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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Understanding IEC 60068-2: A Comprehensive Guide

IEC 60068-2 is a globally recognized standard that outlines a series of tests for products, components, and equipment to assess their ability to withstand environmental conditions. By simulating the different climatic conditions and mechanical stresses a product can undergo during its lifetime, environmental testing can help manufacturers validate the ruggedness, durability, and performance of their products.

One of the key tests within this series is the shock test, which is designed to simulate the effects of sudden impacts or abrupt changes in motion that a product might encounter during its lifecycle. Specifically, the International Electrotechnical Commission (IEC) manages two well-known shock and drop-shock standards for electrical and electronic-related technologies, IEC 60068-2-27 and IEC 60068-2-31. 

  • IEC 60068-2-27 Environmental testing Part 2-27: Test Ea: Shock
  • IEC 60068-2-31 Environmental testing Part 2-31: Test Ec: Rough Handling Shocks

IEC 60068-2 shock testing is a critical part of product development for several reasons:

  • Real-world conditions simulation: Products often encounter shocks and impacts during shipping, handling, and everyday use. IEC 60068-2 shock testing simulates these conditions to assess how well the product can withstand them.
  • Identification of potential weaknesses: Shock testing can reveal design or manufacturing flaws that might cause the product to fail prematurely. Identifying these issues early in the development process can save time and money on product recalls or redesigns.
  • Ensuring product reliability: For products that are used in critical applications, such as medical devices or aerospace components, shock testing is crucial to ensure they can perform reliably under all conditions.
  • Worldwide recognition: IEC 60068-2 is an international standard, so products tested to this standard are accepted worldwide. This can simplify the process of selling your product in international markets.

At DES, we understand the importance of detailed and accurate shock testing. Our experienced team can guide you through the process, ensuring your product meets all relevant standards and is ready for the rigors of real-world use.

IEC 60068-2-27: A Detailed Look at the Shock Testing Standard

IEC 60068-2-27 is a specific test within the IEC 60068-2 series that focuses on shock testing. This test is designed to simulate the shock conditions that products, components, and equipment may encounter during transportation, storage, handling, or in use. The purpose of this test is to reveal mechanical deficiencies, degradation, and/or accumulate damage caused by shocks.

The IEC 60068-2-27 test is a crucial part of the product development process. It provides manufacturers with valuable insights into the potential weaknesses of their products, allowing them to make necessary improvements to enhance product durability.

The test involves subjecting the product to specified levels of shock impulses in a controlled environment. There are 3 types of shocks in IEC 60068-2-27, half-sine impulse, saw-tooth impulse, and the trapezoidal impulse.  Much of this standard defines the pulse shapes and control of the shock parameters.  Other sections cover the test severities such as the peak acceleration level, duration, and number of shocks.  The user specifies which test severities are applicable to their products.  Annex A provides guidance and examples of test severities for various applications.  Annex B gives information about shock response spectra (SRS) and the characteristics of the pulse shapes.  The product’s performance may be evaluated during the shocks or just before/after the test.

At Delserro Engineering Solutions, we have extensive experience conducting IEC 60068-2-27 shock testing. Our meticulous approach to testing ensures that your product is thoroughly evaluated for potential weaknesses, providing you with the information you need to make informed decisions about product improvements. Our commitment to quality and accuracy ensures that our testing procedures meet the highest standards of reliability and precision.

IEC 60068-2-31: Shocks Intended to Simulate Rough Handling

IEC60068-2-31 is another critical standard within the IEC 60068-2 series, focusing on simulating the effects of rough handling shocks.  Rough handling shocks are knocks, jolts, and falls typically encountered during repair work, rough handling or dropping.  IEC 60068-2-31 defines 3 types of rough handling shock tests:

  • Drop and Topple is intended to assess the effects of knocks or jolts typically occurring during repair work or rough handling on a table or work-bench.  The drop tests are accomplished by raising an edge or corner of an item to a prescribed height, then releasing it allowing the face under test to drop onto a hard surface.  The topple test is performed by raising an edge slowly until instability occurs, then allowing the specimen to topple over onto an adjacent face.  The number of drops or topples is usually 4.
  • Free Fall – Procedure 1 is aimed at evaluating the effects of falls from rough handling.  The entire specimen is raised to a defined height, then released allowing it to free fall onto a hard surface.  The product can be oriented to allow the impact to occur on a face, edge or corner.  Typically the number of free falls is 2.
  • Free Fall – Procedure 2 is intended to reproduce repetitive shock conditions likely to occur on component-type specimens such as electrical connectors.  The test specimens are subjected to a prescribed number of falls from a specified height onto a hard surface.  The number of falls in procedure 2 typically ranges from 50 to 1,000. 

