Device Under Test:
Multiple
Environmental Test:
Thermal Shock, Thermal Shock MIL, Salt Fog 48 Hrs, Salt Fog 96 Hrs
Physical Test:
Sinusoidal Vibration, Mechanical Shock, Rotational Life, Mounting Strength,
Label Adhesion
Test Report Number:
SP03-128
Test Start Date:
October 7, 2014
Test Completion Date:
December 22, 2014
Test Facility:
Grayhill Inc. La Grange, IL Facility
Test Requested By:
Troy Naumes
Test Performed By:
Greg Dombrowski
Laboratory Technician
Report Written By:
Greg Dombrowski
Laboratory Technician
Report Approved By:
Nicole Jachna
Quality Lab Manager
TABLE OF CONTENTS
SUBJECT
PAGE #
1.0
REVISION HISTORY ................................................................................................................................................... 4
2.0
SUMMARY ................................................................................................................................................................... 4
2.1. PURPOSE ................................................................................................................................................................ 4
2.2. REQUIREMENTS & METHODS .............................................................................................................................. 4
2.3. TEST SUMMARY ..................................................................................................................................................... 4
3.0
FLOW CHART ............................................................................................................................................................. 5
4.0
MOUNTING TORQUE ................................................................................................................................................. 6
4.1. PURPOSE ................................................................................................................................................................ 6
4.2. TEST SETUP DETAILS............................................................................................................................................ 6
4.3. TEST SETUP PHOTO .............................................................................................................................................. 7
4.4. ACCEPTANCE CRITERIA ....................................................................................................................................... 7
4.5. TEST RESULTS ....................................................................................................................................................... 7
5.0
SALT FOG (MIL-STD-810G, METHOD 509.4) ........................................................................................................... 8
5.1. PURPOSE ................................................................................................................................................................ 8
5.2. TEST SETUP DETAILS............................................................................................................................................ 8
5.3. TEST SETUP PHOTOS ........................................................................................................................................... 9
5.4. ACCEPTANCE CRITERIA ..................................................................................................................................... 10
5.5. TEST RESULTS ..................................................................................................................................................... 10
6.0
SALT FOG 96 Hrs (MIL-STD-810G, METHOD 509.4) ............................................................................................. 12
6.1. PURPOSE .............................................................................................................................................................. 12
6.2. TEST SETUP DETAILS.......................................................................................................................................... 12
6.3. TEST SETUP PHOTOS ......................................................................................................................................... 13
6.4. ACCEPTANCE CRITERIA ..................................................................................................................................... 14
6.5. TEST RESULTS ..................................................................................................................................................... 14
7.0
SINUSOIDAL VIBRATION TEST .............................................................................................................................. 16
7.1. PURPOSE .............................................................................................................................................................. 16
7.2. TEST SETUP DETAILS.......................................................................................................................................... 16
7.3. TEST SETUP PHOTOS ......................................................................................................................................... 17
7.4. ..................................................................................................................................................................................... 18
7.5. ACCEPTANCE CRITERIA ..................................................................................................................................... 18
7.6. TEST RESULTS ..................................................................................................................................................... 18
8.0
MECHANICAL SHOCK ............................................................................................................................................. 19
8.1. PURPOSE .............................................................................................................................................................. 19
8.2. TEST SETUP DETAILS.......................................................................................................................................... 19
8.3. TEST SETUP PHOTOS ......................................................................................................................................... 20
8.4. ACCEPTANCE CRITERIA ..................................................................................................................................... 21
8.5. TEST RESULTS ..................................................................................................................................................... 21
9.0
THERMAL SHOCK (MIL-STD-202G, METHOD 107, TEST CONDITION A) ........................................................... 22
9.1. PURPOSE .............................................................................................................................................................. 22
9.2. TEST SETUP DETAILS.......................................................................................................................................... 22
9.3. TEST SETUP PHOTOS ......................................................................................................................................... 23
9.4. ACCEPTANCE CRITERIA ..................................................................................................................................... 23
9.5. TEST RESULTS ..................................................................................................................................................... 23
10.0
ROTATIONAL LIFE ............................................................................................................................................... 24
10.1.
PURPOSE ........................................................................................................................................................... 24
10.2.
TEST SETUP DETAILS ...................................................................................................................................... 24
10.3.
TEST SETUP PHOTOS ...................................................................................................................................... 25
10.4.
ACCEPTANCE CRITERIA .................................................................................................................................. 25
10.5.
TEST RESULTS ................................................................................................................................................. 25
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11.0
ROTATIONAL LIFE AT TEMPERATURE ............................................................................................................. 26
11.1.
PURPOSE ........................................................................................................................................................... 26
11.2.
TEST SETUP DETAILS ...................................................................................................................................... 26
11.3.
ACCEPTANCE CRITERIA .................................................................................................................................. 27
11.4.
TEST RESULTS ................................................................................................................................................. 27
12.0
THERMAL SHOCK ................................................................................................................................................ 28
12.1.
PURPOSE ........................................................................................................................................................... 28
12.2.
TEST SETUP DETAILS ...................................................................................................................................... 28
12.3.
TEST SETUP PHOTOS ...................................................................................................................................... 29
12.4.
ACCEPTANCE CRITERIA .................................................................................................................................. 29
12.5.
TEST RESULTS ................................................................................................................................................. 29
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Report SP03-128 Rev. A
1.0 REVISION HISTORY
Revision
A
Date
01/12/2015
Written By
G. Dombrowski
Description
New
2.0 SUMMARY
2.1.
