451 Understanding MIL-STD-810G

Introduction  The United States Department of Defense's MIL-STD-810G, Environmental Engineering Considerations and Laboratory Tests, released 31 October, 2008, is the most comprehensive collection of test methods and guidance for using them available today. It covers 29 basic tests with numerous procedures for most of them. Almost all the tests can be tailored to some degree, to ensure that the testing will meet its intended goal. While written with defense contractors in mind, 810G is just as valuable for commercial enterprises. Along with test methods, it includes guidance on what team members should be involved and their roles starting with the acquisition process and going through the final test report. It also contains world climatic information to help the test team to choose the proper environments for test. As a living document, MIL-STD-810G has continued to grow and evolve since its inception in 1962, and no test lab would be complete without both a copy of the document and at least one individual who understands how to apply it.

For Whom Intended  This course is applicable to individuals from a wide range of commercial and government activities such as defense contractors, aerospace, aviation, shipbuilding, weapons systems, land vehicles and all branches of the Armed Forces. The course is intended for personnel involved with developing, applying, or reviewing environmental design and test specifications, standards and requirements. The target audience includes

  • Environmental engineering specialists
  • Environmental test laboratory personnel
  • Reliability and product assurance engineers
  • Product designers
  • Integrated Product Development Team leaders
  • Contract writers and administrators

Brief Course Description  This course provides understanding and guidance about the contents and proper application of MIL-STD-810G. The instructor follows the standard section by section, starting with the introduction and providing detailed information about each of the 29 methods, guiding the students not only in preparation of test methodologies but also in the type of equipment necessary to run each test.

For newcomers, this course will make MIL-STD-810G less mysterious and formidable. Those with some experience will gain a better understanding, to recognize mistakes and repeat successes.

Environmental design and test standards are a combination of valuable lessons learned and repetitive dogma. The ability to recognize the conflicting statements in referenced documents and obtain clarification as to which statement needs to be followed in a particular case will prove valuable to participants. This course will be presented in an interactive lecture-discussion format; lectures will be interspersed with class project work sessions to reinforce the students' understanding of the course material. Students are encouraged to introduce problems and questions from their own work for group discussions.

Diploma Programs  This course is required for TTi's Environmental Engineering Specialist (EES) and Climatic Test Specialist (CTS) Diploma programs. It may be used as an optional course for any TTi Specialist Diploma Programs.

Related Courses  An excellent follow-on course is course 405, Procedure Writing for MIL-STD-810G.

Prerequisites  This course is intended for individuals with basic familiarity with environmental test procedures and facilities.

Text  Each student will receive access to the on-line electronic course workbook, including most of the slides used in the course presentation. An initial subscription is included in the price of the course and renewals are available for an additional fee. Printed textbooks are also available for purchase.

Course Hours, Certificate and CEUs  Open courses meet seven hours per day. Upcoming presentation dates can be found on our current open course schedule. Class hours/days for on-site courses can vary from 14-35 hours over 2-5 days as requested by our clients. Upon successful course completion, each participant receives a certificate of completion and one Continuing Education Unit (CEU) for every ten class hours.

  • Part Two - Environmental Test Procedures
    • The following topics are discussed for each of the methods listed below:
      • Introduction
      • Limitations
      • History and Rationale
      • Changes
      • Effects of the Environment
      • Test Sequence
      • Procedures
      • Analysis of Results
      • Equipment Needed

Click for a printable course outline (pdf).


Course Outline

Chapter 1 - Part One: Introduction, History and Scope

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  • What is MIL-STD-810G?
  • What Came Before
  • Specifications
  • Basis for 810
  • Army-Air Force Specification 41065
  • Evolution
  • Changes from D to E
  • Changes from E to F
  • New Methods for F
  • Relationship to STANAG 4370
  • Base Documents for 4370
  • Changes from F to G
  • Popularity
  • DLA/ASSIST
  • MIL-STD-810 Version History
  • New Methods for G
  • Temperature Cycling in G
  • Updates: Who is Involved?
  • Further Improvements
  • Overview of Parts
  • A Living Document
  • Reason for Tailoring
  • History of Testing
  • Scope
  • Intent
  • History and Rationale Coverage for Each Method (H&R)

Chapter 2 - The Team; General Test Guidelines

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  • The Team
    • How They Work Together
    • Program Manager
    • Environmental Engineering Specialist
    • Environmental Engineering Design / Test Engineers & Facility Operators
    • Considerations for a Program Manager
  • Generalized Life Cycle History
    • LCEP By Mission
  • General Laboratory Test Guidelines
    • Test Sequence
    • Where to find the information
    • Interrupted Tests
    • Test Interruption Flowchart

Chapter 3 - Environmental Management and Engineering Tasks — Annex A

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  • Task 401: Environmental Engineering Management Plan (EEMP)
  • Task 402: Life Cycle Environmental Profile (LCEP)
  • Task 403: Operational Environment Documentation (OED)
  • Task 404: Environmental Issues/Criteria List (EICL)
    • Pretest Information

Chapter 4 - Annexes B, C, D Guidance for Program Management and Environmental Tailoring

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  • Annex B: Detailed Program Management Guidance

  • Annex C: Environmental Tailoring Guidelines for Environmental Engineering Specialists

    • Climatic Categories
    • Material Categories/Modes
    • Conditions Table
    • Climatic Categories
  • Annex D: Terminology for Dynamic (Mechanical) Test Methods

Chapter 5 - Part Two: Typical Format used for Environmental Test Methods; Commonly cited paragraphs from Part One

