MIL-STD-810 Salt Fog Testing

MIL-STD 810, Method 509 Salt Fog Testing is performed to evaluate the effectiveness of protective coatings and finishes on materials, ingress of moisture into connectors and sealed components.  Salt Fog Testing does not correlate to field life, but it provides an indication of potential problem areas associated with exposure to the salt (marine) environment.  The latest revision is Method 509.7 from MIL-STD-810H.

Ensuring Durability with Comprehensive Corrosion Testing

Salt is one of the most pervasive substances in the world, found in oceans, the atmosphere, ground surfaces, lakes, and rivers. It is impossible to avoid. Performing corrosion testing to exacting standards is crucial for product durability. Exposure to a salt corrosive atmosphere can lead to several detrimental effects, including:

Corrosion Effects

  • Corrosion due to electrochemical reaction
  • Accelerated stress corrosion
  • Formation of acidic/alkaline solutions following salt ionization in water

Electrical Effects

  • Impairment of electrical material due to salt deposits
  • Production of conductive coatings
  • Corrosion of insulating materials and metals

Physical Effects

  • Clogging or binding of moving parts of mechanical components and assemblies
  • Blistering of paint because of electrolysis

MIL-STD-810 Salt Fog Testing Procedures

MIL-STD-810 Salt Fog Testing is performed in a specially constructed chamber.  DES has one of the leading brands of a salt fog testing chambers.  MIL-STD-810 requires a 5% (±1%) by weight salt solution dissolved in water with a pH between 6.5 to 7.2.  The salt solution is atomized into the chamber as a fine wet salt fog or mist while the air temperature in the chamber is maintained at 35 ±2 °C (95 ±3.6 °F).   Two collection receptacles are placed inside of the chamber to measure the salt fog fallout rate.  The fallout rate is required to be 1 to 3 ml per hour for each 80 cm2 of horizontal collecting area. 

Test samples should be configured and oriented as they would normally be stored, shipped, or used.  The recommended duration is 48 hours of salt fog exposure followed by 48 hours of drying in ambient air with less than 50% humidity.  An alternating 24 hour test cycle (24 fog, 24 drying, 24 fog, 24 drying) has proven to be more destructive and is the way the MIL-STD-810 Salt Fog Test is most commonly run.  After the test, the samples are inspected for physical, electrical and corrosion effects.

Choose DES for Unmatched Salt Fog Testing Expertise

Choosing DES for your salt fog testing needs ensures:

  • Accredited Lab: DES is an accredited MIL-STD-810 test lab.
  • Experience: We have performed numerous MIL-STD-810 salt fog tests.
  • State-of-the-Art Equipment: DES has advanced salt fog testing equipment.
  • Precision: We possess the required calibrated support instruments to accurately measure the pH and salt solutions required in MIL-STD-810.

Contact us today to discuss your MIL-STD-810 testing project with one of our engineers. 

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MIL-STD-810 Temperature Shock Testing

Method 503 in MIL-STD-810 covers procedures for temperature shock or thermal shock testing.  Temperature shock testing (as defined in MIL-STD-810H) is a rapid change in air temperature greater than 10°C (18°F) per minute.  Temperature shock testing is used to determine if products can withstand sudden changes in the surrounding temperature environment without experiencing physical damage or deterioration in performance.   The latest revision is Method 503.7 from MIL-STD-810H.

Some of the Effects of Temperature Shock Environments are:

  • Shattering of glass and optical material.
  • Binding or slackening of moving parts.
  • Differential contraction or expansion rates or induced strain rates of dissimilar materials.
  • Deformation or fracture of components.
  • Cracking of surface coatings.
  • Leaking of sealed compartments.
  • Failure of insulation protection.
  • Changes in electrical and electronic components.
  • Electronic or mechanical failures due to frost formation.

