EVA-EXP-0034.pdf

EVA-CM-001 07/31/2020

EVA-EXP-0034

National Aeronautics and Space Administration

REVISION B

EFFECTIVE DATE: JULY 31, 2020

EXTRAVEHICULAR ACTIVITY (EVA) OFFICE

EXPLORATION EVA SYSTEM TECHNICAL

STANDARDS

This document has been reviewed for Proprietary, SBU, and Export Control (ITAR/EAR) and has been determined to be non-sensitive. It has been released to the public via the NASA

Scientific and Technical Information (STI) Process DAA 20205004275.

Verify that this is the correct version before use

Revision: B Document No: EVA-EXP-0034 Release Date: 07/31/2020 Page: 2 of 47 Title: Exploration EVA System Technical Standards

This document has been approved for public release per DAA 20205004275.

ECCN Notice: This document does not contain any export controlled information.

Prepared by:

XX/John Swatkowski, Book Manager

Concurred by:

XX/Jesse Buffington, Lead, Exploration EVA System

XX/Stacie Cox, EVA Chief Engineer

Approved by:

XX/Christopher Hansen, EVA Office Manager

Release Date: 07/31/2020 Page: 3 of 47 Title: Exploration EVA System Technical Standards

This document has been approved for public release per DAA 20205004275.

ECCN Notice: This document does not contain any export controlled information.

The following signatures represent technical concurrence of the subject matter experts with respect to their particular subject matter area covered in this document.

ES/Sarah Luna, Materials and Processing

EP/Eric Darcy, Batteries

ES/Brandan Robertson, Mechanisms

EP/Todd Hinkel, Pyrotechnics

ES/James Smith, Structures

ES/Lynda Estes, Windows

ES/James McMahon, Fracture Mechanics and Control

EV/Matthew McCollum, EMI/EMC

EV/Carlton Faller, EEE Parts

EV/Anthony Wong, Electrical Workmanship pfoltz Stamp pfoltz Stamp pfoltz Stamp pfoltz Stamp pfoltz Stamp pfoltz Stamp pfoltz Stamp pfoltz Stamp pfoltz Stamp pfoltz Stamp

Release Date: 07/31/2020 Page: 4 of 47 Title: Exploration EVA System Technical Standards

This document has been approved for public release per DAA 20205004275.

ECCN Notice: This document does not contain any export controlled information.

ES/Kenneth Schultz, Loads and Dynamics

NT/David Dyer, Quality Engineering

NT/Nelson Eng, Quality Assurance

EA/Alan Balusek, Ground Testing pfoltz Stamp pfoltz Stamp pfoltz Stamp pfoltz Stamp

Release Date: 07/31/2020 Page: 5 of 47 Title: Exploration EVA System Technical Standards

This document has been approved for public release per DAA 20205004275.

ECCN Notice: This document does not contain any export controlled information.

REVISION AND HISTORY PAGE

Revision No.

Change No. Description Release

Date

EVA-EXP-0034 Revision History

B Rev B per CR# EVA-CR-00078

• Replaced MIL-STD-461 and MIL-STD-464 with

GP 11461 and GP 11464

• Added NASA-HDBK-4002

• Added NPR 8735.1

• Dis-allowed using alternate standards for NPR

7150.2. Not allowing alternates in this document

for 7150.2, does not supersede tailoring allowed by NPR 7150.2.

• Added standards for Collaborative Simulation Technologies.

July 2020

A Rev A per CR# EVA-CR-00057

• Added NASA-HDBK-7004

• Updated Introduction to explain compatibility with

Exploration Programs

• Removed Appendix D and made Appendix C, the alternate/tailored standard process

• Added Appendix D EVA-EXP-0035 Applicability

Matrix

• Replaced JSC 65829 with NASA-STD-5002

• Added toxicity standards

• Added JSC 67035

• Added AIAA-S-080A-2018 and AIAA-S-081B-2018 as applicable standards

July 2019

Baseline Baseline per CR# EVA-CR-00039, administrative changes:

- Update of EVA-RD-003 to EVA-EXP-0034

- Update of title from Design and Construction

Document to Exploration EVA System Technical Standards

- Removal of “Sensitive But Unclassified” (SBU) classification on the document

- Clean up of EVA Office Exploration Document Number and titles throughout the document

December

Release Date: 07/31/2020 Page: 6 of 47

EVA-RD-003 Revision History

Baseline Baseline per CR# EVA-CR-00028, Sept 27 2017 09/27/17

Release Date: 07/31/2020 Page: 7 of 47

TABLE OF CONTENTS

SECTION PAGE

1.0 INTRODUCTION 10

1.1 PURPOSE 10

1.2 SCOPE 10

1.3 CHANGE AUTHORITY/RESPONSIBILITY 12

1.4 EXPLORATION COMPATABILITY 12

2.0 DOCUMENTS 13

2.1 ALTERNATE/TAILORING STANDARDS 13

2.2 APPLICABLE DOCUMENTS 14

2.3 REFERENCE DOCUMENTS 18

3.0 DESIGN AND MANUFACTURING STANDARDS 20

3.1 MATERIALS AND PROCESSES 20

3.1.1 Materials and Processes 20

3.1.2 Cabin Materials Flammability 20

3.1.3 Toxic Hazard Level 20

3.2 FLIGHT AND GROUND SOFTWARE 21

3.2.1 Software Engineering Requirements 21

3.3 ELECTRICAL AND AVIONICS 21

3.3.1 Use of Silver 21

3.3.2 Printed Wiring Boards 21

3.3.3 Printed Wiring Assemblies 22

3.3.4 Fiber Optics 22

3.3.5 Staking/Conformal Coating 22

3.3.6 Electrical Soldering 22

3.3.7 Electrical Crimping 23

3.3.8 Electrical Wire Wrapped Connections 23

3.3.9 Electrical Bonding 23

3.3.10 Batteries 23

3.3.11 Other Processes 24

3.3.12 Integrated Space Vehicle Electrostatic Charge Control 24

3.3.13 Electromagnetic Interference Control 25

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3.3.14 Electromagnetic Environmental Effects 25

