Attachment_H_-_NASA-STD-6016.pdf

NASA-STD-6016A

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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DOCUMENT HISTORY LOG

Status Document Revision

Change Number

Approval Date Description

Interim 2006-09-11 Interim Release Baseline 2008-07-11 Baseline Release

Transitioned Interim Standard NASA-STD- (I)-6016 to NASA Technical Standard

NASA-STD-6016.

Revision A 2016-11-30 Significant changes were made to the document. It is recommended that the document be reviewed in its entirety before implementation.

Key changes were:

Updated applicable standards to the latest verified acceptable versions.

Simplified requirements on M&P control process.

Revised requirements on material design values.

Restructured standard to place all heat treatment and weld process requirements in Processes section.

Added controls on use of pure tin (replacing previous prohibition).

Added first article and production controls for castings.

Imposed AWS and other voluntary consensus standards for welding as alternative to NASA-STD-5006A.

Added high-level requirement on additive manufacturing.

Added requirements on control of intermetallic compounds.

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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DOCUMENT HISTORY LOG (Continued)

Status Document Revision

Change Number

Approval Date Description

Revision A Continued Replaced prohibition on liquid-locking compounds with imposition of (less restrictive) NASA-STD-5020.

Retired Category III MUA codes and incorporated rationales into the standard as exceptions to the requirements.

Added appendix with rationales for each requirement.

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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FOREWORD

This NASA Technical Standard is published by the National Aeronautics and Space Administration (NASA) to provide uniform engineering and technical requirements for processes, procedures, practices, and methods that have been endorsed as standard for NASA programs and projects, including requirements for selection, application, and design criteria of an item.

This NASA Technical Standard is approved for use by NASA Headquarters and NASA Centers and Facilities and may be cited in contract, program, and other Agency documents as a technical requirement. It may also apply to the Jet Propulsion Laboratory and other contractors only to the extent specified or referenced in applicable contracts.

This NASA Technical Standard defines the minimum requirements for Materials and Processes (M&P) and provides a general control specification for incorporation in NASA program/project hardware procurements and technical programs.

Requests for information should be submitted via “Feedback” at https://standards.nasa.gov.

Requests for changes to this NASA Technical Standard should be submitted via MSFC Form 4657, Change Request for a NASA Engineering Standard.

______Original Signed By__________ _________11/30/2016__________ Ralph R. Roe, Jr. Approval Date NASA Chief Engineer

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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SECTION

TABLE OF CONTENTS

PAGE

DOCUMENT HISTORY LOG

FOREWORD

TABLE OF CONTENTS

LIST OF APPENDICES

1. SCOPE

1.1 Purpose

1.2 Applicability

1.3 Tailoring

2. APPLICABLE DOCUMENTS

2.1 General

2.2 Government Documents

2.3 Non-Government Voluntary Consensus Standards

2.4 Order of Precedence

3. ACRONYMS AND DEFINITIONS

3.1 Acronyms and Abbreviations

3.2 Definitions

4. REQUIREMENTS

4.1 General Requirements

4.1.1 Materials and Processes Selection, Control, and Implementation Plan

4.1.1.1 Coordination, Approval, and Tracking

4.1.1.2 Approval Signature

4.1.1.3 Manufacturing Planning

4.1.2 M&P Controls

4.1.2.1 Standard and Specification Obsolescence

4.1.3 Commercial Off-The-Shelf (COTS) Hardware

4.1.4 M&P Control Panel

4.1.5 M&P Usage Documentation

4.1.6 Material Usage Agreements (MUAs)

4.1.6.1 Human-Rated Spacecraft

4.1.6.1.1 Category I MUAs

4.1.6.1.2 Category II MUAs

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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TABLE OF CONTENTS (Continued)

SECTION PAGE

4.1.6.1.3 Category III MUAs

4.1.7 Materials Certification and Traceability

4.1.8 Material Design Values

4.1.8.1 Requirements for Design Values

4.1.8.2 Design Value Implementation in Design

4.1.8.3 Structural Fastener Design Values

4.2 Detailed Requirements

4.2.1 Flammability, Offgassing, and Compatibility Requirements

4.2.1.1 Flammability Control

4.2.1.2 Toxic Offgassing

4.2.1.3 Fluid Compatibility (Fluids Other Than Oxygen)

4.2.1.4 Oxygen Compatibility

4.2.1.5 Electrical Wire Insulation Materials

4.2.2 Metals

4.2.2.1 Aluminum

4.2.2.2 Steel

4.2.2.3 Titanium

4.2.2.4 Magnesium

4.2.2.5 Beryllium

4.2.2.6 Cadmium

4.2.2.7 Zinc

4.2.2.8 Mercury

4.2.2.9 Refractory Metals

4.2.2.10 Superalloys (Nickel-Based and Cobalt-Based)

4.2.2.11 Tin

4.2.3 Nonmetallic Materials

4.2.3.1 Elastomeric Materials

4.2.3.2 Polyvinyl Chloride

4.2.3.3 Composite Materials

4.2.3.4 Lubricants

4.2.3.5 Limited-Life Items

4.2.3.6 Thermal Vacuum Stability

4.2.3.7 External Environment Survivability

4.2.3.8 Fungus Resistance

4.2.3.9 Glycols

4.2.3.10 Etching Fluorocarbons

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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TABLE OF CONTENTS (Continued)

