Jamie Hamilton

Ballistic Shock MIL-STD-810 Method 522 evaluates equipment designed for armored combat vehicles’ ability to withstand the shock associated with non-perforating large caliber munition impact or blast.  This testing can be used to provide a degree of confidence in the the equipment’s ability to function after such a shock, or be used to evaluate shock mitigation designs and mounting configurations.

Ballistic Shock Characteristics

Ballistic shock characteristics include high acceleration from 300 to 1,000,000 g’s within a short duration time (generally under 180 msec).  These mechanical shocks have a very wide bandwidth extending from 10 Hz to 1 MHz and are highly random in nature.  It should be noted that effects of the shock are highly dependent on the distance from the actual impact as high frequencies will be filtered by the structure of the vehicle.

Ballistic shock can have a number of adverse effects on electrical, mechanical, and electronic devices.  Aside from complete mechanical failure of the test item, ballistic shock can cause integrated circuits failures, printed circuit card damage,  and electronic connector failures.  Failures can also occur due to fractures in crystals, ceramics, epoxies, or glass envelopes.  Additionally, intermittent, functional failures can also occur due to relay chatter and piezo electric effects of high frequency shock on electronics.  

Procedures for Shock Testing

There are six procedures available for Ballistic Shock testing:

• Procedure I – Ballistic and Turret (BH&T), Full Spectrum Ballistic Shock Qualification incorporates the firing of projectiles on an armored hull or turret.  
• Procedure II – Large Scale Ballistic Shock Simulator (LSBSS) uses a shock machine to produce a shock spectrum from 10 Hz to 100 kHz.  It can be used for items weighing up to 1,100 lbs. (500 kg).
• Procedure III – Limited Spectrum, Light Weight Shock Machine (LWSM) is for components weighing less than 250 lb. (113.6 kg) and items that are shock mounted to filter frequencies above 3 kHz.
• Procedure IV – Limited Spectrum, Mechanical Shock Simulator for components from 1 to 4 lb. (0.5 to 1.8 kg)  Machines for this testing can produce Shock Response Spectrums (SRS) up to 10 kHz.
• Procedure V – Limited Spectrum, Medium Weight Shock Machine (MWSM)is available for components weighing less than 5,000 lb. (2273 kg) that are not sensitive to frequencies above 10 kHz.
• Procedure VI – Drop Table testing is acceptable for the majority of ballistic shock qualification testing.  Although drop testing over-tests at low frequencies and under-tests at high frequency the reduction of cost in testing makes it an attractive alternative.

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 Department of Defense standard 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 Ballistic Shock MIL-STD-810 Method 522) 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.

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 relevant to the test item’s expected life cycle. 

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 services can assist your engineering team with Ballistic Shock MIL-STD-810 Method 522 or any other MIL-STD-810 test and evaluation concern.

Icing/Freezing Rain MIL-STD-810 Method 521 testing is used to verify that equipment can operate when exposed to ice accumulations from rain, drizzle, or sea spray.  Freezing rain tests can also be used to evaluate de-icing equipment and techniques.

Types of Ice Used in Testing

Two types of icing is likely to occur in natural exposures: 

• Rime ice is formed when supercooled water drops come in contact with a surface.  These deposits of ice are white, opaque, and granular.  Rime ice is categorized into Hard rime which is often deposited on vertical surfaces by freezing fog and soft rime which is which can often occur on the windward side of an object and has a structure similar to frost.  
• Glaze ice deposits are clear and smooth but may contain some air pockets.  These deposits occur when supercooled water droplets freeze from drizzle or rain.  These coatings of ice are denser and have a greater likelihood of posing structural stresses.  Glaze ice is generally used in this test method.

Test Tailoring Considerations

Consideration should be given to the expected ice loading based on the anticipated Life Cycle Environmental Profile (LCEP) of the test item.  The standard recommends thicknesses of 0.24 inches (6 mm) to 3 inches (75mm).  Heavier loading are representative of marine deck and mast loadings.

The standard recommends a water delivery rate sufficient to create a coating of 1 inch/hour (25mm/h).  It is important that water purity as specified in Part 1 of the standard be used in testing.

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 Icing/Freezing Rain MIL-STD-810 Method 521) 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.

