E.1 Purpose of Appendix E
Due to the complexity and uniqueness of space flight, it is unlikely that all of the requirements in a NASA technical standard will apply. The Requirements Compliance Matrix below contains this NASA Technical Standard’s technical authority requirements and may be used by programs and projects to indicate requirements that are applicable or not applicable to help minimize costs. Enter “Yes” in the “Applicable” column if the requirement is applicable to the program or project or “No” if the requirement is not applicable to the program or project. The “Comments” column may be used to provide specific instructions on how to apply the requirement or to specify proposed tailoring.
| Section | Description | Requirement in this Standard | Applicable (Enter Yes or No) | Comments | |||
|---|---|---|---|---|---|---|---|
| 4.1 | Fastening System Control Plan | [TFSR 1] At the Preliminary Requirements Review, equivalent program milestone review, or project milestone review, each hardware developer shall submit a Fastening System Control Plan to the delegated NASA Technical Authority that: a. Shows how the requirements in this NASA Technical Standard are to be satisfied; and b. Includes any organization-specific requirements and criteria for design, analysis, fastener installation, and verification; and c. Captures or refers to organization-specific processes for ensuring quality and integrity. | |||||
| 4.2.1 | Factor of Safety | [TFSR 2] Threaded fastening system hardware shall be designed using the structural factors of safety specified by the program or project for general structural design. | |||||
| 4.2.2 | Fitting Factor | [TFSR 3] Threaded fastening system hardware shall be designed using a fitting factor (FF). | |||||
| 4.2.3 | Separation Factor of Safety | [TFSR 4] Threaded fastening system hardware shall be designed using the separation factor of safety (FSsep) specified by Figure 1, Logic Flow for Minimum Separation Factor of Safety. Could joint separation credibly lead to a catastrophic hazard?(1) YES NO Could joint separation credibly NO FSsep = greater of 1.0 and lead to a critical hazard? (2) program levied value for test factor(3) YES YES FSsep = program levied FSsep = greater of 1.2 and value for FSu program levied value for FSy (1)A hazard that could result in a mishap causing fatal injury to personnel, and/or loss of one or more major elements of the flight vehicle or ground facility. A condition that may cause death or permanently disabling injury, major system or facility destruction on the ground, or loss of crew, major systems, or vehicle during the mission. (2)A condition that may cause severe injury or occupational illness, or major property damage to facilities, systems, or flight hardware. (3)If testing, such as proof or acceptance, is to be performed at higher than limit load, the factor should be increased to envelope test conditions to preclude separation during test. Figure 1—Logic Flow for Minimum Separation Factor of Safety | |||||
| 4.3.1 | Maximum and Minimum Preload | [TFSR 5] Maximum and minimum preload calculations shall account for the potential preload variation associated with the method of developing initial preload, relaxation, creep, and the effects of maximum and minimum expected temperatures. | |||||
| 4.3.2 | Nominal Preload | [TFSR 6] Calculation of the nominal (mean) initial preload, Ppi-nom, shall be substantiated by tests of a minimum of six sets of the fastening system hardware per Table 2, Nominal Preload Determination, to determine the relationship between initial preload and the parameter controlled during installation (torque, turn-of-nut, turn-angle, or bolt stretch). | |||||
| Section | Description | ||||||
| Requirement in this Standard | Applicable (Enter Yes or No) | Comments | |||||
| Table 2—Nominal Preload Determination | |||||||
| Torque Control(1,2) | Turn-of-Nut or Turn-Angle | Bolt Stretch | |||||
| The fastening system hardware has the same diameter and thread form, the same type and number of washers, same materials, and same nut/nut plate/insert as the flight assembly. The clamped part and washer that are adjacent to a non- rotating bolt head or non-rotating nut are not critical and are allowed to vary from the flight assembly. | R | R | R | ||||
| Cleaning, lubricants, and lubrication process are the same as flight assembly. | R | R | NR | ||||
| The fastening system hardware is the same specification (part number) as the flight assembly hardware. | NR | R | R | ||||
| Installation process is the same as flight assembly. | NR | R | R | ||||
| R="Required," NR="Desirable" but not required | |||||||
| (1) At least three tests (install, torque, and removal) should be performed on each of the six sets of fastening system hardware for a total of eighteen tests, unless reuse is prohibited in the flight assembly. | |||||||
| (2) See NASM 1312-15, Fastener Test Methods, Method 15, Torque-Tension, for guidance for torque- tension testing. | |||||||
| 4.3.3 | Preload Variation | [TFSR 7] The preload variation, I, used to calculate the minimum and maximum initial preload shall be based on the criteria of Table 3, Preload Variation Determination. | |||||
| Section | Description | Requirement in this Standard | Applicable (Enter Yes or No) | Comments | |||
| Table 3 – Preload Variation Determination | |||||||
| Method | Separation Critical | Non-Separation Critical | |||||