PURPOSE
Qualify sulfamate nickel testing
2.2.
REQUIREMENTS & METHODS
Tests to be performed to flow chart of report.
2.3.
TEST SUMMARY
Table 1 – Test Summary
Test Description
Group A
Mounting
Strength
Group B
48 Hour
Salt Fog
96 Hour
Salt Fog
Group C
Sinusoidal
Vibration
Mechanical
Shock
Thermal
Shock (MIL)
Group D
Life (Rotational)
Basic Standard
Test Results
Test Date
Test Location
MIL-DTL-3786J
4.8.3.3
PASS
12/22/2014
Grayhill, Inc.
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-DTL-3786J 4.8.7
MIL-STD-202G 201A
MIL-DTL-3786J 4.8.8
MIL-STD-202G 213B
MIL-STD-202G
107 Test Condition A
PASS
PASS
PASS
PASS
10/07/2014 –
10/09/2014
10/07/2014 10/11/2014
11/12/2014 –
11/21/2014
11/24/2014 –
12/12/2014
Grayhill, Inc.
Grayhill, Inc.
Grayhill, Inc.
Grayhill, Inc.
PASS
12/19/2014
Grayhill, Inc.
MIL-DTL-3786J 4.8.18
MIL-STD-202G 206
PASS
10/27/2014 –
12/11/2014
Grayhill, Inc.
MIL-DTL-3786J 4.8.18
MIL-STD-202G 206
PASS
11/21/2014 –
12/08/2014
Grayhill, Inc.
Grayhill Custom
PASS
12/04/2014 –
12/18/2014
Grayhill, Inc.
Group E
Life at temperature
(Rotational)
Group F
Thermal
Shock (Grayhill)
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3.0 FLOW CHART
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4.0 MOUNTING TORQUE
Test
Specification
Mounting Strength
MIL-DTL-3786J
4.8.3.3
4.1.
DUT Part Number
71A30-01-1-12N-C-NI
77P36-01-1-10N-NI
51A30-01-1-10N-NI
50A36-01-1-10N-NI
26ASD22-01-1-AJS-NI
56A36-01-1-10N-C-NI
50YY50812-NI
75BP36-01-1-10N-C-NI
38-401-BLK
DUT Serial Number Test Location Test Date
1-3
1-3
1-3
1-3
1-3
Grayhill Inc.
12/22/2014
1-3
1-3
1-3
1-3
PURPOSE
The purpose for this test is to determine if the DUT can withstand the maximum torque directly applied to the nuts.
4.2.
TEST SETUP DETAILS
1.
2.
3.
4.
5.
6.
Mount DUT onto a metal brackets whose hole is the recommended size for the DUT.
Use standard nut and lock washer for testing.
Use torque wrench to tighten the nut to the maximum allowable torque.
Inspect the DUT for any visible damage.
Perform functional tests after mounting.
Re-mount and torque nut until breakage or damage occurs and record FT-lbs.
Table 2 - Equipment List
Equipment ID
GT-400
Equipment Type
Torque Wrench
Model Number
CAL-36/4
Manufacturer
Sturtvant Richmont
Calibration Due Date
04/ 2015
Table 3 – Mounting Torque Test Conditions
Test Condition
Quantity
Operational Mode
Maximum Mounting Torque
Units
Parameters
In-LB
57
Unpowered
15
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4.3.
TEST SETUP PHOTO
Figure 1 – Mounting Torque test setup
4.4.
ACCEPTANCE CRITERIA
The DUT must have no part breakage and no disassembly of parts. The DUT must be functionally tested and operate
as intended after test.
4.5.
TEST RESULTS
There was no sign of part breakage or disassembly of parts for Max torque of 15 FT-lbs. The DUT were mechanically
and electrically operative.
Table 4 – Test Results
DUT
71A30-01-1-12N-C-NI
51A30-01-1-10N-NI
50A36-01-1-10N-NI
26ASD22-01-1-AJS-NI
56A36-01-1-10N-C-NI
50YY50812-NI
75BP36-01-1-10N-C-NI
38-401-BLK
Initial
15 FT-lbs
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
Failed FT-lbs
34
36
36
34
34
34
36
30
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5.0 SALT FOG (MIL-STD-810G, METHOD 509.4)
Test
Specification
Salt Fog
MIL-STD-810G
Method 509.4
5.1.
DUT Part Number
71A30-01-1-12N-C-NI
77P36-01-1-10N-NI
51A30-01-1-10N-NI
50A36-01-1-10N-NI
26ASD22-01-1-AJS-NI
56A36-01-1-10N-C-NI
50YY50812-NI
75BP36-01-1-10N-C-NI
75AY23083-NI
38-401-BLK
DUT Serial Number
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
Test Location
Test Date
Grayhill Inc.
10/07/2014 –
10/09/2014
PURPOSE
The Salt Fog method is performed to determine the effectiveness of protective coatings and finished on materials. It
may also be applied to determine the effects of salt deposits on the physical and electrical aspects of DUT.
5.2.
TEST SETUP DETAILS
1. Prepare a 5 +/-1% solution by dissolving 5 parts by weight of salt in 95 parts by weight of water.
2. Adjust to and maintain the solution at a specific gravity by using the measured temperature and density of the
salt solution.
