all sizes, from start up to established product developers, face challenges in product test and evaluation.  This can particularly be the case when a product is developed for a new market sector or expanding sales internationally.

Properly tested products prevent costly product recalls, product redesign, and product liability.  They maintain customer satisfaction and keep your company’s reputation in good standing.  Contact CVG Strategy to see how our testing services can assist your engineering team with Immersion MIL-STD-810 Method 512.5, IEC 60529 or any other test and evaluation concern.

Explosive Atmosphere, MIL-STD-810, Method 511, is used to evaluate how equipment will function in an explosive fuel-air environment.  This method has two procedures.  Procedure I – Explosive Atmosphere evaluates the ability of equipment to operate in a fuel-air environment without causing the fuel air mixture to ignite.  Procedure II – Explosive Containment evaluates the equipment’s ability to contain an explosion resulting from a malfunction.

This testing is appropriate for equipment designed for environments where aircraft, automotive, and marine fluids or vapors exist.  The test is representative of conditions at or above sea level where flammable fluids or vapors are present.  This testing is performed in a test chamber and should only be performed by qualified personnel.

Test Fuel

These tests normally use N-hexane for fuel sources as these have similar properties to JP-4 and JP-8 jet engine fuel, and high-octane aviation gasoline.  It is important to keep in mind that N-hexane is a hazardous material and that exposure to humans should be limited.  

The fuel-air ratios are specified in detail for the explosive atmosphere test.  These ratios must be homogeneous in the test chamber.  Temperature for chamber is to be the highest ambient temperature that the test item is to operate in during its life cycle.  

Altitude Simulation

Because the corona effect makes electrical devices more susceptible to arcing and creating sparks, both procedures are performed at simulated altitudes.  For Procedure I the test item is normally exposed to a chamber pressure of 40,000 ft. (12,200 m) plus 6,600 ft (2,000 m). 

The specified volume of n-hexane is introduced into the chamber and is allowed to mix and circulate with the chamber air.  The pressure is then adjusted to 40,000 ft. (12,200 m).  After each chamber pressure and corresponding n-hexane a test sample of the fuel-air mixture is subjected to a spark to verify the mixture’s explosiveness. 

Because of the low levels of oxygen present at the 40,000 ft. level, ignition may not always occur.  If the test sample is not ignited the chamber must be purged and the test restarted.

If the fuel-air mixture is verified, then the test item is exercised to simulate all operational modes.  If the test item does not cause ignition, the sequence is repeated for at least three more sequences at lower altitudes.  The final test occurring at site ambient pressure.

Procedure II Test Sequence

For Procedure II – Explosion Containment, the test item of model of same volume is installed into the test chamber.  Humidity, dew point and specified operating temperatures are established in the chamber.  The air pressure is set for a simulated altitude of 6,600 ft (2,000 m). 

The fuel-air mixture is introduced, and the chamber pressure is returned to site ambient pressure.  The mixture within the test item is ignited and if explosion occurs the test is complete.

Detailed Environmental Test Plan Templates

CVG Strategy offers EZ Test Plan Templates for MIL-STD environmental (climatic/dynamic) and EMI/EMC test documentation.  Our Detailed Environmental Test Plans (DETP)s are written as specified in MIL-STD-810 Task 405.  They are available for specific applications such as Ground Mobile, Ground Stationary, and Shipboard Controlled, Shipboard Uncontrolled, and Aircraft Military.

These DETPs include appropriate methods, (such as Explosive Atmosphere MIL-STD-810 Method 511) addendums for product specific information, test labels for photo identification and data sheets for collection of required data. Profile (LCEP). 

Our Electromagnetic Interference Test Plans are written as specified in MIL-STD-461.  They contain the test methodology, addendums for product specific information, test labels for photo identification and data sheets.  These plans are available for procedures listed in MIL-STD-461 and are also available for MIL-STD-1275, MIL-STD-704, and MIL-STD-1399-300. 

Custom Test Plans are also available for applications not covered in the EZ Test Plan offerings.  These plans can be written for any number of applications and their relevant standards.

Put CVG Strategy’s Experience to Work for You

Companies of all sizes, from start up to established product developers, face challenges in product test and evaluation.  This can particularly be the case when a product is developed for a new market sector or expanding sales internationally.

Properly tested products prevent costly product recalls, product redesign, and product liability.  They maintain customer satisfaction and keep your company’s reputation in good standing.  Contact CVG Strategy to see how our services can assist your engineering team with Explosive Atmosphere MIL-STD-810 Method 511 or any other test and evaluation concern.

 

Sand and Dust MIL-STD-810, Method 510 testing is used to evaluate equipment’s ability to withstand exposure to blowing sand and dust.  This test is to be performed in environmental chambers and replicates natural exposures expected in hot-dry regions of the world.

The standard defines dust as particles with a diameter less than 150 μm.  Sand is defined as particles with a diameter between 150 to 850 μm.  The standard further defines the prescribed composition of these particles to be used in the procedures.

Effects of Exposure to Sand and Dust

Sand and Dust can cause numerous effects on equipment that can result in serious degradation of performance or complete failure.  Abrasion, erosion, and penetration of seals can occur.  Effects caused by the interference of moving parts as particles enter into crevices, bearings, and joints can render equipment ineffective or hinder use.  Additionally, when particles obstruct openings and vents, they can cause overheating.

Recent Revisions to This Test Method

The Sand and Dust test method was completely rewritten in Revision H, which was released in 2019.  Changes were made to ensure that a more realistic distribution of particles in test chambers during a test.  These changes led to the redesign of chambers in many test facilities and resulted in dust chambers being reduced in size.  It is therefore important to make certain that chambers are available if you are testing larger equipment.

