SIST EN 16603-32-01:2014
(Main)Space engineering - Fracture control
Space engineering - Fracture control
This ECSS Engineering Standard specifies the fracture control requirements to be imposed on space segments of space systems and their related GSE. The fracture control programme is applicable for space systems and related GSE when required by ECSS-Q-ST-40 or by the NASA document NST 1700.7, incl. ISS addendum. The requirements contained in this Standard, when implemented, also satisfy the fracture control requirements applicable to the NASA STS and ISS as specified in the NASA document NSTS 1700.7 (incl. the ISS Addendum). The NASA nomenclature differs in some cases from that used by ECSS. When STS/ISS-specific requirements and nomenclature are included, they are identified as such. This standard may be tailored for the specific characteristic and constrains of a space project in conformance with ECSS-S-ST-00.
Raumfahrttechnik - Überwachung des Rissfortschritts
Ingénierie spatiale - Maîtrise de la rupture
Vesoljska tehnika - Kontrola razpok
Ta tehnični standard ECSS določa zahteve za kontrolo razpok, ki se izvaja na vesoljskih delih vesoljskih sistemov in njihovih povezanih GSE. Program za kontrolo razpok velja za vesoljske sisteme in z njimi povezane GSE, če to zahteva standard ECSS-Q-ST-40 ali Nasin dokument NST 1700.7, vklj. z dodatkom ISS. Ko se izvajajo zahteve iz tega standarda, te izpolnjujejo tudi zahteve za kontrolo razpok, ki veljajo za NASA STS in ISS, kot je določeno v Nasinem dokumentu NSTS 1700.7 (vklj. z dodatkom ISS). Nasina nomenklatura se v nekaterih primerih razlikuje od tiste, uporabljene pri ECSS. Ko so vključene zahteve, določene s STS/ISS, in nomenklatura, so prepoznane kot take. Ta standard se lahko prilagodi posameznim lastnostim in omejitvam vesoljskega projekta v skladu s standardom ECSS-S-ST-00.
General Information
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Standards Content (Sample)
SLOVENSKI STANDARD
SIST EN 16603-32-01:2014
01-november-2014
1DGRPHãþD
SIST EN 14165:2004
Vesoljska tehnika - Kontrola razpok
Space engineering - Fracture control
Raumfahrttechnik - Überwachung des Rissfortschritts
Ingénierie spatiale - Maîtrise de la rupture
Ta slovenski standard je istoveten z: EN 16603-32-01:2014
ICS:
49.140 Vesoljski sistemi in operacije Space systems and
operations
SIST EN 16603-32-01:2014 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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SIST EN 16603-32-01:2014
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SIST EN 16603-32-01:2014
EUROPEAN STANDARD
EN 16603-32-01
NORME EUROPÉENNE
EUROPÄISCHE NORM
August 2014
ICS 49.140 Supersedes EN 14165:2004
English version
Space engineering - Fracture control
Ingénierie spatiale - Maîtrise de la rupture Raumfahrttechnik - Überwachung des Rissfortschritts
This European Standard was approved by CEN on 10 February 2014.
CEN and CENELEC members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving
this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning
such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN and CENELEC
member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN and CENELEC member into its own language and notified to the CEN-CENELEC Management Centre
has the same status as the official versions.
CEN and CENELEC members are the national standards bodies and national electrotechnical committees of Austria, Belgium, Bulgaria,
Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece,
Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia,
Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom.
CEN-CENELEC Management Centre:
Avenue Marnix 17, B-1000 Brussels
© 2014 CEN/CENELEC All rights of exploitation in any form and by any means reserved Ref. No. EN 16603-32-01:2014 E
worldwide for CEN national Members and for CENELEC
Members.