3. Maintain the pH of the salt solution between 6.5 and 7.2.
4. Set the test chamber to 35C and condition the DUT for at least 2 hours before introducing the salt fog.
5. Atomize a salt solution into the test chamber for a period of 48 hours.
6. Dry the DUT at standard ambient temperatures and a relative humidity of 50% for 24 hours.
7. Perform physical and electrical.
8. Rinse or use a gentle wash the DUT in running water and conduct the corrosion examination.
9. Perform functional test.
Table 5 – Equipment List
Equipment ID
Equipment Type
Model Number
GT-115
Salt Fog Chamber
MX9204
GT-401
GT-110
NA
NA
Pressure Gauge
PH Meter
Gravity meters
Graduated Cylinders
595-05
HI 98108
NA
100: 2ml
Manufacturer
Associated Environmental
System
Ashcroft
PHEP+
NA
Azcon
Calibration Due Date
04/2015
04/2015
10/2015
NA
NA
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Table 6 - Test Conditions
Test Condition
Quantity
Duration
Salt Solution
Type of Water
Duration
pH Levels
Temperature
Volume of solution
measured per hour
5.3.
Units
DUT
Hours
parts
Parameters
°C
100
48
5 ± 1 parts per 95 parts water by mass
Distilled or De-ionized water
96
6.5 to 7.2
35
mL
1.0 to 2.0 mL
hours
TEST SETUP PHOTOS
Figure 2– Salt Fog Test Setup
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Figure 3– DUT after 48 hours Salt Fog and 24 hours drying
(STD plating on the left and NI plating on the right)
5.4.
ACCEPTANCE CRITERIA
The DUT shall satisfactorily withstand the salt fog conditions specified without physical damage.
fully functional after the test.
5.5.
The DUT shall be
TEST RESULTS
There was no visible corrosion, seal break down, or material breakdown on any DUT. The DUT exhibited normal
posttest operation.
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Table 7 – Test Results
DUT
Test
71A30-01-1-12N-C-NI
Salt Fog 48 Hrs
77P36-01-1-10N-NI
Salt Fog 48 Hrs
51A30-01-1-10N-NI
Salt Fog 48 Hrs
50A36-01-1-10N-NI
Salt Fog 48 Hrs
26ASD22-01-1-AJS-NI
Salt Fog 48 Hrs
56A36-01-1-10N-C-NI
Salt Fog 48 Hrs
50YY50812-NI
Salt Fog 48 Hrs
75BP36-01-1-10N-C-NI
Salt Fog 48 Hrs
75AY23083-NI
Salt Fog 48 Hrs
38-401-BLK
Salt Fog 48 Hrs
Specification
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
Pass
Test Location
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
Test Date
10/07/2014 –
10/09/2014
10/07/2014 –
10/09/2014
10/07/2014 –
10/09/2014
10/07/2014 –
10/09/2014
10/07/2014 –
10/09/2014
10/07/2014 –
10/09/2014
10/07/2014 –
10/09/2014
10/07/2014 –
10/09/2014
10/07/2014 –
10/09/2014
10/07/2014 –
10/09/2014
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6.0 SALT FOG 96 Hrs (MIL-STD-810G, METHOD 509.4)
Test
Specification
Salt Fog
MIL-STD-810G
Method 509.4
6.1.
DUT Part Number
71A30-01-1-12N-C-NI
77P36-01-1-10N-NI
51A30-01-1-10N-NI
50A36-01-1-10N-NI
26ASD22-01-1-AJS-NI
56A36-01-1-10N-C-NI
50YY50812-NI
75BP36-01-1-10N-C-NI
75AY23083-NI
38-401-BLK
DUT Serial Number
4-8
4-8
4-8
4-8
4-8
4-8
4-8
4-8
4-8
4-8
Test Location
Test Date
Grayhill Inc.
10/07/2014 –
10/11/2014
PURPOSE
The Salt Fog method is performed to determine the effectiveness of protective coatings and finished on materials. It
may also be applied to determine the effects of salt deposits on the physical and electrical aspects of DUT.
6.2.
TEST SETUP DETAILS
1. Prepare a 5 +/-1% solution by dissolving 5 parts by weight of salt in 95 parts by weight of water.
2. Adjust to and maintain the solution at a specific gravity by using the measured temperature and density of the
salt solution.
3. Maintain the pH of the salt solution between 6.5 and 7.2.
4. Set the test chamber to 35C and condition the DUT for at least 2 hours before introducing the salt fog.
5. Atomize a salt solution into the test chamber for a period of 96 hours.
6. Dry the DUT at standard ambient temperatures and a relative humidity of 50% for 24 hours.
7. Perform physical and electrical.
8. Rinse or use a gentle wash the DUT in running water and conduct the corrosion examination.
9. Perform functional test.
Table 8 – Equipment List
Equipment ID
Equipment Type
Model Number
GT-115
GT-401
GT-110
NA
NA
Salt Fog Chamber
Pressure Gauge
PH Meter
Gravity meters
Graduated Cylinders
MX9204
595-05
HI 98108
NA
100: 2ml
Manufacturer
Associated
Environmental System
Ashcroft
PHEP+
NA
Azcon
Calibration Due Date
04/2015
04/2015
10/2015
NA
NA
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Table 9 - Test Conditions
Test Condition
Quantity
Duration
Salt Solution
Type of Water
Duration
pH Levels
Temperature
Volume of solution
measured per hour
6.3.
Units
DUT
Hours
parts
Parameters
°C
100
96
5 ± 1 parts per 95 parts water by mass
Distilled or De-ionized water
96
6.5 to 7.2
35
mL
1.0 to 2.0 mL
hours
TEST SETUP PHOTOS
Figure 4– Salt Fog Test Setup
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Figure 5– DUT after 96 hours Salt Fog and 24 hours drying
(STD plating on the left and NI plating on the right)
6.4.
