Standard Materials and Processes Requirements for Spacecraft Hardware

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This document is directed toward materials and processes (M&P) used in the design, fabrication, and testing of flight components for manned, unmanned, robotic, launch vehicle, lander, in-space and surface systems, and spacecraft program/project hardware elements. Fflight hardware is covered by the M&P requirements of this document, including vendordesigned, off-the-shelf, and vendor-furnished items.

Open: Standard Materials & Processes Requirements for Spacecraft Hardware

1. SCOPE 7
1.1 Purpose 7
1.2 Applicability 7

2. APPLICABLE DOCUMENTS 8
2.1 General 8
2.2 Government Documents 8
2.3 Non-Government Documents 10
2.3.1 Voluntary Consensus Standards 10
2.4 Order of Precedence 12

3. ACRONYMS AND DEFINITIONS 13
3.1 Acronyms 13
3.2 Definitions 14

4. REQUIREMENTS 16
4.1 General Requirements 17
4.1.1 Materials and Processes Selection, Control, and Implementation Plan 17
4.1.1.1 Coordination, Approval, and Tracking 17
4.1.1.2 Approval Signature 17
4.1.1.3 M&P Controls 18
4.1.1.4 Commercial Off-The-Shelf (COTS) Hardware 19
4.1.1.5 M&P Control Board 20
4.1.2 M&P Usage Documentation 20
4.1.2.1 Human-Rated Spacecraft 20
4.1.2.2 Non-Human Rated Spacecraft 21
4.1.2.3 MIUL Content 21
4.1.3 MUAs 22
4.1.3.1.1 Category I MUAs 23
4.1.3.1.2 Category II MUAs 23
4.1.3.1.3 Category III MUAs 23
4.1.3.2 Non-Human Rated Spacecraft 23
4.1.4 Manufacturing Planning 24
4.1.5 Materials Certification and Traceability 24
4.1.6 Material Design Allowables 24
4.2 Detailed Requirements 25
4.2.1 Flammability, Offgassing, and Compatibility Requirements 25
4.2.1.1 Flammability Control 25
4.2.1.2 Toxic Offgassing 26
4.2.1.3 Fluid Compatibility (Fluids Other Than Oxygen) 27
4.2.1.4 Oxygen Compatibility 27
4.2.1.5 Electrical Wire Insulation Materials 28
4.2.2 Metals 29
4.2.2.1 Aluminum 29
4.2.2.2 Steel 30
4.2.2.3 Titanium 31
4.2.2.4 Magnesium 33
4.2.2.5 Beryllium 33
4.2.2.6 Cadmium 34
4.2.2.7 Zinc 34
4.2.2.8 Mercury 34
4.2.2.9 Refractory Metals 34
4.2.2.10 Superalloys (Nickel-Based and Cobalt-Based) 35
4.2.2.11 Tin 35
4.2.3 Nonmetallic Materials 36
4.2.3.1 Elastomeric Materials 36
4.2.3.2 Polyvinylchloride 36
4.2.3.3 Composite Materials 36
4.2.3.4 Lubricants 36
4.2.3.5 Limited-Life Items 37
4.2.3.6 Thermal Vacuum Stability 37
4.2.3.7 External Environment Survivability 38
4.2.3.8 Fungus Resistance 38
4.2.3.9 Glycols 39
4.2.3.10 Etching Fluorocarbons 40
4.2.4 Processes 40
4.2.4.1 Forging 40
4.2.4.2 Castings 41
4.2.4.3 Adhesive Bonding 41
4.2.4.4 Welding 42
4.2.4.5 Brazing 42
4.2.4.6 Structural Soldering 43
4.2.4.7 Electrical Discharge Machining and Laser Machining 43
4.2.5 Material Nondestructive Inspection 43
4.2.5.1 Nondestructive Evaluation (NDE) Plan 43
4.2.5.2 NDE Etching 44
4.2.5.3 Nickel Plating 44
4.2.6 Special Materials Requirements 44
4.2.6.1 Residual Stresses 44
4.2.6.2 Sandwich Assemblies 45
4.2.6.3 Corrosion Prevention and Control 45
4.2.6.4 Hydrogen Embrittlement 46
4.2.6.5 Fastener Installation 47
4.2.6.6 Contamination Control 48
4.2.6.7 Packaging 48
4.3 Verification
48 Appendix A Typical MUA Form 50

Appendix B Category III MUA Rationale Codes 51
Appendix C Recommended Data Requirements Documents 55
Appendix D Guidance 67

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