ECSS-Q-ST-70-45C

31 July 2008

Space product assurance

Mechanical testing of metallic materials

ECSS Secretariat ESA-ESTEC Requirements & Standards Division Noordwijk, The Netherlands

ECSSQST7045C 31July2008

Foreword This Standard is one of the series of ECSS Standards intended to be applied together for the management, engineering and product assurance in space projects and applications. ECSS is a cooperative effort of the European Space Agency, national space agencies and European industry associations for the purpose of developing and maintaining common standards. Requirements in this Standard are defined in terms of what shall be accomplished, rather than in terms of how to organize and perform the necessary work. This allows existing organizational structures and methods to be applied where they are effective, and for the structures and methods to evolve as necessary without rewritingthestandards. This Standard has been prepared by the ECSS Executive Secretariat, endorsed by the Document and DisciplineFocalpoints,andapprovedbytheECSSTechnicalAuthority.

Disclaimer ECSSdoesnotprovideanywarrantywhatsoever,whetherexpressed,implied,orstatutory,including, butnotlimitedto,anywarrantyofmerchantabilityorfitnessforaparticularpurposeoranywarranty that the contents of the item are errorfree. In no respect shall ECSS incur any liability for any damages, including, but not limited to, direct, indirect, special, or consequential damages arising out of, resulting from, or in any way connected to the use of this Standard, whether or not based upon warranty, business agreement, tort, or otherwise; whether or not injury was sustained by persons or property or otherwise; and whether or not loss was sustained from, or arose out of, the results of, the item,oranyservicesthatmaybeprovidedbyECSS.

Publishedby:

Copyright:

ESARequirementsandStandardsDivision ESTEC, P.O. Box 299, 2200 AG Noordwijk The Netherlands 2008 by the European Space Agency for the members of ECSS

ECSSQST7045C 31July2008

Change log

ECSSQ7045A 7April2006 ECSSQ7045B ECSSQST7045C 31July2008

TransformationofESAPSS01745intoECSSformat

Neverissued RedraftingofECSSQ7045AaccordingtonewECSStemplateandECSS draftingrules. Inparticular: IntroductionofSection4Principlestocollectdescriptivetext, containedformerlyinrequirementssection. CollectionofallrequirementsinoneSection5Requirements DeletionofAnnexA(informative)andmovingofrequirementsinto bodytext. Revisionofnormativeannexes(nowAnnexA,BandC)accordingto newtemplateandadaptationoforderofappearance(AnnexA:DRDfor testrequest,AnnexB:DRDfortestproposal,AnnexC:DRDfortest report) EditingoftexttocomplywithECSSdraftingrules

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Table of contents

Change log .................................................................................................................3 1 Scope.......................................................................................................................7 2 Normative references .............................................................................................8 3 Terms, definitions and abbreviated terms..........................................................10
3.1 3.2 3.3 3.4 Terms defined in other standards............................................................................. 10 Terms specific to the present standard .................................................................... 10 Abbreviated terms .................................................................................................... 11 Symbols.................................................................................................................... 12

4 Principles ..............................................................................................................13
4.1 4.2 4.3 Overview .................................................................................................................. 13 Tensile test ............................................................................................................... 13 Fracture toughness test............................................................................................ 13 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.4 4.4.1 4.4.2 4.4.3 4.5 4.5.1 4.5.2 4.6 4.7 Overview..................................................................................................... 13 Determination of fracture toughness using the KIc test method.................. 13 Determination of fracture toughness using the JIc test method .................. 14 Characterization of fracture toughness using the R-curve test method...... 14 Characterization of fracture toughness using the CTOD test method ........ 14 General....................................................................................................... 15 Force controlled constant amplitude axial fatigue test................................ 15 Strain-controlled fatigue test....................................................................... 15 Stable crack growth rate............................................................................. 15 Crack propagation threshold ...................................................................... 16

Fatigue test............................................................................................................... 15

Fatigue crack propagation test ................................................................................. 15

Fracture and fatigue test in special environment...................................................... 16 Stress corrosion cracking test .................................................................................. 16 4.7.1 Overview..................................................................................................... 16

ECSSQST7045C 31July2008 4.7.2 4.7.3 4.8 4.9 Stress corrosion cracking test using smooth specimens............................ 16 Stress corrosion cracking test using pre-cracked specimens..................... 17

Creep test................................................................................................................. 17 Test results presentation .......................................................................................... 17

5 Requirements........................................................................................................18
5.1 5.2 Customer agreement................................................................................................ 18 Tensile testing .......................................................................................................... 18 5.2.1 5.2.2 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.4 5.4.1 5.4.2 5.5 5.5.1 5.5.2 5.6 5.7 General....................................................................................................... 18 Tensile testing of weldments ...................................................................... 18 KIc test method............................................................................................ 19 JIc test method ............................................................................................ 19 R-curve test method ................................................................................... 19 CTOD test method...................................................................................... 19 Force controlled constant amplitude axial fatigue test................................ 20 Strain-controlled fatigue test....................................................................... 20 Determination of fatigue crack growth rate................................................. 21 Determination of a fatigue crack propagation threshold ............................. 21

