This document provides the hardware developer with the requirements, rationale, and methodologies to implement fracture control requirements. It also provides a guide to the Responsible Fracture Control Board (RFCB) when reviewing the Fracture Control Plan (FCP).
This document contains 26 requirements that are numbered as Fracture Control Requirements [FCRs] and that begin in section 4. These requirements use the word “shall.” Narrative text and requirement rationale are provided in italic format beginning in section 4. Narrative text is provided as guidance for the associated requirement. It is recommended that fracture control practitioners become familiar with all portions of this NASA Technical Standard.
The FCRs are summarized and briefly described in table 1, Overview of Fracture Control Requirements in NASA-STD-5019A. Figure 1, NASA-STD-5019A Fracture Control Requirements Diagram, shows a diagram of the FCRs and the section in this NASA Technical Standard in which that particular FCR appears.
A viable fracture control program relies on design, analysis, testing, non-destructive evaluation (NDE), and tracking of fracture critical hardware. It is expected that all spaceflight hardware will be manufactured consistent with industry or aerospace standards, practices, and quality. It is beyond the scope or intent of this document to address technical or quality disciplines that should already exist and be in place regardless of fracture control. Fracture control is imposed and required, not to correct deficiencies in other disciplines, rather to enhance the safety and mission reliability of systems by reducing the risk of catastrophic failure caused by the presence of flaws.
NASA-HDBK-5010, Fracture Control Implementation Handbook for Payloads, Experiments, and Similar Hardware, contains examples and additional guidance for interpretation and implementation of the requirements of this Standard. NASA-HDBK-5010, Revision A, is under development and may not be released at the time of publication of this NASA Technical Standard. Before the release of NASA-HDBK-5010A, the current handbook may provide interim guidance for applying this NASA Technical Standard. Note that NASA-HDBK-5010A will include guidelines for NASA-STD-5019A and will likely undergo a title change to reflect a broader scope than payloads and experiments.
Non-Fracture Critical (NFC) Classification: Requirement=[FCR 9], Description=Additional activities for composite or bonded NFC hardware, Section=6.3 Flaw screening and evaluation, traceability, and material requirements for fracture critical parts and other: Requirement=[FCR 15], Description=Flaw screen requirement, Section=8 Flaw screening and evaluation, traceability, and material requirements for fracture critical parts and other: Requirement=[FCR 16], Description=NDE requirement for metallic parts, Section=8.1.1 Flaw screening and evaluation, traceability, and material requirements for fracture critical parts and other: Requirement=[FCR 17], Description=NDE requirement for composite or bonded parts, Section=8.1.2 Flaw screening and evaluation, traceability, and material requirements for fracture critical parts and other: Requirement=[FCR 18], Description=Optional proof test requirement, Section=8.1.3 Flaw screening and evaluation, traceability, and material requirements for fracture critical parts and other: Requirement=[FCR 19], Description=Optional process control requirement, Section=8.1.4 Flaw screening and evaluation, traceability, and material requirements for fracture critical parts and other: Requirement=[FCR 20], Description=Detected flaw requirement, Section=8.1.5
NASA-STD-5019A w/CHANGE 4
NASA-STD-5019A w/CHANGE 4
Figure description:
Fracture Control Requirements (FCR Process Flow
Initial Requirements and Planning
- Establishment: Development of the Fracture Control Plan, identification of the Responsible Fracture Control Board (RFCB, and program implementation.
- Classification: Parts are categorized to determine specific implementation requirements.
Primary Classification Paths
- Exempt Parts: Directed straight to final documentation and verification.
- Assessment of Non-Fracture Critical (NFC Parts:
- Involves specific and general assessment approaches.
- If a part is composite or bonded, it must undergo additional flaw screening, NDE, and traceability requirements.
- Assessment of Fracture Critical (FC Parts:
- Requires detailed assessment for metallic, composite, or bonded hardware.
- Mandatory follow-up includes flaw screening, NDE (metallic/composite, proof tests, process controls, and material selection.
Common Requirements
- Alternatives: Any alternative approach (FCR 26 requires RFCB approval across all critical paths.