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EN 16603-32-01:2014 (E)
Table of contents
Foreword . 6
1 Scope . 7
2 Normative references . 8
3 Terms, definitions and abbreviated terms . 10
3.1 Terms from other standards . 10
3.2 Terms specific to the present standard . 11
3.3 Abbreviated terms. 17
4 Principles . 19
5 Fracture control programme . 21
5.1 General . 21
5.2 Fracture control plan . 21
5.3 Reviews . 22
5.3.1 General . 22
5.3.2 Safety and project reviews . 23
6 Identification and evaluation of PFCI . 25
6.1 Identification of PFCIs . 25
6.2 Evaluation of PFCIs . 26
6.2.1 Damage tolerance . 26
6.2.2 Fracture critical item classification . 28
6.3 Compliance procedures . 28
6.3.1 General . 28
6.3.2 Safe life items . 28
6.3.3 Fail-safe items . 29
6.3.4 Contained items . 30
6.3.5 Low-risk fracture items . 31
6.4 Documentation requirements . 36
6.4.1 Fracture control plan . 36
6.4.2 Lists . 36
6.4.3 Analysis and test documents . 36
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6.4.4 Fracture control summary report . 36
7 Fracture mechanics analysis . 38
7.1 General . 38
7.2 Analytical life prediction . 39
7.2.1 Identification of all load events . 39
7.2.2 Identification of the most critical location and orientation of the crack . 39
7.2.3 Derivation of stresses for the critical location. 40
7.2.4 Derivation of the stress spectrum . 40
7.2.5 Derivation of material data . 41
7.2.6 Identification of the initial crack size and shape . 41
7.2.7 Identification of an applicable stress intensity factor solution . 42
7.2.8 Performance of crack growth calculations . 43
7.3 Critical crack-size calculation . 43
8 Special requirements . 45
8.1 Introduction . 45
8.2 Pressurized hardware . 45
8.2.1 General . 45
8.2.2 Pressure vessels . 45
8.2.3 Pressurized structures . 48
8.2.4 Pressure components . 48
8.2.5 Low risk sealed containers . 49
8.2.6 Hazardous fluid containers . 49
8.3 Welds . 50
8.3.1 Nomenclature . 50
8.3.2 Safe life analysis of welds . 50
8.4 Composite, bonded and sandwich structures . 51
8.4.1 General . 51
8.4.2 Defect assessment. 51
8.4.3 Damage threat assessment . 53
8.4.4 Compliance procedures . 54
8.5 Non-metallic items other than composite, bonded, sandwich and glass items . 57
8.6 Rotating machinery . 58
8.7 Glass components . 58
8.8 Fasteners . 59
9 Material selection . 61
10 Quality assurance and Inspection . 62
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10.1 Overview . 62
10.2 Nonconformances. 62
10.3 Inspection of PFCI . 62
10.3.1 General . 62
10.3.2 Inspection of raw material . 63
10.3.3 Inspection of safe life finished items . 64
10.4 Non-destructive inspection of metallic materials . 65
10.4.1 General . 65
10.4.2 NDI categories versus initial crack size . 65
10.4.3 Inspection procedure requirements for standard NDI . 69
10.5 NDI for composites, bonded and sandwich parts . 72
10.5.1 General . 72
10.5.2 Inspection requirements . 73
10.6 Traceability . 74
10.6.1 General . 74
10.6.2 Requirements . 75
10.7 Detected defects . 75
10.7.1 General . 75
10.7.2 Acceptability verification . 76
10.7.3 Improved probability of detection . 77
11 Reduced fracture control programme . 78
11.1 Applicability. 78
11.2 Requirements . 78
11.2.1 General . 78
11.2.2 Modifications . 78
Annex A (informative) The ESACRACK software package . 80
Annex B (informative) References . 81
Bibliography . 82
Figures
Figure 5-1: Identification of PFCI . 22
Figure 6-1: Fracture control evaluation procedures . 27
Figure 6-2: Safe life item evaluation procedure for metallic materials . 33
Figure 6-3: Safe life item evaluation procedure for composite, bonded and sandwich
items . 34
Figure 6-4: Evaluation procedure for fail-safe items . 35
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Figure 8-1: Procedure for metallic pressure vessel and metallic liner evaluation . 47
Figure 10-1: Initial crack geometries for parts without holes . 71
Figure 10-2: Initial crack geometries for parts with holes . 72
Figure 10-3: Initial crack geometries for cylindrical parts . 72
Tables
Table 8-1: Factor on stress for sustained crack growth analysis of glass items . 59
Table 10-1: Initial crack size summary, standard NDI . 68
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Foreword
This document (EN 16603-32-01:2014) has been prepared by Technical
Committee CEN/CLC/TC 5 “Space”, the secretariat of which is held by DIN.