Method 503 Has One Procedure with Four Variations:

  1. Procedure I-A – One-way Shock(s) from Constant Extreme Temperature
    This procedure is for material that is only rarely exposed to thermal shock in one direction.  At least one shock is performed from low to high temperature, or vice versa. 
  2. Procedure I-B – Single Cycle Shock from Constant Extreme Temperature.  For items that are exposed to only one thermal shock cycle (one in each direction).  One shock is performed from low-to-high temperature (or vice versa) and then one shock in the opposite direction.
  3. Procedure I-C – Multi-Cycle Shocks from Constant Extreme Temperature.  A minimum of three shocks are performed at each condition, i.e., three transfers from cold to hot, three transfers from hot to cold, and a stabilization period after each transfer. 
  4. Procedure I-D – Shocks to or from Controlled Ambient Temperature.  Procedure I-D follows the durations of Procedures I-A to I-C, except all shocks are to and/or from controlled ambient temperatures. 

Test levels for MIL-STD-810 Temperature Shock Testing 

Consider the following typical conditions from MIL-STD-810H:

  1. Aircraft flight exposure. For materiel exposed to desert or tropical ground heat with possible direct solar heating, then, immediately afterwards, exposed to the extreme low temperatures associated with high altitude.  The item could be subjected to multiple thermal shocks occurring in multiple missions. 
  2. Air delivery – desert. For products that are delivered over desert terrain from unheated, high altitude aircraft, then exposed to hot ambient air temperature (no solar loading).
  3. Ground transfer – ambient to or from either cold regions or desert. For items that move from a controlled ambient indoor environment or enclosure to a cold region or desert environment.

For MIL-STD-810 temperature shock testing, the transfer time between the temperatures should be within one minute.  The test sample is soaked for as long as necessary to ensure a uniform temperature throughout at least its outer portions.  If the Life Cycle Environmental Profile indicates a duration less than that required to achieve stabilization, this duration should be used.  If the critical point of interest is near the surface of the item, a shorter duration may apply rather than complete stabilization of the item.

H4: Choosing DES for MIL-STD-810 Temperature Shock Testing

When it comes to MIL-STD-810 Temperature Shock Testing, selecting the right laboratory is crucial for accurate and reliable results. DES stands out for several reasons:

  • DES has run numerous MIL-STD-810 Method 503.7 Temperature Shock tests for many military manufacturers
  • DES’s lab is A2LA accredited to MIL-STD-810, Method 503 Temperature Shock Testing
  • DES has multiple chambers capable of performing MIL-STD-810 Temperature Shock compliance testing

Contact us today to discuss your MIL-STD-810 testing with one of our engineers. 

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MIL-STD-810 Low Temperature Testing

MIL-STD 810, Method 502 Low Temperature Testing is used to evaluate the effects of low temperatures on cold storage, operation, and manipulation.  Method 502 is applicable for testing products that will be exposed to cold temperatures during their life cycle.  The latest revision is Method 502.7 from MIL-STD-810H.

MIL-STD-810 low temperature testing is not intended to simulate a high altitude, low temperature environment associated with an unpressurized aircraft at altitude.  However, it may be used in combination with Method 500.6 to simulate a high altitude, low temperature environment. 

Some of the Effects of Low Temperature Environments are:

  • Hardening and embrittlement of materials.
  • Binding of parts from differential contraction of dissimilar materials.
  • Loss of lubrication and lubricant flow due to increased viscosity.
  • Changes in electronic components (resistors, capacitors, etc.).
  • Changes in performance of transformers and electromechanical components.
  • Stiffening of shock mounts.
  • Cracking, change in impact strength, and reduced strength.
  • Effects due to condensation and freezing of water in or on the materiel.

Method 502 Has Three Procedures Starting with Low Temperature Storage:

  1. Procedure I – Storage.  Procedure I is used to evaluate products that are stored at Low temperatures.  After the Low temperature storage test is completed, an operational test at ambient conditions is performed. 
  2. Procedure II – Operation.  Procedure II is used to determine how well an item will operate in low temperature environments.  Operation during this procedure assumes minimum contact by personnel.
  3. Procedure III – Manipulation.  Manipulation is used to investigate the ease with which the materiel can be assembled, operated, and disassembled by personnel wearing heavy, cold-weather clothing. In addition, this could also include maintenance procedures. 