Fracture toughness test............................................................................................ 19

Fatigue test............................................................................................................... 20

Fatigue crack propagation test ................................................................................. 21

Fracture and fatigue tests in special environments .................................................. 22 Stress corrosion cracking test .................................................................................. 22 5.7.1 5.7.2 Stress corrosion cracking test using smooth specimens............................ 22 Stress corrosion cracking test using pre-cracked specimens..................... 22

5.8 5.9

Creep test................................................................................................................. 22 Evaluation of test results .......................................................................................... 22

5.10 Storage..................................................................................................................... 23 5.11 Reporting.................................................................................................................. 23 5.12 Quality assurance..................................................................................................... 23 5.12.1 5.12.2 5.12.3 5.12.4 5.12.5 General....................................................................................................... 23 Calibration .................................................................................................. 23 Quality control of raw materials .................................................................. 24 Nonconformance ........................................................................................ 24 Traceability and records ............................................................................. 24

Annex A (normative) Request for mechanical testing of materials DRD.........25 Annex B (normative) Proposal for mechanical testing of materials DRD........27

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Annex C (normative) Report of mechanical testing of materials DRD.............29 Annex D (informative) References .........................................................................32 Bibliography.............................................................................................................33

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1 Scope

This Standard specifies requirements for mechanical testing of metallic materialstobeusedinthefabricationofspacecrafthardware. This Standard establishes the requirements for most relevant test methods carried out to assess the tensile, fatigue and fracture properties of metallic materials. Itdoes not give a completereview of all the existing test methods for theevaluationofmechanicalpropertiesofmetallicmaterials. Furthermore, this Standard specifies requirements for the evaluation, presentationandreportingoftestresults. This standard may be tailored for the specific characteristic and constrains of a spaceprojectinconformancewithECSSSST00.

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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 encouragedtoinvestigatethepossibilityofapplyingthemorerecenteditionsof the normative documents indicated below. For undated references, the latest editionofthepublicationreferredtoapplies. ECSSSST0001 ECSSQST1009 ECSSQST70 ECSSQST7037 ECSSQST7046 ASTME139 ASTME399 ASTME466 ECSSsystemGlossaryofterms Nonconformancecontrolsystem SpaceproductassuranceMaterials,mechanical partsandprocesses SpaceproductassuranceDeterminationofthe susceptibilityofmetalstostresscorrosioncracking SpaceproductassuranceRequirementsfor manufacturingandprocurementofthreadedfasteners Standardtestmethodsforconductingcreep,creep rupture,andstressrupturetestsofmetallicmaterials Standardtestmethodforplanestrainfracture toughnessofmetallicmaterials Standardpracticeforconducingforcecontrolled constantamplitudeaxialfatiguetestsofmetallic materials StandardpracticeforRcurvedetermination Standardpracticeforstraincontrolledfatiguetesting Standardtestmethodformeasurementoffatigue crackgrowthrates Standardpracticeforstatisticalanalysisoflinearor linarizedstresslife(SN)andstrainlife(eN)fatigue data Standardtestmethodforcracktipopeningdisplace ment(CTOD)fracturetoughnessmeasurement Standardtestmethodformeasurementoffracture

ASTME561 ASTME606 ASTME647 ASTME739

ASTME1290 ASTME1820

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toughness EN100021 EN100022 MetallicmaterialsTensiletestingPart1:Method oftestatambienttemperature MetallicmaterialsTensiletestingPart2: Verificationoftheforcemeasuringsystemofthe tensiletestingmachines MetallicmaterialsTensiletestingPart4: Verificationoftheextensometersusedinuniaxial testing Fracturetoughness(KIc)valuesofsomealuminium alloys CorrosionofmetalsandalloysStresscorrosion testingPart6:Preparationanduseofprecracked specimensfortestsunderconstantloadorconstant displacement

EN100024

ESDU96013:1996 ISO75396:2003

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3 Terms, definitions and abbreviated terms

3.1

Terms defined in other standards

For the purpose of this Standard, the terms and definitions from ECSSSST0001andECSSQST70apply.