SECTION PAGE

4.2.4 Processes

4.2.4.1 Heat Treatment

4.2.4.2 Forging

4.2.4.3 Castings

4.2.4.4 Formed Panels

4.2.4.5 Adhesive Bonding

4.2.4.6 Welding

4.2.4.7 Brazing

4.2.4.8 Structural Soldering

4.2.4.9 Electrical Discharge Machining and Laser Machining

4.2.4.10 Nickel Plating

4.2.4.11 Additive Manufacturing

4.2.5 Material Nondestructive Evaluation (NDE)

4.2.5.1 Nondestructive Evaluation (NDE) Plan

4.2.5.2 NDE Etching

4.2.6 Special Materials Requirements

4.2.6.1 Residual Stresses

4.2.6.2 Sandwich Assemblies

4.2.6.3 Corrosion Prevention and Control

4.2.6.4 Hydrogen Embrittlement

4.2.6.5 Intermetallic Compounds

4.2.6.6 Fastener Installation

4.2.6.7 Contamination Control

4.2.6.8 Packaging

4.3 Verification

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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LIST OF APPENDICES

APPENDIX PAGE

A Standard Materials and Processes Requirements for Spacecraft – Requirements Compliance Matrix with Requirements Justifications

B Typical MUA Form C Retired Category III MUA Rationale Codes D Recommended Data Requirements Documents E References

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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STANDARD MATERIALS AND PROCESSES

REQUIREMENTS FOR SPACECRAFT

1. SCOPE

This NASA Technical Standard is directed toward materials and processes (M&P) used in the design, fabrication, and testing of space program flight hardware for NASA, including but not limited to crewed, uncrewed, robotic, launch vehicle, lander, in-space and surface systems, and spacecraft program/project hardware elements. All spaceflight hardware is covered by the M&P requirements of this document, including vendor-designed, off-the-shelf, and vendor-furnished items.

M&P used in interfacing ground support equipment (GSE), test equipment, hardware processing equipment, hardware packaging, and hardware shipment is covered by the M&P requirements of this NASA Technical Standard only to the extent required to prevent damage to or contamination of spaceflight hardware (see Section 4.0). M&P used in NASA aircraft and aircraft operations are not covered by the M&P requirements of this document.

1.1 Purpose

The purpose of this NASA Technical Standard is to define the minimum requirements for M&P and to provide a general control specification for incorporation in NASA program/project hardware procurements and technical programs.

1.2 Applicability

The controls described here are applicable to all NASA spacecraft programs:

a. [MPR 1] Programs shall apply these controls to program/project hardware. Programs, projects, and elements are responsible for flowing requirements down to contractors, subcontractors, and the lowest component-level suppliers.

b. [MPR 2] Programs shall be responsible for demonstrating compliance with these requirements.

This NASA Technical Standard is approved for use by NASA Headquarters and NASA Centers and Facilities and may be cited in contract, program, and other Agency documents as a technical requirement. It may also apply to the Jet Propulsion Laboratory and other contractors only to the extent specified or referenced in applicable contracts.

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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Verifiable requirement statements are numbered and indicated by the word “shall” beginning in section 4; this NASA Technical Standard contains 209 requirements. Explanatory or guidance text is indicated in italics beginning in section 4. To facilitate requirements selection and verification by NASA programs and projects, a Requirements Compliance Matrix is provided in Appendix A. This appendix also contains justifications for each verifiable requirement statement.

1.3 Tailoring

a. [MPR 3] Tailoring of this NASA Technical Standard’s requirements in the Materials and Processes Selection, Control, and Implementation Plan for specific programs/projects shall be formally documented as part of program or project requirements and approved by the responsible program/project NASA M&P organization, the responsible project/program, and the responsible Technical Authority in accordance with NPR 7120.5, NASA Space Flight Program and Project Management Requirements, or NPR 7120.8, NASA Research and Technology Program and Project Management Requirements. These requirements may be tailored simply by constructing a matrix of applicable paragraphs and paragraphs that are not applicable. Tailoring also includes using existing or previously developed contractor processes and standards as a submittal of the various required plans. Otherwise, the tailoring of requirements may be documented in the Materials and Processes Selection, Control, and Implementation Plan by providing the degree of conformance and the method of implementation for each requirement identified here.

b. When a Materials and Processes Selection, Control, and Implementation Plan has been approved by the responsible program/project as an acceptable means of compliance with the technical requirements of this NASA Technical Standard, the Plan may be used for the implementation and verification of M&P requirements on the applicable program/project.