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 services can assist your engineering team with Icing/Freezing Rain MIL-STD-810 Method 521 or any other test and evaluation concern.

Monitoring of operational testing and the recording of all critical performance parameters has become a requirement in MIL-STD-810H.  Operational testing has been a part of MIL-STD-810 since Revision C in 1975.  It refers to testing the item in a manner that represents service use as documented in the mission profile.  

Changes in Monitoring Requirements

Successive revisions of this Department of Defense standard have placed more stringent requirements on this mode of testing.  Monitoring of operational tests is one such requirement.   Requirements as specified in Revision G change 1 Part 1; paragraph 5.10 reads as follows:

“Performance check. Monitoring and recording of test item’s critical performance parameters is required before and after all tests. Monitoring of performance parameters is not required during non-operational tests such as storage and transportation. Monitoring of performance parameters during operational tests is strongly suggested.

Where cost concerns preclude monitoring during an operational test, consideration should be given to the consequences of undetected, intermittent failures.”

Revision H has changed the wording of the last two sentences of that paragraph to:

“ Monitoring and recording of the critical performance parameters during operational tests is required. If unable to monitor during operational tests, obtain test sponsor approval prior to the start of testing and document rationale in the test report.”

Development of Monitoring and Simulation Equipment

Environmental testing has the capability of inducing intermittent failures in equipment.  Detection of these failures is critical in Developmental Testing and Evaluation to ensure a product’s capabilities during field testing and deployment.  These increased requirements call for a more diligent approach to the design and planning of monitoring equipment used in operational testing. 

Designing, building, and programming the required (off chamber) equipment requires time and resources.  Monitoring equipment should be capable of detecting recording and capturing intermittent failure conditions.  It should then notify test personnel of failures.  It should record all critical functions and exercise the Unit Under Test (UUT) to simulate in service operation. 

Additionally, it should be able to aid in the performance of functional and operational tests.  These tests are used to verify all modes of operation of the UUT before, during and after environmental tests.

Evolution of MIL-STD-810 Environmental Testing

Many issues have evolved during various revisions of MIL-STD-810.  A study of the history of these issues shows a repeated effort by those writing the standard to stress areas where materiel developers have fallen short in developmental test and evaluation.  This has been the case with test parameter tailoring, power requirements, and yes, the methods utilized in operational testing.

There are numerous issues that can cause intermittent issues in electrical and electronic equipment.  These intermittent failures can lead to unexpected behaviors from equipment.  The increased requirements in MIL-STD-810 no doubt can be traced to issues encountered during operational testing or during service.

In essence, a “green light” on the UUT is no longer a suitable solution, if indeed it ever was.  Properly designed equipment is required for monitoring operational laboratory testing. It is impossible for a human to monitor a test of long duration or perceive short intermittent failures.

Other Requirements for Monitoring and Simulation Equipment

Such monitoring equipment is also useful in EMI/EMC testing for detecting susceptibility issues.  It can also exercise the equipment under test to provide representative operation necessary for adequate evaluation of equipment emissions.  Operational testing is a requirement for most EMI/EMC testing. 

It is definitely a requirement for MIL-STD-461 testing.  Operation of equipment in standard modes is required for modes of testing in this standard including conducted emissions, radiated emissions, conducted susceptibility, and radiated susceptibility. 

For emissions testing, exercising the Equipment Under Test (EUT) exercises it to create a nominally characteristic level of electromagnetic behavior.  During susceptibility testing however, great care must be taken to monitor the EUT for operational failures caused by the presence of electromagnetic fields and electrostatic discharges.  The same holds true for electrical compatibility testing for standards such as MIL-STD-704, MIL-STD-1275, and MIL-STD-1399-300B parts 1 and 2.

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 Department of Defense standard 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 addendums for specifying procedures for monitoring of operational testing, 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.

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 relevant to the test item’s expected life cycle. 

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.

Combined Environments MIL-STD-810 Method 520 is used to evaluate the synergistic effects of multiple environmental stressors on equipment intended airborne applications.  The use of synergetic effects can uncover failures effecting the performance, or integrity of equipment under test that individual stresses would not reveal.  

