DLA MIL-STD-981 C-2010 Design Manufacturing and Quality Standards for Custom Electromagnetic Devices for Space Applications.pdf

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1、 MIL-STD-981C 1 July 2010 SUPERSEDING MIL-STD-981B 31 January 1992 DEPARTMENT OF DEFENSE STANDARD PRACTICE Design, Manufacturing and Quality Standards for Custom Electromagnetic Devices for Space Applications AMSC N/A FSC 5950 DISTRIBUTION STATEMENT A. Approved for public release; distribution is un

2、limited. INCH-POUND Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-981C ii FOREWORD 1. This standard is approved for use by all Departments and Agencies of the Department of Defense (DoD). 2. Beneficial comments (recommendations, additions,

3、deletions) and any pertinent data which may be of use in improving this document should be addressed to: Defense Supply Center Columbus ATTN: DSCC-VAT P.O. Box 3990 Columbus, Ohio 43218 Since contact information can change, you may want to verify the currency of this address information using the AS

4、SIST Online database at https:/assist.daps.dla.mil. 3. This standard is the technical baseline for the design, manufacturing, and quality standards of custom electromagnetic devices. The intent of this standard is to provide uniform requirements for devices that are used in critical space applicatio

5、ns and mission-essential ground equipment. This standard also covers devices in noncritical flight and non-mission-essential ground support applications. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-981C iii CONTENTS PARAGRAPH PAGE 1. SCOP

6、E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Classification . . . . . . . . .

7、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. APPLICABLE DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2.2 Government documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8、 . . . . . . . . . . . . . . . 2 2.3 Non-government documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.4 Order of precedence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3. DEFINITIONS . . . .

9、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4. GENERAL REQUIREMENTS . . . . . . . . . . . . . . . . . . .

10、 . . . . . . . . . . . . . . . . . . . . . . . . . 4 4.1 Procurement documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4.2 Power transformers, power inductors, etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4.3 Ra

11、dio frequency, fixed and variable transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4.4 Radio frequency, fixed and variable coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4.5 Low power pulse transformers . . . . . . . . . . . . . . . . . . . . .

12、. . . . . . . . . . . . . . . . . . . . . . 4 4.6 Radio frequency, chip, fixed and variable coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4.7 Frequency, molded, fixed, established reliability, coils . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5. DETAILED REQUIREME

13、NTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5.1 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5.2 Internal elements . . . . . . . . . . . . . . . . . . . . . . . .

14、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 5.3 Radiographic inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 5.4 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15、. . . . . . . . . . . . 7 5.5 Manufacturing practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5.6 Quality assurance provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 6. NOTES . . . . . . .

16、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.1 Subject term (key word) listings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.2 Environmentally preferable material . . . . . . . . . . .

17、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.3 Changes from previous issue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 FIGURES 1. Recommended bobbin coil termination anchoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18、0 2. A recommended toroidal coil termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3. Recommended magnet wire-to-post termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15 4. Antirotation features . . . . . . . . . . . . . . . . . . . . .

19、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 B-1. A typical transformer/inductor construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-51 B-2. Axial orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20、 . . . . . . . . . . . 52 B-3. Unacceptable extraneous material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-57 B-4. Unacceptable alignment and clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 B-5. Unacceptable processing .

21、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 B-6. Unacceptable processing damage toroidal core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 B-7. Unacceptable workmanship for radio frequency coils . . . . . . . . . . . . . . . . .

22、 . . . . . . . . . . 61 B-8. Unacceptable workmanship for radio frequency coils (Surface Mount) . . . . . . . . . . . . . . . 62 B-9. Unacceptable workmanship for radio frequency coils (Surface Mount) . . . . . . . . . . . . . . . 63 Provided by IHSNot for ResaleNo reproduction or networking permitt

23、ed without license from IHS-,-,-MIL-STD-981C iv TABLES I. Device types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 II. Wire limitations for magnet wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24、. . . . 5 III. Termination limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 IV. Inspection of transformers and inductors similar to transformers and inductors that have been qualified by test . . . . . . . . . . . . . . . . . . . . . . 2

25、4 V. Group A screening tests for families 03, 04, etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 VI. Group A screening tests for families 11 and 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 VII. Group A screening tests for families 13 and 14 . . . . . . .

26、 . . . . . . . . . . . . . . . . . . . . . . . . 27 VIII. Group A screening tests for family 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 IX. Group A screening tests for families 50 and 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 X. Grou

27、p A screening tests for family 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 XI. Group B tests for power transformers, etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 XII. Group B tests for RF coils . . . . . . . . . . . . . . . . .