3.2

Terms specific to the present standard

3.2.1 crack tip plastic zone
plasticallydeformedregioninamaterialadjacenttoacracktip

3.2.2

creep

timedependentincreaseinstraininamaterialresultingfromforce

3.2.3

damage tolerance

in a material or structure, the capability to withstand stresses or loads in the presenceofdefects

3.2.4

failure

conditiongenerally causedby break or collapse so that astructuralelement can nolongerfulfilitspurpose

3.2.5

fatigue

in a material, the failure phenomenon which results from repeated fluctuation ofstress

3.2.6

fracture toughness

inherentresistanceofamaterialinthepresenceofacracklikedefect

3.2.7

finite life range

liferange,inwhichalltestpiecesbeforeapredeterminednumberofcyclesfail

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ECSSQST7045C 31July2008 3.2.8 mechanical properties

those properties of a material that are associated with elastic and inelastic reaction when force is applied, or that involve the relationship between stress andstrain

3.2.9

mechanical testing

determinationofmechanicalproperties

3.2.10

raw material

materialfromwhichspecimensaremanufactured

3.2.11

specimen

representative fraction of material tested or analysed in order to determine mechanicalproperties

3.2.12

transition range

predetermined number of cycles of stress cycles (typically 5 x 106 to 5 x 107 cycles),wherefailureaswellasnonfailureoccur.

3.2.13

threaded fastener

device composed by a cylindrical screwed bar provided with a head and a metal collar, screwed internally, to fit the cylindrical bar that is to hold parts firmlytogetherinanassembly

3.2.14

weld heat affected zone (HAZ)

portion of material in a welded joint whose microstructure and physical propertiesareaffectedbytheheatinputduringwelding

3.3

Abbreviated terms
For the purpose of this Standard, the abbreviated terms from ECSSSST0001 andthefollowingapply:

Abbreviation ASTM CEN CTOD ESDU HAZ ISO NCR NDI RMC

Meaning
AmericanSocietyforTestingandMaterials EuropeanCommitteeforStandardization cracktipopeningdisplacement engineeringsciencesdataunit heataffectedzone InternationalOrganizationforStandardization nonconformancereport nondestructiveinspection rawmaterialcertificate

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3.4

Symbols
Symbol C(T) J JIc K KIc Kmax ModeI R Rsx M(T) da/dn K Kth KISCC Meaning
compacttensionspecimen Jintegral Jintegralplanestrainfracturetoughness stressintensityfactor stressintensityplanestrainfracturetoughness maximumstressintensityfactor openingmodeofloading stressratio specimenstressratio middletensionspecimen crackgrowthrate stressintensityfactorrange fatiguecrackpropagationthreshold thresholdstressintensityfactorforsusceptibility tostresscorrosioncracking

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4 Principles

4.1

Overview
This Standard specifies requirements to conduct tests in order to characterize mechanical behaviour and properties of metallic materials. Selection criteria of mechanical tests are based on the significance and use of each specified test method. Test methods, which are covered in this Standard, are characterized in thefollowingparagraphs.

4.2

Tensile test
Tensile tests provide information on the strength and ductility of materials under uniaxial tensile stresses. Test results can be used in comparing materials, alloy development, design and quality control. The test method covers the tension testing of metallic materials in any form at room temperature, and specifically the methods determine yield strength, yield point elongation, tensilestrength,elongationandreductionofarea.

4.3

Fracture toughness test

4.3.1 Overview

Thistestreferstomethodstodeterminefracturetoughnessofmetallicmaterials usingthefollowingparameters:stressintensityfactor(K),Jintegral(J),Rcurve and crack tip opening displacement (CTOD). The fracture toughness determined in accordance with this method is for opening mode (ModeI) of loading.

4.3.2

Determination of fracture toughness using the KIc test method

This method provides the measurement of crackextension resistance at the start of a crack extension for slow rates of loading and when the cracktip

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plastic zone is small compared to both the crack size and to the specimen dimensioninthedirectionoftheconstraint. The method covers the determination of linear elastic planestrain fracture toughness (KIc) of metallic materials by tests using a variety of fatigue precrackedspecimens.

4.3.3

Determination of fracture toughness using the JIc test method

This method provides the measurement of crackextension resistance near the onset of stable crack extension for slow rates of loading and substantial plastic deformation. The method covers the determination of the Jintegral planestrain fracture toughness(JIc)ofmetallicmaterials.

4.3.4

Characterization of fracture toughness using the R-curve test method

This method provides a characterization of the resistance to fracture of metallic materials during incremental slow stable crack extension and result from growth of the plastic zone as the crack extends from a sharp notch. Materials that can be tested for Rcurve development are not limited by strength, thickness, ortoughness provided that specimens areof sufficient size to remain predominantlyelastic. The method covers the determination of resistance to fracturing of metallic materials by Rcurves obtained by testing compact tension specimens C(T) or middletensionspecimensM(T).

4.3.5

Characterization of fracture toughness using the CTOD test method

This test method provides a characterization of the fracture toughness of metallicmaterialsandisusedformaterialsthatexhibitachangefromductileto brittle behaviour with decreasing temperature. This method is also used to characterize the toughness of materials for which the properties and thickness of interest preclude the determination of KIc fracture toughness in accordance withASTME399. The specimen dimensions can affect the values of CTOD. For this reason specimensofsamedimensionsareusedwhencomparingtestresults. The method covers the determination of critical crack tip opening displacement (CTOD)valuesatoneormoreofseveralcrackextensionevents.TheseCTODis usedasmeasuresoffracturetoughnessformetallicmaterials.