Environmental factors that are applicable to this method are vibration, temperature, humidity, and altitude.  Fluctuations in input electrical power were added to this list in revision H of the military standard.  These fluctuations include variations in voltage and frequency in addition to expected power transients.  Additionally, revision H changed the title of this method from Temperature, Humidity, Vibration, and Altitude to Combined Environments.

Special Considerations When Applying Method 520

The United States Department of Defense originally used this multi-stress analysis approach in the development of the F-15 Eagle.  While its primary application is for rotor and fixed wing platforms, it is also applicable for equipment destined for other platforms.  Regardless of platform type, test tailoring is essential in creating test procedures.  This tailoring should be based on the test item’s Life Cycle Environmental Profile (LCEP).

Performance of this method does not remove requirements for separate testing of each environmental stress included in this method.  This method is not intended to include short duration, infrequent dynamic effects such as Gunfire Shock.  Additionally, this test is primarily intended for operational testing, with the Unit Under Test (UUT) being powered and functional.

Procedures for Combined Environments

There are three procedures available for Method 520, Combined Environments.  

• Procedure I – Engineering Development is typically used early in the development stage or on modifications of a product to reveal design defects.  Once a defect is identified, further testing may then be conducted to determine root causes.
• Procedure II – Flight or Mission Support can be used to replicate specific mission scenarios where troubleshooting on a specific combination of effects.  It is particularly useful in cases where troubleshooting issues during actual flight is not practical or safe.
• Procedure III – Platform Envelope is used to demonstrate compliance to specification requirements where specific combinations of stressors are concerned.

Information of Interest

Method 520 provides information on a number of topics that can be used in other forms of testing.  It contains information about thermal stresses at specific altitudes.  It provides guidance for analysis of stresses caused by low pressures experienced at specific altitudes.  It also provides guidance for evaluating potential stresses from vibration, humidity, and electrical supply fluctuations.  Most importantly, it includes guidance for developing test profiles based on generalized mission profiles.

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 Department of Defense standard 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 Combined Environment MIL-STD-810 Method 520) 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.

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 relevant to the test item’s expected life cycle. 

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 services can assist your engineering team with Combined Environment MIL-STD-810 Method 520 or any other MIL-STD-810 test and evaluation concern.

Gunfire Shock MIL-STD-810 Method 519 testing is performed to ensure that equipment can operate and structurally withstand short duration, high-rate shocks from gunfire.  This test method is not intended for single shot gunfire from large Navy or tank guns.  Types of gunfire shock are referred to as gunfire schedules.  These shocks can include a combination of shock transmitted through a structure or an airborne shock generated by gun muzzle blast pressure waves.

Procedures for Gunfire Shock Testing

There are three test procedures available for Gunfire Shock:

• Procedure I: Measured Materiel Input/Response Time History Under TWR.  This procedure is applicable when measured time trace information is available.  This data would be replicated with Single-Exciter/Single-Axis (SESA), using Time Waveform Replication (TWR).
• Procedure II: SRS Generated Shock Time History Pulse Sequence Under TWR.  This procedure is used when previously processed Shock Response Spectrum (SRS) is available.  This single shock is then concatenated into a shock pulse series.
• Procedure III: Stochastically Generated Materiel Input from Preliminary Design Spectrum Under TWR.  This procedure is to be used when no measured data is available.  This procedure, while of value for engineering analysis, is not suitable for materiel qualification.

Testing Considerations

In most cases, testing can be performed at ambient temperature.  However, when the operational environment of Unit Under Test (UUT) as determined in the Life Cycle Environmental Profile (LCEP) indicates operation at extreme temperatures, testing at high or low temperatures may be preferable.

Testing is normally performed on all axes with regards to structure born vibrations.  Specific testing on appropriate axis may be performed to assess the effects of muzzle pressure pulses.  The number of pulses used in testing should be based on an LCEP analysis as to frequency of expected exposures.

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 Department of Defense standard 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 Gunfire Shock MIL-STD-810 Method 519) 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.

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 relevant to the test item’s expected life cycle. 

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 services can assist your engineering team with Gunfire Shock MIL-STD-810 Method 519 or any other MIL-STD-810 test and evaluation concern.

Acidic Atmosphere MIL-STD-810 Method 518 is used to evaluate protective coatings and materials resistance to corrosive atmospheres.  It is applicable for equipment that will be stored or operated in acidic atmospheres during its lifecycle.  This would include urban and industrial area environmental conditions or equipment that will be mounted near exhausts.