28、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 XIII. Group B tests for RF transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 XIV. Group B tests for RF chip coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29、 . . . . . 36 XV. Group B tests for RF fixed coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 APPENDICES A. Product assurance program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 B. Radiographic inspect

30、ion (Real time X-ray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-981C 1 1. SCOPE 1.1 Scope. This standard establishes the requirements for acceptable design, manu

31、facturing, and quality control criteria for custom electromagnetic, open and closed construction, leaded and surface mount devices for space applications. 1.1.1 Intended use of or reference to MIL-STD-981. When this document is referenced or is used as a standard for the design, processing, manufact

32、uring and screening of custom electromagnetic devices for space flight applications, such design, processing, manufacturing, and screening will be in full conformance with all the applicable general and detailed requirements of this standard for the individual device type. Any device meeting only se

33、lected provisions of this standard is considered noncompliant. 1.1.2 Compliant electromagnetic devices. Compliant electromagnetic devices will meet without exception all of the applicable requirements and quality standards of MIL-STD-981. Any device that is processed with deviations, omissions, or d

34、oes not meet the full intent of this standard will not be claimed to be compliant. 1.1.3 Noncompliant electromagnetic devices. Any device that is processed with deviations and is not processed in compliance with the provisions of this standard will not be claimed to be compliant and will not be mark

35、ed in any manner that would indicate compliance or partial compliance. All applicable documentation (including detail specifications and responses to Request for Quotations invoking MIL-STD-981) will clearly and specifically define the areas of nonconformance and identify each as a deviation. Such d

36、eviations will be approved by the acquiring activity. 1.2 Classification. 1.2.1 Families. Table I shows numerical designations that are used in this standard to indicate various device types: TABLE I. Device types. Device Type Family Applicable Military Specification Transformer, power 03 MIL-PRF-27

37、 Inductor, power 04 MIL-PRF-27 Transformer, R.F. fixed 11 MIL-T-55631 Transformer, R.F. variable 12 MIL-T-55631 Coil, R.F., fixed 13 MIL-PRF-15305 Coil, R.F., variable 14 MIL-PRF-15305 Inductor, audio 20 MIL-PRF-27 Transformer, audio 21 MIL-PRF-27 Transformer, pulse, low, power 31 MIL-PRF-21038 Tran

38、sformer, pulse, high, power 36 MIL-PRF-27 Inductor, charging 37 MIL-PRF-27 Transformer, saturable 40 MIL-PRF-27 Inductor, saturable 41 MIL-PRF-27 Coil, R.F., chip, fixed 50 MIL-PRF-83446 Coil, R.F., chip, variable 51 MIL-PRF-83446 Coil, R.F., fixed 52 MIL-PRF-39010 1.2.2 Classes. Two classes of requ

39、irements are defined in this standard. Class S parts are intended for critical flight and mission essential ground support applications and any application that is critical to safety. Class B parts are for use in noncritical flight and non-mission essential ground support applications. Provided by I

40、HSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-981C 2 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this standard. This section does not include documents cited in other sections of this

41、 standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this standard, whether or not they ar

42、e listed. 2.2 Government documents 2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or cont

43、ract. SPECIFICATION DEPARTMENT OF DEFENSE MIL-PRF-27 - Transformers and Inductors (Audio, Power, and High-Power Pulse), General Specification For MIL-PRF-15305 - Coils, Fixed and Variable, Radio Frequency, General Specification For. MIL-PRF-21038 - Transformers, Pulse, Low Power, General Specificati

44、on For MIL-PRF-39010 - Coil, Radio Frequency, Fixed, Molded, Established Reliability and Non-established Reliability, General Specification For. MIL-T-55631 - Transformers, Intermediate Frequency, Radio Frequency and Discriminator, General Specification For. MIL-PRF-83446 - Coils, Radio Frequency, C

45、hip, Fixed or Variable General Specification For STANDARDS DEPARTMENT OF DEFENSE MIL-STD-202 - Test Methods for Electronic and Electrical Component Parts. MIL-STD-1285 - Marking of Electrical and Electronic Parts MIL-STD-1580 - Destructive Physical Analysis for Electronic, Electromagnetic, and Elect

46、romechanical Devices (Copies of these documents are available online at https:/assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.3 Non-Government publications. The following documents form a part of this

47、 document to the extent specified herein. Unless otherwise specified, the issues of the documents are those cited in the solicitation or contract. AMERICAN NATIONAL STANDARDS J-STD-004 - Requirements for Soldering Fluxes. J-STD-005 - Requirements for Soldering Pastes. J-STD-006 - Requirements for El

48、ectronic Grade Solder Alloys and Fluxed and Non-Fluxed Solder Solders for Electronic Soldering Applications. (DoD activities may obtain copies of American National Standards from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094. The private sector and other Government agencies may purchase copies from the Institute for Interconnecting and Packaging Electronic Circuits (IPC), 7380 N. Lincoln Avenue, Lincolnwood, IL 60646-1776. http:/www.ipc.org/). Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,