2. APPLICABLE DOCUMENTS

2.1 General

The documents listed in this section contain provisions that constitute requirements of this NASA Technical Standard as cited in the text.

2.1.1 [MPR 4] The latest issuances of cited documents shall apply unless specific versions are designated.

2.1.2 [MPR 5] Non-use of specifically designated versions shall be approved by the responsible Technical Authority.

The applicable documents are accessible at https://standards.nasa.gov, may be obtained directly from the Standards Developing Body or other document distributors, or information for obtaining the document is provided.

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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2.2 Government Documents

The documents in these paragraphs are applicable to the extent specified. The citations below refer to the sections in this NASA Technical Standard.

National Aeronautics and Space Administration (NASA)

NPR 7120.5 (Cited in section 1.3)

NPR 7120.8 (Cited in section 1.3)

NASA-STD-5006A

with Change 1 (2016) (Cited in section 4.2.4.6)

NASA Space Flight Program and Project Management Requirements

NASA Research and Technology Program and Project Management Requirements

General Welding Requirements for Aerospace Materials

NASA-STD-5009 (2008)

(Cited in section 4.2.5.1)

Nondestructive Evaluation Requirements for Fracture-Critical Metallic Components

NASA-STD-5020 (2012)

(Cited in section 4.2.6.6.1)

Requirements for Threaded Fastening Systems in Spaceflight Hardware

NASA-STD-6001B (2011)

with Change 2 (2016) (Cited in sections 4.2.1, 4.2.1.1, 4.2.1.2, 4.2.1.4, and 4.2.1.5)

Flammability, Offgassing, and Compatibility Requirements and Test Procedures

NASA-STD-6012 (2012)

(Cited in section 4.2.6.3)

Corrosion Protection for Space Flight Hardware

JSC 20584 (2008) (Cited in section 4.2.1.2)

Spacecraft Maximum Allowable Concentrations for Airborne Contaminants

JSC 29353 (Cited in section 4.2.1.1)

Flammability Configuration Analysis for Spacecraft Applications

Materials and Processes Technical Information System (MAPTIS) (Cited in section 4.2.1.2)

Materials Selection List for Space Hardware Systems

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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MSFC-SPEC-445A (1990)

(Cited in section 4.2.4.5)

Adhesive Bonding, Process and Inspection, Requirements for

MSFC-STD-3029A (2005)

(Cited in section 4.2.2)

Guidelines for the Selection of Metallic Materials for Stress Corrosion Cracking Resistance in Sodium Chloride Environments

Department of Defense

MIL-STD-810G (2008),

with Change 1 (2014) (Cited in section 4.2.3.8)

Department of Defense Test Method Standard for Environmental Engineering Considerations and Laboratory Tests

MIL-STD-1252 (1975)

(Cited in section 4.2.4.6.4) (Inactive for New Design effective 3/11/1998 but determined by NASA to be the best existing standard for use)

Inertia Friction Welding Process, Procedure and Performance Qualification

MIL-HDBK-454B (Cited in section 4.2.3.8)

General Guidelines for Electronic Equipment

MIL-HDBK-6870B (2012)

(Cited in section 4.2.5.1)

Nondestructive Inspection Program Requirements for Aircraft and Missile Materials and Parts

2.3 Non-Government Voluntary Consensus Standards

The citations below refer to the sections in this NASA Technical Standard.

ASTM International (ASTM)

ASTM B689-97 (Reapproved 2013) (Cited in section 4.2.4.10)

Standard Specification for Electroplated Engineering Nickel Coatings

ASTM B733-15 (Cited in sections 4.2.4.10 and 4.2.6.3)

Standard Specification for Autocatalytic (Electroless) Nickel-Phosphorus Coatings on Metal

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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ASTM E595-15 (Cited in section 4.2.3.6)

Standard Test Method for Total Mass Loss and Collected Volatile Condensable Materials from Outgassing in a Vacuum Environment

ASTM E1548 (2009) (Cited in section 4.2.6.7)

Standard Practice for Preparation of Aerospace Contamination Control Plans

American Welding Society (AWS)

AWS C3.2M/C3.2 (2008)

(Cited in section 4.2.4.7)

Standard Method for Evaluating the Strength of Brazed Joints

AWS C3.3 (2008) (Cited in section 4.2.4.7)

Recommended Practices for Design, Manufacture, and Examination of Critical Brazed Components

AWS C3.4M/C3.4 (2016)

(Cited in section 4.2.4.7)

Specification for Torch Brazing

AWS C3.5M/C3.5 (2016)

(Cited in section 4.2.4.7)

Specification for Induction Brazing

AWS C3.6M/C3.6 (2016)

(Cited in section 4.2.4.7)