Considerations for Acidic Atmosphere Testing

Acidic Atmosphere testing is one of several tests in MIL-STD-810 that could degrade finishes and coatings of test items.  This method should not be performed on units that have had or will have testing for Sand and Dust, or method 509 Salt Fog/Corrosive Environments.  Acidic Atmosphere should be conducted after Fungus, or Humidity testing.  

This test method should be conducted at qualified test laboratories.  It should not be performed in a salt fog chamber because sulfur dioxide which is used in this testing may permanently contaminate the chamber for any future salt fog tests.

Test Duration and Severity

Two severity levels are provided in this test procedure.  For cases in which the Life Cycle Environmental Profile (LCEP) indicates infrequent exposure, the test item is to be subjected to 3 separate 2-hour spraying exposures with a 22-hour storage period after each spraying.  For more frequent expected exposures, 4 spraying exposures, each for 2-hours with 7 days storage after each spraying should be performed.

The second, more severe test, is representative of a 10-year natural exposure in a moist environment with industrial pollution.  For environments such as installations near exhaust pipes or ship funnel exhausts the test is representative of shorter natural exposures.

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 Department of Defense standard 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 Acidic Atmosphere MIL-STD-810 Method 518) 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.

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 relevant to the test item’s expected life cycle. 

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 services can assist your engineering team with Acidic Atmosphere MIL-STD-810 Method 518 or any other MIL-STD-810 test and evaluation concern.

Pyroshock MIL-STD-810 Method 517 is a test to evaluate equipment’s ability to withstand mechanical transients caused by the detonation of devices such as explosive bolts and Flexible Linear Shape Charges (FLSC).  

Characteristics of Pyroshock Events

Pyroshocks can produce excitation in a broad range of frequencies.  These typically range from 100 Hz to 1 MHz with a duration of 50 microseconds to 20 milliseconds.  This is of special concern for electronic equipment as the excitation at high frequencies will be comprised of wavelengths that can induce failures and unexpected behaviors from micro-electronic components.

The effects of pyroshock can include the aforementioned failure of micro-electronic devices.  It can also cause relay chatter, and failures due to cracks and fractures in crystals, epoxies, ceramics, or glass envelopes.  

Pyroshock Zones

Levels of expected exposure to pyroshock events are classified in the test standard into near field, mid field, and far field.  Near-field testing requires testing above 10,000 Hz and amplitudes greater than 10,000 g’s.  Mid-field requires pyroshock tests to include frequencies between 3,000 Hz and 10,000 with amplitudes less than 10,000 g’s.  Far-field testing is limited to frequencies no higher than 3,000 Hz and less than 1,000g’s.

Procedures for Pyroshock

As of MIL-STD-810H change 1, the pyroshock method includes five different procedures:

• Procedure I – Near-Field with an Actual Configuration requires testing with actual intended platform of the test item and a specified explosive device.
• Procedure II – Near-field with a Simulated Configuration involves mounting the test item on a steel plate to minimize testing costs.
• Procedure III – Mid-field with mechanical test device incorporates the use of laboratory test equipment in lieu of explosive devices.  These devices include shock machines used in MIL-DTL-901 Shipboard Shock or Resonant Beam Shock Machine.  Shocks should be applied to all three orthogonal axes.
• Procedure IV – Far-field with a mechanical device as in Procedure III with reduced severity.  Shocks should be applied to all three orthogonal axes.
• Procedure V – Far-field with an Electrodynamic Shaker uses the same test devices used for vibration testing as in Method 514.

Considerations for Pyroshock

It is advisable to check with test facilities as to the intended accelerometers to be used in testing, especially in the near field.  It may be advisable to employ more sophisticated measurement devices to prevent loss or distortion of measurements.  In such cases the use of laser Doppler devised may be advisable.  

When using shock machines for mid-field and far-field testing, threaded accelerometers are advised, as adhesives used to mount accelerometers during normal shock testing will not withstand the higher frequencies encountered in pyroshock and break free during testing.

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 Department of Defense standard 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 Pyroshock MIL-STD-810 Method 517) 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.

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 relevant to the test item’s expected life cycle. 