3.3.15 Custom Electromagnetic Devices 25

3.4 MECHANISMS 25

3.4.1 Mechanism Design 25

3.5 PYROTECHNICS 25

3.5.1 Pyrotechnics 25

3.6 STRUCTURES 26

3.6.1 Structural Design and Factors of Safety 26

3.6.2 Loads and Structural Dynamics 26

3.6.3 Fasteners 27

3.7 FLUIDS, PROPELLANTS, EXPLOSIVES, AND OXYGEN SYSTEMS 27

3.7.1 Flexible Lines and Flow-Induced Vibration 27

3.7.2 Bellow Threat Assessment and Damage Control 27

3.7.3 Best Practices for a Thin Walled Pressure Boundaries 28

3.8 PROPULSION SYSTEMS 28

3.8.1 Strength and Life Requirements for Propulsion Systems 28

3.9 FRACTURE CONTROL 28

3.9.1 Fracture Control 28

3.10 EEE PARTS 29

3.10.1 EEE Parts 29

3.11 TESTING 29

3.11.1 Ground Testing 29

3.12 MODELS AND SIMULATIONS 30

3.12.1 Models and Simulations 30

3.13 EVA SUIT COMPATIBILITY 31

3.14 STITCHES, SEAMS, AND SEWIING 31

3.15 QUALITY ASSURANCE 31

3.15.1 Quality Assurance 31

3.15.2 Electrical Workmanship 32

3.15.3 Quality Assurance Clauses 32

3.16 PLANETARY PROTECTION 37

3.16.1 Planetary Protection of Exploration Sites (Forward Contamination) 37

3.16.2 Protection of Crew from Planetary Environments (Reverse Contamination)

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APPENDIX

APPENDIX A ACRONYMS AND ABBREVIATIONS 39

APPENDIX B OPEN WORK 40

APPENDIX C PROCESS FOR USING ALTERNATE/TAILORED STANDARDS 41

APPENDIX D EVA-EXP-0035 APPLICABILITY MATRIX 45

APPENDIX E FORWARD WORK 46

TABLE

TABLE B1-1 TO BE DETERMINED ITEMS 40

TABLE B2-1 TO BE RESOLVED ISSUES 40

TABLE E1-1 FORWARD WORK ITEMS 46

FIGURE

FIGURE C2.0-1 ALTERNATE AND TAILORED STANDARDS PROCESS 43

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1.0 INTRODUCTION

1.1 PURPOSE

The purpose of this Extravehicular Activity (EVA) Office specification is to define the types of Programmatic-level standards to be used for design, manufacturing, testing, and quality control for the Exploration EVA (xEVA) System. The xEVA system includes both space suits and EVA hardware elements (e. EVA Tools, Airlock hardware, etc.). Many of the standards referenced in this document can be substituted for similar standards used in industry; this document provides the scope of which standards need to be considered.

This document is the EVA-centric implementation of Chapter 3 of NPR 7120.10, Technical Standards for National Aeronautics and Space Administration (NASA) Programs and Projects: Select technical standards for use as program/project requirements. This also addresses the intent of Section 2.2.6 of NPR 8705.2, Human- Rating Requirements for Space Systems.

1.2 SCOPE

The standards discussed in this document apply to all domestic space suit, Extravehicular Activity flight hardware and software, including any ancillary systems. There are also specific standards for Ground Support Equipment (GSE), along with software standards for ground software that are needed to perform a primary mission objective, have direct interaction with human space flight systems, or have a direct impact on the health and safety of the crew.

The standards discussed in this document are not assumed to apply to space suit or EVA flight hardware and software produced by International Partners. Appropriate standards for International Partner-produced equipment which interfaces with domestically-produced space suits or Extravehicular Activity hardware will be negotiated in International Partnership agreements on a case-by-case basis for each Program.

There are several ways a developer may encounter this document. In order to provide context for interpretation of the original intent, several examples are provided below for appropriate application of this document:

1) For hardware previously developed for legacy programs or systems such as the International Space Station (ISS) Program or the Extravehicular Mobility Unit (EMU), including EVA tools.

a. Intent: This document is not appropriate for use in this scenario. There is no intent for existing flight hardware to be re-certified to this document. For example, this document could be used for new-build hardware that flies on ISS, but only after negotiation with the ISS Program leading to a conclusion to use this instead of existing ISS Program requirements and processes.

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2) For development activities leading to construction or modification of a space suit built in compliance with SSP 51073, Exploration EVA Suit Systems Requirements Document,

a. Intent: This document is appropriate for use in this scenario. This would be a specific example where a new-build product which flies on a legacy program/platform would intentionally choose to build to this set of documentation. Reasons for doing so might include preservation of system requirements in a manner that would allow them to be transferred to other programs for operation beyond Low Earth Orbit (LEO) after initial fielding on ISS.

3) For new Space Vehicle builders such as those for Exploration Class missions beyond LEO or other design reference missions (specifically those whose formulation post-dates the ISS Program),

a. This document has limited applicability. In general, the specifications in this document are not appropriate. It is not the intent for EVA to drive quality of construction expectations on the Space Vehicle itself. Rather, the Space Vehicle should be compatible for EVA operations; see EVA-EXP-0035, Exploration EVA System Compatibility.

4) For new xEVA System hardware (i.e. EVA Tools, Airlock hardware, etc., not identified as hardware categorized as Legacy, ISS or EMU/Tools; see subsection 1),

a. Intent: This document is appropriate for use in this scenario. Sections of this document which are not relevant to the hardware in question should be documented as “not applicable” in the project’s certification products. It is applicable to the development of EVA tools and airlock hardware related to new suit builds or new suit development systems. This document is not appropriate for hardware developed for the ISS program or developed exclusively for the EMU. Hardware and tools being carried forward to future programs and project will have to be evaluated against the project objectives and environment.

5) For Payload builders with potential contact by EVA crewmembers for planned or contingency operations.

a. Intent: This document has limited applicability. In general, the specifications in this document are not appropriate. It is not the intent for EVA to drive quality of construction expectations on the Payload itself. Rather, the Payload should be compatible for EVA operations; see EVA-EXP-0035, Exploration EVA System Compatibility Document for these requirements.

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1.3 CHANGE AUTHORITY/RESPONSIBILITY

Proposed changes to this document shall be submitted by an EVA Office Change Request (CR) to the EVA Configuration Control Board (EVA CCB) for consideration and disposition.