ACCEPTANCE CRITERIA
The DUT shall satisfactorily withstand the salt fog conditions specified without physical damage.
fully functional after the test.
6.5.
The DUT shall be
TEST RESULTS
There was no visible corrosion, seal break down, or material breakdown on any DUT. The DUT exhibited normal
posttest operation.
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Table 10 – Test Results
DUT
Test
71A30-01-1-12N-C-NI
Salt Fog 96 Hrs
77P36-01-1-10N-NI
Salt Fog 96 Hrs
51A30-01-1-10N-NI
Salt Fog 96 Hrs
50A36-01-1-10N-NI
Salt Fog 96 Hrs
26ASD22-01-1-AJS-NI
Salt Fog 96 Hrs
56A36-01-1-10N-C-NI
Salt Fog 96 Hrs
50YY50812-NI
Salt Fog 96 Hrs
75BP36-01-1-10N-C-NI
Salt Fog 96 Hrs
75AY23083-NI
Salt Fog 96 Hrs
38-401-BLK
Salt Fog 96 Hrs
Specification
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
MIL-STD-810G
Method 509.4
Pass
Test Location
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
Test Date
10/07/2014 –
10/11/2014
10/07/2014 –
10/11/2014
10/07/2014 –
10/11/2014
10/07/2014 –
10/11/2014
10/07/2014 –
10/11/2014
10/07/2014 –
10/11/2014
10/07/2014 –
10/11/2014
10/07/2014 –
10/11/2014
10/07/2014 –
10/11/2014
10/07/2014 –
10/11/2014
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7.0 SINUSOIDAL VIBRATION TEST
Test
Specification
Sinusoidal
Vibration
MIL-DTL-3786J 4.8.7
MIL-STD0202G 201A
7.1.
DUT Part Number
71A30-01-1-12N-C-NI
77P36-01-1-10N-NI
51A30-01-1-10N-NI
50A36-01-1-10N-NI
26ASD22-01-1-AJS-NI
56A36-01-1-10N-C-NI
5050YY50812-NI
75BP36-01-1-10N-C-NI
DUT Serial Number
14-23
14-23
14-23
14-23
14-23
14-23
14-23
14-23
Test Location
Test Date
Grayhill Inc.
11/12/2014 11/21/2014
PURPOSE
The purpose of this test is to evaluate the DUT of its ability to withstand sinusoidal vibration. The potential product
failure modes and effects detected in this test are:
•
•
•
•
•
Cracked housing/components
Broken product/components
Open solder joints
Dislodged parts
Loose mounting interfaces.
7.2.
TEST SETUP DETAILS
Test Profile and Setup Details:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Visual Inspection of the DUT is to be performed before and after testing
Attach characterization sample(s) to the test fixture on the test table in specified orientation.
Characterize set-up conditions.
Attach DUT in specified orientation.
Attach connector(s) and tie down wire harness(es) at appropriate lengths, if required.
Power and monitor DUT output.
Apply vibration, temperature and voltage per specified levels and verify operation, if required.
Vibrate the DUT for specified duration.
Subject DUT to conditions in Test Checkpoint Table.
Repeat steps D thru I until all DUT have been tested for their total duration.
Perform the Visual Examination and Functional Check after the test.
Table 11 – Equipment List
Equipment ID
Equipment Type
Model Number
Manufacturer
Calibration Due Date
GT-353
Shaker Table
Shaker Table
Amplifier
Shaker Table
Controller
Shear
Accelerometer
DS-11000VH/1.7-50
Dynamic Solutions
Calibration Not Required
SA-50
Dynamic Solutions
Calibration Not Required
DVC-8
Vibration World
05/2015
JTLD352C04
PCB Piezotronics
10/2015
GT-354
GT-355
GT-535
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Table 12 - Test Condition
Test Condition
Units
Parameters
Quantity
Duration
Operational Mode
Applicable Axes
Temperature
Lower Limit Frequency
Upper Limit Frequency
Sweep Rate
Pass/Fail Criteria
DUT
Hours
Volts
3
C
Hz
Hz
Min./Cycle
170
2 per axis
Monitored with Chatterbox
Longitudinal, Transverse, and Vertical
Ambient
10
55
1
See below
Table 13 – Profile Break Points
Frequency (Hz)
Displacement (th)
10
55
60
60
7.3.
TEST SETUP PHOTOS
Figure 6 – Sinusoidal Vibration for DUT being monitored.
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Figure 7 – Sample of finished test profile
7.4.
7.5.
ACCEPTANCE CRITERIA
Upon completion of the Sinusoidal Vibration test, the DUT must be functionally tested and operate as intended. There
shall not be any visible damage such as broken, loose, deformed or displaced parts. There shall be no change in the
shaft position. All DUT shall be monitored and show no evidence of false activation.
7.6.
TEST RESULTS
All DUT passed the functional testing and showed no evidence of damage. All DUT were powered and monitored by
use of a chatter box to insure no impaired function during and after the test.
All mounting hardware was intact.
