DI-SESS-82236A

Materials and Processes Substantiating Data and Analysis Test Plan

Identifies the approach for documenting test plans and procedures that substantiate the materials and processes used to develop materiel, ensuring system performance requirements are met.

Approval DateMay 10, 2023

AMSC NumberN10401

Preparing ActivityAS

Project NumberSESS-2023-020

OPR—

DTIC Applicable—

GIDEP ApplicableNo

Limitation—

Applicable Forms—

Approval Limitation—

Form Version—

DID Formatfree_text

963C CompliantYes

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

Supersedes

DI-SESS-82236

DI-SESS-82237A

Description & Purpose

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Application & Interrelationship

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Use & Relationship

The Materials and Processes Substantiating Data and Analysis Test Plan identifies the approach for documenting test plans and procedures that will substantiate the materials and processes used to develop materiel. The plan will be used to assess the materiel development approach to ensure system performance requirements are met.

This Data Item Description (DID) contains the format, content, and intended use information for the data product resulting from the work task described by the contract SOW.

This DID interfaces with DI-SESS-82237A, Materials and Processes Substantiating Data and Analysis Test Report.

This DID supersedes DI-SESS-82236.

Preparation Instructions

1Reference documentsThe applicable issue of the documents cited herein, including their approval dates and dates of any applicable amendments, notices, and revisions, shall be as specified in the contract.

2FormatContractor format acceptable.

3ContentThe Materials and Processes Substantiating Data and Analysis Test Plan shall contain the following:

3.1Materials and Processes EvaluationDescribe the plan used to evaluate all proposed materials and processes to be used on the system for their ability to meet system performance requirements.

3.2Testing Methods for Material Properties

3.2.1Describe plans for all research anddevelopment, testing, and fabrication studies to be accomplished with respect to materials and processes development.

3.2.2Describe plans to conduct materials testing

3.2.3Describe the tasks to be performed for theevaluation and substantiation of material properties.

3.2.4Describe plans for developing non-destructive testaccept/reject criteria, materials processing effects and parameters, material fabrication techniques, and manufacturing procedures.

3.2.5Describe program specific test objectivestest methods, test procedures, test conditions, and test matrices.

3.2.6Describe plans to validate the methods tobe used in the testing and evaluation of materials.

3.2.7Describe the plan for materials testing andevaluation to ensure that materials and processes are characterized in a statistically significant manner relative to the design application.

3.3Material Properties Testing Plans and Procedures

3.3.1Describe the plans to use atesting and evaluation strategy supports the building block approach (coupon, element, sub component). Describe the rationale for using approaches other than the building block approach.

3.3.2Describe the plan for the implementation ofprocedures used for monitoring and controlling processes critical to satisfying part design requirements.

3.3.3Describe the plan for identifyingmonitoring, controlling, and analyzing key process parameters.

3.3.4Describe the process for determining andevaluating process capability, including management and reduction of process variation.

3.3.5Describe the methodology to be usedto determine and substantiate thermal exposure time histories.

3.3.6Describe the plan to substantiate compositesandwich construction properties, including those analytically derived from sandwich constituent properties to permit for the statistical determination of the material properties.

3.3.7Describe the methodology that will beused for process verification testing of test coupons (representative of the production part) and their associated acceptance criteria.

3.4Material Properties Test ScheduleDescribe a materials and processes testing schedule that includes the characterization, testing, and analysis planned with respect to critical path milestones against the contractor's integrated master schedule.

3.5Material Properties Substantiation

3.5.1Describe the methods that will beused to substantiate material properties by using standardized documentation, analyses, tests, and inspections to characterize the following properties: static strength, fatigue strength, modulus, effect of stress concentrations, fracture toughness, crack growth, impact resistance, effects of defects, resistance to environmentally-assisted cracking, wear, general corrosion, pitting, stress corrosion cracking, exfoliation, galvanic corrosion, crevice corrosion, filiform corrosion, moisture absorption, chemical, solvent, fuel, and lubricant exposure; hydrolytic instability, thermal exposure, electromagnetic compatibility, adhesion strength, peel resistance, dielectric constant, resistivity, glass transition temperature, and erosion.

3.5.2Describe the approach for substantiating theeffects of environmental exposure and operating environment on material properties.

3.5.3Describe the methods that will beused to substantiate materials specifications selected for protective finishes, protective coatings, and sealants for corrosion protection.

3.6Material Allowables Development

3.6.1Describe the design allowable philosophy thatwill be used to develop the system materials, and document how the data will be generated and used to determine material properties.

3.6.2Describe the analytical procedures that willbe used to calculate static and dynamic material allowables.

3.6.3Describe the static material allowables methodologyin statistical terms of confidence levels and exceedance values.

3.6.4Describe the methodology used to substantiatethe impact of inorganic finish systems on material allowables.

3.6.5Describe the approach to generate compositelaminate data (including data analytically derived from single-ply properties) to permit for a statistical determination of the laminate properties.

3.6.6Describe a plan to substantiate thesystem materials' fracture toughness values used in the residual strength analysis of metallic parts will be the minimum substantiated fracture toughness values.

References

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