Low Temperature Test Parameters and Procedures Under MIL-STD-810 

First, identify the Low temperature test parameters and applicable procedures. DES can help determine the appropriate low temperature test conditions based on the equipment’s intended use.  Consider the following cold temperatures in various world-wide locations from Table 502.7-I. (MIL-STD-810H):

Design TypeLocationAmbient Air Temperature oC(oF)Induced Environment Temperature
(Storage & Transit)
Basic Cold (C1)Most of Europe; Northern contiguous US; Costal Canada; High-Latitude coasts (e.g., southern coast of Alaska); High elevations in lower latitudes-21 to -32
(-5 to -25)
-25 to -33
(-13 to -28)
Cold (C2)Canada, Alaska (excluding the interior); Northern Scandinavia; Northern Asia (some areas), High Elevations (Northern and Southern Hemispheres); Alps; Himalayas; Andes-37 to -46
(-35 to -50)
-37 to -46
(-35 to -50)
Severe Cold (C3)Interior of Alaska; Yukon (Canada); Interior of Northern Canadian Islands; Greenland ice cap; Northern Asia-51
Source: Table 502.7-I. (MIL-STD-810H)

The recommended test duration from MIL-STD-810H is four hours after stabilization for nonhazardous or non-safety-related (non-life-support type) material.  Munitions, rubber and plastics may continue to deteriorate following low temperature stabilization.  For these items, a minimum duration of 72 hours following temperature stabilization is recommended.  For restrained glass, ceramics, and glass-type products (such as those used in optical systems, laser systems, and electronic systems) a minimum storage period of 24 hours following temperature stabilization is recommended. 

Advantages of MIL-STD-810H Low Temperature Testing with DES:

DES excels in MIL-STD-810H Low Temperature Testing. With our lab’s accreditation and equipped with advanced temperature chambers, we ensure your equipment meets the cold-weather performance standards required by MIL-STD-810H.  Some of the reasons that DES is trusted by many companies for MIL-STD-810H Low Temperature Testing are:

  • DES has extensive experience running MIL-STD-810 Method 502.7 Low Temperature tests
  • DES’s lab is A2LA accredited to MIL-STD-810, Method 502 Low Temperature Testing
  • DES is trusted by many military manufacturers to perform their testing
  • DES has numerous temperature chambers capable of performing MIL-STD-810 Low temperature compliance testing

Contact us today to discuss testing your product in our MIL-STD-810 accredited Test Laboratory. 

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MIL-STD-810 High Temperature Testing

MIL-STD 810, Method 501 High Temperature Testing is used to evaluate the effects of high temperature conditions on performance, materials, and integrity.  Method 501 is applicable for temperature testing products that are deployed in areas where temperatures (ambient or induced) are higher than standard ambient.  Note, the latest revision of this method is 501.7 from MIL-STD-810H.

Method 501 is limited to evaluating the effects of relatively short-term (months, as opposed to years), even distributions of heat throughout the test item. This method is not typically practical for evaluating materials where solar radiation produces thermal gradients or photochemical effects.  Method 505 is used to test the effects of solar radiation.  It is also not practical to evaluate degradation that occurs from continuous long-term exposure to high temperatures where synergetic effects may be involved.

The following are typical failures that could occur from products used in high temperature environments.

  • Parts bind from the differential expansion of dissimilar materials.
  • Lubricants become less viscous; joints lose lubrication by the outward flow of lubricants.
  • Materials change in dimension.
  • Packing, gaskets, seals, bearings, and shafts become distorted, bind, and fail causing mechanical failures.
  • Gaskets display permanent sets.
  • Closure and sealing strips deteriorate.
  • Fixed-resistance resistors change in values.
  • Electronic circuit stability varies with differences in temperature gradients and differential expansion of dissimilar materials.
  • Transformers and electromechanical components overheat.
  • Operating/release margins of relays and magnetic or thermally activated devices alter.
  • Shortened operating lifetimes.
  • High pressures are created within sealed cases (batteries, etc.).
  • Discoloration, cracking, or crazing of organic materials.
  • Out-gassing of composite materials or coatings.
  • Failure of adhesives.