The appropriate NASA Office of Primary Responsibility (OPR) identified for this document is the EVA Office. As such, the EVA CCB manages this document on behalf of the designated exploration program.

1.4 EXPLORATION COMPATABILITY

EVA-EXP-0034 was written to provide technical standards for xEVA System hardware being developed for low earth orbit and exploration destinations (cislunar, lunar surface). It is expected that future programs will levy additional technical standards on hardware planned to be used with their respective program or modifications to those defined within. With that possibility in mind, this document was developed to be program agnostic where possible by utilizing NASA Agency, military and industry standards and allowing for this document to be applicable to xEVA hardware being developed across multiple Exploration programs. As the controlling change authority the EVA Office will ensure that the standards called out in EVA-EXP-0034 comply with each exploration program’s standards that the xEVA hardware is to be utilized with. As of April 2020, EVA-EXP-0034 aligns with HEMOD-003 Type 2 Technical Authority (TA) Standards and are allowable alternates to the Gateway Technical Standard documents.

Gateway Tech Standards development resulted in a Gateway tailoring of the HEMOD- 003 Type 2 TA Standards, but still made it acceptable for hardware developers to use the Agency, military and industrial specifications called out in HEOMD-003. The EVA Office participates in the Gateway Program’s review cycle and is actively aware of changes to the technical standards levied by the program. EVA-EXP-0034 will be updated as needed to reflect the technical standards of all Exploration Programs, either through direct reference of a standard or a provided tailoring of an Exploration Program Standard.

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2.0 DOCUMENTS

The design, manufacturing, testing, and quality control standards in this document apply to EVA space flight hardware and software. There are also specific standards for GSE, along with software standards for ground software that are needed to perform a primary mission objective, have direct interaction with human space flight systems, or have a direct impact on the health and safety of the crew.

NASA has identified two basic types of standards for EVA:

1) One type of standard must be followed completely with no deviation or alternative proposal. They are identified by the words “meet” within the corresponding sections of this document. Within the Applicable Documents list below these standards will be shown as fully applicable

2) The majority of the standards identified use the language “meet the intent of.”

These contain requirements that can be met explicitly by following the standard or by proposing alternate standards that meet or are consistent with the requirement levied in the requirement statement. For clarification purposes, “meet the intent of” meaning is consistent between this document and the standards from which they are derived from. Within the Applicable Documents list below these standards will be shown as “Alternative Allowed.” Because these standards are unique, Appendix C, was developed to define an EVA Office process to evaluate and approve alternative standards.

The documents and their revisions listed in the Applicable Documents Table in Section

2.1 are the approved EVA Office standards for the design and construction for space suits and EVA hardware. This document is a snapshot in time of what is currently applicable and expected to be used during the design, fabrication and testing of EVA hardware. Following approval of every revision of EVA-EXP-0034, documents in Section 2.1 will be independently revised and will eventually become out of sync with what is prescribed in this document. When such a case occurs, the revision referenced here will take precedence. If a user intends to use a revision not specified in Section 2, that revision will have to be evaluated per the alternate standards process Appendix C.

2.1 ALTERNATE/TAILORING STANDARDS

Alternate and tailoring of standard referred to in document are to follow the process defined in Appendix C Process for Using Alternate/Tailored Standards.

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2.2 APPLICABLE DOCUMENTS

Document Number

Document Revision Document Title Applicability

Alternative Documents (allowed/not allowed)

AIAA-S-080A-

4/13/18 Metallic Pressure Vessels, Pressurized Structures, and Pressure Components

ALL Not Allowed

AIAA-S-081B-

4/13/18 Composite Overwrapped Pressure Vessels

ALL Not Allowed

ANSI/ESD

S20.20

Edition 14 (6/11/14)

For the Development of an Electrostatic Discharge Control Program for – Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices)

ALL Allowed

ASTM D6193 (2016) Standard Practice for Stitches and Seams

ALL Allowed

EP-19-001 (3/25/19) Interpretation Memo for the Battery TR Propagation Requirements in JSC 20793 Rev D

All Allowed

GEIA-STD-

0005-1

A (3/1/12)

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

ALL Allowed

GEIA-STD-

0005-2

A (5/1/12)

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

ALL Allowed

GP 11461 Baseline Gateway Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

ALL Allowed

GP 11464 Baseline Gateway Electromagnetic Environmental Effects (E3) Requirements

ALL Allowed

IEC 61000-4-2 Edition 2.0 (12/08)

Electromagnetic Compatibility (EMC) – Part 4-2: Testing and Measurement Techniques – Electrostatic Discharge Immunity Test

ALL Allowed

IPC-2152 Baseline (8/1/09)

Standard for Determining Current Carrying Capacity in Printed Board Design

ALL Allowed

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Document Number

Document Revision Document Title Applicability

Alternative Documents (allowed/not allowed)

IPC-2220

Series

2221: B 2222: A 2223: E 2224: Baseline 2225: Baseline 2226: A

Family of Printed Board Design Standards

ALL Allowed

IPC-6010

Series

6011: BL

6012: E

6013: D AMD 1

6015: Baseline 6017: Baseline

6018: CS

Family of Printed Board Fabrication Standards

ALL Allowed

IPC-CM-770E E

(1/1/04)

Guidelines for Printed Board Component Mounting

ALL Allowed

IPC J-STD-

001G

G (9/1/18)

Requirements for Soldered Electrical and Electronic Assemblies

ALL Allowed

IPC J-STD-

001GS

(3/18) Space Applications Electronic Hardware Addendum to IPC J- STD-001GS Requirements for Soldered Electrical and Electronic Assemblies

ALL Allowed

ISO 9001 Fifth Edition (9/15/15)

Quality Management Systems – Requirements

ALL Allowed

JPR-1800.5 (7/19/17) Biosafety Review Board Operations and Requirements

ALL Not Allowed

JSC-08080-2 B

(9/24/15)

JSC Design and Procedural Standards

ALL Allowed

JSC 20793 D

(3/28/17)

Crewed Space Vehicle Battery Safety Requirements

ALL Allowed

JSC 26895 Rev A (4/2014)

Guidelines for Assessing the Toxic Hazard for Spacecraft Chemicals and Test Materials