| Torque Control | Envelope of statistical basis(1) and variation to satisfy Table 2(2) while using a. Lot-specific testing (testing the procurement lot of fastening system hardware that will be used for spaceflight)(3) or b. Testing equal numbers of sets of fastening system hardware of the same specification as the flight- assembly hardware, from each of at least three procurement lots(3) | a. Statistical basis(1) , or b. Greater of (1) 25 percent (if lubricated), (2) 35 percent (if non- lubricated or as-received), (3) Variation from tests to satisfy Table 2(2) | |||||
| Turn-of-Nut or Turn Angle | Envelope of statistical basis(1) and variation to satisfy Table 2(2) | a. Statistical basis(1) , or b. Greater of (1) 25 percent (2) Variation from tests to satisfy Table 2(2) | |||||
| Bolt Stretch | Envelope of statistical basis(1) and variation to satisfy Table 2(2) | a. Statistical basis(1) , or b. Greater of (1) 10 percent (2) Variation from tests to satisfy Table 2(2) | |||||
| Section | Description | ||||||
| Requirement in this Standard | Applicable (Enter Yes or No) | Comments | |||||
| (1)90 percent probability and 95 percent confidence (two-sided distribution), with tests meeting the configuration requirements of Table 2. (2)The variation from the tests to satisfy Table 2 is given by the minimum and maximum values of preload relative to the nominal preload such that a-max="P" pi-maxa/P pi-nom-1 and a-min="1-P" pi-mina/P pi-nom. (3)Each fastener to be installed, torqued, and removed at least three cycle times unless reuse is prohibited for the flight assembly. When reuse is prohibited, only the data from the first cycle is used. | |||||||
| 4.4.1 | Ultimate Design Loads | [TFSR 8] Threaded fastening system hardware shall withstand ultimate design loads (limit load times the ultimate factor of safety and fitting factor) without failure when subjected to: a. The accompanying service environments (for example, temperature) and b. A coefficient of friction between clamped parts equal to zero (applicable only to verification by analysis, not applicable by test) [see TFSR 13]. | |||||
| 4.4.2 | Yield Design Loads | [TFSR 9] Threaded fastening system hardware shall withstand yield design loads (limit load times the yield factor of safety and fitting factor) without detrimental yielding or detrimental deformation when subjected to the accompanying service environments (for example, temperature). | |||||
| 4.4.3 | Separation Loads | [TFSR 10] Threaded fastening system hardware shall withstand design separation loads (limit load times the separation factor of safety and fitting factor) without loss of compression between the joint members or detrimental deformation due to separation when subjected to the accompanying service environments (for example, temperature). | |||||
| 4.4.4 | Combination of Loads | [TFSR 11] The limit, yield, ultimate, and separation applied loads shall account for interaction of the combined loading (simultaneously applied tensile, shear, and bending loads) and under all design environmental conditions. | |||||
| 4.4.5 | Inclusion of Preload in Yield and Ultimate Load Strength | [TFSR 12] If rupture occurs before separation, preload shall be included in the determination of the total tensile load in the preloaded bolt. | |||||
| 4.4.6a | Use of Friction at Limit and Yield Load | [TFSR 13] Use of friction to react shear loads shall only be permissible for analysis at limit load (alignment, fatigue, and fracture) or yield load. | |||||
| 4.4.6b | Use of Friction at Limit and Yield Load | [TFSR 14] Unless otherwise substantiated by test, the coefficient of friction for joint-slip analysis shall be no greater than: (1) 0.20 for uncoated, non-lubricated metal surfaces that are cleaned by a qualified process and visibly clean at and after assembly. (2) 0.10 for all other surfaces, including nonmetallic (coated or uncoated) surfaces and metallic surfaces that are coated with any substance, including lubricant, paint, and conversion coating. | |||||
| 4.5 | Fatigue Life | [TFSR 15] All threaded fastening systems shall be designed to withstand the entire service life, including the life scatter factor specified by the program or project, and service environment without fatigue failure. | |||||
| 4.6.1 | Preload Independent Locking Feature | [TFSR 16] Regardless of the magnitude of preload, each threaded fastening system in spaceflight hardware shall incorporate a minimum of one locking feature that does not depend upon preload to function. | |||||
| 4.6.2 | Mechanical Locking Feature | [TFSR 17] A mechanical locking feature shall be used on any bolt subject to rotation in operation. | |||||
| 4.6.3 | Liquid Locking Compound Process Control | [TFSR 18] When using locking adhesives, whether as thread-locking compounds or staking materials, installation processes shall be developed and validated prior to implementation to ensure adhesives cure, adhere, and function as expected. | |||||
| 4.6.4 | Locking Feature Verification | [TFSR 19] The presence and performance (locking moment) of locking features shall be verified using the methods of Table 4, Locking Feature Torque Verification. | |||||
| Table 4—Locking Feature Torque Verification | |||||||
| Locking Feature Type | Method | ||||||
| Mechanical | Visual inspection after | ||||||
| Section | Description | ||||||
| Requirement in this Standard | Applicable (Enter Yes or No) | Comments | |||||