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  • Laboratory Test Methods
  • MIL-STD-810G Test Methods
  • Overall Notes on Methods
  • What Each Method Holds
  • Typical Format of Environmental Test Methods
    • References to Part One
    • Opening Note
    • 4.2.2 Environmental Engineering Tasks
    • 5.  General Laboratory Test Method Guidelines
    • 5.5 Test Sequence
    • 5.7  Pretest Information for Facility Operators
    • 5.9  Pretest Baseline Data
    • 5.10 Information During Test
    • 5.13 Post Test Data
    • 5.18 Monitoring
    • 5.11 Interrupted Tests
    • 5.8 Test Setup
    • 5.14  Environmental Effects and Failure Criteria

Chapter 6 - Method 500.5 Low Pressure (Altitude)

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Chapter 7 - Method 501.5 High Temperature

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Chapter 8 - Method 502.5 Low Temperature

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Chapter 9 - Method 503.5 Temperature Shock

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Chapter 10 - Method 504.1 Contamination by Fluids

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Chapter 11 - Method 505.5 Solar Radiation (Sunshine)

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Chapter 12 - Method 506.5 Rain

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Chapter 13 - Method 507.5 Humidity

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Chapter 14 - Method 508.6 Fungus

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Chapter 15 - Method 509.5 Salt Fog

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Chapter 16 - Method 510.5 Sand and Dust

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Chapter 17 - Method 511.5 Explosive Atmosphere

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Chapter 18 - Method 512.5 Immersion

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Chapter 19 - Method 513.6 Acceleration

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Chapter 20A - Dynamic Primer: Shock and Vibration

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  • Laws of Motion
  • Weight vs. Mass
    • System of Units
    • Common Units of Mass
    • Weight, Mass and Gravity
    • Weight, Specific Weight, Density and Specific Gravity
  • Work, Power, Energy
  • A Simple Dynamic System
    • Degrees of Freedom
    • Single-Degree-of-Freedom (SDoF)
    • Relationship between Displacement, Velocity and Acceleration
  • Vibration Considerations for Design Engineers
  • Fixture Design for Vibration and Shock Testing
    • Purpose of a Fixture
    • Basic Considerations for Fixtures
  • Quick Look vs. Detailed Analysis
  • Power Spectral Density .. PSD
  • What is Shock?
    • Causes of Shock
    • Effects, Remedies of Shock
    • Terms Used in Mechanical Shock
    • Input Pulse and Response of a Sprung Mass
    • Typical Complex Shock Pulses
    • Shock Pulse Shapes, Parameters
    • Classical Shock Pulse Shapes
  • Selecting a Test Procedure
    • Steady-State
    • Random
    • Impact Testing
    • Burst Random / Chirp
    • Shaker Testing
    • The "Light-Weight" Shock Tester
    • High-Amplitude, High-Frequency “Impact” Transient Simulators
    • Electrodynamic Shakers
    • Drop Testing Machine
    • Shock Testing Problem Areas

Chapter 20A - Dynamic Primer: Shock and Vibration (SI Units)

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Chapter 20B - Method 514.6 Vibration

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Chapter 21 - Method 515.6 Acoustic Noise

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Chapter 22 - Method 516.6 Shock

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Chapter 23 - Method 517.1 Pyroshock

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Chapter 24 - Method 518.1 Acidic Atmosphere

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Chapter 25 - Method 519.6 Gunfire Shock

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Chapter 26 - Method 520.3 Temperature, Humidity, Vibration and Shock

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Chapter 27 - Method 521.3 Icing/Freezing Rain

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Chapter 28 - Method 522.1 Ballistic Shock

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Chapter 29 - Method 523.3 Vibro-Acoustic/Temperature

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Chapter 30 - Method 524 Freeze/Thaw

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Chapter 31 - Method 525 Time Waveform Replication

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Chapter 32 - Method 526 Rail Impact

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Chapter 33 - Method 527 Multi-Exciter Testing (MET)

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Chapter 34 - Method 528 Mechanical Vibrations of Shipboard Equipment

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Chapter 35 - Part Three: World Climatic Regions— Guidance

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  • Induced Climatic Conditions
  • Types of Failures
  • Area of Occurrence of Climatic Design Types
  • Summary of Climatic Conditions and Daily Cycles of Temperature, Solar Radiation, RH
  • Climatic Considerations
  • Snow
  • Miscellaneous Extremes

Chapter 36 - Developing Life Cycle Environmental Profiles (LCEPs)

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  • Task 402: Life Cycle Environmental Profile (LCEP)
  • LCEP, Description
  • Contents of an LCEP
    • Special Considerations
  • Details to be Provided by the Acquisition Agency
  • What is a Life Cycle Environmental Profile?
  • Life Cycle Environmental Profiles as the Foundation for Test Tailoring
    • Integrating Engineering Information
    • Support for Technical Management
    • Role of the LCEP in Product Development
  • LCEP and Design Margins
  • LCEP Should be a Living Document
  • Level of Effort and Time Required
  • LCEP Development Overview
  • A Building Block Approach to Developing LCEPs
    • Step 1: Identify Product Service Use Requirements
    • Step 2: Identify Applicable Platform Types
    • Step 3: Identify Product & Platform Characteristics
    • Step 4: Characterize Logistics, Deployment, & Distribution Modes
    • Step 5: Characterize and Quantify Service Use Environments
  • Time Histories: A Starting Point for Identifying Service Environments
    • Environment Characterization

Appendices A, B and C - Excerpts from MIL-STD-810G

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  • Appendix A: METHOD 501.5, HIGH TEMPERATURE
  • Appendix B: METHOD 514.6, VIBRATION
  • Appendix C: METHOD 516.6, SHOCK

Course Review and Summary

Award of Certificates for Successful Course Completion

 

Printable (.pdf) version of Course Outline no. 451