Revisions in MIL-STD-810 usually occur to create more realistic test environments using the latest available technology.  In most cases there are few reasons to test to older revisions of the standard.  This would especially be the case for this particular method.

Test Procedures for Method 510

There are two procedures in Method 510, Procedure I – Blowing Dust, and Procedure II – Blowing Sand:  

Procedure I – Blowing Dust

Blowing Dust is conducted using specific air velocities.  When measured data is not available the following representative values are to be used:  An air velocity of 300 ±200 ft/min (1.5 ±1 m/s) is to be used to maintain test temperature conditions, and an air velocity of 1750 ±250 ft/min (8.9 ±1.3 m/s) is to be used to replicate desert winds.  Typically, these wind speeds are to be uniformly across the area of the test item.

Temperatures should reflect the intended environments expected to be encountered in the equipment’s life cycle.  Normally, this would include Hot Dry (A1) temperatures that would be found in the deserts of Asia, Africa, Australia, and North America.  For ambient exposures, this would be 120 °F (49 °C), although higher temperatures can be employed to account for solar loading on equipment.

As moisture in the test chamber can result in caking of the dust, it is important to control the levels of relative humidity (RH).  For the blowing dust procedure, the RH should not exceed 30 percent.

As previously mentioned, dust composition is specified in the standard.  Normally, red China clay or silica flour is used, unless otherwise specified.  Testing should be conducted for at least 6 hours at ambient temperature and 6 hours at the specified high temperature. 

The test item may be rotated during testing to ensure that all faces have equal exposure.  If necessary, operational tests should be conducted.  These should be performed for at least 10-minute durations.

Procedure II – Blowing Sand

Blowing Sand should, unless otherwise specified, use the same temperatures as used in Blowing Dust.  Generally, a wind velocity of 40 mph (18 m/s) or higher is used for testing.  As the sand used in testing should have an angular composition, the reuse of sand from previous tests is not allowed, as the impact of particles will result in increased roundness of sand particles.

This test should be performed for a minimum of 90 minutes per side of equipment normally vulnerable to exposure.  Required operational testing should be considered when writing a test plan.  

Special Considerations for Sand and Dust Testing

Test Sequencing

Sand and Dust MIL-STD-810 Method 510 testing causes abrasion and will produce a coating of dust on test items.  This could influence the results of testing performed after this method for Humidity, Solar Radiation, Fungus, Salt Fog/Corrosive Environments, and Acidic Environments.  Care should be taken when developing the Test and Evalution Master Plan.

Safety Concerns

Inhalation of particles of dust and sand pose significant health hazards.  Silica flour which is composed of ground quartz can cause silicosis.  Appropriate personal protective equipment should be utilized to prevent exposure.

Electrostatic Energy

High levels of electrostatic electricity can buildup due to the combination of dry air with moving particles.  It is important to consider adequate grounding schemes to prevent discharges that could damage the test unit.

Detailed Environmental Test Plan Templates

CVG Strategy offers EZ-Test Plan Templates for MIL-STD environmental (climatic/dynamic) and EMI/EMC testing documentation.  Our Detailed Environmental Test Plans (DETP)s are written as specified in MIL-STD-810 Task 405.  They are available for specific applications such as Ground Mobile, Ground Stationary, and Shipboard Controlled, Shipboard Uncontrolled, and Aircraft Military.

These DETPs include appropriate test methods, (such as Sand and Dust MIL-STD-810 Method 510) addendums for product specific information, test labels for photo identification and data sheets for collection of required data. Profile (LCEP). 

Our Electromagnetic Interference Test Plans are written as specified by the Department of Defense.  They contain the test methodology, addendums for product specific information, test labels for photo identification and data sheets.  These plans are available for procedures listed in MIL-STD-461 and are also available for MIL-STD-1275, MIL-STD-704, and MIL-STD-1399-300. 

Custom Test Plans are also available for applications not covered in the EZ-Test Plan offerings.  These plans can be written for any number of applications and their relevant standards.

Put CVG Strategy’s Experience to Work for You

Companies of all sizes, from start up to established product developers, face challenges in product test and evaluation.  This can particularly be the case when a product is developed for a new market sector or expanding sales internationally.

Properly tested products prevent costly product recalls, product redesign, and product liability.  They maintain customer satisfaction and keep your company’s reputation in good standing.  Contact CVG Strategy to see how our testing services can assist your engineering team with Sand and Dust MIL-STD-810 Method 510, or any other test and evaluation concern.

Fungus MIL-STD-810 Method 508 evaluation is employed to assess a product’s susceptibility to support fungal growth. This test method is an important part of a testing program because fungus is present in a large number of environments and has numerous detrimental effects.

Effects of Fungus 

Direct and indirect attacks can occur to products of natural origin as well as synthetic materials such as polyvinylchlorides, polyurethanes, polyethers, paints, and varnishes. Additionally, fungus can cause damage to electrical systems and optical systems.

Health effects from ingestion or inhalation of mycotoxins from certain species of Aspergillus mold, a fungus, can lead to skin rash, inflammation of mucus membranes, liver damage, and cancers.

Considerations

Although the standard contains an Annex to identify the basic resistance of materials to fungal growth test by analysis is not recommended.  This is because of the combination of materials and their ability to support fungal growth are beyond the scope of such an analysis.

Fungus testing should not normally be conducted on the same item as used for Salt Fog/Corrosive Environments, Sand and Dust, Humidity, or Acidic Atmosphere.  If these methods are performed before the Fungus method, residues left on the test item may hinder or accelerate fungal growth.

Fungus Species

A number of species are used in this method.  These include Asperfillus flavus, Tricoderma virens, Talaromyces pinophilus, Chaetomium globosum, and Aspergillus brasilensis.  These species are representative of destructive fungi found around the world.  These species have also been selected as they are rated at Biosafety Level 1 and therefore present minimal threat to human health.