Table 14– Test Results
DUT
Test
71A30-01-1-12N-C-NI
Sinusoidal Vibration
77P36-01-1-10N-NI
Sinusoidal Vibration
51A30-01-1-10N-NI
Sinusoidal Vibration
50A36-01-1-10N-NI
Sinusoidal Vibration
26ASD22-01-1-AJS-NI
Sinusoidal Vibration
56A36-01-1-10N-C-NI
Sinusoidal Vibration
50YY50812-NI
Sinusoidal Vibration
75BP36-01-1-10N-C-NI
Sinusoidal Vibration
Specification
MIL-DTL-3786J 4.8.7
MIL-STD0202G 201A
MIL-DTL-3786J 4.8.7
MIL-STD0202G 201A
MIL-DTL-3786J 4.8.7
MIL-STD0202G 201A
MIL-DTL-3786J 4.8.7
MIL-STD0202G 201A
MIL-DTL-3786J 4.8.7
MIL-STD0202G 201A
MIL-DTL-3786J 4.8.7
MIL-STD0202G 201A
MIL-DTL-3786J 4.8.7
MIL-STD0202G 201A
MIL-DTL-3786J 4.8.7
MIL-STD0202G 201A
Pass
Test Location
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
Test Date
11/12/2014 11/21/2014
11/12/2014 11/21/2014
11/12/2014 11/21/2014
11/12/2014 11/21/2014
11/12/2014 11/21/2014
11/12/2014 11/21/2014
11/12/2014 11/21/2014
11/12/2014 11/21/2014
18 of 29
OPS Form #333, Rev A
11/12/12
Report SP03-128 Rev. A
8.0 MECHANICAL SHOCK
Test
Specification
MIL-DTL-3786J
4.8.8
Mechanical Shock
MIL-STD0202G
213B
8.1.
DUT Part Number
71A30-01-1-12N-C-NI
77P36-01-1-10N-NI
51A30-01-1-10N-NI
50A36-01-1-10N-NI
26ASD22-01-1-AJS-NI
56A36-01-1-10N-C-NI
50YY50812-NI
75BP36-01-1-10N-C-NI
DUT Serial Number Test Location Test Date
14-23
14-23
14-23
14-23
11/24/2014 Grayhill Inc.
14-23
12/12/2014
14-23
14-23
14-23
PURPOSE
The purpose of this test is to validate the manufacturing process in its ability to produce a product capable of
withstanding the effects of shipping, handling, installation, and operational shock. The potential product issue modes
and effects detected in this test are:
•
•
•
Housing cracks
Product/component breakage
Inadvertent activation
8.2.
TEST SETUP DETAILS
1.
2.
3.
4.
5.
6.
7.
8.
Visual Inspection of the DUT is to be performed before and after testing.
Verify specified test conditions table with test fixture on test table.
Place product in a holding fixture in specified orientation.
Attach connector(s) and tie down wire harness at appropriate lengths, if required.
Monitor DUT outputs, if required.
Test product for specified shocks/axis.
Repeat until all DUT have completed their total shocks/unit.
Perform the Visual Examination and Functional Check after the test.
Table 15 – Equipment List
Equipment ID
GT-535
Equipment Type
Accelerometer
Model Number
JTLD352C04
Manufacturer
PCB Piezotronics
GT-141
Mechanical Shock
Table
M-RAD
1616(100)PA-MP
MRAD
Calibration Due Date
10/2015
verified by controller’s
software & Accelerometer
GT-532
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OPS Form #333, Rev A
11/12/12
Report SP03-128 Rev. A
Table 16 - Test Conditions
Test Condition
Quantity
Operational Mode
Pulse Type
Acceleration
Pulse duration
Drops
Direction
8.3.
Units
DUT
G
‘msec.
per/axis
Parameters
170
Unpowered / Chatter Box
Saw Tooth
100
6
3
3 in each of +/-X, +/-Y, +/-Z (18 shocks total)
TEST SETUP PHOTOS
Figure 8– Mechanical Shock Test Setup
Figure 9 – Mechanical Shock Test Monitoring
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OPS Form #333, Rev A
11/12/12
Report SP03-128 Rev. A
Figure 10 – Mechanical Shock Wave Form
8.4.
ACCEPTANCE CRITERIA
As MIL-DTL-3786J states, any pair of mating switch section contacts shall not open for a period of time longer
than 10 µs unless otherwise specified. After the test, there shall be no change in shaft position, or evidence of
broken, loose, deformed, or displaced parts.
8.5.
TEST RESULTS
Functional status was verified by monitoring DUT with a Chatter Box during testing. After testing there was no change
in shaft position, no evidence of broken, loose, deformed or displaced parts. All DUT passed the functional testing.
Table 17 – Test Results
DUT
Test
71A30-01-1-12N-C-NI
Mechanical Shock
77P36-01-1-10N-NI
Mechanical Shock
50A36-01-1-10N-NI
Mechanical Shock
26ASD22-01-1-AJS-NI
Mechanical Shock
56A36-01-1-10N-C-NI
Mechanical Shock
50YY50812-NI
Mechanical Shock
75BP36-01-1-10N-C-NI
Mechanical Shock
Specification
MIL-DTL-3786J 4.8.8
MIL-STD0202G 213B
MIL-DTL-3786J 4.8.8
MIL-STD0202G 213B
MIL-DTL-3786J 4.8.8
MIL-STD0202G 213B
MIL-DTL-3786J 4.8.8
MIL-STD0202G 213B
MIL-DTL-3786J 4.8.8
MIL-STD0202G 213B
MIL-DTL-3786J 4.8.8
MIL-STD0202G 213B
MIL-DTL-3786J 4.8.8
MIL-STD0202G 213B
Pass
Test Location
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
PASS
Grayhill Inc.
