DI-SESS-82237A

Materials and Processes Substantiating Data and Analysis Test Report

Documents the data required to substantiate the materials and processes used to develop materiel, ensuring system performance requirements are met throughout the system's operational service life.

Approval DateMay 10, 2023

AMSC NumberN10402

Preparing ActivityAS

Project NumberSESS-2023-021

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-82237

DI-SESS-82236A

Description & Purpose

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Application & Interrelationship

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Use & Relationship

The Materials and Processes Substantiating Data and Analysis Test Report documents the data required to substantiate the materials and processes used to develop materiel. The data will be used to substantiate the materiel's design to ensure system performance requirements are met throughout the system's operational service life.

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-82236A, Materials and Processes Substantiating Data and Analysis Test Plan.

This DID supersedes DI-SESS-82237.

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 Report shall contain the following:

3.1Testing Methods for Material Properties

3.1.1Describe the results from all research and developmentDescribe the results from all research and development, testing, and fabrication studies accomplished with respect to materials and processes development.

3.1.2Describe the results from conducting materials testingDescribe the results from conducting materials testing.

3.1.3Describe the work performed to support the evaluationDescribe the work performed to support the evaluation and substantiation of material properties.

3.1.4Describe the results from developing non-destructive test accept/rejectDescribe the results from developing non-destructive test accept/reject criteria, materials processing effects and parameters, material fabrication techniques, and manufacturing procedures.

3.1.5Describe the ability to meet program specific testDescribe the ability to meet program specific test objectives, test methods, test procedures, test conditions, and test matrices proposed in the Materials and Processes Substantiating Data and Analysis Test Plan.

3.1.6Describe the data generated to validate the methodsDescribe the data generated to validate the methods being used in the testing and evaluation of materials.

3.1.7Describe the data generated from materials testing andDescribe the data generated from materials testing and evaluation to ensure that materials and processes are characterized in a statistically significant manner relative to the design application.

3.2Material Properties Testing Plans and Procedures

3.2.1Describe the data available to substantiate that theDescribe the data available to substantiate that the testing and evaluation strategy supports the building block approach (coupon, element, sub component). Describe the rationale for using approaches other than the building block approach.

3.2.2Describe the data available to substantiate the implementationDescribe the data available to substantiate the implementation of procedures used for monitoring and controlling processes critical to satisfying part design requirements.

3.2.3Describe the process for identifying, monitoring, controlling, andDescribe the process for identifying, monitoring, controlling, and analyzing key process parameters.

3.2.4Describe the process for determining and evaluating processDescribe the process for determining and evaluating process capability, including management and reduction of process variation.

3.2.5Describe the methodology used to determine and substantiateDescribe the methodology used to determine and substantiate thermal exposure time histories.

3.2.6Describe the data to substantiate composite sandwich constructionDescribe the data to substantiate composite sandwich construction properties, including those analytically derived from sandwich constituent properties to permit for the statistical determination of the material properties.

3.2.7Describe the methodology and results for process verification testingDescribe the methodology and results for process verification testing of test coupons (representative of the production part) and their associated acceptance criteria.

3.3Material Properties Test ScheduleDescribe the 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.

3.4Material Properties Substantiation

3.4.1Describe the methods used to substantiate material propertiesDescribe the methods used 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.

3.4.2Describe the data to substantiate the effects ofDescribe the data to substantiate the effects of environmental exposure and operating environment on material properties.

3.4.3Describe the data to substantiate materials specifications selectedDescribe the data to substantiate materials specifications selected for protective finishes, protective coatings and sealants for corrosion protection.

3.5Material Allowables Development

3.5.1Describe the design allowable philosophy used to developDescribe the design allowable philosophy used to develop the system materials, and document how the data was generated and used to determine material properties.

3.5.2Describe the analytical procedures used to calculate staticDescribe the analytical procedures used to calculate static and dynamic material allowables.

3.5.3Describe the static material allowables methodology in statisticalDescribe the static material allowables methodology in statistical terms of confidence levels and exceedance values.

3.5.4Describe the methodology used to substantiate the impactDescribe the methodology used to substantiate the impact of inorganic finish systems on material allowables.

3.5.5Describe the methods used to generate composite laminate dataDescribe the methods used to generate composite laminate data (including data analytically derived from single-ply properties) to permit for a statistical determination of the laminate properties.

3.5.6Describe the data to substantiate the materials' fracture toughnessDescribe the data to substantiate the materials' fracture toughness values to be used in the residual strength analysis of metallic parts will be the minimum substantiated fracture toughness values.

References

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