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4.4

Fatigue test
4.4.1 General

Fatigue test refers to tests methods for the determination of fatigue strength of metallicmaterialssubjectedtoconstantamplitudecyclingloading.

4.4.2

Force controlled constant amplitude axial fatigue test

The force controlled axial fatigue test is used to determine the effect of variations in stress, material, geometry and surface condition on the fatigue resistanceofmaterialssubjectedtofatigueloading.Theresultscanalsobeused asaguidelinefortheselectionofmetallicmaterialsforserviceunderconditions ofrepeateddirectstress. The method covers axial force controlled fatigue tests to obtain the fatigue strength of materials in the fatigue regime, where the strainsarepredominately elasticthroughoutthetest.

4.4.3

Strain-controlled fatigue test

Straincontrolled fatigue is important for situations in which components or portions of components undergo either mechanically or thermally induced cyclic plastic strains that cause failure within relatively few cycles (i.e. fatigue life<105cycles). The method covers axial straincontrolled fatigue tests to obtain the fatigue strength of materials in the fatigue regime where the strains are predominately plastic.

4.5

Fatigue crack propagation test

4.5.1 Stable crack growth rate

Fatigue crack growth rate (da/dn) expressed as a function of crack tip stress intensity factor range (K), characterizes a materials resistance to stable crack propagation under cyclic loading. Results from this test together with data on toughness are used in the prediction of the damage tolerance behaviour (typicallythecyclesorserviceperiodtogrowacracktoacertaincracksize,the maximum permissible crack size and residual strength) and fatigue life predictionforstructuralcomponents. The method covers the determination of stable crack growth rates from near threshold propagation regime to controlled crack propagation instability. Resultsareexpressedintermsofda/dnversusK.

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4.5.2

Crack propagation threshold

Although the fatiguecrack propagation threshold (Kth) is defined as the asymptoticvalueofKatwhichda/dnapproacheszero,anoperational,though arbitrary, definition of Kth is given for most materials. This value is defined as K, which corresponds to a specified fatigue crack growth rate (typically for crackgrowthratesof108m/cycleorless). It is found that the propagation threshold behaviour of long cracks can be described in terms of stress ratio (R) as well as in terms of maximum stress intensityKmax,(seereferences[1],[2]and[3]inAnnexD).Fromapracticalpoint of view, testing at constant Kmax allows to proceed faster compared to testing at constant R, since load history effects are generally negligible. The approach is basedontheobservationthatformanyalloysKthvs.Kmaxrelationshipsshowa quasilinear dependency above certain Kmax values. Similarly, Kmax vs. R relationshipsatlowRvaluescanbeapproximatedbylinearrelations. Under the assumption of linear dependence, Kth vs. Kmax or Kmax vs. R, relationsforamaterialcanbedeterminedbyarelativelylownumberoftests. Accordingly the requirement section covers two methods to determine the fatiguecrackpropagationthresholdformetallicmaterials: DeterminationofanoperationalvalueofKth)accordingtoASTME647. Determinationof(Kth)bytestingatconstantKmax.

4.6

Fracture and fatigue test in special environment

Fatigue and crack propagation behaviour of metallic materials exposed to gaseousorliquidenvironmentscandifferfromthatexhibitedinair.Testresults obtained from fatigue and fracture tests in environments representative of the service conditions are used to evaluate the influence of specific environments onthematerialbehaviour. The method covers tests to determine the influence of environments representative of service conditions on the fatigue and fracture behaviour of metallicmaterials.

4.7

Stress corrosion cracking test

4.7.1 Overview

The test refers to methods for the determination of the susceptibility of metallic materialstostresscorrosioncracking.

4.7.2

Stress corrosion cracking test using smooth specimens

The results of this tests are used to classify alloys, weldments and their individual heat treatment conditions with respect to the material resistance

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against stress corrosion cracking. When sufficient stress corrosion data exists the alloy designation can be submitted for inclusion into relevant tables containedinECSSQST7036. The method covers the determination of the susceptibility of metals and weldments to stress corrosion cracking by alternate immersion in 3,5% sodium chloridewatersolutionunderconstantload.

4.7.3

Stress corrosion cracking test using precracked specimens

This test method allows the determination of the threshold stress intensity factor value for stress corrosion cracking KISCC, and the kinetics of crack propagation. Theuseofprecrackedspecimensacknowledgesthefactthatdefectsintroduced during manufacturing and subsequent services are always present in real structures. Furthermore, the presence of such defects can cause a susceptibility tostresscorrosioncracking,whichinsomematerials(e.g.titaniumalloys)isnot alwaysevidentfromtestsconductedonsmoothspecimens. This test method covers preparing and testing of precracked specimens for investigatingsusceptibilitytostresscorrosioncrackingofmetallicmaterials.