ALL Allowed

JSC 62809 D

(4/22/10)

Human Rated Spacecraft Pyrotechnic Specification

ALL Allowed

JSC 65828 B, Change 1 (7/15/14)

Structural Design Requirements and Factors of Safety for Spaceflight Hardware

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Document Number

Document Revision Document Title Applicability

Alternative Documents (allowed/not allowed)

JSC 67035 A

(8/2017) Best Practices and Guidelines for Thin Will Pressure Boundaries for Human Spaceflight Applications

ALL Allowed

MIL-STD-981 C, Change 2 (8/13/15)

Design, Manufacturing and Quality Standards for Custom Electromagnetic Devices for Space Applications

ALL Allowed

MSFC-DWG-

20M02540

E (1/15/92)

Assessment of Flexible Lines for Flow-Induced Vibration

ALL Allowed

MSFC-SPEC-

Baseline (2/28/90)

Test Control Document for Assessment of Flexible Lines for Flow Induced Vibration

ALL Allowed

NASA-HDBK-

C

Forced Limited Vibration Testing ALL Allowed

NASA-HDBK-

A w/change 10/19/17

Mitigating In-Space Charging Effects – A Guideline

All Allowed

NASA-STD-

A (2/5/13)

Electrical Bonding for NASA Launch Vehicles, Spacecraft, Payloads, and Flight Equipment

ALL Allowed

NASA-STD-

A (2/1/16)

Low Earth Orbit Spacecraft Charging Design Standard

ALL Allowed

NASA-STD-

Baseline 6/21/96

Load Analyses of Spacecraft and Payloads

ALL Allowed

NASA-STD-

B (6/16/16)

Strength and Life Assessment Requirements for Liquid Fueled Space Propulsion System Engines

ALL Allowed

NASA-STD-

A, Change 1 (7/31/15)

Design and Development Requirements for Mechanisms

ALL

Allowed

NASA-STD-

Baseline (8/12/11)

Strength Design and Verification Criteria for Glass, Ceramics, and Windows in Human Space Flight Applications

Sections 4.6.3, 5.6.3,

4.10.2 and

5.10.2 are not applicable

Allowed

NASA-STD-

A, Change 2 (2/29/18)

Fracture Control Requirements for Spaceflight Hardware

ALL Allowed

NASA-STD-

A, Change 1 (2/11/19)

Requirements for Threaded Fastening Systems in Spaceflight Hardware

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Document Number

Document Revision Document Title Applicability

Alternative Documents (allowed/not allowed)

NASA-STD-

A (11/30/16)

Standard Materials and Processes Requirements for Spacecraft

ALL Allowed

NASA-STD-

Baseline (7/13/16)

Standard For Models And Simulations

4.1.1, 4.7, 4.8

Allowed

NASA-STD-

Baseline (3/05/19)

Leak Test Requirements ALL Allowed

NASA-STD-

8739.1

A, Change 2 (6/30/16)

Workmanship Standard for Polymeric Application on Electronic Assemblies

ALL Allowed

NASA-STD-

8739.4

A, Change 2 (6/30/16)

Workmanship Standard for Crimping, Interconnecting Cables, Harnesses, and Wiring

ALL Allowed

NASA-STD-

8739.5

A (9/15/15)

Fiber Optic Terminations, Cable Assemblies, and Installation

ALL Allowed

NASA-STD-

8739.6

A, Change 1 (5/31/2017)

Implementation Requirements for NASA Workmanship Standards

ALL Allowed

NPD 8730.5 B, Change 3 (10/31/16)

NASA Quality Assurance Program Policy

Attachment A Not Allowed

NPR 7150.2 C

(8/2/19)

NASA Software Engineering Requirements

ALL Not Allowed

NPR 8735.1 D

6/29/18

Exchange of Problem Data Using NASA Advisories and the Government-Industry Data Exchange Program (GIDEP)

Sections 2.3, 3.1.6, 3.2.4 – 3.2.5, 3.3.3, 3.4.1, 3.4.3, 3.4.6, 3.5.1, and Appendix C

Not Allowed

SAE-AS7928 C

(5/1/19)

General Specification for Terminals, Lug: Splices, Conductor: Crimp Style, Copper

ALL Not Allowed

SAE AS9003 A

(2012)

Inspection and Test Quality Systems Requirements for Aviation, Space, and Defense Organizations

ALL Allowed

SAE AS9100 D

(9/1/16)

Quality Management Systems – Requirements for Aviation, Space and Defense Organizations

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Document Number

Document Revision Document Title Applicability

Alternative Documents (allowed/not allowed) SMC-S-016 (9/5/14) Space and Missile Systems

Center Standard Test Requirements for Launch, Upper- Stage and Space Vehicles

ALL Allowed

SSP 30312

Volume 1

L (10/24/14)

Electrical, Electronic, and Electromechanical (EEE) Parts Management and Implementation Plan for the Space Station Program

ALL Allowed

SSP 41172 AC

(6/29/15)

Qualification and Acceptance Environmental Test Requirements

4.2.11, 4.4.4, 5.1.7, 5.1.8, 5.2.3, 6.1.2

Allowed

SSP 51073 B

(12/19)

Exploration Extravehicular (EVA) Suit Systems Requirements Document

All Not Allowed

2.3 REFERENCE DOCUMENTS

The following documents contain supplemental information to guide the user in the application of this document.