Test Date
11/24/2014 12/12/2014
11/24/2014 12/12/2014
11/24/2014 12/12/2014
11/24/2014 12/12/2014
11/24/2014 12/12/2014
11/24/2014 12/12/2014
11/24/2014 12/12/2014
21 of 29
OPS Form #333, Rev A
11/12/12
Report SP03-128 Rev. A
9.0 THERMAL SHOCK (MIL-STD-202G, METHOD 107, TEST CONDITION A)
Test
Specification
DUT Part Number
71A30-01-1-12N-C-NI
77P36-01-1-10N-NI
51A30-01-1-10N-NI
50A36-01-1-10N-NI
26ASD22-01-1-AJS-NI
56A36-01-1-10N-C-NI
50YY50812-NI
75BP36-01-1-10N-C-NI
MIL-STD-202G,
METHOD 107,
Thermal Shock
TEST CONDITION
A
9.1.
DUT Serial Number
39-43
39-43
39-43
39-43
39-43
39-43
39-43
39-43
Test Location
Test Date
Grayhill Inc.
12/19/2014
PURPOSE
This test was conducted for the purpose of determining the resistance of DUT from sudden changes in the
temperature of the surrounding atmosphere without experiencing physical, mechanical, and electrical damage or
deterioration in performance.
9.2.
TEST SETUP DETAILS
1. Visual examination of the test item with special attention to stress areas such as corners of molded housing
and document the results.
2. Take picture of the test item.
3. Set Temperature Chamber as specified in the test plan for thermal shock.
4. Maintain the thermal shock temperature for a period as specified in the test plan.
5. Adjust Temperature Chamber to standard ambient and maintain until the test item has achieved temperature
stabilization.
6. Conduct a complete visual examination of the test item and document the results.
7. Compare these data with the initial visual examination.
8. Perform functional check on the test item.
Table 18 – Equipment List
Equipment ID
Equipment Type
Model Number
Manufacturer
Calibration Due Date
GT- 1008
Thermal Shock
VTS-3-6-6-SC/WC
Cincinnati Sub Zero
10/2015
GT-542
Thermometer
EasyView 15
Extech
08/2015
Table 19 - Test Conditions
Test Condition
Quantity
Duration
Dwell Time
Transfer time
Operational Mode
Minimum Temperature
Maximum Temperature
Units
DUT
Cycles
Hours Or
Minute
Minute
C
C
Parameters
170
5
1 Hour
1
Unpowered
-65
85
22 of 29
OPS Form #333, Rev A
11/12/12
Report SP03-128 Rev. A
9.3.
TEST SETUP PHOTOS
Figure 11 – Thermal Shock Test Setup
9.4.
ACCEPTANCE CRITERIA
Upon completion of the Thermal Shock Test, DUT contact resistance shall not exceed 500 milliohms, and there shall
be no mechanical or electrical damage, loosing of rivets, or other fastening devices.
9.5.
TEST RESULTS
DUT contact resistance did not exceed 500 milliohms. There was not any evidence of damage to DUT housing and
shaft.
Table 20 – Test Results
DUT
Test
71A30-01-1-12N-C-NI
Thermal Shock
77P36-01-1-10N-NI
Thermal Shock
51A30-01-1-10N-NI
Thermal Shock
50A36-01-1-10N-NI
Thermal Shock
26ASD22-01-1-AJS-NI
Thermal Shock
56A36-01-1-10N-C-NI
Thermal Shock
50YY50812-NI
Thermal Shock
75BP36-01-1-10N-C-NI
Thermal Shock
Specification
MIL-STD-202G
107G
MIL-STD-202G
107G
MIL-STD-202G
107G
MIL-STD-202G
107G
MIL-STD-202G
107G
MIL-STD-202G
107G
MIL-STD-202G
107G
MIL-STD-202G
107G
Pass
Test Location
Test Date
PASS
Grayhill Inc.
12/19/2014
PASS
Grayhill Inc.
12/19/2014
PASS
Grayhill Inc.
12/19/2014
PASS
Grayhill Inc.
12/19/2014
PASS
Grayhill Inc.
12/19/2014
PASS
Grayhill Inc.
12/19/2014
PASS
Grayhill Inc.
12/19/2014
PASS
Grayhill Inc.
12/19/2014
23 of 29
OPS Form #333, Rev A
11/12/12
Report SP03-128 Rev. A
10.0
ROTATIONAL LIFE
Test
Specification
Rotational Life
MIL-DTL-3786J
DUT Part Number
71A30-01-1-12N-C-NI
77P36-01-1-10N-NI
51A30-01-1-10N-NI
50A36-01-1-10N-NI
26ASD22-01-1-AJS-NI
56A36-01-1-10N-C-NI
50YY50812-NI
75BP36-01-1-10N-C-NI
DUT
Test Location
Test Date
24 To 33
Grayhill Inc.
10/27/2014 –
12/11/2014
10.1. PURPOSE
The purpose of this test is to determine the ability of DUT to operate satisfactorily under simultaneously applied
varying conditions of high / low temperature.
10.2. TEST SETUP DETAILS
1.
2.
3.
4.
5.
6.
Visual Inspection of the DUT is to be performed before and after testing
Measure and record the Initial torque values.
Program the Rotational Life Tester at 20RPM for 25000 cycles.
The cycle rate was approximately 10 cycles per minute.
Mount DUT onto Rotational Life Tester.
After 25000 cycles, measure and record Torque.