Specification for Furnace Brazing

AWS C3.7M/C3.7 (2011)

(Cited in section 4.2.4.7)

Specification for Aluminum Brazing

AWS C7.4/C7.4M (2008)

(Cited in section 4.2.4.6.1)

Process Specification and Operator Qualification for Laser Beam Welding

AWS D17.1/D17.1M (2010)

AMD1 (2012) (Cited in section 4.2.4.6.1)

Specification for Fusion Welding for Aerospace Applications

AWS D17.2/D17.2M (2013)

(Cited in section 4.2.4.6.2)

Specification for Resistance Welding for Aerospace Applications

AWS D17.3/D17.3M (2016)

(Cited in section 4.2.4.6.3)

Specification for Friction Stir Welding of Aluminum Alloys for Aerospace Applications

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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Battelle Memorial Institute

MMPDS-10 (2015) (Cited in section 4.1.8.1, 4.1.8.2, and 4.2.4.1)

Metallic Materials Properties Development and Standardization (MMPDS)

Government Electronics and Information Technology Association (GEIA) (SAE International)

GEIA-STD-0005-1A (2012)

(Cited in section 4.2.2.11)

Performance Standard for Aerospace and High Performance Electronic Systems Containing Lead-Free Solder

GEIA-STD-0005-2A (2012)

(Cited in section 4.2.2.11)

Standard for Mitigating the Effects of Tin Whiskers in Aerospace and High Performance Electronic Systems

National Aerospace Standards (NAS)

NAS 410, Revision 4 (2014) (Cited in section 4.2.5.1)

NAS Certification and Qualification of Nondestructive Test Personnel

NAS 412, Revision 1 (2013) (Cited in section 4.2.6.7)

Foreign Object Damage/Foreign Object Debris (FOD) Prevention

SAE International (SAE)

SAE AMS2175A (2010)

(Cited in section 4.2.4.3)

Castings, Classification and Inspection of

SAE AMS2375D (2007,

Reaffirmed 2012) (Cited in section 4.2.4.2)

Control of Forgings Requiring First Article Approval

SAE AMS2403N (2015)

(Cited in section 4.2.4.10)

Plating, Nickel General Purpose

SAE AMS2404G (2013)

(Cited in section 4.2.4.10 and 4.2.6.3)

Plating, Electroless Nickel

SAE AMS2423E (2015)

(Cited in section 4.2.4.10)

Plating, Nickel Hard Deposit

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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SAE AMS2488D (2000,

Reaffirmed 2011) (Cited in section 4.2.2.3.2)

Anodic Treatment - Titanium and Titanium Alloys Solution, pH 13 or Higher

SAE AMS2491F (2015)

(Cited in section 4.2.3.10)

Surface Treatment of Polytetrafluoroethylene, Preparation for Bonding

SAE AMS2680C (2001,

Reaffirmed 2010) (Cited in section 4.2.4.6.1)

Electron-Beam Welding for Fatigue Critical Applications

SAE AMS2759E (2008,

Reaffirmed 2014) (Cited in section 4.2.4.1)

Heat Treatment of Steel Parts, General Requirements

SAE AMS2759/9D (2009)

(Cited in sections 4.2.6.4)

Hydrogen Embrittlement Relief (Baking) of Steel Parts

SAE AMS2770N (2015)

(Cited in section 4.2.4.1)

Heat Treatment of Wrought Aluminum Alloy Parts

SAE AMS2771E (2013)

(Cited in section 4.2.4.1)

Heat Treatment of Aluminum Alloy Castings

SAE AMS2772G (2016)

(Cited in section 4.2.4.1)

Heat Treatment of Aluminum Alloy Raw Materials

SAE AMS2773E (2013)

(Cited in section 4.2.4.1)

Heat Treatment, Cast Nickel Alloy and Cobalt Alloy Parts

SAE AMS2774E (2016)

(Cited in section 4.2.4.1)

Heat Treatment, Wrought Nickel Alloy and Cobalt Alloy Parts

SAE AMS2801B (2003,

Reaffirmed 2014) (Cited in section 4.2.4.1 and 4.2.4.6.1)

Heat Treatment of Titanium Alloy Parts

SAE AMS-H-6875B (2010)

(Cited in 4.2.4.1)

Heat Treatment of Steel Raw Materials

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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SAE AMS-H-81200D

(2014) (Cited in sections

4.2.4.1 and 4.2.4.6.1)

Heat Treatment of Titanium and Titanium Alloys

SAE AMS-STD-401 (1999)

(Cited in section 4.2.6.2)

Sandwich Constructions and Core Materials: General Test Methods

SAE AS22759C (2014)

(Cited in section 4.2.1.5)

Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy

SAE CMH-17:

SAE CMH-17-1G (2012)

(Cited in section 4.1.8.1)

Composite Materials Handbook Volume 1 - Polymer Matrix Composites Guidelines for Characterization of Structural Materials