Document Number

Document Revision Document Title

EVA-EXP-0035 Baseline 9/12/18 Exploration EVA System Compatibility

HEOMD-003 Draft Type 2 Technical Authority (TA) Standards ISS MD 1049 B Charter for the Extravehicular Activity (EVA)

Configuration Control Board (CCB) JSC 20584 Baseline

September 2017 Spacecraft Maximum Allowable Concentrations for Airborne Contaminants

JSC 65829 A

(6/11/14)

Loads and Structural Dynamics Requirements for Spaceflight Hardware

JSC 66901 Baseline (8/28/16)

Damage Threat Assessment and Damage Control Panel Template for Composite Overwrapped Pressure Vessel

JSC-67283 Draft Damage Threat Assessment (DTA) and Damage Control Plan (DCP) Template for Bellows and Flexhoses

NASA-STD-3001

V2

Rev B NASA Space Flight Human-Systems Standard Volume 2: Human Factors, Habitability, and Environmental Health

NASA-STD-

8719.13

C (5/7/13)

Software Safety Standard

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Document Number

Document Revision Document Title

NPR 7120.5 E, Changes 1-15 (8/14/12)

NASA Space Flight Program and Project Management Requirements

NPR 7120.10 A

(2/21/17)

Technical Standards for NASA Programs and Projects

NPR 8705.2 C

(7/10/17)

Human-Rating Requirements for Space Systems

NPR 8705.4 Baseline, Change 3 (6/14/04)

Risk Classification for NASA Payloads

SMC-S-010 (4/12/13) Space and Missile Systems Center Standard Technical Requirements for Electronic Parts, Materials, and Processes Used in Space Vehicles

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3.0 DESIGN AND MANUFACTURING STANDARDS

3.1 MATERIALS AND PROCESSES

3.1.1 Materials and Processes

[STD-0001] The xEVA System shall meet the intent of NASA-STD-6016, Standard Materials and Processes Requirements for Spacecraft. Deviations from materials and processes requirements shall be documented and approved using the Materials Usage Agreement (MUA) process as defined in NASA-STD-6016.

Note: The xEVA System on the advice of JSC M&P had decided to stay with NASA- STD-6016 Rev A. Changes in Rev B are not relevant to the xEVA System and the NASA-STD-6016 revision applicability will be assessed when future revision are released.

3.1.2 Cabin Materials Flammability

[STD-0002] The xEVA System shall use materials in the pressurized cabin that meet the flammability requirements of NASA-STD-6016 in their worst-case operating environment.

Rationale: The most severe environment for material flammability will be 100% oxygen at 23.5 psia inside the suit during suited operations within a cabin or during ground test (8.4 psia + 14.7 psia + margin). Outside of the suit, the most severe environment for material flammability with be either 30% oxygen at 10.2 psia (determined by the ISS cabin depressurization case) or 34% oxygen at 8.2 psia (for non-ISS missions using Exploration Atmosphere). <TBR-003-001>

Note: The xEVA System on the advice of JSC M&P had decided to stay with NASA- STD-6016 Rev A. Changes in Rev B are not relevant to the xEVA System and the NASA-STD-6016 revision applicability will be assessed when future revision are released.

3.1.3 Toxic Hazard Level

[STD-0061] The xEVA System shall limit the use of and properly contain catastrophic hazardous substances as defined in JSC 26895, Guidelines for Assessing the Toxic Hazard of Spacecraft Chemicals and Test Materials to critical function components.

Rationale: The intent of this requirement is to restrict the use of system components that could pose an immediate risk to human health. Substances that cannot be contained or cleaned up by the crew therefore represent the greatest risk. All liquids, gases, particles, and gels contained within suit sub-systems will be submitted for review per JSC 27472 and assessed per JSC 26895. Supplies for crew protection and spill containment should be provided to allow crewmembers to clean contaminated surfaces when possible. Materials off-gassing and human metabolic

Release Date: 07/31/2020 Page: 21 of 47 contaminants must be controlled below the SMAC limits (JSC 20584) defined in section 6.4.2, Atmosphere Contamination Limit – Airborne Contaminants [V2 6050], of NASA-STD-3001 V2.

3.2 FLIGHT AND GROUND SOFTWARE

3.2.1 Software Engineering Requirements

[STD-0003] The xEVA System shall meet NPR 7150.2, NASA Software Engineering Requirements for all flight and ground software products classified as Class A software per Appendix E of NPR 7150.2, or safety critical as defined in NASA-STD-8719.13, Software Safety Standard, Appendix A, that adversely affects the operation of the Class A products. A requirements mapping matrix is provided for each software class and criticality in Appendix D of NPR 7150.2.

3.3 ELECTRICAL AND AVIONICS

3.3.1 Use of Silver

Electrically Deposited Silver

[STD-0004] The xEVA System shall not use electrically deposited silver as plating on printed wiring boards and terminal boards because of potential dendrite growth.

Silver Plating

[STD-0005] The xEVA System shall not use silver plating on bus bars and mechanical electrical contacts, such as connector pins and sockets, because it can tarnish and degrade electrical conductivity.

3.3.2 Printed Wiring Boards

Printed Board Design Standards

[STD-0006] The xEVA System shall meet the intent of the requirements defined in IPC- 2221, Generic Standard on Printed Board Design, as well as the associated technology performance specification under the IPC-2220 series per Performance Class 3.

Qualification of Printed Boards Standard

[STD-0007] The xEVA System shall meet the intent of the requirements defined in IPC- 6011, Generic Performance Specification for Printed Boards, as well as the associated technology performance specifications of the IPC-6010 series per Performance Class 3 with the exception for IPC-6012, where the Space Addendum is applicable instead of Performance Class 3.

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Conductor Size Standard

[STD-0008] The xEVA System shall meet the intent of the requirements defined in IPC- 2152, Standards for Determining Current Carrying Capacity in Printed Board Design, per Performance Class 3.

3.3.3 Printed Wiring Assemblies

Printed Wiring Assemblies

[STD-0009] Electrical circuitry shall be designed and fabricated to prevent the production of unwanted current paths by debris or foreign materials floating in the spacecraft microgravity environment.

3.3.4 Fiber Optics

Fiber Optic Connection Standard

[STD-0010] The xEVA System shall meet the intent of NASA-STD-8739.5, Fiber Optic Terminations, Cable Assemblies, and Installation.

3.3.5 Staking/Conformal Coating

Staking/Conformal Coating

[STD-0011] The xEVA System shall meet the intent of the requirements in NASA-STD- 8739.1, Workmanship Standard for Polymeric Application on Electronic Assemblies.

3.3.6 Electrical Soldering

Soldering Process and Controls Standard

[STD-0012] The xEVA System shall meet the intent of IPC J-STD-001FS, Space Applications Electronic Hardware Addendum and IPC J-STD-001F, Requirements for Soldered Electrical and Electronic Assemblies.

Soldering Performance Standard

[STD-0013] The xEVA System shall meet the intent of GEIA-STD-0005-1, Performance Standard for Aerospace and High Performance Electronic Systems Containing Lead-Free Solder.