Table 21 – Equipment List
Equipment ID
GT-143
PAL-7
RLS-46
RLS-83
RLS-84
RLS-85
RLS-64
Equipment Type
Hygrometer
Torque Force
Reader
Smart Motor
Rotational Life
Smart Motor
Rotational Life
Smart Motor
Rotational Life
Smart Motor
Rotational Life
Smart Motor
Rotational Life
Model Number
MDM25
Manufacturer
Mitchell Instrument
Calibration Due Date
06/2014
BGI
Mark-10
09/2015
SM3416D-PLS2
Animatics
NA
SM3416D-PLS2
Animatics
NA
SM3416D-PLS2
Animatics
NA
SM3416D-PLS2
Animatics
NA
SM3416D-PLS2
Animatics
NA
24 of 29
OPS Form #333, Rev A
11/12/12
Report SP03-128 Rev. A
Table 22 - Test Conditions
Test Condition
Units
Parameters
Quantity
Operational Mode
Test Temperature
Humidity
Cycle Rate
Assemblies
170
Unpowered
24.6
26.1
20
°C
%Rh
RPM
10.3. TEST SETUP PHOTOS
Figure 12 – Rotational Life Test Setup
10.4. ACCEPTANCE CRITERIA
The DUT must function normally before, during, and after the Rotational Life Tests. There shall be no mechanical
damage, loosening of rivets or other fastening devices. The rotational torque shall be in between 0.5 in-lbs and 1.5
in-lbs.
10.5. TEST RESULTS
There was no evidence of any electrical, physical, or mechanical damage. All DUT were function normally after the
Rotational Life Tests.
Table 23 – Test Results
DUT
Test
Specification
Pass
Test Location
71A30-01-1-12N-C-NI
Rotational Life
MIL-DTL-3786J
PASS
Grayhill Inc.
77P36-01-1-10N-NI
Rotational Life
MIL-DTL-3786J
PASS
Grayhill Inc.
50A36-01-1-10N-NI
Rotational Life
MIL-DTL-3786J
PASS
Grayhill Inc.
26ASD22-01-1-AJS-NI
Rotational Life
MIL-DTL-3786J
PASS
Grayhill Inc.
56A36-01-1-10N-C-NI
Rotational Life
MIL-DTL-3786J
PASS
Grayhill Inc.
50YY50812-NI
Rotational Life
MIL-DTL-3786J
PASS
Grayhill Inc.
75BP36-01-1-10N-C-NI
Rotational Life
MIL-DTL-3786J
PASS
Grayhill Inc.
Test Date
10/27/2014 –
12/11/2014
10/27/2014 –
12/11/2014
10/27/2014 –
12/11/2014
10/27/2014 –
12/11/2014
10/27/2014 –
12/11/2014
10/27/2014 –
12/11/2014
10/27/2014 –
12/11/2014
25 of 29
OPS Form #333, Rev A
11/12/12
Report SP03-128 Rev. A
11.0
ROTATIONAL LIFE AT TEMPERATURE
Test
Specification
Rotational Life
at Temperature
MIL-DTL-3786J
4.8.19
MIL-STD-202G
108A
DUT Part Number
26ASD22-01-1-AJS (NI,STD)
50A36-01-1-10N (NI, STD)
50YY50812 (NI, STD)
51A30-01-1-10N (NI, STD)
71A30-01-1-12N-C (NI, STD)
75BP36-01-1-10H-C (NI, STD)
75YY50033 STD
77P36-01-10N (NI, STD)
DUT
Test Location
Test Date
34 - 38
Grayhill Inc.
11/21/14 –
12/08/14
11.1. PURPOSE
The purpose of this test is to determine the ability of DUT to operate satisfactorily under simultaneously applied
varying conditions of high / low temperature.
11.2. TEST SETUP DETAILS
1.
2.
3.
4.
5.
6.
Visual Inspection of the DUT is to be performed before and after testing
Measure and record the Initial torque values.
Program the Rotational Life Tester at 20RPM for 25000 cycles.
The cycle rate was approximately 10 cycles per minute.
Mount DUT onto Rotational Life Tester.
After 25000 cycles, measure and record Torque.
Table 24 – Equipment List
Equipment ID
GT-143
PAL-7
GT-1003
RLS-46
RLS-83
RLS-84
RLS-85
RLS-64
Equipment Type
Hygrometer
Torque Force
Reader
Temperature and
Humidity Chamber
Smart Motor
Rotational Life
Smart Motor
Rotational Life
Smart Motor
Rotational Life
Smart Motor
Rotational Life
Smart Motor
Rotational Life
Model Number
MDM25
Manufacturer
Mitchell Instrument
Calibration Due Date
06/2015
BGI
Mark-10
09/2015
SM-8-3800
Thermotron
03/2015
SM3416D-PLS2
Animatics
NA
SM3416D-PLS2
Animatics
NA
SM3416D-PLS2
Animatics
NA
SM3416D-PLS2
Animatics
NA
SM3416D-PLS2
Animatics
NA
26 of 29
OPS Form #333, Rev A
11/12/12
Report SP03-128 Rev. A
Table 25 - Test Conditions
Test Condition
Units
Parameters
Quantity
Operational Mode
Test Temperature
Duration
Cycle Rate
Assemblies
85
Unpowered
85
25,000
20
°C
Cycles
RPM
11.3. ACCEPTANCE CRITERIA
The DUT must function normally before, during, and after the Rotational Life Tests. There shall be no mechanical
damage, loosening of rivets or other fastening devices. The rotational torque shall be in between 0.5 in-oz and 1.5 inoz.