Because of the threat to human health and the fact that the procedure calls for highly-specialized techniques, it is essential that only technically qualified individuals perform these activities.  

Facility Requirements

Test chambers are to be used that prevent condensation from dripping on the test item.  The chamber should be monitored with sensors to allow for control of temperature and humidity.  Minimal airflow is used for this method, generally under 0.5 meters/second.  The chamber should be decontaminated in accordance to the guidance of Annex A in the standard.

Preparation of Test Item

It is preferable to use a new test item for this method.  Before being introduced into the chamber, the unit should be cleaned, not sterilized, using a damp cloth.  This cleaning should be conducted at least 72 hours before placing the item in the chamber.  If cleaners other than water are used it should be noted in the test report.

A mixed sport suspension is then created and incubated.   It is then verified for its ability to create fungus growth.  Control strips are created from unbleached, plain weave cotton and sterilized.  These are placed in the chamber to verify the spore solution is capable of producing fungus in the chamber. 

The test item and cotton strips are then inoculated and left in the chamber.  The chamber is kept at 86 ± 3.6 °F (30 ± 2 °C) and a relative humidity between 90 percent and 100 percent for the test duration of 28 days.  

Fungus Procedure

On day 7 the cotton control strips are inspected to verify at least 90 percent coverage from mold growth and again at 14 days.  If there is no increase in mold growth after 14 days the test must be restarted.

Once the 28-day duration has passed with successful results, the test item is inspected for fungus growth.  It should be noted that operational or use of the test item is only to be used if essential to requirements.  The results of the inspection are then recorded for the final report.

Decontamination

A complete procedure for the decontamination of equipment is described in Annex A of Method 508.  Again, this activity, as with others described above, are to be performed by suitably trained personnel (e.g., microbiologists).  This should be performed in a suitable facility with appropriate personal protective equipment.

Detailed Environmental Test Plans

CVG Strategy offers EZ-Test Plan Templates for MIL-STD environmental (climatic/dynamic) and EMI/EMC testing documentation.  Our DETPs are written as specified in MIL-STD-810 Task 405.  They are available for specific applications such as Ground Mobile, Ground Stationary, and Shipboard Controlled, Shipboard Uncontrolled, and Aircraft Military.

These DETPs include appropriate methods, (such as Fungus MIL-STD-810 Method 508) addendums for product specific information, test labels for photo identification and data sheets for collection of required data. Profile (LCEP). 

Our Electromagnetic Interference Test Plans are written as specified in MIL-STD-461.  They contain the test methodology, addendums for product specific information, test labels for photo identification and data sheets.  These plans are available for procedures listed in MIL-STD-461 and are also available for MIL-STD-1275, MIL-STD-704, and MIL-STD-1399-300. 

Custom Test Plans are also available for applications not covered in the EZ-Test Plan offerings.  These plans can be written for any number of applications and their relevant standards.

Put CVG Strategy’s Experience to Work for You

Companies of all sizes, from start up to established product developers, face challenges in product test and evaluation.  This can particularly be the case when a product is developed for a new market sector or expanding sales internationally.

Properly tested products prevent costly product recalls, product redesign, and product liability.  They maintain customer satisfaction and keep your company’s reputation in good standing.  Contact CVG Strategy to see how our services can assist your engineering team with Fungus MIL-STD-810 Method 508 or any other test and evaluation concern.

 

Humidity MIL-STD-810 Method 507 is used to evaluate the ability of products to resist the effects of exposure to warm humid climates.  This evaluation can be performed in a test facility using environmental chambers where costs or product scheduling is a consideration.  The method provides test cycles for natural or induced exposures representative of a variety of global exposures.

Effects of Humidity Exposure

Temperature-humidity conditions can have a wide array of effects on equipment.  It can cause accelerated oxidation of metals, increase the rate of chemical reactions, breakdown coatings, interact with dusts and other deposits to create corrosive film, and cause binding or sticking.  Additionally, it can cause changes in the properties of materials that result in loss of strength, delamination, degradation of lubricants, and degradation of insulators.  When allowed to condense, humidity can cause short circuits and change thermal transfer characteristics.

Procedures for Humidity Testing

There are two procedures available for Humidity in MIL-STD-810: 

• Procedure I – Induced and Natural Cycles are designed to replicate natural exposures to warm humid environments.  Induced cycles are designed to replicate conditions in contained environments where air circulation is limited such as storage and transit conditions.   
• Procedure II – Aggravated does not replicate naturally occurring cycles of humidity but exposes the test item to extreme temperature and humidity for shorter durations (usually 10 twenty-four-hour cycles).  This can be useful for ascertaining if the test item is susceptible to humidity, but the standard recommends caution in the interpretation of results.

Humidity Cycles

MIL-STD-810 in conjunction with MIL-HDBK-310 and NATO STANAG 4370 define three geographical categories for humidity that are applicable to Procedure I:

• Constant high humidity (B1) is typical of tropical, and seasonally, some mid-latitude locations.  These locations are typically in heavily forested areas during rainy seasons where solar radiation exposure is unlikely.  
• Cyclic high humidity (B2) can be found in the same locations as B1 but where forest cover is limited (such as in urban areas) and solar radiation creates a more differentiated diurnal exposure.  
• Hot-Humid (B3) represents conditions that occur on a narrow coastal strip in the Red Sea and Persian Gulf.  These conditions occur naturally about 10 to 15 times a year.  Although this cycle is in many ways the most extreme, it is not to be used in lieu of testing in other exposures if expected in the Life Cycle Environmental Profile (LCEP).

The standard provides diurnal cyclical test schedules for all three environmental profiles for both natural and induced conditions.