This standard (EN 16603-32-01:2014) originates from ECSS-E-ST-32-01C Rev. 1.
This European Standard shall be given the status of a national standard, either
by publication of an identical text or by endorsement, at the latest by February
2015, and conflicting national standards shall be withdrawn at the latest by
February 2015.
Attention is drawn to the possibility that some of the elements of this document
may be the subject of patent rights. CEN [and/or CENELEC] shall not be held
responsible for identifying any or all such patent rights.
This document supersedes EN 14165:2004.
This document has been developed to cover specifically space systems and has
therefore precedence over any EN covering the same scope but with a wider
domain of applicability (e.g. : aerospace).
According to the CEN-CENELEC Internal Regulations, the national standards
organizations of the following countries are bound to implement this European
Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic,
Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France,
Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania,
Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United
Kingdom.
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1
Scope
This ECSS Engineering Standard specifies the fracture control requirements to
be imposed on space segments of space systems and their related GSE.
The fracture control programme is applicable for space systems and related
GSE when required by ECSS-Q-ST-40 or by the NASA document NST 1700.7,
incl. ISS addendum.
The requirements contained in this Standard, when implemented, also satisfy
the fracture control requirements applicable to the NASA STS and ISS as
specified in the NASA document NSTS 1700.7 (incl. the ISS Addendum).
The NASA nomenclature differs in some cases from that used by ECSS. When
STS/ISS-specific requirements and nomenclature are included, they are
identified as such.
This standard may be tailored for the specific characteristic and constrains of a
space project in conformance with ECSS-S-ST-00.
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2
Normative references
The following normative documents contain provisions which, through
reference in this text, constitute provisions of this ECSS Standard. For dated
references, subsequent amendments to, or revision of any of these publications
do not apply, However, parties to agreements based on this ECSS Standard are
encouraged to investigate the possibility of applying the more recent editions of
the normative documents indicated below. For undated references, the latest
edition of the publication referred to applies.
EN reference Reference in text Title
EN 16601-00-01 ECSS-S-ST-00-01 ECSS system – Glossary of terms
EN 16603-32 ECSS-E-ST-32 Space engineering – Structural
EN 16603-32-02 ECSS-E-ST-32-02 Space engineering – Structural design and
verification of pressurized hardware
EN 16602-20 ECSS-Q-ST-20 Space product assurance – Quality assurance
EN 16602-40 ECSS-Q-ST-40 Space product assurance – Safety
EN 16602-70 ECSS-Q-ST-70 Space product assurance – Materials, mechanical
parts and processes
EN 16602-70-36 ECSS-Q-ST-70-36 Space product assurance – Material selection for
controlling stress-corrosion cracking
EN 16602-70-45 ECSS-Q-ST-70-45 Space product assurance – Mechanical testing of
metallic materials
ASTM E 164 Standard Practice for Ultrasonic Contact Examination
of Weldments
ASTM E 426 Standard Practice for Electromagnetic (Eddy-
Current) Examination of Seamless and Welded
Tubular Products, Austenitic Stainless Steel and
Similar Alloys
ASTM E 1417 Standard Practice for Liquid Penetrant Examination
ASTM E 1444 Standard Practice for Magnetic Particle Examination
ASTM E 1742 Standard Practice for Radiographic Examination
DOT/FAA/AR- Metallic Materials Properties Development and
MMPDS Standardization (MMPDS) (former MIL-HDBK-5)
EN 4179 Aerospace – Qualification and Authorization of
Personnel for Non-destructive Testing
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EN reference Reference in text Title
EN ISO 6520-1 Welding and allied processes – Classification of
geometric imperfections in metallic materials – Part
1: Fusion welding
ISO 17659 Welding – Multilingual terms for welded joints with
illustrations
MIL-HDBK-6870 Inspection program requirements, nondestructive,
for aircraft and missile materials and parts
NAS-410 Nondestructive testing personnel qualification and
certification
NSTS 1700.7 Safety Policy and Requirements For Payloads Using
the Space Transportation System (STS)
NSTS 1700.7 ISS Safety Policy and Requirements For Payloads Using
Addendum the International Space Station
SAE AMS-STD-2154 Process for inspection, ultrasonic, wrought metals
SAE AMS 2644 Inspection Material, Penetrant
NSTS/ISS 13830 Payload Safety Review and Data Submittal
Requirements For Payloads Using the Space Shuttle
& International Space Station
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3
Terms, definitions and abbreviated terms
3.1 Terms from other standards
For the purpose of this Standard, the terms and definitions from ECSS-ST-00-01
apply, in particular for the following terms:
customer
NOTE In this standard, the customer is considered to
represent the responsible fracture control or
safety authority.