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 services can assist your engineering team with Pyroshock MIL-STD-810 Method 517 or any other MIL-STD-810 test and evaluation concern.

Shock MIL-STD-810 Method 516 is an environmental test that can be used to verify that equipment can withstand shocks encountered during transportation, service, and handling.  It can also be used to assess fragility levels for determination of stowage, packaging, or mounting requirements and is used to test the strength of devices such as fasteners to ensure that equipment does not create hazards in crash scenarios.

Mechanical Shock Characteristics

There are multiple types of shock addressed in Department of Defense Standard MIL-STD-810 including Gunfire Shock, Ballistic Shock, and Shipboard Shock.  Method 516 is focused on mechanical shocks.  These shocks generally are limited to durations of 0.1 seconds or less and comprised of frequencies below 4,000 Hz. 

These shocks cause the test item to respond to the forced frequencies of the shock profile and excitation of that item’s resonant frequencies.  These environmental stresses can lead to a large number of adverse effects on equipment’s physical and functional integrity.  These effects include, not only the expected deformations and accelerated fatiguing of components but can also include piezoelectric activities of electronic components and changes in electrical characteristics of components.

Procedures for Method 516 Shock

As of MIL-STD-810H change 1 there are eight procedures available for testing:

• Procedure I – Functional Shock assesses the ability of equipment to operate during and after exposure to shocks representative of those expected to be experienced during the operational life cycle of the item.
• Procedure II – Transportation Shock addresses shocks expected during logistic and tactical transportation phases of the life cycle.  
• Procedure III – Fragility is normally conducted early in a product’s development to assess requirements for the design of packaging, stowage, and mounting configurations necessary to protect equipment.
• Procedure IV – Transit Drop uses actual physical drop tests to assess probable accidental incidents caused by loading, unloading, or being carried by personnel.
• Procedure V – Crash Hazard Shock Test is intended for components mounted in ground or air vehicles.  It assesses the design of materiel mounts, containment configurations, and tiedowns so as to prevent hazards to occupants and bystanders.
• Procedure VI – Bench Handling replicates shocks that may be experienced during handling, maintenance, or packaging.  Requirements are based on the nature of the item to be tested and its use in its life cycle.
• Procedure VII – Pendulum Impact is intended for large shipping containers.  It assesses the container’s ability to withstand horizontal impacts without inducing damage to intended cargo.
• Procedure VIII – Catapult Launch/Arrested Landing is intended for equipment mounted on fixed wing aircraft that is expected to be subjected to take off and landings on aircraft carriers.

Considerations for Test Selection

 MIL-STD-810 testing for Method 516 Shock presents many possibilities for testing.  When considering which test scenarios to include in a test program, it is important to consider test duration, amplitude, and bandwidth of shock response spectrum profiles.  It is generally unfeasible to test for all shock profiles, so risk assessment is required to determine those shocks that present the greatest concern.

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 Shock MIL-STD-810 Method 516) 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.

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 services can assist your engineering team with Shock MIL-STD-810 Method 516 or any other test and evaluation concern.

Vibration, MIL-STD-810 Method 514 evaluates equipment’s ability to withstand vibration exposures expected in a product’s life cycle.  These laboratory tests simulate environmental stresses that may be experienced during manufacture / maintenance, transportation, or operational life phases. 

This testing can be used for for development, qualification, or reliability purposes.  This method is not applicable for Environmental Stress Screening (ESS),  or multiple exciter testing.

Procedures for Vibration Method 514

Four procedures are available for vibration testing in this method:

Procedure I – General Vibration is for evaluating equipment that is to be transported or deployed for use on ground vehicles, fixed winged aircraft, or rotary wing aircraft. 

Procedure II – Loose Cargo Transportation replicates the vibration and shock environment of equipment being transported as loose cargo in military vehicles across rough terrain.  This procedure is performed on a package tester that applies a circular synchronous motion of 5 Hz in the vertical axis.

Procedure III – Large Assembly Transportation is performed with vehicles on test surfaces that are representative of expected operational or transportation phases in the test item’s life cycle.  These test surface courses are located at specific defense facilities such as U.S. Army Aberdeen Test Center. 

Procedure IV – Assembled Aircraft Store Captive Carriage and Free Flight uses laboratory shakers to replicate vibrational stresses encountered by equipment designed for under wing deployment during flight when attached to an aircraft and when released.