Test Durations

An effective humidity test requires long periods of exposure.  This can place strains on schedules and budgets, especially when multiple profiles must be run.  Test duration requirements are broken down into two categories, hazardous items and nonhazardous items.  Hazardous items are defined as equipment that if subject to unknown deterioration could result in damage to equipment or result in injury or death to personnel.  

For Cycles B1 and B2 this means that for hazardous items, a minimum of ninety cycles is required to simulate natural exposures and one hundred and eighty for induced (storage and transit).  For non-hazardous items the durations are half of these values.  B3 cycle durations are thirty for hazardous and fifteen for non-hazardous.  

As previously mentioned, Aggravated humidity, requires a minimum of ten cycles which can make it an attractive alternative if permitted by requirements or when perceived vulnerability to humidity exposure is minimal.  

Test Sequence Considerations

Prolonged exposures to humidity may compromise the integrity of seals, coatings, and plastics among other components.  It therefore is not advisable to use the same item for this method as for Salt Fog/Corrosive Environments, Sand and Dust, Acidic Atmosphere, or Fungus.  Additionally, the standard recommends performing dynamic testing, such as shock and vibration, prior to humidity, as the cumulative effects of these tests could identify design flaws.

Detailed Environmental Test Plan Templates

CVG Strategy offers EZ Test Plan Templates for MIL-STD environmental (climatic/dynamic) and EMI/EMC test documentation.  Our Detailed Environmental Test Plans (DETP)s are written as specified in MIL-STD-810 Task 405.  They are available for specific applications such as Ground Mobile, Ground Stationary, and Shipboard Controlled, Shipboard Uncontrolled, and Aircraft Military.

These DETPs include appropriate methods, (such as Humidity MIL-STD-810 Method 507) addendums for product specific information, test labels for photo identification and data sheets for collection of required data. Profile (LCEP). 

Our Electromagnetic Interference Test Plans are written as specified in MIL-STD-461.  They contain the test methodology, addendums for product specific information, test labels for photo identification and data sheets.  These plans are available for procedures listed in MIL-STD-461 and are also available for MIL-STD-1275, MIL-STD-704, and MIL-STD-1399-300. 

Custom Test Plans are also available for applications not covered in the EZ Test Plan offerings.  These plans can be written for any number of applications and their relevant standards.

Put CVG Strategy’s Experience to Work for You

Companies of all sizes, from start up to established product developers, face challenges in product test and evaluation.  This can particularly be the case when a product is developed for a new market sector or expanding sales internationally.

Properly tested products prevent costly product recalls, product redesign, and product liability.  They maintain customer satisfaction and keep your company’s reputation in good standing.  Contact CVG Strategy to see how our services can assist your engineering team with Humidity MIL-STD-810 Method 507 or any other test and evaluation concern.

Rain, MIL-STD-810, Method 506 is used to evaluate materiel likely to be exposed to rain, water spray, or dripping water during storage, transit, or operation.  It can  also be used to evaluate seals, enclosures, and covers to prevent ingress of water, access effectiveness of water removal systems, and evaluate the physical deterioration of materials due to exposure to water.

The method is not appropriate, however, for evaluating the effects of flight through rain, evaluation of pressure washers or decontamination devices, or the effects of extended light precipitation.  It is also not intended for evaluating equipment to atmospheric effects caused by rain. 

Available Procedures for Rain Testing

MIL-STD-810 has three procedures to evaluate materials ability to withstand rain:

• Procedure I – Rain and Blowing Rain is used to evaluate items that  will be deployed in conditions that are unprotected from rain.  This procedure uses a rainfall drip rate of 4 inches per hour (1.7 mm per minute) as a minimum for testing. 

The simulated rain must be comprised of droplets of approximately 500 μm in diameter.  Unless otherwise tailored, the test uses a wind velocity of 40 mph (18 m/s).   The test item should be stabilized to a temperature 18 °F (10 °C) higher than the water being used for rain. 

• Procedure II – Exaggerated uses rain simulated with overlapping pressure nozzles.  This method is often used when the test item is too large to be tested with the blowing rain method.  While it does not simulate rain, it can be used to a degree of confidence in the watertightness of an item.  The test incorporates a 50 psig (276 kPa) pressure with a flow rate of 5.5 gallons per minute (20.8 liters per minute).
• Procedure III – Drip is used to simulate the conditions where items may be exposed to falling water from leakage in a storage area or drops caused by condensation.  This test uses a minimum rate of 7 gallons per square foot per hour (280 liters per square meter per hour).

The Challenges of Preventing the Penetration of Water

Wind blown rain creates resonances that can penetrate gasketing materials used in covers, cases, and seals. In many cases, test items that have passed immersion testing can still have ingress problems with blowing rain.  These problems create issues for designers in any number of fields where rain exposure is expected.  Where MIL-STD testing is not applicable, other standards are available for ingress protection testing such as IEC 60529. 

IEC 60529 is typically applied to commercial products and their ability to keep the environment from interfering with the operation of a product. Ratings are defined by the letters IP followed by two digits and an optional letter.  It classifies the degrees of protection provided against the intrusion of solid objects (including body parts like hands and fingers), dust, accidental contact, and water in electrical enclosures. The standard aims to provide users more detailed information than vague marketing terms such as waterproof.

Detailed Environmental Test Plan Templates

CVG Strategy offers EZ-Test Plan Templates for MIL-STD environmental (climatic/dynamic) and EMI/EMC testing documentation.  Our Detailed Environmental Test Plans (DETP)s are written as specified in MIL-STD-810 Task 405.  They are available for specific applications such as Ground Mobile, Ground Stationary, and Shipboard Controlled, Shipboard Uncontrolled, and Aircraft Military.

