MIL-HDBK-510 Revision A:2014
Current
The latest, up-to-date edition.
Aerospace Fuels Certification
English
04-08-2014
1. SCOPE
2. APPLICABLE DOCUMENTS
3. DEFINITIONS
4. GENERAL GUIDANCE
5. DETAILED REQUIREMENTS
6. NOTES
APPENDIX A - REQUIREMENTS DECOMPOSITION AND TRACEABILITY
APPENDIX B - FUEL PROPERTIES/CHARACTERISTIC TESTING
APPENDIX C - BASELINE AEROSPACE FUEL PROPERTY INFORMATION
APPENDIX D - EVALUATING THE COMPATIBILITY OF ADDITIVES OR
ALTERNATIVE FUELS WITH FUEL SYSTEM MATERIALS
APPENDIX E - TOXICITY TEST PROTOCOL AND ESOH BASELINE
INFORMATION
APPENDIX F - FIRE PROTECTION AND SURVIVABILITY/VULNERABILITY
APPENDIX G - AIRCRAFT PROPULSION FUELS CERTIFICATON PROCESS
APPENDIX H - AEROSPACE FUELS INFRASTRUCTURE REQUIREMENTS
APPENDIX I - RISK ASSESSMENT RESULTS
APPENDIX J - CERTIFICATION LESSONS LEARNED
APPENDIX K - ENVIRONMENTAL, SAFETY AND OCCUPATIONAL HEALTH
APPENDIX L - FUEL PROPERTY TRACEABILITY INDEX
APPENDIX M - EVALUATION OF POTENTIAL CANDIDATE FUELS FOR
CERTIFICATION
APPENDIX N - STREAMLINED CERTIFICATION PROCESS
APPENDIX O - EVALUATION OF COMMERCIAL FUEL SPECIFICATION
CHANGES
Defines and documents a lean, knowledge-based process to evaluate, approve, and certify fuels and fuel additives for use in military aviation-fuel using and handling equipment.
| DevelopmentNote |
Supersedes MIL HDBK 510-1 (A) & MIL HDBK 510-2. (09/2014) NEW CHILD NOT 1 IS ADDED
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| DocumentType |
Standard
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| Pages |
370
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| ProductNote |
NEW CHILD NOT 1 IS ADDED
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| PublisherName |
US Military Specs/Standards/Handbooks
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| Status |
Current
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| Supersedes |
This military handbook documents a lean, knowledge-based process to evaluate, approve, and certify fuels and fuel additives for use in military aviation-fuel using and handling equipment. This document was developed to fill the knowledge and experience gaps that currently exist when considering all aspects of the military enterprise related to fuels in a single integrated and cost effective manner instead of a system by system evaluation. This document defines an approach and process to assure that a candidate fuel is suitable for aviation, support equipment and vehicles, interchangeable in the logistics infrastructure, and meets military standards related to the environment, safety and health. Any new fuel or fuel additive will be compared to a baseline (e.g., JP-8 for kerosene fuels) in terms of safety of operation, performance, durability, survivability, material compatibility, environmental impact, safety and health. A streamlined process, specifically aimed at certifying fuels that are “drop-in” (functionally interchangeable and fully mixable) relative to the baseline, is described in Appendix N. Any new fuel found to be suitable might be listed specifically in technical orders like TO 42B-1-1-14 with a reference to the pertinent fuel specification, or an allowance may be made for this fuel in terms of specific requirements in a fuel specification like MIL-DTL-83133, the specification for JP-8. Any new fuel additive found to be suitable might be added to an already-existing Qualified Products List (QPL) for that particular type of additive or might be listed specifically in revisions to fuel specifications like MIL-DTL-83133.