Considerations for Test Selection

Vibration testing presents many possibilities for testing.  When considering which test scenarios to include in a test scenario, it is important to consider test duration, amplitude, and bandwidth of vibration profiles. 

In many cases vibration experienced in transport may exceed those expected in operational modes.  In other cases operational vibration will be of greater severity.  In the end risk analysis is essential in identifying the optimal test and evaluation plan.

Tailoring Guidance

Given the highly technical nature of vibration testing, care must be taken when tailored testing is required. To address this issue Method 514 provides ample supplementary information in the included Annexes. 

• Annex A provides engineering information for a variety of topics including: reliability testing, reliability growth testing, worthiness testing, Environmental Stress Screening (ESS), test time compression and fatigue relationship, and many other topics. 
• Annex B provides guidance for Manufacture/Maintenance Vibration exposure.  It is useful in assisting in determining vibration levels and durations for testing concerns such as manufacturing and maintenance practices, shipping and handling, and Environmental Stress Screening.
• Annex C contains information about transportation tailoring.  This includes guidance for setting design and test exposure values of many typical life cycle events.  It provides typical mission scenarios that include such information as standard military land vehicle transport distances from port staging areas to forward using units.  It also provides standardized vibration profiles for various vehicle types.
• Annex D includes information concerning operational vibration in the life cycle of equipment.  This includes vibration profiles for fixed and rotary wing aircraft, aircraft stores, ground vehicles, missiles, and watercraft.
• Annex E provides guidance for vibration specific to minimum integrity tests and cantilevered loads.
• Annex F contains information critical to the development of vibration test schedules.  This is and extremely detailed annex and contains six appendices.

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 Vibration MIL-STD-810 Method 514) 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.

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 services can assist your engineering team with Vibration MIL-STD-810 Method 514 or any other test and evaluation concern.

Acceleration MIL-STD-810 Method 513 is a test method used to evaluate equipment’s ability to withstand steady state inertia loads and ensure that the test item does not create a hazard after being subjected to crash inertia loads.  This testing is intended primarily for equipment that will be installed on aircraft, helicopters, aerospace vehicles, aircraft stores, and ground-launched missiles.  Acceleration should not be mistaken for shock which excites a dynamic resonant response as opposed to a steady inertial stress.  

Procedures for Acceleration 

Four test procedures are available for acceleration testing:

• Procedure I – Structural Test; ensures that equipment can structurally withstand in service acceleration loads.
• Procedure II – Operational Test; Is used to evaluate equipment’s ability to operate while being subjected to acceleration g forces expected in its service environment.
• Procedure III – Crash Hazard Acceleration Test; is used to ensure that restraining mechanisms such as fasteners do not fail in a crash scenario, creating a hazard to personnel or blocking paths of ingress and egress.
• Procedure IV – Strength Test; added in revision H, uses sine burst testing on a vibration table to expose the test item to quasi-static loads.

Selection of tests to be performed should be based on requirements and criteria derived from the Life Cycle Environmental Profile (LCEP).  This testing should be conducted after environmental transportation and storage methods towards the end of the test sequence.

Test Levels 

System specific g levels for various platforms are provided in the standard.  These designate values for fore, aft, up, down, and lateral axes.  While these values are representative of forces expected in vehicle types, measured data should be used when available.  

Levels for fighter and attack aircraft include provisions for materiel that is intended for locations away from the aircraft’s center of gravity.  Formulae are provided for calculating the additional loads experienced in roll, pitch and yaw maneuvers in various directions.  

Test Apparatus for Performing Acceleration Testing

Acceleration testing can be performed using different types of test equipment.  For most applications, centrifuge testing is performed due to scheduling and budget considerations.  However, when required, Track/rocket powered sled testing can be performed.  Due to vibration caused by the rocket engine and track roughness, sled testing is generally more severe than that expected in general service life of the test item.

Additionally, sine burst testing is used for Procedure IV.  This testing, although limited in its level of evaluation, offers an economical alternative for verification testing performed early in development because vibration tables are generally more available and testing on them requires less set up time.

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 Acceleration Mil-Std-810 method 513) 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 testing standards. 

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 MIL-STD-810 acceleration testing or any other product test and evaluation concern.

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.