These DETPs include appropriate test methods, (such as Rain MIL-STD-810 Method 506) addendums for product specific information, test labels for photo identification and data sheets for collection of required data. Profile (LCEP). 

Our Electromagnetic Interference Test Plans are written as specified by the Department of Defense.  They contain the test methodology, addendums for product specific information, test labels for photo identification and data sheets.  These plans are available for procedures listed in MIL-STD-461 and are also available for MIL-STD-1275, MIL-STD-704, and MIL-STD-1399-300. 

Custom Test Plans are also available for applications not covered in the EZ-Test Plan offerings.  These plans can be written for any number of applications and their relevant standards.

Put CVG Strategy’s Experience to Work for You

Companies of all sizes, from start up to established product developers, face challenges in product test and evaluation.  This can particularly be the case when a product is developed for a new market sector or expanding sales internationally.

Properly tested products prevent costly product recalls, product redesign, and product liability.  They maintain customer satisfaction and keep your company’s reputation in good standing.  Contact CVG Strategy to see how our testing services can assist your engineering team with Rain, MIL-STD-810, Method 506, or any other test and evaluation concern.

Solar Radiation (Sunshine), MIL-STD-810 Method 505 is used to evaluate thermal and actinic effects on equipment caused by exposure to the sun.  This testing is performed in specially designed environmental chambers.  This test methodology can be tailored to simulate spectral exposures at high altitudes where increased levels of Ultraviolet (UV) light are present. 

This method has two procedures, Procedure 1 – Cycling and Procedure 2 – Steady State.  Procedure 1 is used to evaluate response temperatures caused by simulated solar exposure.  Procedure 2 investigates the actinic effects on test items to simulated long term exposure to sunlight. 

While both procedures use artificial lighting to simulate solar exposures, different levels of radiation are used in testing.  While cycling uses expected levels of exposure, steady state uses levels of approximately 2.5 times normal exposure.

Thermal Solar Radiation Effects and Testing

Equipment can experience numerous effects from solar induced temperatures.  These include changes in strength or elasticity, degradation of elastomers and polymers, delamination of coatings and adhesives, and loss of seal integrity.  

Equipment that is exposed to solar radiation in induced conditions, such as a vehicle crew compartment, may experience extreme differential heating.  In such cases it preferred that Solar Radiation (Sunshine) testing be performed as opposed to solely relying on Method 501 High Temperature testing.  This testing can be performed using mocked up enclosures that simulate the expected exposures.  

Normal test duration for this procedure is at least three 24-hour cycles.  If the maximum of the previous 24-hour during three cycles, then the cycles are repeated until the peak temperatures are reached or seven cycles have been performed.

Actinic Effects of Solar Radiation and Testing

Actinism is a property of solar radiation that causes photochemical and photobiological reactions to occur.  Materials exposed to the sun can be degraded by Ultraviolet radiation.  This can result in chalking and fading of coatings, deterioration of elastomers and polymers, and fading of colors in plastics and fabrics.  Natural exposures of UV rays vary according with altitude as there is less atmospheric interference at higher altitudes.  

Testing for actinic effects with Procedure 2 requires a 4-hour lights off period for each 24-hour cycle to allow for thermal cycling.  For equipment that is continuously in an outdoor environment a minimum of 56 cycles is recommended.

Special Considerations for Testing

There are a number of items that should receive special consideration when planning solar radiation testing:

• Tailoring is required to determine which method and level of testing is required.  This is of great importance as this testing is costly and can require significant time.  Guidance for irradiance and spectral distribution at high altitudes can be found in Annex A of the standard.
• The use of arc type lights presents significant dangers to humans and can cause sunburn and blindness.  Care should be taken to ensure that exposure to high UV levels is prevented.
• Arc lamps can cause a buildup of ozone.  Care should be taken in adequately monitoring ozone and removing concentrations of the gas from enclosed areas.
• Care should be taken to ensure that temperatures do not exceed desired levels as ignition of materials may occur.  
• The combined effects of temperature and solar radiation can cause outgassing of VOCs, Carbon monoxide, and Phthalates.  Care should be taken to monitor for these gasses with sensors to protect personnel.
• Xenon lamps ignition pulses can exceed 60 kV.  Additionally, these bulbs can explode violently.  
• Finally, spectral power distribution must be monitored and maintained.  This involves the use of pyranometers and spectroradiometers. Significant guidance is provided in the standard in Annexes B and C to address these concerns.

Detailed Environmental Test Plan Templates

CVG Strategy offers EZ-Test Plan Templates for MIL-STD environmental (climatic/dynamic) and EMI/EMC testing documentation.  Our Detailed Environmental Test Plans (DETP)s are written as specified in MIL-STD-810 Task 405.  They are available for specific applications such as Ground Mobile, Ground Stationary, and Shipboard Controlled, Shipboard Uncontrolled, and Aircraft Military.

These DETPs include appropriate test methods, (such as MIL-STD-810 Solar Radiation (Sunshine) addendums for product specific information, test labels for photo identification and data sheets for collection of required data. Profile (LCEP). 

Our Electromagnetic Interference Test Plans are written as specified by the Department of Defense.  They contain the test methodology, addendums for product specific information, test labels for photo identification and data sheets.  These plans are available for procedures listed in MIL-STD-461 and are also available for MIL-STD-1275, MIL-STD-704, and MIL-STD-1399-300. 

Custom Test Plans are also available for applications not covered in the EZ-Test Plan offerings.  These plans can be written for any number of applications and their relevant standards.

Put CVG Strategy’s Experience to Work for You

Companies of all sizes, from start up to established product developers, face challenges in product test and evaluation.  This can particularly be the case when a product is developed for a new market sector or expanding sales internationally.