Mitigation of Tin Whiskers

[STD-0014] The xEVA System shall meet the intent of GEIA-STD-0005-2, Standard for Mitigating the Effects of Tin Whiskers in Aerospace and High Performance Electronics.

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Note: GEIA-STD-0005-2 has a selection of five control levels. The EVA Office will indicate the appropriate level of control in program and project documentation such as the request for proposal, contract statement of work, or project management plan. If the level of control is not stated, the user is to contact the EVA Office for direction. Typically, for EVA space suit hardware, a control level of 2C will be required.

3.3.7 Electrical Crimping

Wiring, Cables, Harnesses and Crimping

[STD-0015] The xEVA System shall meet the intent of IPC/WHMA-A-620B-S, Space Applications Electronic Hardware Addendum to IPC/WHMA-A-620B.

Rationale: IPC/WHMA-A-620B-S is superior to NASA-STD-8739.4 Crimping, Interconnecting Cables, Harnesses, and Wiring in both content and technical requirements. NASA-STD-8739.4 is no longer being actively supported by update of technical content. NASA-STD-8739.6, Chapter 10 ““Cable Harness Assembly Standard Implementation” implements IPC/WHMA-A-620B-S.

Terminal Lugs and Splices

[STD-0054] Terminal lugs, splices, and two-piece shield termination rings shall meet the tensile strength and electrical requirements of SAE-AS7928, General Specification for Terminals, Lug: Splices, Conductor: Crimp Style, Copper.

3.3.8 Electrical Wire Wrapped Connections

Electrical Wire Wrapped Connections

[STD-0016] The xEVA System shall not use wire wrapping.

3.3.9 Electrical Bonding

Electrical Bonding

[STD-0017] The xEVA System, subsystems, and systems shall be designed, manufactured, and integrated to meet the intent of NASA-STD-4003, Electrical Bonding for NASA Launch Vehicles, Spacecraft, Payloads, and Flight Equipment.

3.3.10 Batteries

Batteries

The xEVA System battery systems shall meet the intent of the requirements defined in JSC 20793, Crewed Space Vehicle Battery Safety Requirements. [STD-0018]

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[STD-0154] The xEVA System battery systems shall meet interpretation memo EP-19- 001 which defines verification requirements for single cell thermal runaway hazard severity mitigation.

3.3.11 Other Processes

Component Mounting Guidelines

[STD-0019] The xEVA System shall meet the intent of IPC-CM-770E, Component Mounting Guidelines for Printed Boards per Performance Class 3.

3.3.12 Integrated Space Vehicle Electrostatic Charge Control

LEO Charging Design Standard

The xEVA System shall meet the intent of the requirements contained in NASA-STD- 4005, Low Earth Orbit Spacecraft Charging Design Standard. [STD-0020]

Electrostatic Discharge Control Program

The xEVA System shall meet the intent of ANSI/ESD S20.20, For the Development of an Electrostatic Discharge Control Program for – Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices), which will include establishing and maintaining an electrostatic discharge control program. [STD-0021]

Electrostatic Design Thresholds

[STD-0022] The xEVA System shall meet the intent of IEC 61000-4-2, Electromagnetic Compatibility (EMC) Testing and Measurement Techniques-Electrostatic Discharge Immunity Test, for Human Body Model (HBM) subassemblies, assemblies and equipment discharge levels, which do not apply to electrically-initiated explosive devices.

[STD-0062] The xEVA System shall meet the intent of the guidance provided in NASA- HDBK-4002A, Mitigating In-Space Charging Effects – A Guideline.

Rationale: NASA-STD-4005, Low Earth Orbit Spacecraft Charging Design Standard and GP 11464, Gateway Electromagnetic Environmental Effects Requirements for Systems with guidance from NASA-HDBK-4002A, Mitigating In-Space Charging Effects – A Guideline serve to encompass design considerations for the relatively benign low earth orbit and highly variable lunar charging environments

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3.3.13 Electromagnetic Interference Control

Electromagnetic Interference Control

[STD-0023] The xEVA System, subsystems, and systems shall be designed, manufactured, and integrated to meet the intent of GP 11461, Gateway Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment.

3.3.14 Electromagnetic Environmental Effects

Electromagnetic Environmental Effects

[STD-0024] The xEVA System, subsystems, and systems shall be designed, manufactured, and integrated to meet the intent of the GP 11464, Gateway Electromagnetic Environmental Effects Requirements for Systems. The following sections are not applicable: 3.5 Lightning, and 3.9.3 Hazards of electromagnetic radiation to ordnance.

Rationale: The charging environments in cis-lunar space and on the lunar surface are significantly different than that in low-earth orbit and the requirements of GP 11464 and additional guidance of NASA-HDBK-4002A are needed to ensure that the hardware provider appropriately designs for these environments.

3.3.15 Custom Electromagnetic Devices

Custom Electromagnetic Devices

[STD-0025] Custom Electromagnetic Devices used in the xEVA System, subsystems, and systems shall be designed, manufactured, and integrated to meet the intent of MIL- STD-981, Design, Manufacturing, and Quality Standards for Custom Electromagnetic Devices for Space Applications.

3.4 MECHANISMS

3.4.1 Mechanism Design

[STD-0026] The xEVA System shall meet the intent of NASA-STD-5017, Design and Development Requirements for Mechanisms.

3.5 PYROTECHNICS

3.5.1 Pyrotechnics

[STD-0027] The xEVA System shall meet the intent of JSC 62809, Human Rated Spacecraft Pyrotechnic Specification.

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3.6 STRUCTURES

3.6.1 Structural Design and Factors of Safety

Structural Design Requirements

[STD-0028] All flight hardware structures of the xEVA System, except for glass or ceramic windows, shall meet the intent of JSC 65828, Structural Design Requirements and Factors of Safety for Spaceflight Hardware. The following sections of JSC 65828 are not applicable: 3.2.7 Parachute and Parafoil Systems, 3.2.8.4 Pressure Vessels, 3.8.35 Composite Overwrapped Pressure Vessels, 3.2.8.7 Doors and Hatches in Habitable Modules, 3.2.9 Liquid Propulsion Engine Structures, 3.2.10 Solid Rocket Motors.