11.4. TEST RESULTS
There was no evidence of any electrical, physical, or mechanical damage. DUT function normally after the Rotational
Life Tests
Table 26 – Test Results
DUT
Test
Specification
Pass
Test Location
71A30-01-1-12N-C-NI
Rotational Life
MIL-DTL-3786J
PASS
Grayhill Inc.
77P36-01-1-10N-NI
Rotational Life
MIL-DTL-3786J
PASS
Grayhill Inc.
50A36-01-1-10N-NI
Rotational Life
MIL-DTL-3786J
PASS
Grayhill Inc.
26ASD22-01-1-AJS-NI
Rotational Life
MIL-DTL-3786J
PASS
Grayhill Inc.
56A36-01-1-10N-C-NI
Rotational Life
MIL-DTL-3786J
PASS
Grayhill Inc.
50YY50812-NI
Rotational Life
MIL-DTL-3786J
PASS
Grayhill Inc.
75BP36-01-1-10N-C-NI
Rotational Life
MIL-DTL-3786J
PASS
Grayhill Inc.
Test Date
11/21/14 –
12/08/14
11/21/14 –
12/08/14
11/21/14 –
12/08/14
11/21/14 –
12/08/14
11/21/14 –
12/08/14
11/21/14 –
12/08/14
11/21/14 –
12/08/14
27 of 29
OPS Form #333, Rev A
11/12/12
Report SP03-128 Rev. A
12.0
THERMAL SHOCK
Test
Specification
Thermal Shock
LREQ-SP03-128
DUT Part Number
71A30-01-1-12N-C-NI
77P36-01-1-10N-NI
51A30-01-1-10N-NI
50A36-01-1-10N-NI
26ASD22-01-1-AJS-NI
56A36-01-1-10N-C-NI
50YY50812-NI
75BP36-01-1-10N-C-NI
75AY23083-NI
38-401-BLK
DUT Serial Number
39-43
39-43
39-43
39-43
39-43
39-43
39-43
39-43
39-43
39-43
Test Location
Test Date
Grayhill Inc.
12/04/2014 –
12/18/2014
12.1. PURPOSE
This test was performed to determine if DUT would maintain the structural integrity after being subjected to a rapid
change in temperature multiple times.
12.2. TEST SETUP DETAILS
1. Visual examination of the test item with special attention to stress areas such as corners of molded housing
and document the results.
2. Take picture of the test item.
3. Set Temperature Chamber as specified in the test plan for thermal shock.
4. Maintain the thermal shock temperature for a period as specified in the test plan.
5. Adjust Temperature Chamber to standard ambient and maintain until the test item has achieved temperature
stabilization.
6. Conduct a complete visual examination of the test item and document the results.
7. Compare these data with the initial visual examination.
Table 27 – Equipment
Equipment ID
Equipment Type
Model Number
Manufacturer
Calibration Due Date
GT- 1008
Thermal Shock
VTS-3-6-6-SC/WC
Cincinnati Sub Zero
10/2015
GT-542
Thermometer
EasyView 15
Extech
08/2015
Table 28 – Test Condition
Test Condition
Quantity
Test Duration
Operational Mode
Dwell Duration
Transfer Time
Minimum Temperature
Maximum Temperature
Units
Assemblies
Cycles
min
min
C
C
Parameters
100
1000
Unpowered
10
1
-40
85
28 of 29
OPS Form #333, Rev A
11/12/12
Report SP03-128 Rev. A
12.3. TEST SETUP PHOTOS
Figure 13 – Thermal Shock Setup
12.4.
ACCEPTANCE CRITERIA
Upon completion of the Thermal Shock Test, there shall not be any visible damage or tin whiskers to DUT.
12.5.
TEST RESULTS
There was no physical damage to the NI plated DUT after completing the test.
Table 29 – Test Results
DUT
Test
Specification
Pass
Test Location
71A30-01-1-12N-C-NI
Thermal Shock
Grayhill Custom
PASS
Grayhill Inc.
77P36-01-1-10N-NI
Thermal Shock
Grayhill Custom
PASS
Grayhill Inc.
51A30-01-1-10N-NI
Thermal Shock
Grayhill Custom
PASS
Grayhill Inc.
50A36-01-1-10N-NI
Thermal Shock
Grayhill Custom
PASS
Grayhill Inc.
26ASD22-01-1-AJS-NI
Thermal Shock
Grayhill Custom
PASS
Grayhill Inc.
56A36-01-1-10N-C-NI
Thermal Shock
Grayhill Custom
PASS
Grayhill Inc.
50YY50812-NI
Thermal Shock
Grayhill Custom
PASS
Grayhill Inc.
75BP36-01-1-10N-C-NI
Thermal Shock
Grayhill Custom
PASS
Grayhill Inc.
75AY23083-NI
Thermal Shock
Grayhill Custom
PASS
Grayhill Inc.
38-401-BLK
Thermal Shock
Grayhill Custom
PASS
Grayhill Inc.
Test Date
12/04/2014 12/18/2014
12/04/2014 12/18/2014
12/04/2014 12/18/2014
12/04/2014 12/18/2014
12/04/2014 12/18/2014
12/04/2014 12/18/2014
12/04/2014 12/18/2014
12/04/2014 12/18/2014
12/04/2014 12/18/2014
12/04/2014 12/18/2014
29 of 29
OPS Form #333, Rev A
11/12/12
Report SP03-128 Rev. A