At Delserro Engineering Solutions, we use a thorough approach when conducting IEC 60068-2-27 and IEC 60068-2-31 shock testing, ensuring that the test is performed under repeatable conditions and your product is evaluated for rugged usage.

Our testing process begins with a thorough understanding of your product and its intended use. This allows us to assess the shocks and impacts your product is likely to encounter. We then subject your product to a specified level of shocks or impacts in a controlled environment. This test can reveal defects in the product’s design or construction that might not be evident.

Throughout the testing process, our team of experts will keep you informed of our findings and will deliver a detailed report upon test completion. Our goal is to help you improve your product’s reliability and durability, ultimately enhancing its market success.

Our commitment to quality and accuracy is demonstrated by our compliance with ISO/IEC 17025, a globally recognized standard for testing and calibration laboratories. Furthermore, our lab is accredited by A2LA, the country’s leading accreditation agency. This ensures that all tests conducted are technically competent, reliable, and of the highest quality. Clients can have peace of mind knowing that their products are tested with precision and accuracy, minimizing the risk of product failures in the market.

IEC 60068 2: Why Choose DES for Your Shock Testing Needs

Choosing the right partner for your shock testing needs is crucial. At Delserro Engineering Solutions, we offer a comprehensive suite of services designed to ensure your products meet the stringent IEC 60068-2 standards. Here’s why DES should be your first choice:

  1. Experience: With over 30 years in the industry, we have the expertise to conduct thorough and accurate shock testing for a wide range of products. Our team has managed testing projects for clients all over the world, including renowned organizations like Adidas, Crayola, Medtronic, Rolls Royce, Boeing, Lockheed Martin, NASA and the U.S. Army.
  2. Quality Assurance: Our lab is ISO/IEC 17025 compliant and A2LA accredited, ensuring the highest level of quality and reliability in our testing procedures. This commitment to quality is demonstrated in every test we conduct, providing you with confidence that your product has been thoroughly evaluated and meets all relevant standards.
  3. Customized Solutions: We understand that every product is unique, so we tailor our testing methods to meet your specific needs. Our team works closely with you to understand your product and its intended use, allowing us to customize our testing process to accurately simulates the shocks and impacts your product is likely to encounter.
  4. Client Satisfaction: We’ve worked with global clients and have received positive feedback on our seamless procedures, high level of service, and impressive test results. Our commitment to client satisfaction is evident in every project we undertake, and we strive to exceed your expectations at every turn.

Contact DES today to discuss your IEC 60068-2 shock testing requirements with one of our experts. We’re here to help you ensure your product’s success in the market.

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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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MIL-STD 810, Method 516, Shock Testing Procedure VI – Bench Handling

This is the final part of a series of blog posts concerning the MIL-STD 810 Shock Section, Method 516.  This blog was written with reference to MIL-STD-810G w/Change 1 dated 15 April 2014.  DES has the experience and expertise to run your MIL-STD-810 test.  For more information, please check out our DES shock testing services page and our other MIL-STD-810 shock testing blog articles:

MIL-STD 810, Method 516, Shock Testing Overview

MIL-STD 810, Method 516, Shock Testing Procedure I – Functional Shock

MIL-STD 810, Method 516, Shock Testing Procedure II – Transportation Shock

MIL-STD 810, Method 516, Shock Testing Procedure III – Fragility

MIL-STD 810, Method 516, Shock Testing Procedure IV – Transit Drop

MIL-STD 810, Method 516, Shock Testing Procedure V – Crash Hazard Shock

Continue reading MIL-STD 810, Method 516, Shock Testing Procedure VI – Bench Handling

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