MIL-STD-810 Method 501 Tests: High Temperature Procedures

  1. Procedure I – Storage.  Procedure I is for testing products that are stored at high temperatures.  After the high temperature storage test is completed, an operational test at ambient conditions is performed.  Procedure I can be either a cyclic temperature test or a constant temperature test. 
  2. Procedure II – Operation.  Procedure II is used to investigate how high temperatures could affect the performance of items while they are operating.  Temperature Procedure II can be performed as either a cyclic temperature test or a constant temperature test. 
  3. Procedure III – Tactical-Standby to Operational.  This temperature procedure evaluates the material’s performance at normal operating temperatures after being presoaked at high non-operational temperatures.  An example of Procedure III is a product that is stored in an enclosed environment that develops high internal temperatures before being removed and then operated in a relatively short period of time.

What is the procedure for MIL-STD-810 High Temperature Testing? 

First, identify the high temperature levels, test conditions, and applicable procedures. DES can help determine the appropriate temperature ramp rates and durations of the tests based on the equipment’s intended use and the operating environmental conditions.  Consider the following climatic temperatures from Table 501.7-I. (MIL-STD-810H):

Design TypeLocationAmbient Air oC (oF)Induced2 oC (oF)
Basic Hot (A2)Many parts of the world, extending outward from the hot dry category of southwestern United States, northwestern Mexico, central and western Australia, Saharan Africa, South America, Southern Spain, and southwest and south central Asia.30 – 43

(86 – 11)
30 – 63

(86 – 145)
Hot Dry (A1)Southwest and south central Asia, southwestern United States, Saharan Africa, central and western Australia, and northwestern Mexico.32 – 49

(90 – 120)
33 – 71

(91 – 160)
Table 501.7-I from MIL-STD-810H

Next, determine whether a constant temperature test or a cyclic temperature test is appropriate.  Constant temperature testing is used only for items situated near heat-producing equipment or when it is necessary to verify the operation of an item at a specified constant temperature.  The duration for constant temperature test temperature is at least two hours following test specimen stabilization.

For cyclic exposure, there are two 24-hour cyclic profiles contained in Tables 501.7-II and 501.7-III.  The number of cycles for the Procedure I storage test is a minimum of seven to coincide with the one percent frequency of occurrence of the hours of extreme temperatures during the most severe month in an average year at the most severe location.   The minimum number of cycles for the Procedure II operational testing is three. This number is normally sufficient for the test item to reach its maximum response temperature.

You can trust the DES MIL-STD-810 High Temperature Testing lab

Advantages with DES : 

  • DES is A2LA accredited to MIL-STD-810, Method 501 High Temperature Testing
  • DES has extensive experience running MIL-STD-810 Method 501.7 high temperature Tests
  • DES has multiple temperature chambers capable of performing MIL-STD-810 high temperature compliance testing

Contact us today to to discuss testing your product in our MIL-STD-810 accredited Test Laboratory. 

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Medical Device Industry: Producing Reliable Products

medical device industry showing stethoscope and other devices

In the fast-evolving medical device industry, the pathway to market success is marked by stringent standards. Delserro Engineering Solutions (DES) plays a pivotal role in this journey, offering expert testing services for both medical devices and their packaging. Recognizing that each product—from intricate surgical instruments to complex diagnostic machinery—requires rigorous scrutiny, DES employs cutting-edge environmental, vibration, HALT, and shock testing in its state-of-the-art facilities.

The comprehensive range of tests at DES is designed to address the specific challenges faced by medical devices in real-world conditions. By simulating various environmental factors and stressors, DES ensures that both the device and its packaging maintain integrity and functionality throughout their lifecycle. This attention to detail is crucial in the medical device industry where precision is paramount, and the smallest oversight can have significant consequences.

Our team delves into the nuances of each project, partnering with manufacturers to understand their unique needs and challenges. This collaborative approach allows for customized testing solutions that cater to the diverse requirements of the medical device sector.