SAE CMH-17-2G (2012)

(Cited in section 4.1.8.1)

Composite Materials Handbook Volume 2 - Polymer Matrix Composites Materials Properties

SAE CMH-17-3G (2012)

(Cited in section 4.1.8.1)

Composite Materials Handbook Volume 3 - Polymer Matrix Composites Materials Usage, Design, and Analysis

SAE CMH-17-4B (2013)

(Cited in section 4.1.8.1)

Composite Materials Handbook Volume 4 - Metal Matrix Composites

MIL-HDBK-17-5

(2002) (Reference section 4.1.8.1)— (Use until SAE CMH-17-5 is published, scheduled in 2017)

Composite Materials Handbook Volume 5 - Ceramic Matrix Composites

SAE CMH-17-6 (2013)

(Cited in section 4.1.8.1)

Composite Materials Handbook Volume 6 – Structural Sandwich Composites

Refer to Appendix E for References.

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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2.4 Order of Precedence

2.4.1 The requirements and standard practices established in this NASA Technical Standard do not supersede or waive existing requirements and standard practices found in other Agency documentation.

2.4.2 [MPR 6] Conflict between this NASA Technical Standard and other requirements documents shall be resolved by the responsible Technical Authority.

3. ACRONYMS AND DEFINITIONS

3.1 Acronyms and Abbreviations

/sec Per Second AIAA American Institute of Aeronautics and Astronautics AM Additively Manufactured AMS Aerospace Material Specification ANSI American National Standards Institute AS Aerospace Standard ASTM ASTM International (formerly American Society for

Testing and Materials) AWS American Welding Society BZT Benzotriazole CCP Contamination Control Plan CDR Critical Design Review cm Centimeter CMH Composite Materials Handbook COTS Commercial Off-The-Shelf CP Commercially Pure CR Contractor Report CVCM Collected Volatile Condensable Materials °C Degrees Celsius °F Degrees Fahrenheit D Dimensional DMLS Direct Metal Laser Sintering DOT Department of Transportation DRD Data Requirements Description EDM Electrical Discharge Machining EEE Electrical, Electronic, and Electromechanical ELI Extra Low Interstitial ESD Electrostatic Discharge ETFE Ethylene Tetrafluoroethylene

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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FAA Federal Aviation Administration FEP Fluorinated Ethylene Propylene FOD Foreign Object Damage/Debris FRR Flight Readiness Review g Gram GEIA Government Electronics and Information Technology

Association GOX Gaseous Oxygen GSE Ground Support Equipment HDBK Handbook HEE Hydrogen Environmental Embrittlement HRE Hydrogen Reaction Embrittlement IHE Internal Hydrogen Embrittlement in Inch JSC Johnson Space Center kPa Kilopascals ksi Kilopounds per Square Inch lb Pound LM Laser Machining LOX Liquid Oxygen M&P Materials and Processes MAPTIS Materials and Processes Technical Information System MIL Military MIUL Materials Identification and Usage List mm Millimeter MMPDS Metallic Materials Properties Development and

Standardization MNL Manual MPa Megapascals MPR Materials and Processes Requirement MSFC Marshall Space Flight Center MUA Material(s) Usage Agreement NAS National Aerospace Standard NASA National Aeronautics and Space Administration NDE Nondestructive Evaluation NDI Nondestructive Inspection NDT Nondestructive Testing NPR NASA Procedural Requirements PDF Portable Document Format PDP Part Development Plans PDR Preliminary Design Review PFA Perfluoroalkoxy PH Precipitation Hardened/Hardenable

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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PQR Procedure Qualification Record PSIA Pounds per Square Inch Absolute PTFE Polytetrafluoroethylene PVC Polyvinyl Chloride RH Relative Humidity RSW Resistance Spot Welding RTV Room Temperature Vulcanizing (rubber) SAGBOE Stress Assisted Grain Boundary Oxidation

Embrittlement SAE SAE International (formerly Society of Automotive

Engineers) SDR System Definition Review sec Second SLM Selective Laser Melting SMAC Spacecraft Maximum Allowable Concentration SOW Statement of Work SPEC Specification SRR System Requirements Review STD Standard TM Technical Memorandum TML Total Mass Loss UTS Ultimate Tensile Strength UV Ultraviolet VCM Volatile Condensable Materials WPS Welding Procedure Specification

Weld Process Specification WVR Water Vapor Recovery

3.2 Definitions

Additive Manufacturing: Any process for making a three-dimensional object from a 3-D model or other electronic data source primarily through processes in which successive layers of material are deposited under computer control.

Catastrophic Hazard: Presence of a risk situation that could directly result in a catastrophic event, which is defined as loss of life, disabling injury, or loss of a major national asset.

Corrosive Environment: Solid, liquid, or gaseous environment that deteriorates the materials by reaction with the environment. Clean rooms and vacuum are normally considered noncorrosive.