Properly tested products prevent costly product recalls, product redesign, and product liability.  They maintain customer satisfaction and keep your company’s reputation in good standing.  Contact CVG Strategy to see how our testing services can assist your engineering team with Solar Radiation (Sunshine) MIL-STD-810 Method 505, or any other test and evaluation concern.

 

Contamination by Fluids, MIL-STD-810 Method 504 evaluates equipment’s ability to withstand exposure to various chemical agents that equipment may come in temporary contact during its life cycle.  These chemicals include oils, insecticides, coolants, disinfectants, fire extinguishants, de-icing and anti-freeze fluids, oils,  solvents and cleaning fluids.

Chemicals can have a wide number of effects on the operation and reliability of equipment.  It can among other things, compromise surface coatings, cause failure of gasket materials, compromise insulting materials, cause swelling of rubbers and plastics, and induce corrosion. 

Health Warnings

The chemicals used for fluid contamination can be injurious to health and unsafe for the environment.  Care should be taken as specified in suppliers Safety Data Sheets (SDS).  Appropriate Personal Protective Equipment (PPE) should be used when using these chemicals.  This test procedure involves mixing of chemicals and, upon occasion, applying them at high temperatures. 

Care must be taken to ensure that harmful reactions do not occur and that ignition of the chemicals does not occur.  This procedure should only be performed by personnel that have received appropriate training. Additionally, chemicals used in this testing must be disposed of in accordance with federal, state, and local regulations.

Contamination by Fluids Exposures

Three levels of exposure are defined in MIL-STD-810:

• Occasional – For occasional the test item is to be exposed to the chemical(s) for 5 to 10 minutes.  If this exposure is to be at above ambient temperature based on typical life cycle environmental exposure then the item is to be held at temperature for 8 hours.
• Intermittent – Intermittent exposures to chemicals are for 8 continuous hours.  The test item is then to be air dried with the chemical for 16 hours at the temperature identified in the Life Cycle Environmental Profile (LCEP) plus one hour at ambient.
• Extended – For extended contamination the test item is to be exposed for 24 hours, held at specified temperature for 8 hours and then brought to ambient temperature.

Test Temperatures

Equipment can be often be exposed to chemicals at elevated temperatures when operated.  This exposure could be normal or accidental such as a hydraulic fluid leak.  When this is the case it is important to consider the flash point of chemicals involved and potential evaporation so that ignition does occur and adequate ventilation is applied.

Test temperatures may also be lower than ambient when expected environmental conditions during exposure are expected as would be the case when exposed to de-icing agents.

Contaminant Fluid Groups

Method 504 – Contamination by Fluids contains a list of chemicals used in military applications.  This is a useful tool, as the list provides most of the commonly used chemicals along with possible uses and source documents.  There may be other chemicals, however, that have been identified in the LCEP process.  If this is the case be certain that the test facility has access to all necessary information for those chemicals.

Detailed Environmental Test Plan Templates

CVG Strategy offers EZ-Test Plan Templates for MIL-STD environmental (climatic/dynamic) and EMI/EMC testing documentation.  Our Detailed Environmental Test Plans (DETP)s are written as specified in MIL-STD-810 Task 405.  They are available for specific applications such as Ground Mobile, Ground Stationary, and Shipboard Controlled, Shipboard Uncontrolled, and Aircraft Military.

These DETPs include appropriate test methods, (such as MIL-STD-810 Contamination by Fluids) addendums for product specific information, test labels for photo identification and data sheets for collection of required data. Profile (LCEP). 

Our Electromagnetic Interference Test Plans are written as specified in MIL-STD-461.  They contain the test methodology, addendums for product specific information, test labels for photo identification and data sheets.  These plans are available for procedures listed in MIL-STD-461 and are also available for MIL-STD-1275, MIL-STD-704, and MIL-STD-1399-300. 

Custom Test Plans are also available for applications not covered in the EZ-Test Plan offerings.  These plans can be written for any number of applications and their relevant standards.

Put CVG Strategy’s Experience to Work for You

Companies of all sizes, from start up to established product developers, face challenges in product test and evaluation.  This can particularly be the case when a product is developed for a new market sector or expanding sales internationally.

Properly tested products prevent costly product recalls, product redesign, and product liability.  They maintain customer satisfaction and keep your company’s reputation in good standing.  Contact CVG Strategy to see how our testing services can assist your engineering team with Contamination by Fluids MIL-STD-810 testing or any other test and evaluation concern.

MIL-STD-810 Temperature Shock testing (Method 503) is used to evaluate equipment’s ability to withstand sudden changes in temperature.  This laboratory test method is conducted in environmental test chambers and can be tailored to replicate the anticipated thermal profiles during storage, transit, and operation.  Such shock could be experienced when a jet fighter on a tarmac in the desert rapidly climbs to high altitudes or conversely an article being air delivered by means of parachute to a high temperature environment.

Rapid change in temperature per this standard is defined as a change greater than 18 °F (10°C) per minute.  Exposure to these environmental stresses can cause failures due to differential expansion and contraction of dissimilar materials.  It can cause failures in electronics due to changes in components due to temperature changes.  It can also cause failures in equipment due to the formation of frost.

Procedure Selection

The military standard MIL-STD-810 provides four test procedures for Temperature Shock: 

• Procedure I-A: One-way Shock(s) from constant extreme temperature  This procedure is appropriate for equipment that will be not regularly exposed to thermal shock and when those shocks will occur only in one direction.  Equipment air dropped from aircraft would be an example.
• Procedure I-B:  Single Cycle Shock from constant extreme temperature  This is intended for equipment that is expected to be exposed to a single shock in each direction.
• Procedure I-C:  Multi-cycle shocks from constant extreme temperature  An example of this would be a jet fighter taking off from a desert location and then landing at the same location. 
• Procedure I-D:  Shocks to or from controlled ambient temperatures  This would be applicable to equipment that is stored in environmentally controlled structures that must work in extreme hot or cold environments.

