MIL-HDBK-1530B(USAF)
5.1.4 Selection of materials, processes, and joining methods. Materials, processes, and joining methods should be selected to result in a lightweight, cost-effective airframe that meets the strength, durability, and damage tolerance requirements of the applicable specifications. New materials and/or processes should have been subjected to a technology transition criteria based on: 1.) stabilized materials and processes, 2.) producibility, 3.)
characterized mechanical properties, 4.) prediction of structural performance, and 5.) supportability. A primary factor in the final selection should be the results of the design concept/material/weight/cost trade studies performed as a part of the durability and damage tolerance control.
5.1.4.1 Structural materials, processes, and joining methods selection criteria. In response to the Request For Proposal (RFP), prospective contractors should identify the proposed materials, processes, and joining methods to be used in each of the structural components and the rationale for the individual selections. After contract award and during the design activity, this rationale should include all pertinent data upon which the selections were based-including the database, previous experience, and trade study results. The requirement and verification for Materials and processes (3.2.19 and 4.2.19) in JSSG-2006 should be used for material requirements and processes, respectively.
5.1.5 Design service goal and design usage. The U.S. Air Force will provide the required design service goal and typical design usage as part of the contract specifications. These data should be used in the initial design and analysis of the airframe. The design service goal and design usage will be established through close coordination between the procuring activity and the advanced planning activities (i.e., Headquarters U.S. Air Force, Headquarters Air Force Materiel Command, and Using Commands). Design mission profiles, mission mixes, and environmental exposure mixes which are realistic estimates of expected service usage will be established using requirement and verification guidelines for Service life and usage (3.2.14 and 4.2.14) in JSSG-2006. It is recognized that special force management actions will probably be required (i.e., early retirement, early modification, or rotation of selected air vehicle) if the actual usage and/or environmental exposure is more severe than the design usage.
5.1.6 Nondestructive testing and inspection (NDT/I). NDT/I guidelines are provided in JSSG-2006 and MIL-HDBK-6870. Nondestructive testing and inspection requirements should be considered early in the design development and the appropriate tools and methods integrated into the overall risk management process.
5.2 Design analyses and development tests (Task II). The objectives of the design analyses and development tests task are to: 1.) determine the environments in which the airframe must operate (load, temperature, chemical, abrasive, and vibratory and acoustic environment), 2.) perform preliminary and final analyses and tests based on these environments, and 3.) size the airframe to meet the strength, rigidity, damage tolerance, and durability requirements.
5.2.1 Material and joint allowables. Materials and joint allowables data in MIL-HDBK-5,
MIL-HDBK-17, MIL-HDBK-23, MCIC-HDBK-01, and WL-TR-94-40152/3/4/5/6 may be used to support the use of existing materials in various design analyses. Other data sources may also be used, but should be reviewed by the concerned SPO and contractor elements. For new materials and those existing materials for which there are insufficient data available, experimental programs to obtain the data and generate analysis test data should be formulated and performed using the requirement and verification guidelines for Materials (3.2.19.1 and 4.2.19.1) in JSSG-2006.
5.2.2 Loads analysis. Loads analysis should determine the magnitude and distribution of significant static and dynamic loads which the airframe may encounter when operated within the envelope established by the structural design criteria. This analysis consists of a determination of the flight loads, ground loads, powerplant loads, control system loads, and weapon effects. When applicable, this analysis should include the effects of temperature, aeroelasticity, and dynamic response of the airframe.
5.2.3 Design service loads spectra. Detail guidance for design service loads spectra are established in JSSG-2006 and in the contract specifications. The purpose of the design service loads spectra is to develop the distribution and frequency of loading that the airframe will experience based on the design service goal and typical design usage. The design service loads spectra and the design chemical/thermal environment spectra as defined in
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