Note: Due to JSC 65828 sections 3.2.8.4 and 3.2.8.5, referencing outdated version of AIAA-S-80 and AIAA-S-081, EVA hardware is to be designed to the standards called out in EVA-EXP-0034 standards STD-0058 and STD-0059.

Windows Design

[STD-0029] The xEVA System shall meet the intent of NASA-STD-5018, Strength Design and Verification Criteria for Glass, Ceramics, and Windows in Human Space Flight Applications, for components that utilize glass or ceramic materials. The following sections of NASA-STD-5018 are not applicable: 4.6.3 and 5.6.3, 4.10.2 and 5.10.2. For window systems (or portions of window systems) that use non-brittle materials such as plastic panes refer to requirement 3.6.1.1 of EVA-EXP-0034.

Pressure Vessels

[STD-0058] The xEVA System shall meet ANSI/AIAA-S-080, Standard for Space Systems - Metallic Pressure Vessels, Pressurized Structures, and Pressure Components.

Composite Overwrap Pressure Vessels

[STD-0059] The xEVA System shall meet ANSI/AIAA-S-081, Standard for Space Systems - Composite Overwrapped Pressure Vessels (COPVs).

3.6.2 Loads and Structural Dynamics

Loads and Structural Dynamics

[STD-0030] The xEVA System shall meet the intent of NASA-STD-5002: Load Analyses of Spacecraft and Payloads.

Rationale: NASA-STD-5002 defines the methodologies, practices, and requirements for the conduct of load analyses. JSC 65829 Loads and Structural Dynamics Requirements for Spaceflight Hardware is written for spacecraft and launch vehicle providers with an

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EVA Section focused on the compatibility impacts of supporting EVA by the spacecraft providers. JSC 65829 is not directly applicable to spacesuit development.

3.6.3 Fasteners

[STD-0031] The xEVA System shall meet the intent of NASA-STD-5020, Requirements for Threaded Fastening Systems in Spaceflight Hardware.

3.7 FLUIDS, PROPELLANTS, EXPLOSIVES, AND OXYGEN SYSTEMS

3.7.1 Flexible Lines and Flow-Induced Vibration

[STD-0032] The xEVA System shall prevent Flow-Induced Vibration (FIV) in metal bellows and flexhoses over their operating flow range +/-10% or show that part life is 4 times the operational life when FIV cannot be eliminated.

a. The FIV analysis to determine the predicted FIV flow range shall be performed to meet the intent of MSFC-DWG-20M02540, Assessment of Flexible Lines for Flow-Induced Vibration.

b. The procedures for flow testing metal bellows and flexhoses to show acceptable operational life shall meet the intent of MSFC-SPEC-626, Test Control Document for Assessment of Flexible Lines for Flow Induced Vibration.

c. For those metal bellows and flexhoses used in the xEVA System which experience an operating flow excitation environment that is different (atypical) than the grazing flow environment described by MSFC-DWG-20M02540, then an alternative analysis technique shall be used.

Rationale: The occurrence of flow-induced vibrations in convoluted metal bellows and flexhoses can result in a structural fatigue failure. These flow-induced vibrations are a result of the coupling of vortex shedding from the flexible line convolutes with the natural frequencies of the flexible line. It is the intent of this requirement to avoid those flow ranges which produce FIV or to pursue other robust design and demonstration activities necessary to minimize the likelihood of a catastrophic failure of bellows and flexhoses. The alternative analysis technique is meant to address flow situations where the MSFC-DWG-20M02540 would not be applicable.

3.7.2 Bellow Threat Assessment and Damage Control

[STD-0060] The xEVA System shall create a damage threat assessment and damage control plan for bellows and flexhoses.

Rationale: Steps need to be taken to help mitigate the possibility of damage to a bellows or flexhose during manufacturing, handling, testing, packaging, storage, transportation, installation, in-service use and maintenance, including integration, launch, re-entry, landing and re-flight, as applicable. The standard template JSC

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67283 Damage Threat Assessment (DTA) and Damage Control Plan (DCP) Template for Bellows and Flexhoses can be used as a guide for bellows damage threat assessment. JSC 67283 provides a template that can be used to evaluate and mitigate defined threats to bellows or metallic convoluted lined flexhoses.

3.7.3 Best Practices for a Thin Walled Pressure Boundaries

[STD-0055] The xEVA System shall meet the intent of JSC 67035, Best Practices and Guidelines for Thin Wall Pressure Boundaries for Human Spaceflight.

Rationale: JSC 67035 is intended to serve as recommendations to supplement hardware Program requirements as defined in existing standards (e.g. NASA-STD-

6016, NASA-STD-5006, NASASTD-5012, NASA-STD-5017, NASA-STD-5001, AIAA-S-

080, MSFC-DWG-20M02540, MSFC-SPC-166 and SMC-S-016 or approved alternate standards). While the guidelines address elements across many standards, they are intended to provide elements for an alternative approach that meets the intent of NASA requirement for fracture control. Alternative approaches are acceptable per NASA-STD- 5019/5019A but must provide a risk neutral alternative to the specific requirements and must be approved by the responsible fracture control board. The need for alternative approaches for fracture critical thin wall pressure barriers arises in cases where the traditional safe life analysis based on linear-elastic fracture mechanics cannot be applied due to complexity in geometry, inaccuracy of determining the initial stress state, nonlinear material behavior, and lack of sensitivity of the current nondestructive evaluation (NDE) techniques to detect the required small initial flaw sizes. Complexity of configuration, dependence on manufacturing process controls, stress concentrations, monotonic versus cyclic material behaviors, residual stresses, and process operations such as welding and forming with a potential for introducing material damage also contribute to a need for a consistent, structured approach for addressing thin wall pressure barriers.

3.8 PROPULSION SYSTEMS

3.8.1 Strength and Life Requirements for Propulsion Systems

[STD-0033] The xEVA System shall meet the intent of NASA-STD-5012, Strength and Life Assessment Requirements for Liquid Fueled Space Propulsion Systems Engines.

3.9 FRACTURE CONTROL

3.9.1 Fracture Control

[STD-0034] The xEVA System shall meet the intent of fracture control requirements in NASA-STD-5019, Fracture Control Requirements for Spaceflight Hardware.