4.8

Creep test
The results of this test method are used to assess the loadcarrying ability of a material at high temperatures for limited deformations and as a function of time.Thetestprovidesinformationtoassessthesuitabilityofmaterialsforhigh temperaturestructuralapplications. The method covers the determination of the amount of deformation as a functionoftime(creeptest)andofthetimeforfracturetooccur(rupturetest)in materialssubjectedtoconstanttensileforcesatconstanttemperature.

4.9

Test results presentation

Before results obtained from mechanical tests can be applied with confidence, allowable values are statistically determined. The applicability of statistical methodstotheevaluationofnumericalresultsdependson: the number of tests performed on a specific material and test conditions, which should be large enough to constitute a statistically significant sample; the assumption that test data constitute a random sample of (or representationof)thepopulationofthematerialunderinvestigation.

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5 Requirements

5.1

Customer agreement
a. Test methods and procedures shall be agreed with the customer prior to testing.

5.2

Tensile testing
5.2.1
a. b.

General

Test apparatus, specimens, test procedures, precision and bias shall be in conformancewithEN100021. A minimum number of three tests shall be carried out for each set of materialandtestconditions.

5.2.2
a. b. c.

Tensile testing of weldments

Specimens with a transverse weld shall be manufactured with the weld jointlineonthecentreofthespecimengaugelength. Specimenswithalongitudinalweldshallbemanufacturedwiththeweld jointlineonthespecimenlongitudinalaxis. For specimens with a transverse weld, the specimen gauge length shall beequalorgreaterthantheweldheataffectedzone(HAZ). NOTE1 When testing specimens with a transverse weld, note that the strain distribution within the HAZ varies as a function of the distance from the weld centre line. This implies that elongation varies as a functionofthegaugelength. NOTE2 Weldments are characterized by nonuniformity in tensileproperties.

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5.3

Fracture toughness test

5.3.1
a. b.

KIc test method

Test apparatus, specimens, test procedures, precision and bias shall be in conformancewithASTME399. The crack plane orientation code for rectangular sections, for bars and hollow cylinders in conformance with ASTME399 shall be used throughouttestingandreporting. A minimum number of three KIc valid tests, in conformance with the validity criteria of ASTME399, shall be carried out for each set of materialandtestcondition. If any dimension of the available stock of a material is insufficient to provide a specimen of the required size to produce a valid KIc result, the specimen strength ratio (Rsx) shall be used to provide a comparative measure of the toughness when the specimens are of the same form and size. NOTE In certain materials (e.g. some structural grade steels)theplanestraintoughnessissensitivetothe loading rate. In these cases the testloading rate is selected with respect to the specific application of thetestresults.

c.

d.

5.3.2
a. b.

JIc test method

Test apparatus, specimens, test procedures, precision and bias shall be in conformancewithASTME1820. A minimum number of three JIc valid tests, in conformance with the validity criteria of ASTME1820, shall be carried out for each set of materialandtestcondition.

5.3.3
a. b.

R-curve test method

Test apparatus, specimens, test procedures, precision and bias shall be in conformancewithASTME561. Aminimumnumberofthreevalidtests,inconformancewiththevalidity criteria of ASTME561, shall be carried out for each set of material and testcondition.

5.3.4
a. b.

CTOD test method

Test apparatus, specimens, test procedures, precision and bias shall be in conformancewithASTME1290. Aminimumnumberofthreevalidtests,inconformancewiththevalidity criteria of ASTME1290, shall be carried out for each set of material and testcondition.

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5.4

Fatigue test
5.4.1
a. b. c.

Force controlled constant amplitude axial fatigue test

Test apparatus, specimens, test procedures, precision and bias shall be in conformancewithASTME466. Fatigue strength values shall be determined in the finite life range and in thetransitionrange. The minimum number of tests and load levels shall be established in relationtothetypeoftestprogrammeconducted. NOTE For example: exploratory research and development tests, design allowables data, reliabilitydata.

d.

Forthefiniteliferange,thefollowingminimumsshallapply: 1. 2. aminimumofsixtestsperselectedstresslevel; aminimumofthreestresslevels.

e.

In the transition range (infinite life range), the selection of the test stress levelsshallbeaccordingtothestaircasemethod,theboundarymethodor thearcsinemethod. NOTE A review of these methods can be found in ISO3800

f. g. h. i.

Fatigue test stress levels shall be selected in order to obtain constant stressratio(R)stresslifedatasets. Statisticalanalysisoftestresultsshallbecarriedoutinconformancewith ASTME739. When testing a nominally homogeneous material, specimens with continuousradiusbetweenendsshallbeused. Axial load fatigue testing of threaded fasteners shall be carried out in conformancewithclauseFatiguetestofECSSQST7046. NOTE Fatiguestrengthofweldedcomponentsistypically influenced by weld residual stress. For this reason, fatigue testing of weld coupons is not representative of the effects of weld residual stress onthefatiguestrengthofrealcomponents.

