MIL-STD-1530C(USAF)
5.1.7.1 Stability.
Maturity of material, process, and joining method choices shall be assessed by determining if these choices result in consistent and repeatable quality and if predicable costs are likely to be achieved to meet production requirements. This can be demonstrated by robust and documented approaches for controlling process parameters/methods, i.e., specifications exist.
5.1.7.2 Producibility.
Quality control shall be ensured through the use of appropriate process control measures employed during the manufacture of the aircraft structure.
5.1.7.3 Mechanical and physical properties.
Mechanical and physical properties include all the key mechanical and physical properties that have been determined in the appropriate environments in the as-fabricated condition using the manufacturing processes and joining methods that will be utilized. Key mechanical properties include but are not limited to: strength, elongation, fracture toughness, damage growth rates, stress corrosion and fatigue crack
growth thresholds. Key physical properties include but are not limited to: density, corrosion resistance, defect population, reflectivity, and surface roughness.
5.1.7.4 Supportability.
Legacy experience and health/environmental regulations must be considered when the capability of proposed approaches is evaluated. The selection of preventive and repair methods shall consider the potential for repeated use on individual aircraft. These preventive and repair methods include corrosion preventive coatings, hot bonding of composites, mechanical fastened repairs, field welding and stress relief, grinding, shot peening, etc.
5.1.7.5 Risk mitigation actions.
Risk mitigation actions shall be defined and implemented in the program based on an estimate of the level of risk associated with the selection of the new materials, processes, joining methods, and/or structural concepts. The specific actions required will depend on the classification of the structural component
(e.g., safety-of-flight structure), the design concept (i.e., safe-life, fail-safe, or slow damage growth), and the estimated risk level. Possible risk mitigation actions include: using higher factors of safety, fabrication and durability testing of one or more large structural components in the appropriate thermal/chemical environments, special in-service inspections of test and/or operational aircraft, and special in-process testing (such as periodic strength proof testing of bonded joints) conducted throughout the production of the aircraft. In addition, the use of fail-safe design concepts is preferred when flight safety depends on the integrity of the bonded joint.
5.2 Design analyses & development testing (Task II).
The objectives of the design analyses and development tests task are to: 1) determine the environments in which the aircraft structure must operate (load, temperature, chemical, abrasive, and vibratory and aeroacoustic environment), 2) perform preliminary and final analyses and tests based on these environments, and 3) size the aircraft structure to meet the strength, rigidity, damage tolerance, and durability requirements. Test plans, procedures, and schedules shall be approved by the USAF.
5.2.1 Material and joint allowables.
Material and joint allowables data identified in FAA MMPDS-Handbook, Damage Tolerant Design Handbook, CINDAS Aerospace Structural Metals Handbook, and CINDAS Structural Alloys Handbook may be used to support the use of existing materials in design analyses. Other data sources may also be used, but shall first be reviewed by the USAF and the contractor. Experimental programs to obtain the
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