| Prevailing Torque (including, but not limited to, deformed thread features and non-metallic pellets, strips, or patches) | Torque measurement during installation(1) | ||||||
| Liquid Locking Compounds (including, but not limited to, adhesives, sealants, thread lockers, and chemical thread pre-coats that are applied to the threads and cured prior to joint assembly) | Torque measurement on witness specimens using the same materials and processes, and processed at the same time, as the hardware being verified(2) | ||||||
| (1)Verification of prevailing torque locking features by torque measurement may be omitted with prior approval of the delegated NASA Technical Authority if loss of fastener does not credibly cause a catastrophic hazard and if other controls are utilized to minimize the likelihood of assembly with inadequate locking features. Examples of such controls are fastener lot acceptance testing of locking feature performance, locking feature surveillance with periodic measurement of prevailing torque on like fasteners in flight hardware assemblies, technician training to recognize when no prevailing torque is present, etc. The rationale for this approach needs to properly consider fastener reuse if fastener reuse is permitted in the flight assembly. Preloaded joint analyses cannot assume a specified torque 'above running torque' if prevailing torque is not measured. Relaxation of this verification requirement is generally intended for secondary or tertiary structures such as P-clamps. (2)For adhesive locking features that are not sensitive to the threaded fastening system materials or configuration, cure samples processed at the time of application/processing may be used for verification. | |||||||
| 4.7.1 | Materials | [TFSR 20] Materials used in threaded fastening systems shall comply with NASA-STD-6016, Standard Materials and Processes Requirements for Spacecraft. | |||||
| Thread Form Compatibility | [TFSR 21] Mating threaded parts shall have compatible thread forms. | ||||||
| 4.7.2 4.7.3 | Use of Washers and Chamfered Bolt Holes | [TFSR 22] Clearance shall be provided for the head-to-shank fillet radius as needed to avoid interference with the clamped parts through the use of chamfered holes or countersunk washers installed under bolt heads with the countersink facing the bolt head (see Figure 2, Dimensional Considerations in Selecting Fastening Hardware). | |||||
| Washer under head, with countersink if needed to accommodate head-to- shank fillet radius Joint grip Bolt grip ≥0.75 For shear joints, to have negligible effect on bearing strength ≥2p (To avoid interference with incomplete runout threads; may require more than one washer under nut) Incomplete runout threads over distance up to 2p Incomplete lead threads over distance up to 2p (To ensure full thread engagement) p is the thread pitch <center>Figure 2—Dimensional Considerations in Selecting Fastening Hardware</center> | |||||||
| 4.7.4 | Fastener Length Selection for Thread Engagement | ||||||
| 4.7.5a | Bolt Grip Selection to Prevent Interference | ||||||
| 4.7.5b | Bolt Grip Selection to Prevent Interference | ||||||
| 4.8.1 | Design Documentation NASA-STD-5020B | [TFSR 26] The engineering documentation shall specify a. The part or identifying numbers of fastening system hardware, and b. Required lubricants, coatings, or sealants used in threaded fastening systems, the area to which they are applied, as well as their application processes, and c. Dimensions and tolerances necessary to manufacture and assemble the fastened joint and its constituent parts, and | |||||
| d. The types, locations, and allowable quantities of washers, and e. The installation methods and parameters for achieving preload, and f. The installation torque range or applicable standard that defines the installation torque range, and g. Whether the specified torque is total torque or the torque above running torque. | |||||||
| 4.8.2 | As-Built Documentation | [TFSR 27] Records documenting the as-built procedures and configuration of each assembly shall be created and maintained by the hardware developer and provided for review upon request by the delegated NASA Technical Authority. | |||||
| 4.8.3 | Training | [TFSR 28] Personnel installing fastening system hardware shall be trained per program-, project-, or organization-specific quality process. | |||||
| 4.8.4a | Tools and Instruments | [TFSR 29] Tools and instruments used to install fastening system hardware shall be verified to be in calibration prior to use and used within their design and calibration ranges. | |||||
| 4.8.4b | Tools and Instruments | [TFSR 30] Torque instruments shall conform to ASME B107.300-2010, Torque Instruments, or a NASA-approved alternative. | |||||
| 4.8.5 | Threaded Fastening System Hardware Inspection | [TFSR 31] Threaded fastening system hardware shall be inspected prior to installation to verify that part number(s), cleanliness, and orientation are in accordance with the engineering documentation. | |||||
| 4.8.6 | Fastening System Hardware Procurement, Inspection, and Storage | [TFSR 32] Procurement, receiving inspection, and storage of threaded fastening system hardware that joins or retains components or structural elements shall meet the requirements of NASA-STD-8739.14, NASA Fastener Procurement, Receiving Inspection, and Storage Practices for NASA Mission Hardware. | |||||