5.4.2
a. b.

Strain-controlled fatigue test

Test apparatus, specimens, test procedures, precision and bias shall be in conformancewithASTME606. Fatiguestrengthvaluesshallbedeterminedinthefiniteliferangeuptoa predeterminednumberofstresscycles. NOTE The number of predetermined stress cycles for the finiteliferangeistypically105straincycles

c.

Test requirements as specified in 5.4.1c, 5.4.1d, 5.4.1e and 5.4.1f shall apply.

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5.5

Fatigue crack propagation test

5.5.1
a.

Determination of fatigue crack growth rate

Test apparatus, specimens, test procedures, precision and bias shall be in conformancewithASTME647. NOTE C(T)specimensshouldbeusedfortestscarriedout at positive stress ratios, and M(T) specimens for tests carried out at negative stress ratios. Specimen configurations other than C(T) and M(T) may be used providing that well established stress intensity factor solutions are available and that specimens are of sufficient planar size to remain predominantlyelasticduringtesting.

b.

A minimum of three valid tests shall be carried out for each set of materialsandtestconditions. NOTE ForvaliditycriteriaseeASTME647. Accuracy and resolution of selected crack length measurement methods shallbeassessedbeforetesting. NOTE Measurement methods are optical, direct current potentialdroptechniqueandcompliancemethods.

c.

d. e.

The film replica technique should be used to measure the length of short cracks. At the end of the test crack length values obtained with the selected measurement method shall be correlated to the physical crack length by fractographicexamination. Tests to characterize the crack propagation behaviour in the threshold regime shallbe carried out to meet crack growth rates as specified by the customer. NOTE Typical growth rates of the threshold regime are lessthan108m/cycles.

f.

5.5.2

Determination of a fatigue crack propagation threshold

Operational value of Kth

5.5.2.1
a.

Determination of operational values of Kth shall be carried out accordingtothetestprocedureofASTME647,clause9.4.

5.5.2.2
a.

Alternative determination of Kth values by testing at constant Kmax

Crack propagation tests shall be carried out under constant maximum stressintensityfactorKmaxandinconformancewithclause5.5.1.

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5.6

Fracture and fatigue tests in special environments

a. b. Test apparatus, specimens, test procedures, precision and bias shall be agreedwiththecustomerpriortotesting. Transportation, handling and disposal of hazardous substances shall be inagreementwiththeapplicablehealthandsafetyrules. NOTE c. For example: material safety data sheets, national healthandsafetyrules.

Composition and purity of the test environment shall be monitored and controlledthroughoutthetest.

5.7

Stress corrosion cracking test

5.7.1
a.

Stress corrosion cracking test using smooth specimens

Test apparatus, specimens, test procedures, precision and bias shall be in conformancewithECSSQST7037.

5.7.2
a. b. c. d. e.

Stress corrosion cracking test using precracked specimens

Test apparatus, specimens, test procedures, precision and bias shall be in conformancewithISO75396:2003. Testsshallbecarriedoutunderconstantload. The number of tests to be carried out for each set of material and test conditionsshallbeagreedwiththecustomer. Specimens shall be stressed after being brought into contact with the test environment, Alternatively the specimens shall be exposed to the test environment as soonaspossibleafterstressing.

5.8

Creep test
a. b. Test apparatus, specimens, test procedures, precision and bias shall be in conformancewithASTME139. Theminimumofnumberofteststobecarriedoutforeachsetofmaterial andtestconditionshallbeagreedwiththecustomer.

5.9

Evaluation of test results

a. Arithmetic mean value and standard deviation shall be calculated from eachsetofnumericalresultsobtainedbytestingaspecificmaterialunder sametestconditions.

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b. c. d. Statistical analysis of numerical results of toughness tests shall be conductedinconformancewithclause4ofESDU96013. Statisticalanalysisofnumericalresultsoffatiguetestsshallbeconducted inconformancewithclause5.4.1g. Data reduction of numerical results of fatigue crack propagation tests shallbeconductedinconformancewithASTME647,AppendixX1.

5.10 Storage
a. Storageofmaterialsandspecimensshallbeagreedwiththecustomer.

5.11 Reporting
a. b. The Request for mechanical testing of materials shall be issued by the customerinconformancewiththeDRDofAnnexA. TheProposal for mechanical testing of materials shall be issued by the supplier in conformance with the DRD of Annex B and submitted to the customerforreviewandapproval. The Report of mechanical testing of materials shall be issued by the supplier in conformance with the DRD of Annex C and submitted to the customerforreviewandapproval.

c.

5.12 Quality assurance

5.12.1
a. b. c.

General

The supplier shall implement quality assurance, inspection and quality controlproceduresbeforeanytestactivity. The implementation of the procedures shall be maintained for the entire durationofthetestactivity. The supplier shall establish and implement quality control actions and inspectionstoprovideevidenceofconformitytotestrequirements. NOTE Quality control actions and inspections for test activities carried out by subcontracted laboratories are under the responsibility of the supplier.