For the purpose of this Standard, the following term and definition from ECSS-
E-ST-10-03 apply:
proof test
For the purpose of this Standard, the following terms and definitions from
ECSS-E-ST-32 apply:
flaw
NOTE The term defect is used as a synonymous.
maximum design pressure (MDP)
service life
For the purpose of this Standard, the following term and definition from ECSS-
E-ST-32-02 apply:
burst pressure
hazardous fluid container
leak before burst, LBB
pressure component
pressure vessel
pressurized structure
sealed container
special pressurized equipment
visual damage threshold, VDT
NOTE 1 For typical implementation of thin-walled
composite structure, the VDT is sometimes more
specifically defined as the impact energy of an
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impactor with a hemi-spherical tip of 16 mm
diameter resulting in 0,3 mm or more remaining
surface deflection, after sufficiently long time to
cover potential evolution of the indentation over
time (due to e.g. wet ageing, fatigue loading,
viscoelasticity of the resin) between impact and
inspection.
NOTE 2 It can be time consuming to determine the VDT
based on remaining surface deflection of 0,3 mm
(see NOTE 1) after a sufficiently long time.
Therefore, tests which cause mechanical damage
corresponding to a deflection of at least 1 mm,
immediately after impact, are sometimes used to
determine the VDT.
For the purpose of this Standard, the following term and definition from ECSS-
Q-ST-40 apply:
catastrophic hazard
critical hazard
3.2 Terms specific to the present standard
3.2.1 aggressive environment
combination of liquid or gaseous media and temperature that alters static or
fatigue crack-growth characteristics from normal behaviour associated with an
ambient temperature and laboratory air environment
3.2.2 analytical life
life evaluated analytically by crack-growth analysis or fatigue analysis
3.2.3 catastrophic hazard
see ECSS-Q-ST-40B
3.2.4 catastrophic hazard
potential risk situation that can result in a
disabling or fatal personnel injury, loss of the NASA orbiter, ISS, ground
facilities, or STS/ISS equipment
[NSTS 1700.7 incl. ISS Addendum, paragraph 302]
3.2.5 close visual inspection
close proximity, intense visual examination of the internal and external surfaces
of a structure, including structural details or locations, for indications of impact
damage, flaws, and other surface defects
NOTE The inspection capability is evaluated by the
surface deflection measurement (impact depth).
The close visual inspection is considered to
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detect reliably a deflection larger than the
visual damage threshold (VDT).
3.2.6 containment
damage tolerance design principle that, if a part fails, prevents the propagation
of failure effects beyond the container boundaries
NOTE 1 A contained part is not considered PFCI, unless its
release can cause a hazard inside the container.
The container is a PFCI, and its structural integrity
after impact is verified as part of fracture control
activities.
NOTE 2 In this standard, the term containment in most
cases also covers items which are e.g. restrained by
a tether to prevent the occurrence of hazardous
events due to failure of the item.
3.2.7 crack-like defect
defect that has the same mechanical behaviour as a crack
NOTE 1 “Crack” and “crack-like defect” are considered
synonymous in this standard.