Determining Appropriate Test Values

It is necessary to tailor appropriate test temperature cycle and temperature range values from requirements, measurements, and those derived from the Life Cycle Environmental Profile (LCEP).  Geographic climatic information is available in Part 3 of the standard to assist in value determinations.  As with most MIL-STD-810 methods, measured data when available is preferred for determining test values.  This is particularly the case in situations in which solar radiation may be a factor in determining maximum temperatures.

Generally, humidity is not a factor in Temperature Shock testing, but when required appropriate values should be determined based on expected areas of use.  For testing of Air delivery the standard recommends a starting temperature equivalent to that found at 26,000 ft (8 km).  These environmental conditions can be found in Method 520 Combined Environments.

Considerations During Testing

Temperature chambers specifically designed for thermal shock testing incorporate dual chambers side by side or on top of each other that allow a rapid transfer between the two test temperatures.  Generally, availability of these chambers at test facilities is limited.  When these chambers are not available the Unit Under Test (UUT) must be transferred between two separate chambers as quickly as possible. 

Transfer time should be recorded during testing and be included in any required post test reporting.  MIL-STD-810 encourages transfers between chambers to one minute or less.  This can be challenging when the item is being tested in an operational mode or where the test item is large.  When this is the case, justification for longer periods of transfer should be documented.

Detailed Environmental Test Plan Templates

CVG Strategy offers EZ-Test Plan Templates for MIL-STD environmental (climatic/dynamic) and EMI/EMC testing documentation.  Our Detailed Environmental Test Plans (DETP)s are written as specified in MIL-STD-810 Task 405.  They are available for specific applications such as Ground Mobile, Ground Stationary, and Shipboard Controlled, Shipboard Uncontrolled, and Aircraft Military.

These DETPs include appropriate test methods, (such as MIL-STD-810 Temperature Shock) addendums for product specific information, test labels for photo identification and data sheets for collection of required data. Profile (LCEP). 

Our Electromagnetic Interference Test Plans are written as specified by the Department of Defense.  They contain the test methodology, addendums for product specific information, test labels for photo identification and data sheets.  These plans are available for procedures listed in MIL-STD-461 and are also available for MIL-STD-1275, MIL-STD-704, and MIL-STD-1399-300. 

Custom Test Plans are also available for applications not covered in the EZ-Test Plan offerings.  These plans can be written for any number of applications and their relevant standards.

Put CVG Strategy’s Experience to Work for You

Companies of all sizes, from start up to established product developers, face challenges in product test and evaluation.  This can particularly be the case when a product is developed for a new market sector or expanding sales internationally.

Properly tested products prevent costly product recalls, product redesign, and product liability.  They maintain customer satisfaction and keep your company’s reputation in good standing.  Contact CVG Strategy to see how our testing services can assist your engineering team with MIL-STD-810 Low Temperature Testing or any other test and evaluation concern.

MIL-STD-810 Low Temperature testing (Method 502) is used to evaluate the effects of low temperature on equipment.  This laboratory test method is conducted in a test chamber and can be tailored to replicate the anticipated thermal profiles during storage, transit, and operation.  This test is intended for evaluating the effects of low temperature on equipment and is not intended for replicating the effects of temperature conditions at high altitudes.

Procedure Selection

Defense standard MIL-STD-810 provides three test procedures for Low Temperature; Storage, Operation, and Manipulation. 

• Procedure I – Storage is used to assess the effects of low temperature on equipment in an induced environment.  An induced environment refers to a man-made condition.  In the case of Low Temperature it would include situations natural airflow is restricted by means of packaging or unconditioned enclosures.  In such cases temperatures may reach levels as low as -60°F (-51°C) for areas such as the interior of Alaska.
• Procedure II – Operation is used to evaluate the test item’s ability to operate as specified when subjected to low temperatures.  These operating temperatures could be the result of ambient climatic conditions or specific thermal profiles present in an intended operational environment.
• Procedure III – Manipulation is used to assess how easily equipment might be operated, assembled, maintained, or disassembled when operators are wearing heavy winter clothing.

Determining Test Levels

It is necessary to tailor appropriate test temperature cycle and temperature range values from requirements, measurements, and those derived from the Life Cycle Environmental Profile (LCEP).  Geographic climatic information is available in Part 3 of the standard to assist in value determinations.  MIL-STD-810 uses three categories for defining cold environments:

• Basic Cold (C1) describes cold temperatures found in most of Europe, coastal areas of Canada, high latitude coastal areas, and the northern 84 states.
• Cold (C2) describes anticipated cold temperatures in Canada and Alaska (excluding interior areas) Northern Asia and Scandinavia, and high elevations in the mountain ranges of the Alps, and Andes.
• Severe Cold (C3) includes temperatures found in the interior of Alaska and Canada, Canadian Islands, and Greenland.

When the equipment to be tested is considered to be likely to for worldwide use a value the C3 Severe Cold levels should be used for test.  This temperature would be -60°F (-51°C).

Test Duration

Low Temperature can cause a large number of effects on equipment.  For certain types of equipment the standard calls for extended durations of exposure to cold temperatures to ensure that the material can perform as specified without degradation of integrity or safety.

• For equipment that is not safety related or nonhazardous a storage period of four hours is required
• For munitions and explosives or equipment that have rubber or plastic components seventy-two hours of exposure is required.  This is due the fact that these materials may degrade or deteriorate after long periods of exposure.
• For equipment that include restrained glass, or ceramics, twenty-four hours of exposure is required.