5.12.2
a. b. c.

Calibration

Calibration of test equipment shall be carried out and maintained throughoutthetestactivity. Calibrationoftensiletestingmachinesandextensometersshallbecarried outinconformancetoEN100022andEN100024,respectively. Calibration records shall be readily accessible and retrievable on customerrequestfortheentiredurationofthebusinessagreement.

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5.12.3
a. b.

Quality control of raw materials

The supplier shall provide documented evidence that only materials in conformancewiththecustomerspecificationsareusedinthetestactivity. The supplier of raw materials shall include a raw material certificate (RMC)ineachtestreportinconformancewiththeDRDofAnnexC.

5.12.4
a.

Nonconformance

Nonconformance of materials, specimen preparation, testing, evaluation and reporting shall be documented in a nonconformance report in conformance with the NCR DRD of ECSSQST1009, and reported to thecustomer. Upon customer request, results affected by nonconformities shall be invalidatedandtestsrepeated.

b.

5.12.5
a. b. c. d.

Traceability and records

Materials shall be durably marked to univocally identify manufacturers code,batchnumber,materialstandarddesignationandgrainorientation. Specimens shall be durably marked to univocally identify individual specimensandgrainorientation. Test records shall be maintained and on customer request accessible and retrievablefortheentiredurationofthebusinessagreement. Thecustomershallauthorizedisposalofmaterialsandspecimens.

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ECSSQST7045C 31July2008

Annex A (normative) Request for mechanical testing of materials DRD

A.1

DRD identification
A.1.1 Requirement identification and source document

ThisDRDiscalledfromECSSQST7045,requirement5.11a.

A.1.2

Purpose and objective

The document Request for mechanical testing of materials specifies the test activity requested by the customer for mechanical testing of metallic materials. Therequestformechanicaltestingisbasisforthesuppliertosubmitaproposal fortherelevanttestactivity.

A.2

Expected response
A.2.1
<1>
a.

Scope and content

Backgroundinformation

Information to the technical, business agreement and project background ofthetestactivityshallbedescribed.

<2>
a.

Objectiveoftestactivity
Theobjectiveoftherequestedtestactivityshallbedescribed.

<3>
a.

Materialidentification
Material, designation, heat treatment, form and configuration, procurementsourceshallbeidentified.

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<4>
a. b.

Testdefinition
Environment, number of tests and measurement techniques shall be identified. Referencetoapplicablestandardsshallbegiven.

<5>
a.

Testoutput
Therequestedtestoutputshallbespecified. NOTE For example: Number of cycles, determined crack lengthandcrackgrowthrates.

<6>
a.

Additionalrequest
Anyotherspecificcustomerrequestshallbespecified.

A.2.2
a. b.

Special remarks to document title

Thedocumentshallbetitled[insertadescriptivemodifier]Requestfor mechanicaltestingofmaterials. The descriptive modifier shall be selected to clearly identify the applicableproduct. NOTE1 For example: Measurement of fracture toughness of AA 7175T7351 plate Request for mechanical testingofmaterials. NOTE2 For example: Fatigue crack propagation behaviour of Ti6Al4V STA sheet at different stress ratios Request for mechanical testing of materials.

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ECSSQST7045C 31July2008

Annex B (normative) Proposal for mechanical testing of materials DRD

B.1

DRD identification
B.1.1 Requirement identification and source document

ThisDRDiscalledfromECSSQST7045,requirement5.11b.

B.1.2

Purpose and objective

The document Proposal for mechanical testing of materials defines the test activity for mechanical testing of metallic materials proposed by the supplier. The supplier prepares the document and submits it to the customer for review andapproval.

B.2

Expected response
B.2.1
<1>
a.

Scope and content

Descriptionofwork

Theproposedtestactivityshallbedescribedintheformofastatementof workincluding: 1. 2. 3. 4. Descriptionoftheobjectiveofthetestactivity. Description of proposed test method including reference to applicablestandards Identificationofthematerialtobetested. Definition and confirmation of test conditions (i.e. environment, specimen geometry and orientation, number of specimens and measurementtechniques) Description of expected test output (i.e. crack length, number of cycles,crackgrowthrates).

5.

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ECSSQST7045C 31July2008

<2>
a.

Testprocedures
Proposed test procedures shall be described and deviations from standardtestproceduresidentified.

<3>
a. 1. 2.

Financialandadministrativeproposal
Afinancialandadministrativeproposalshallbepresentedincluding: Identificationofresponsiblepersonfortheactivity; List of deliverable items including test records with tabulated values of crack length, number of cycles, growth rates, stress intensityandrespectiveunitsofmeasure; Workbreakdownstructuredefiningresponsibilitiesfor: (a) (b) (c) (d) (e) (f) 4. 5. 6. 7. procurementofrawmaterial, preparationofspecimens, heattreatment, testing, evaluationofresults, reporting.