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3.10 EEE PARTS

3.10.1 EEE Parts

[STD-0035] The xEVA System shall meet the intent of SSP 30312 Volume 1, Electrical, Electronic, and Electromechanical (EEE) Parts Management and Implementation Plan for the Space Station Program.

Note: SSP 30312 Volume 1, Electrical, Electronic, and Electromechanical (EEE) Parts Management and Implementation Plan for the Space Station Program defines four grades for parts with the grades varying from grade 1 for most critical applications to class 4 for the least critical applications. The appropriate grade is to be identified and applied at the initiation or the project or at an early project milestone, such as Systems Requirements Review (SRR).

Note: SSP 30312 Grade 1 is equivalent to SMC-S-010, Space and Missile Systems Center Standard, Parts, Materials, and Processes Technical Requirements for Space and Launch Vehicles.

3.11 TESTING

3.11.1 Ground Testing

[STD-0036] The xEVA System and associated subsystems and units shall meet the intent of the environmental and structural ground testing requirements as defined in SMC Standard SMC-S-016, Test Requirements for Launch, Upper-Stage, and Space Vehicles, with the following exceptions:

1) For leak testing, the xEVA System and associated subsystems and units shall meet the intent of the leak testing requirements defined in NASA-STD-7012, Leak Testing.

2) Shock as an acceptance test is not required.

3) For burn-in testing, the xEVA System and associated subsystems and units shall meet the intent of the burn-in testing requirements defined in SSP 41172.

4) For life testing of mechanisms, the life test factor from NASA-STD-5017 shall be used.

5) For vibration, shock, and acoustics qualification testing, a test margin of 3 dB rather than 6 dB is acceptable provided that test tolerances for random vibration are covered and low side tolerance for shock is not below the required design level.

6) Forced limited vibration testing shall meet the intent of NASA-HDBK-7004, Force Limited Vibration testing.

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Note: SSP 41172 is an acceptable alternative with exceptions 1, 2 and 4-6 applying.

3.12 MODELS AND SIMULATIONS

3.12.1 Models and Simulations

[STD-0037] The xEVA System shall meet the intent of sections 4.1.1, 4.1.2, 4.7 and 4.8 of NASA-STD-7009, Standard for Models and Simulations, for all models and simulations that are utilized in making critical decisions.

Rationale: The intent is to ensure that the limitations and credibility of model- and simulation-based analysis results are clearly and consistently communicated to decision makers, since the output data from a model or simulation by itself does not provide sufficient information on which to base a critical decision.

3.12.2 Collaborative Simulation Technologies

Because the Gateway elements will be developed by multiple providers staggered over a significant period of time, mechanisms must be codified to ensure that models, simulations, and their supporting data can be exchanged between NASA and its commercial and International Partners. Complicating the matter is that each provider is likely to have its own modeling tools, simulation execution environment, and data protection requirements.

The Gateway Program intends to leverage international standards to ensure that models and simulations can be used collaboratively to satisfy programmatic needs while allowing appropriate protection of intellectual property.

NOTE: The section on collaborative simulation technologies is only applicable to models and simulations that will be used collaboratively with project and programs external to the xEVA System to satisfy programmatic needs.

[STD-0063] For distributed simulations, the participating simulations shall satisfy IEEE 1516 and the Simulation Interoperability Standards Organization (SISO) Standard for Space Reference Federation Object Model (SpaceFOM).

Rationale: The High Level Architecture mechanism is widely used for cases where loosely coupled simulated vehicles can be tied together in a common environment with known interactions. Examples include large-scale joint NATO military exercises involving hundreds of simulated vehicles, as well as spacecraft training operations involving ISS and international and commercial partners. Ref:

https://standards.ieee.org/standard/1516-2010.html

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The Federation Object Model provides a mechanism to define the types of data that can be exchanged and interactions that can occur between modeled elements in separate HLA-enabled simulations. The SpaceFOM specifies space-unique data and interactions, and has been developed by an international M&S community. Ref:

https://www.sisostds.org/StandardsActivities/DevelopmentGroups/SRFOMPDGS paceReferenceFederationObjectModel.aspx

[STD-0064] For simulations that involve model object code linked together from disparate sources, participating models shall satisfy the Functional Mock-up Interface for Model Exchange and Co-Simulation standard on a Linux host with C/C++ based object code.

Rationale: Functional Mock-up Interface (FMI) is an open, international standard that allows pre-compiled object code from multiple sources to be linked into a common executable. Models may be delivered without delivering associated source code Ref: https://fmi-standard.org

3.13 EVA SUIT COMPATIBILITY

Requirement deleted and moved to SSP51073

3.14 STITCHES, SEAMS, AND SEWIING

[STD-0039] Space Suit and EVA hardware shall meet the intent of ASTM D6193, Standard Practice for Stitches and Seams, for stitches, seams, and sewing.

3.15 QUALITY ASSURANCE

3.15.1 Quality Assurance

[STD-0040] The xEVA System shall meet the intent of the following quality assurance requirements (from Attachment A of NPD 8730.5, NASA Quality Assurance Program Policy, Sections 2a through 2d) as defined below:

1) Work that is both critical and complex shall be performed in accordance with the quality system requirements of SAE AS9100, Quality Management Systems – Requirements for Aviation, Space and Defense Organizations.

a. Critical work is any hardware task that, if performed incorrectly or in violation of prescribed requirements, could result in loss of human life; serious personal injury; loss of a Class A, B, or C payload (see NPR 8705.4); loss of a Category 1 or Category 2 mission (see NPR 7120.5); or loss of a mission resource valued at greater than $2M.

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b. Complex work involves either: a) the design, manufacture, fabrication, assembly, testing, integration, maintenance, or repair of machinery, equipment, subsystems, systems, or platforms; or b) the manufacture/fabrication of parts or assemblies which have quality characteristics not wholly visible in the end item and for which conformance can only be established progressively through precise measurements, tests, and controls applied.

2) Critical, but not complex, work shall be performed in accordance with the quality system requirements of SAE AS9100 or ISO 9001 Quality Management Systems

– Requirements, or the inspection and test quality system requirements of SAE AS9003. Noncomplex work includes manufacture of “build to print” piece parts or performance of a discrete…