- Documentation and Verification: All processes conclude with final documentation including engineering drawings, summary reports, and verification.
Key Entities & Terms
- RFCB: Responsible Fracture Control Board (authorizing body for alternatives.
- NDE: Non-destructive evaluation (required for critical parts.
- NFC: Non-fracture critical.
- Composite/Bonded Parts: Trigger specific additional screening and assessment protocols.
critical Figure 1—NASA-STD-5019A Fracture Control Requirements Diagram
Controlled by: NASA
Figure 1—NASA-STD-5019A Fracture Control Requirements Diagram
| Requirement | Description | Section | |
|---|---|---|---|
| Overarching fracture control requirement | [FCR 1] | Requires that all hardware developers of human-rated spaceflight hardware implement fracture control by selecting the applicable approaches and activities from sections 5, 6, 7, 8, and 9 of this NASA Technical Standard for all parts and document the applicable FCRs in their hardware-specific FCP for review and approval by the RFCB. | 4.1 |
| NASA’s implementation of fracture control on human-rated spaceflight hardware | [FCR 2] | Requires implementation by NASA. | 4.2.1 |
| NASA’s implementation of fracture control on human-rated spaceflight hardware | [FCR 3] | Requires implementation by program. | 4.2.2 |
| NASA’s implementation of fracture control on human-rated spaceflight hardware | [FCR 4] | Requires RFCB involvement. | 4.2.3 |
| Evaluation of all parts | [FCR 5] | Requires the evaluation of all parts used in human-rated spaceflight hardware for fracture control classification. | 4.3 |
| Exempt Classification | [FCR 6] | Criteria for classification of exempt parts | 5 |
| Non-Fracture Critical (NFC) Classification | [FCR 7] | Established approaches and activities for NFC parts for specific hardware types | 6.1 |
| Non-Fracture Critical (NFC) Classification | [FCR 8] | General approaches and activities for NFC categories | 6.2 |
| Non-Fracture Critical (NFC) Classification | [FCR 9] | Additional activities for composite or bonded NFC hardware | 6.3 |
| Fracture Critical Classification | [FCR 10] | Criteria for classification of fracture critical parts | 7 |
| Fracture Critical Classification | [FCR 11] | Established approaches and activities for fracture critical categories for specific hardware types and materials types | 7.2 |
| Fracture Critical Classification | [FCR 12] | Approaches and activities for metallic hardware types not covered by 7.2 or 7.5 | 7.3 |
| Fracture Critical Classification | [FCR 13] | Approaches and activities for composite or bonded parts not covered by 7.2 or 7.5 | 7.4 |
| Fracture Critical Classification | [FCR 14] | Optional approaches and activities for specific hardware types not covered in 7.2 | 7.5 |
| Flaw screening and evaluation, traceability, and material requirements for fracture critical parts and other | [FCR 15] | Flaw screen requirement | 8 |
| Flaw screening and evaluation, traceability, and material requirements for fracture critical parts and other | [FCR 16] | NDE requirement for metallic parts | 8.1.1 |
| Flaw screening and evaluation, traceability, and material requirements for fracture critical parts and other | [FCR 17] | NDE requirement for composite or bonded parts | 8.1.2 |
| Flaw screening and evaluation, traceability, and material requirements for fracture critical parts and other | [FCR 18] | Optional proof test requirement | 8.1.3 |
| Flaw screening and evaluation, traceability, and material requirements for fracture critical parts and other | [FCR 19] | Optional process control requirement | 8.1.4 |
| Flaw screening and evaluation, traceability, and material requirements for fracture critical parts and other | [FCR 20] | Detected flaw requirement | 8.1.5 |
| applicable components | [FCR 21] | Traceability requirement | 8.2 |
| applicable components | [FCR 22] | Materials requirements | 8.3 |
| Documentation | [FCR 23] | Documentation products requirements associated with fracture control | 9.1.2 |
| Documentation | [FCR 24] | Fracture Control Summary Report documenting all parts | 9.1.3 |
| Verification | [FCR 25] | Requirement for verification | 9.2 |
| Alternative approaches | [FCR 26] | Requirement for alternative approaches to the requirements of this NASA Technical Standard | 10 |