3.

Timeschedule; Travelandsubsistenceplan; Itemizedcostlist; Milestonepaymentplan.

B.2.2
a. b.

Special remarks to document title

The document shall be titled [insert a descriptive modifier] Proposal formechanicaltestingofmaterials. The descriptive modifier shall be selected to clearly identify the applicableproduct. NOTE1 For example: Measurement of fracturetoughness of AA7175T7351 plate Request for mechanical testingofmaterials. NOTE2 Forexample: Fatigue crack propagation behaviour of Ti6Al4VSTA sheet at different stress ratios Request for mechanical testing of materials.

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ECSSQST7045C 31July2008

Annex C (normative) Report of mechanical testing of materials DRD

C.1

DRD identification
C.1.1 Requirement identification and source document

ThisDRDiscalledfromECSSQST7045,requirement5.11cand5.12.3b.

C.1.2

Purpose and objective

The document Report of mechanical testing of materials describes and discussestestproceduresandresultsofmechanicaltestingofmetallicmaterials. The document contains the elements and information relevant to the understandingandcorrectinterpretationofthetestactivityandtestresults. The supplier prepares the document and submits it to the customer for review andapproval.

C.2

Expected response
C.2.1
<1>
a.

Scope and contents

Abstract

The abstract shall summarize the test procedure and the most relevant findingsofthetestactivity.

<2>
a.

Introduction
The introduction shall provide background information to the test including: 1. 2. Reasonsforcarryingoutthetestactivity; Reference to any previous relevant test activities and technical reports;

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ECSSQST7045C 31July2008
3. 4. 5. Useandapplicabilityoftheresults; Identification of other organizations that contributed to the test activity; Objectivesofthetestactivity.

<3>
a. b. c.

Informationonrawmaterial
The document shall include a raw material certificate (RMC) issued by thesupplieroftherawmaterial. TheRMCshallbedeliveredtogetherwiththerawmaterial, TheRMCshallinclude: 1. 2. 3. 4. 5. 6. 7. 8. batchsuppliersnameandcode, materialstandarddesignationandheattreatment, dateofbatchmanufacturing, specifiedchemicalcomposition, materialandheattreatmentspecifications, productform,quantity,dimensionsandgrainorientation, surfacetreatment, descriptionofmanufacturingprocesses. NOTE 9. Forexample:welding,cuttingandmilling.

nondestructiveinspection.

d.

The document shall indicate the raw material tensile properties with respecttothegrainorientationandhardness. NOTE1 Tensile properties include elastic modulus, 0,2% proofstress,tensilestrengthandelongation NOTE2 ThesepropertiesareeitherspecifiedintheRMCor obtainedbytestingtherawmaterialupondelivery

<4>
a. b. c. d.

Descriptionoftestprocedures
The document shall provide an univocal and complete description of the specimenpreparation,testequipmentandtestprocedure. Theinformationprovidedshallbeinconformancewiththerequirements specifiedintherelativesectionsoftheapplicableteststandards. Estimated values of precision and bias for the test results shall be indicated. Anomaliesanddeviationsfromstandardproceduresshallbereported.

<5>
a. b.

Testresults
Test results shall be presented in an appropriate format usingdrawings, plots,diagramsandphotos. Test results shall be described and conformance to requirements discussed.

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ECSSQST7045C 31July2008
c. Unitsofmeasureandscalesshallbeconsistentandinagreementwiththe customerspecifications.

C.2.2
a. b.

Special remarks to document title

The document shall be titled [insert a descriptive modifier] Proposal formechanicaltestingofmaterials. The descriptive modifier shall be selected to clearly identify the applicableproduct. NOTE1 For example: Measurement of fracture toughness of AA 7175T7351 plate Request for mechanical testingofmaterials. NOTE2 For example: Fatigue crack propagation behaviour of Ti6Al4V STA sheet at different stress ratios Request for mechanical testing of materials.

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ECSSQST7045C 31July2008

Annex D (informative) References

[1] H. Doeker, Y. Bachmann and G. Marci, A comparison of different methods of determination of the threshold for fatigue crack propagation, Fatigue Thresholds,16June1981,Stockholm. H. Doeker and M. Peters, Fatigue threshold dependence on material environment and microstructure, Fatigue 84, 37 September 1984, Birmingham,UK. H. Doeker, Fatigue crack growth threshold: implications, determination and data evaluation, International Conf. on Fatigue Damage in Structural Materials,EngineeringFoundation,1996,Massachusetts,US.

[2]

[3]

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ECSSQST7045C 31July2008

Bibliography

ECSSSST00 ECSSQST7036 ISO3800

ECSSsystemDescription,implementationand generalrequirements SpaceproductassuranceMaterialselectionfor controllingstresscorrosioncracking ThreadedfastenersAxialloadfatiguetesting Testmethodsandevaluationofresults.

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