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

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Critical Hazard: Hazard that can result in the potential for severe injury, severe occupational illness, or major property/equipment damage.

Design Value: The design value is a statistically determined minimum value of a property, most commonly strength properties of materials, design features/elements, or components/parts used in the design of a structure. For A-basis strength properties, at least 99% of the population of strength values is expected to equal or exceed this lower bound with 95% confidence. For B-basis, 90% of the population of strength values is expected to equal or exceed this lower bound with 95% confidence. For metallic materials S-basis design values, the statistics defined by MMPDS are the same as for A-basis, but the test requirements are less comprehensive. Numbers of lots and test specimens required to develop design values are defined in applicable standards. The terms “material allowables,” “design allowables,” and “design values” are commonly used to address the design values used in structural analysis.

Fretting Corrosion: Occurs when two contacting surfaces under mechanical load are subjected to repeated relative surface motion. Mechanical wear and material transfer at the surfaces can lead to corrosion, metallic debris, and increased contact resistance due to the electrical insulating properties of corrosion products that may build up at the contact interfaces.

Mission Critical Hardware: Hardware, the failure of which may result in the inability to retain operational capability for mission continuation if a corrective action is not successfully performed.

Nondestructive Evaluation (NDE)/Nondestructive Testing (NDT): Inspection techniques which do not cause physical, mechanical, or chemical changes to the part being inspected or otherwise impair its adequacy for operational service. These inspection techniques are applied to materials and structures to verify required integrity and to detect flaws.

Refractory Alloys: Alloys with a melting point above 2000 °C (3632 °F), plus osmium and iridium.

Safety-Critical: Term describing any condition, event, operation, process, equipment, or system that could cause or lead to severe injury, major damage, or mission failure if performed or built improperly, or allowed to remain uncorrected.

Structural: Pertaining to structure.

Structural Adhesive Bond: Structural joint using adhesive bonds for the purpose of transferring structural load between structures.

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

APPROVED FOR PUBLIC RELEASE—DISTRIBUTION IS UNLIMITED

Structure: All components and assemblies designed to sustain loads or pressures, provide stiffness and stability, or provide support or containment.

Structure, Primary: That part of a flight vehicle or element that sustains the significant applied loads and provides main load paths for distributing reactions to applied loads. Also, the main structure that is required to sustain the significant applied loads, including pressure and thermal loads, and that, if it fails, creates a catastrophic hazard. If a component is small enough and in an environment where no serious threat is imposed if it breaks, then it is not primary structure.

Subcontractor: A hardware contractor that reports to a higher level contractor.

Technical Authority: Provides technical checks and balances by assuring that safety and mission success, relevant technical standards, engineering work, and safety and reliability analysis products are being conducted properly in accordance with established, high-reliability processes independent of nontechnical program/project constraints.

Tin Pest: The allotropic transformation of tin that may occur at or below 13.2 °C,

- -phase, a grey, brittle semiconductor that occupies about 27 percent -phase.

Useful Life: Total life span, including storage life, installed life in a nonoperating mode, and operational service life.

Wet Installed: Fasteners covered with primer or sealant during installation to prevent moisture from penetrating the fastener joint and causing corrosion.

Whisker (Metal): A spontaneous growth that may form on surfaces of metals, primarily tin, zinc, and cadmium. Metal whiskers may also detach from the surfaces on which they form, producing conductive FOD.

4. REQUIREMENTS

Requirements for materials used in the fabrication and processing of spaceflight hardware are as follows:

a. [MPR 7] Materials shall meet the worst-case useful-life requirements for the particular application.

The useful-life requirements include, but are not limited to, the following:

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

APPROVED FOR PUBLIC RELEASE—DISTRIBUTION IS UNLIMITED

(1) Operational temperature limits.

(2) Loads.

(3) Contamination.

(4) Life expectancy.

(5) Moisture or other fluid media exposure.

(6) Vehicle-related induced and natural space environments.

Experimental spaceflight hardware and other hardware that do not provide mission-critical functions may have no useful-life requirements, provided that the safety of the crew, the space vehicle, or launch vehicle are not compromised.

Properties to be considered in material selection include, but are not limited to, the following:

(1) Mechanical properties.

(2) Fracture toughness.

(3) Flammability and offgassing characteristics.

(4) Corrosion.

(5) Stress corrosion.

(6) Thermal and mechanical fatigue properties.

(7) Glass-transition temperature.

(8) Coefficient of thermal expansion mismatch.

(9) Vacuum outgassing.

(10) Fluids compatibility.

(11) Microbial resistance.

(12) Moisture resistance.

(13) Fretting.

(14) Galling.

(15) Susceptibility to electrostatic discharge (ESD).

(16) Susceptibility to contamination.

b. [MPR 8] M&P used in interfacing GSE, test equipment, hardware processing equipment, hardware packaging, and hardware shipment shall be controlled to prevent damage to or contamination of spaceflight hardware.