NOTE 2 Crack-like defects can, for example, be initiated
during material production, fabrication or testing
or developed during the service life of a
component.
NOTE 3 The term “crack-like defect” can include:
• For metallic materials flaws, inclusions,
pores and other similar defects.
• For non-metallic materials, debonding,
broken fibres, delamination, impact damage
and other specific defects depending on the
material.
3.2.8 crack aspect ratio, a/c
ratio of crack depth to half crack length
3.2.9 crack aspect ratio, a/c
ratio of crack depth to crack length
3.2.10 crack growth rate
rate of change of crack dimension with respect to the number of load cycles or
time
NOTE For example da/dN, dc/dN, da/dt and dc/dt.
3.2.11 crack growth retardation
reduction of crack-growth rate due to overloading of the cracked structural
member
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3.2.12 critical crack size
the crack size at which the structure fails under the maximum specified load
NOTE The maximum specified load is in many cases
the limit load, but sometimes higher than the
limit load (e.g. for detected defects, composites
and glass items)
3.2.13 critical initial defect, CID
critical (i.e., maximum) initial crack size for which the structure can survive the
specified number of lifetimes.
3.2.14 critical stress-intensity factor
value of the stress-intensity factor at the tip of a crack at which unstable
propagation of the crack occurs
NOTE 1 This value is also called the fracture toughness.
The parameter KIC is the fracture toughness for
plane strain and is an inherent property of the
material. For stress conditions other than plane
strain, the fracture toughness is denoted KC. In
fracture mechanics analyses, failure is assumed to
be imminent when the applied stress-intensity
factor is equal to or exceeds its critical value, i.e.
the fracture toughness. See 3.2.25.
NOTE 2 The term fracture toughness is used as a
synonymous.
3.2.15 cyclic loading
fluctuating load (or pressure) characterized by relative degrees of loading and
unloading of a structure
NOTE For example, loads due to transient responses,
vibro-acoustic excitation, flutter, pressure
cycling and oscillating or reciprocating
mechanical equipment.
3.2.16 damage tolerance threshold strain
maximum strain level below which damage
compatible with the sizes established by non-destructive inspection (NDI),
special visual inspection, the damage threat assessment, or the minimum sizes
6 8
imposed does not grow in 10 cycles (10 cycles for rotating hardware) at a load
ratio appropriate to the application
NOTE 1 Strain level is the maximum absolute value of
strain in a load cycle.
NOTE 2 The damage tolerance threshold strain is a
function of the material type and lay-up and is
determined from test data in the design
environment to the applicable or worst type and
orientation of strain and flaw for a particular
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design and flaw size (e.g. the size determined by
the VDT).
3.2.17 damage tolerant
characteristic of a structure for which the amount of general degradation or the
size and distribution of local defects expected during operation, or both, do not
lead to structural degradation below specified performance
3.2.18 defect
see ‘flaw’ (3.1)
3.2.19 detected defect
defect known to exist in the hardware
3.2.20 fail-safe
damage-tolerance design principle, where a structure has
redundancy to ensure that failure of one structural element does not cause
general failure of the entire structure during the remaining lifetime
3.2.21 fastener
item that joins other structural items and transfers loads from one to the other
across a joint
3.2.22 fatigue
cumulative irreversible damage incurred by cyclic application of loads to
materials and structures
NOTE 1 Fatigue can initiate and extend cracks, which
degrade the strength of materials and structures.
NOTE 2 Examples of factors influencing fatigue behaviour
of the material are the environment, surface
condition and part dimensions
3.2.23 fracture critical item
item classified as such
3.2.24 fracture limited life item
hardware item that requires periodic re-inspection or replacement to be in
conformance with fracture control requirements
3.2.25 fracture toughness
materials’ resistance to the unstable propagation of a crack
NOTE See critical stress intensity factor, 3.2.14.
3.2.26 initial crack size
maximum crack size, as defined by non-destructive inspection, for performing a
fracture control evaluation
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3.2.27 joint
element that connects other structural elements and transfers loads from one to
the other across a connection
3.2.28 load enhancement facto
...
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