Medical Device Testing: Meeting Rigorous Standards with DES

The field of medical device testing necessitates strict adherence to a variety of industry standards to ensure compliance. At Delserro Engineering Solutions (DES), we pride ourselves on aligning our testing services with these critical standards, assuring that medical device packaging meets the highest benchmarks of quality and reliability.

  1. ISTA Compliance for Transportation Durability: As a certified testing laboratory, we conduct packaging tests that comply with International Safe Transit Association (ISTA) standards. These tests simulate the stress that packaging undergoes during transportation, ensuring that it can protect medical devices from damage due to shock, vibration, and other environmental factors.
  2. ASTM Standards for Material Quality: Adhering to ASTM D7386 and other ASTM standards, we evaluate the material quality of packaging, assessing its durability and resilience under various conditions. These tests are crucial for determining if the packaging can maintain the sterility and integrity of medical devices.
  3. ISO/IEC 17025 Accredited Testing: Our ISO/IEC 17025 accreditation signifies our technical competence in conducting standardized tests. This includes ensuring that medical device packaging meets specific environmental testing requirements crucial for maintaining product reliability throughout its lifecycle.
  4. MIL-STD Compliance for Military-Grade Assurance: For products that require a higher level of robustness, such as those used in military applications, we ensure compliance with Military Standards like MIL-STD-810 and MIL-STD-202. This ensures that products can withstand extreme environmental conditions and rough handling.
  5. Customized Testing Protocols: Beyond standard compliance, we offer customized testing solutions tailored to unique client specifications. Whether it’s assessing the resilience of packaging or devices under specific temperature conditions or evaluating its performance under unique mechanical stresses, our state-of-the-art facilities are equipped to handle diverse testing needs.

Navigating Challenges in Medical Device Package Testing

The journey from conception to market for medical devices is fraught with challenges, particularly when it comes to packaging. At Delserro Engineering Solutions (DES), we understand that the package is a crucial component that ensures device safety and efficacy during transit and storage.

With the medical device industry facing ever-tightening regulations, manufacturers must ensure their packaging can withstand a range of environmental stresses. DES’s medical device package testing services are designed to address these exacting standards, from simulating transportation conditions to mimicking the rigors of handling and storage.

Moreover, DES’s commitment to staying ahead in an evolving industry landscape means continuously updating our medical device package testing processes in line with the latest regulations and standards. Our laboratory’s ISO/IEC 17025 and ISTA accreditation are a testament to our capability to execute tests that are both precise and reliable. We engage with the latest industry practices, ensuring that our clients’ medical device packaging is robust, compliant, and above all, safe for the end-user.

Recognizing that off-the-shelf solutions do not fit all, our engineers work closely with clients to develop specialized medical device package testing plans that match the unique needs of their products. Whether it’s fine-tuning temperature cycles to match specific geographic journeys or tailoring shock tests for delicate components, DES ensures that every aspect of packaging is scrutinized and optimized for peak performance. This meticulous attention to detail ensures that when a medical device reaches its destination, it does so with its integrity unblemished and its functionality assured.

DES embraces the challenges of medical device package testing with a blend of accredited procedures, advanced technology, and customized service. By doing so, we ensure that our clients’ products are not only compliant but exemplify the highest standards of the medical device industry. Contact us to learn more about how we can address the specific testing needs for your medical device packaging.

Proven Expertise in the Medical Device Industry at DES

At Delserro Engineering Solutions (DES), our expertise in the medical device industry is more than just a claim—it’s a commitment. With over three decades of experience, DES has established itself as a leader in providing comprehensive testing solutions for both medical devices and their packaging. Our deep understanding of medical device industry standards positions us uniquely to help our clients navigate the complexities of product testing and compliance.

Our team of skilled engineers and technicians is dedicated to delivering results that surpass expectations. At DES, we understand that the medical device industry is rapidly evolving, and staying ahead means being equipped to adapt to new challenges. We offer personalized service, working closely with our clients to understand their specific needs and providing tailored solutions that align with their goals. This partnership approach has made us a trusted name among industry giants.

In the medical device industry, where precision, quality, and reliability are non-negotiable, DES stands as a beacon of excellence. We invite you to experience the DES difference—where quality testing leads to quality products.