The M&P controls in NASA-STD-5005 (Revision D or later), Standard for the Design and Fabrication of Ground Support Equipment, are acceptable for meeting this requirement for interfacing GSE hardware.

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

APPROVED FOR PUBLIC RELEASE—DISTRIBUTION IS UNLIMITED

4.1 General Requirements

4.1.1 Materials and Processes Selection, Control, and Implementation Plan

a. [MPR 9] Each organization that is responsible for the design and fabrication of spaceflight hardware shall provide a Materials and Processes Selection, Control, and Implementation Plan.

The Materials and Processes Selection, Control, and Implementation Plan documents the degree of conformance and method of implementation for each requirement in this NASA Technical Standard and identifies applicable in-house specifications used to comply with the requirement.

Other documents, such as contractor-specific M&P requirements documents and detailed requirements compliance matrices, can be used to form the basis of the Materials and Processes Selection, Control, and Implementation Plan, provided the content addresses the requirements.

b. [MPR 10] The Materials and Processes Selection, Control, and Implementation Plan shall also describe the methods used to control compliance with these requirements by subcontractors and vendors.

Prime contractors may require subcontractors and vendors to develop a tailored plan to comply with NASA-STD-6016 or a tailored plan to comply with the prime contractor's plan.

Alternatively, prime contractors may flow down a limited subset of (or even no) requirements, with the prime making up the difference between the subset and materials control plan.

Whichever approach is selected, prime contractors are responsible for ensuring that hardware designed and fabricated by their subcontractors meet the materials control plan or NASA-STD- 6016.

c. [MPR 11] Upon approval by the procuring activity, the Materials and Processes Selection, Control, and Implementation Plan shall become the M&P implementation document used for verification.

The Materials and Processes Selection, Control, and Implementation Plan should be approved by the responsible design authority.

Additional requirements on the Materials and Processes Selection, Control, and Implementation Plan content follow in sections 4.1.1.1 through 4.1.1.3.

4.1.1.1 Coordination, Approval, and Tracking

[MPR 12] The Materials and Processes Selection, Control, and Implementation Plan shall identify the method of coordinating, approving, and tracking all engineering drawings, NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

APPROVED FOR PUBLIC RELEASE—DISTRIBUTION IS UNLIMITED

engineering orders, and other documents that establish or modify materials and/or processes usage.

4.1.1.2 Approval Signature

[MPR 13] The Materials and Processes Selection, Control, and Implementation Plan shall include a requirement that all hardware design drawings and revisions for spaceflight hardware that provides mission-critical functions contain an M&P approval block, or equivalent, to ensure that the design has been reviewed by the responsible M&P authority and complies with that document.

4.1.1.3 Manufacturing Planning

[MPR 14] The Materials and Processes Selection, Control, and Implementation Plan shall identify how the responsible M&P organization participates in manufacturing and inspection/verification planning to ensure compliance with M&P requirements.

4.1.2 M&P Controls

a. [MPR 15] All M&P for spaceflight hardware that provides mission-critical functions shall be defined by standards and specifications selected from government, industry, and company specifications and standards.

b. [MPR 16] All M&P for spaceflight hardware that provides mission-critical functions shall be identified directly on the appropriate engineering drawing.

c. [MPR 17] Company M&P specifications shall be identified by document number in the Materials and Processes Selection, Control, and Implementation Plan.

d. [MPR 18] All M&P specifications used to produce spaceflight hardware that provides mission-critical functions shall be made available to the responsible NASA Program or Project Office and M&P organization.

e. [MPR 19] Process specifications for spaceflight hardware that provides mission-critical functions shall define process steps at a level of detail that ensures a repeatable/controlled process that produces a consistent and reliable product.

f. [MPR 20] Process qualification shall be conducted to demonstrate the repeatability of all processes for spaceflight hardware that provides mission-critical functions where the quality of the product cannot be directly verified by subsequent monitoring or measurement.

Note: The process requirements in section 4.2.4 of this NASA Technical Standard do not always define process steps at a level of detail that ensures a repeatable/controlled process that

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

APPROVED FOR PUBLIC RELEASE—DISTRIBUTION IS UNLIMITED

produces a consistent and reliable product, so it should not be assumed that they are suitable to be called out as process specifications on engineering drawings. They are intended as higher level documents that state minimum requirements and provide general directions for the design of hardware.

4.1.2.1 Standard and Specification Obsolescence

[MPR 21] A process shall be established for ensuring that updated, alternate, or new material or process standards or specifications from those identified in the Materials and Processes Selection, Control, and Implementation Plan meet or exceed the technical requirements identified in the original material or process standards or specifications.

During a long-term program, M&P standards and specifications identified in this document or in contractor materials control plans could become obsolete. Continued use of obsolete standards and specifications is acceptable for manufacturing series or new-design hardware.