Test Program Considerations

It is often a requirement for product verification that Low Temperature be performed early in a program to determine if design changes or are required.  However, consideration should also be given to the synergetic effects of multiple environmental stressors.  If concerns exist that the test item might become more brittle it may be advantageous to combine Low Temperature testing with dynamic test such as vibration or shock. 

Detailed Environmental Test Plan Templates

CVG Strategy offers EZ-Test Plan Templates for MIL-STD environmental (climatic/dynamic) and EMI/EMC testing documentation.  Our Detailed Environmental Test Plans (DETP)s are written as specified in MIL-STD-810 Task 405.  They are available for specific applications such as Ground Mobile, Ground Stationary, and Shipboard Controlled, Shipboard Uncontrolled, and Aircraft Military.

These DETPs include appropriate test methods, (such as MIL-STD-810 Low Temperature) addendums for product specific information, test labels for photo identification and data sheets for collection of required data. Profile (LCEP). 

Our Electromagnetic Interference Test Plans are written as specified in MIL-STD-461.  They contain the test methodology, addendums for product specific information, test labels for photo identification and data sheets.  These plans are available for procedures listed in MIL-STD-461 and are also available for MIL-STD-1275, MIL-STD-704, and MIL-STD-1399-300. 

Custom Test Plans are also available for applications not covered in the EZ-Test Plan offerings.  These plans can be written for any number of applications and their relevant standards.

Put CVG Strategy’s Experience to Work for You

Companies of all sizes, from start up to established product developers, face challenges in product test and evaluation.  This can particularly be the case when a product is developed for a new market sector or expanding sales internationally.

Properly tested products prevent costly product recalls, product redesign, and product liability.  They maintain customer satisfaction and keep your company’s reputation in good standing.  Contact CVG Strategy to see how our testing services can assist your engineering team with MIL-STD-810 Low Temperature Testing or any other test and evaluation concern.

MIL-STD-810 High Temperature testing (Method 501) is used to evaluate the effects of high temperature on equipment.  This laboratory test method is conducted in a chamber and can be tailored to replicate the anticipated thermal profiles during storage, transit, and operation.  This test is intended for evaluating short term effects of heat on equipment and is not intended for replicating the effects of months or years of exposure.

Procedure Selection

Defense standard MIL-STD-810 provides three test procedures for High Temperature; Storage, Operation, and Tactical-Standby to Operational. 

• Procedure I – Storage is used to assess the effects of high temperature and low humidity on equipment in an induced environment.  An induced environment refers to a man-made condition.  In the case of High Temperature it would include situations natural airflow is restricted by means of packaging or unconditioned enclosures.  In such cases temperatures may reach levels as high as 160°F (71°C).
• Procedure II – Operation is used to evaluate the test item’s ability to operate as specified when subjected to high temperatures.  These operating temperatures could be the result of ambient climatic conditions or specific thermal profiles present in an intended operational environment, such as an engine compartment.
• Procedure III – Tactical-Standby to Operational is used where equipment may be subjected to temperature exposures in enclosed environments such as cockpits and then be immediately required to operate.  In such cases it often recommended to determine maximum temperatures induced from solar radiation.  This can be accomplished by measuring temperatures on the intended platform or conduction Solar Radiation (Sunshine) testing prior to High Temperature. 

Determining Test Levels

It is necessary to tailor appropriate test temperature cycle and temperature range values from requirements, measurements, and those derived from the Life Cycle Environmental Profile (LCEP).  Geographic climatic information is available in Part 3 of the standard to assist in value determinations.  Additionally, twenty-four hour high temperature cycles for both ambient and induced environments are available in the method that include typical relative humidity levels.

As with most MIL-STD-810 methods, measured data when available is preferred for determining test values.  This is particularly the case for environments such as engine compartments or in situations in which solar radiation may be a factor in determining maximum temperatures.

Test Program Considerations

It is often a requirement for product verification that High Temperature be performed early in a program to determine if design changes or are required.  However, consideration should also be given to the effects of High Temperature on the Unit Under Test’s (UUT). 

High Temperature can cause lasting effects that could compromise a products ability to function in other environmental tests.  An example of which could be the failure of an adhesive that could cause failures in dynamic tests.  When this may present a significant risk, it is appropriate to evaluate where this method should line up in the over all test plan’s sequence.

Detailed Environmental Test Plan Templates

CVG Strategy offers EZ Test Plan Templates for MIL-STD environmental (climatic/dynamic) and EMI/EMC testing documentation.  Our Detailed Environmental Test Plans (DETP)s are written as specified in MIL-STD-810 Task 405.  They are available for specific applications such as Ground Mobile, Ground Stationary, and Shipboard Controlled, Shipboard Uncontrolled, and Aircraft Military.

These DETPs include appropriate test methods, (such as MIL-STD-810 Low Pressure) addendums for product specific information, test labels for photo identification and data sheets for collection of required data. Profile (LCEP). 

Our Electromagnetic Interference Test Plans are written as specified in MIL-STD-461.  They contain the test methodology, addendums for product specific information, test labels for photo identification and data sheets.  These plans are available for procedures listed in MIL-STD-461 and are also available for MIL-STD-1275, MIL-STD-704, and MIL-STD-1399-300. 

Custom Test Plans are also available for applications not covered in the EZ Test Plan offerings.  These plans can be written for any number of applications and their relevant standards.

Put CVG Strategy’s Experience to Work for You

Companies of all sizes, from start up to established product developers, face challenges in product test and evaluation.  This can particularly be the case when a product is developed for a new market sector or expanding sales internationally.

Properly tested products prevent costly product recalls, product redesign, and product liability.  They maintain customer satisfaction and keep your company’s reputation in good standing.  Contact CVG Strategy to see how our testing services can assist your engineering team with MIL-STD-810 High Temperature Testing or any other test and evaluation concern.