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Cost Effective, Reliable Service Life Extension Testing of Ordnance Devices


OBJECTIVE: Assess viable approaches to cost effective, reliable service life extension testing of ordnance devices. Investigate the various approaches used in industry to conduct service life extension testing and develop reliable testing solutions. DESCRIPTION: The Missile Defense Agency is seeking technologies to support its Stockpile Reliability Program. Interceptors must function successfully after being exposed to lengthy periods of environmental exposure. Interceptor"one-shot"devices cannot be exposed to any"health monitoring, Built-In-Tests"like electronic components to ensure readiness, making other means of verification critical. Service Life Extension (SLE) testing on units from the same lot of ordnance devices is typically used to assess readiness of units installed on interceptors. However, various approaches are used for SLE testing, with some including high temperature accelerated aging and some without. Further, somewhat arbitrary SLE times are used for different testing and ordnance device components throughout industry. Thus, a focused effort to develop a technically sound, cost-effective means to grant SLE is desired. Reliability of ordnance devices is critical to Interceptor mission success, thus warranting development of a rigorous, cost-effective approach to this testing. Although the specific component design may have satisfied all material compatibility tests and analysis, subtle lot-to-lot manufacturing and processing variations may have adverse effects on a particular production lot of units. While recommended SLE testing approaches for Lots are defined Military and AIAA Standards, they are based on assumptions of linear relationships between test duration and life extension, test quantities required for life extension, and other assumptions. Proposals should address a systematic, technically sound approach to developing a cost-effective SLE approach across various ordnance device components. PHASE I: Development of a thorough assessment of best practices used in industry for Service Life Extension of ordnance devices, recommend a cost-effective approach, and develop analysis tools to facility Service Life assessment. PHASE II: Based on the results/findings of Phase I, this phase would proto-type the process and analysis tools with potential use of Government Furnished Equipment (GFE) for validation over an extended period. Phase III: Verification of overall approach and finalize the methodology. The proposed methodology developed under this effort should advance the state-of-the-art in cost effective service life extension testing of ordnance devices to enhance predicted and demonstrated reliability. This phase may include refinement of analytical tools for SLE assessment, and implementation of the testing process as an MDA Standard on various Interceptor Programs. Further, this phase should include demonstration of commercial scalability of the technology for use in commercial product development, reliability assessment and service life estimates. DUAL USE/COMMERCIALIZATION POTENTIAL: The proposer should demonstrate the commercial prospects of this technology through utilization of the methodology on development of complex commercial product. The envisioned solutions to this effort will have applications in both military and non-military markets to include commercial aircraft and satellite markets, and others. The military applications include various missile systems, Satellites, and UAVs. REFERENCES: 1)"HALT, HASS & HASA Explained, Accelerated Reliability Techniques, Revised Edition"by Harry W.McLean, ASQ ISBN 978-0-87389-766-2. 2)"Management & Technical Guidelines for the ESS Process"IEST-RP-PR001.1, published by the Institute of Environmental Sciences and Technology. 3)"Accelerated Testing"a Practitioners Guide to Accelerated and Reliability Testing, by Bryan Dodson and Harry Schwab. 4)"Accelerated Reliability Engineering", by Gregg Hobbs, ISBN 0-615-12833-5. 5) 6) 7)"Ballistic Missile Defense Review,"Office of the U. S. Secretary of Defense, February 2010. Available via internet at 8) MIL-STD-1512, MILITARY STANDARD: ELECTROEXPLOSIVE SUBSYSTEMS 9) MIL-STD-1576, MILITARY STANDARD: ELECTROEXPLOSIVE SUBSYSTEM SAFETY REQUIREMENTS AND TEST METHODS FOR SPACE SYSTEMS (31 JUL 1984) 10) AIAA-S-113-2005, Criteria for Explosive Systems and Devices on Space and Launch Vehicles (Nov. 2005)
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