Although updated M&P standards or specifications usually meet or exceed earlier standards and specifications, their use can result in requirements creep so that new hardware no longer meets the original design requirements.

4.1.3 Commercial Off-The-Shelf (COTS) Hardware

[MPR 22] A procedure shall be established to ensure that all vendor-designed, off-the-shelf, and vendor-furnished items are covered by the M&P requirements of this document, with the exception that M&P requirements for off-the-shelf hardware and other spaceflight hardware that do not provide mission-critical functions may be limited to those required to ensure safety of flight (for example, flammability, toxic offgassing) and vehicle compatibility (for example, vacuum outgassing).

4.1.4 M&P Control Panel

a. [MPR 23] An M&P control panel shall be established by each contractor hardware provider (excluding subcontractors).

b. [MPR 24] The M&P control panel’s scope and membership shall be described in the Materials and Processes Selection, Control, and Implementation Plan.

The M&P control panel plans, manages, and coordinates the selection, application, procurement, control, and standardization of M&P for the contract.

The panel also resolves and dispositions M&P problems.

The responsible NASA M&P organization is an active member of the panel and has the right of disapproval of panel decisions.

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

APPROVED FOR PUBLIC RELEASE—DISTRIBUTION IS UNLIMITED

4.1.5 M&P Usage Documentation

a. [MPR 25] M&P usage shall be documented in an electronic, searchable parts list or separate electronic searchable Materials Identification and Usage List (MIUL) with the following exceptions:

(1) Electrical, electronic, and electromechanical (EEE) parts other than wire, cable, and exposed surfaces of connectors.

(2) Materials used in hermetically sealed electronic containers (maximum leak rate less than 1 x 10-4 cm3/sec).

b. [MPR 26] The documentation of M&P usage shall cover the final design as delivered.

c. [MPR 27] The documentation approach shall be defined in the Materials and Processes Selection, Control, and Implementation Plan.

Recommended MIUL content is described in Appendix D, Recommended Data Requirements Documents. Material codes and ratings for materials, standard and commercial parts, and components are available in the Materials and Processes Technical Information System (MAPTIS). When required, new material codes will be assigned by NASA’s Marshall Space Flight Center (MSFC). In some cases, MAPTIS contains averages for ratings or test results for generic materials controlled by military or industry specifications; the material codes for the generic materials are used.

MAPTIS is accessible via the Internet at http://maptis.nasa.gov.

Note: Accessibility to MAPTIS is by registration only.

4.1.6 Material Usage Agreements (MUAs)

a. [MPR 28] MUAs containing sufficient information to demonstrate that the application is acceptable shall be submitted by the responsible M&P organization for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

The use of M&P that do not comply with the requirements of this NASA Technical Standard may still be acceptable in the actual hardware applications.

NOTE: Per section 4.1.6: The use of M&P that do not comply with the requirements of this NASA Technical Standard may be acceptable in the actual hardware applications. MUAs are required for all M&P that are technically acceptable but do not meet the requirements of this NASA Technical Standard, as implemented by the approved Materials and Processes Selection, Control, and Implementation Plan.

APPROVED FOR PUBLIC RELEASE—DISTRIBUTION IS UNLIMITED

The MUA generation and approval system should be defined in the Materials and Processes Selection, Control, and Implementation Plan. A recommended MUA approach is described in Appendix D.

b. [MPR 29] MUAs shall not be used to change the M&P requirements for a nonconforming product.

When the nonconformance is a deviation from M&P requirements that is acceptable for future series hardware, an MUA may be generated to provide technical support for a change to the product baseline.

A typical MUA form is shown in Appendix B, Typical MUA Form.

4.1.6.1 Human-Rated Spacecraft

For human-rated spaceflight hardware, a tiered MUA system with three categories is recommended.

4.1.6.1.1 Category I MUAs

Category I MUAs are those that involve M&P usage that could affect the safety of the mission, crew, or vehicle or affect the mission success but have to be used for functional reasons.

Category I MUAs are delivered by the hardware developer and approved by the responsible NASA M&P organization and the NASA Program/Project Office.

4.1.6.1.2 Category II MUAs

Category II MUAs are those that involve M&P usage that fails a screening of M&P requirements and is not considered a hazard in its use application but for which no Category III rationale code exists. Category II MUAs are delivered by the hardware developer and approved by the responsible NASA M&P organization.

4.1.6.1.3 Category III MUAs

Contractors who want to use Category III rationale codes relevant to their hardware may do so through their Materials and Processes Selection, Control, and Implementation Plan. Category III MUAs are those that involve M&P that have not been shown to meet these requirements but have an appropriate rationale code listed in the Materials and Processes Selection, Control, and Implementation Plan. The rationale codes are approved as part of the overall Materials and Processes Selection, Control, and Implementation Plan approval.