Contact us today to learn how our expertise can enhance the reliability and market success of your medical devices.

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What is the Difference Between Thermal Shock and Temperature Cycle Testing?

Our customers often ask, What is the Difference Between Thermal Shock and Temperature Cycle Testing?  Both types of tests expose products to cycles between hot and cold temperatures.  Both tests produce stresses caused by thermal expansion and contraction.  In many cases, components expand and contract differently.  This creates cumulative fatigue damage during each cyclic, which could result in a fatigue failure.

Thermal shock exposes devices to rapid temperature changes greater than 15°C/minute.  Temperature cycle testing uses a transition rate less than 15°C/minute and is usually between 1 to 10°C/minute from our experience. 

Continue reading What is the Difference Between Thermal Shock and Temperature Cycle Testing?

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Accelerated Temperature Humidity Testing Using the Arrhenius-Peck Relationship

Humidity Testing can be used to accelerate the aging of products that are affected by ambient humidity levels. Increasing the humidity above the normal use level humidity can cause defects or failures to occur in shorter times than what would be observed in the field.  Humidity testing is most commonly performed along with testing at elevated temperature so that the resulting acceleration factor is affected by both humidity and temperature. The Acceleration Factor (AF) which is the ratio of the life at use conditions to the accelerated life at test conditions for temperature humidity testing is given by the following Arrhenius-Peck equation:

Acceleration Factor

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MIL-STD-810: Vibration Testing Category 4 – Truck/Trailer – Secured Cargo

This is part two of a series of blog posts concerning the MIL-STD 810 Vibration Section.  This blog was written with reference to MIL-STD-810G w/Change 1 dated 15 April 2014.  DES has the experience and expertise to help you determine what profiles are appropriate for your product and to run your MIL-STD-810 vibration test.  For more information, please check out Part 1 – MIL-STD-810 Vibration Testing Overview blog and our Vibration Testing services page.

Category 4 of Method 514.7 Vibration testing details the transportation random vibration environmental conditions from cargo interaction with vehicle suspension and structures with road and surface discontinuities.  “This environment may be divided into two phases, truck transportation over US highways, and mission/field transportation.  Mission/field transportation is further broken down into two-wheeled trailer and wheeled vehicles categories.”


Truck Transportation over US Highways Vibration Testing

This vibration test method is used when products or equipment will be transported by large trucks tractor-trailers commonly seen on US highways.  The truck transportation over US highways random vibration profile is designed to simulate 1609 km (1000 miles) on interstate highways.  The random vibration profile along each axis can be seen in the plot below in Figure 1.  The length of this profile is 60 minutes per axis for each 1000 miles of transportation.  For example to simulate 2000 highway miles, the vibration test duration would be 2 hours per axis x 3 axes = 6 hours total.

Vibration Testing MIL-STD-810G w/ Change 1
Figure 1. Figure 514.7C-2 from MIL-STD-810G w/ Change 1

Continue reading MIL-STD-810: Vibration Testing Category 4 – Truck/Trailer – Secured Cargo

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Altitude Testing: Low Pressure Vacuum Chamber

Altitude TestAltitude (Low Pressure) Testing makes use of a vacuum chamber to simulate the effects of high altitude conditions. The pressure inside the altitude chamber can be reduced to correspond to the air pressure at a specific altitude. Products can be placed inside the altitude chamber and tested to determine if they will still function after exposure to a given duration at a specified altitude.

Components sealed with internal fluid such as batteries or capacitors may fail or leak during altitude testing because an internal pressure results at rising altitudes as the external pressure is reduced.  It is also possible to power a product during the test to verify that it remains operational during the altitude test. The lower pressure at higher altitudes can reduce the cooling of components which can lead to possible failures. For this type of testing, it is necessary to have power and signal wires that can be fed into the altitude chamber without causing vacuum leaks. DES can provide a generic feed through that can be used for most testing. A custom feed through can also be fabricated if the component to be tested has specialized power or signal cables. It will be necessary to seal these cables to maintain the low pressure.

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