| SAE AIR7484 | Guidance on the Impact of Fuel Properties on Fuel System Design and Operation |
| SAE AMSI7444A | Insulation Sleeving, Electrical, Flexible |
| SAE AMSDTL23053/5A | Insulation Sleeving, Electrical, Heat Shrinkable, Polyolefin, Flexible, Crosslinked |
| ASTM D 7111 : 2016 : REDLINE | Standard Test Method for Determination of Trace Elements in Middle Distillate Fuels by Inductively Coupled Plasma Atomic Emission Spectrometry (ICP-AES) |
| ASTM D 3701 : 2017 : REDLINE | Standard Test Method for Hydrogen Content of Aviation Turbine Fuels by Low Resolution Nuclear Magnetic Resonance Spectrometry |
| SAE AMSQQA250/12A | Aluminum Alloy 7075, Plate and Sheet |
| SAE AMSS8802D | Sealing Compound, Fuel Resistant, Integral Fuel Tanks and Fuel Cell Cavities |
| SAE AMSC27725D | Coating, Corrosion Preventative, for Aircraft Integral Fuel Tanks for Use to 250 °F (121 °C) |
| AFGS 87233 : B NOTICE 1 | SUPPORT SYSTEMS AND EQUIPMENT |
| SAE AMSQQP416E | Plating, Cadmium (Electrodeposited) |
| ASTM D 5452 : 2012 : REDLINE | Standard Test Method for Particulate Contamination in Aviation Fuels by Laboratory Filtration |
| SAE AMS5525J | Steel, Corrosion and Heat-Resistant, Sheet, Strip, and Plate 15Cr - 25.5Ni - 1.2Mo - 2.1Ti - 0.006B - 0.30V 1800 °F (982 °C) Solution Heat Treated |
| MIL-DTL-5624 Revision W:2016 | Turbine Fuel, Aviation, Grades JP-5 (NATO F-44) |
| SAE AMS3361C | Silicone Potting Compound, Elastomeric Two-Part, General Purpose 150 to 400 Poise (15 to 40 Pa·s) Viscosity |
| MIL-PRF-81733 Revision D:1998 | Sealing and Coating Compound, Corrosion Inhibitive |
| SAE AMS3276F | Sealing Compound, Integral Fuel Tanks and General Purpose, Intermittent Use to 360 °F (182 °C) |
| SAE AMS4027N | Aluminum Alloy, Sheet and Plate 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061; -T6 Sheet, -T651 Plate) Solution and Precipitation Heat Treated |
| ASTM D 7170 : 2016 : REDLINE | Standard Test Method for Determination of Derived Cetane Number (DCN) of Diesel Fuel Oils—Fixed Range Injection Period, Constant Volume Combustion Chamber Method |
| ASTM D 3227 : 2016 : REDLINE | Standard Test Method for (Thiol Mercaptan) Sulfur in Gasoline, Kerosine, Aviation Turbine, and Distillate Fuels (Potentiometric Method) |
| MIL-PRF-370 Revision J:2002 | Hose and Hose Assemblies, Nonmetallic: Elastomeric, Liquid Fuel |
| MIL-C-83019 Base Document:1968 | Coating, Polyurethane, for Protection of Integral Fuel Tank Sealing Compound |
| MIL-STD-1787 Revision B:1996 | Aircraft Display Symbology |
| ASTM D 1414 : 2015 : REDLINE | Standard Test Methods for Rubber O-Rings |
| MIL R 6855 : E | RUBBER, SYNTHETIC, SHEETS, STRIPS, MOLDED OR EXTRUDED SHAPES |
| SAE AMS7276H | Rubber: Fluorocarbon (FKM) High-Temperature-Fluid Resistant Low Compression Set For Seals In Fuel Systems and Specific Engine Oil Systems |
| MIL-DTL-83054 Revision C:2003 | Baffle and Inerting Material, Aircraft Fuel Tank |
| AFGS-87139 Revision B:2013 | Landing Gear Systems |
| ASTM D 129 : 2013-08 | TEST METHOD FOR SULFUR IN PETROLEUM PRODUCTS (GENERAL HIGH PRESSURE DECOMPOSITION DEVICE METHOD) |
| SAE AMS5643U | Steel, Corrosion-Resistant, Bars, Wire, Forgings, Mechanical Tubing, and Rings 16Cr - 4.0Ni - 0.30Cb (Nb) - 4.0Cu Solution Heat Treated, Precipitation Hardenable |
| JSSG-2000 Revision B:2004 | Air System |
| SAE AMS6470N | Steel, Nitriding, Bars, Forgings, and Tubing 1.6Cr - 0.35Mo - 1.13Al (0.38 - 0.43C) (135 Mod) |
| ASTM D 924 : 2015 : REDLINE | Standard Test Method for Dissipation Factor (or Power Factor) and Relative Permittivity (Dielectric Constant) of Electrical Insulating Liquids |
| JSSG-2007 Base Document:1998 | Engines, Aircraft, Turbine |
| GOST 10227 : 1986 AMD 6 2012 | |
| SAE AMS 5504 : 2002 | STEEL, CORROSION AND HEAT-RESISTANT, SHEET, STRIP, AND PLATE, 12.5CR (410), ANNEALED |
| SAE AMSR83485A | Rubber, Fluorocarbon Elastomer, Improved Perfrormance At Low Temperatures |
| EI 1581 : 2016 | SPECIFICATIONS AND LABORATORY QUALIFICATION PROCEDURES FOR AVIATION FUEL FILTER/WATER SEPARATORS |
| SAE AMS4037Q | Aluminum Alloy, Sheet and Plate 4.4Cu - 1.5Mg - 0.60Mn (2024; -T3 Flat Sheet, -T351 Plate) Solution Heat Treated |
| JSSG-2010 Base Document:1998 | Crew Systems |
| MIL-DTL-26521 Revision L:2014 | Hose Assembly, Nonmetallic, Fuel, Collapsible, Low Temperature with Non-Reusable Couplings |
| SAE AMS3375C | Adhesive/Sealant, Fluorosilicone Aromatic Fuel Resistant, One-Part Room Temperature Vulcanizing |
| SAE AMSP83461 | Packing, Preformed, Petroleum Hydraulic Fluid Resistant, Improved Performance at 275°F (135°C) |
| ASTM D 5304 : 2015 : REDLINE | Standard Test Method for Assessing Middle Distillate Fuel Storage Stability by Oxygen Overpressure |
| SAE AIR4170B | Reticulated Polyurethane Foam Explosion Suppression Material for Fuel Systems and Dry Bays |
| MIL-STD-2105 Revision D:2011 | Hazard Assessment Tests for Non-Nuclear Munitions |
| ASTM F 146 : 2012 : REDLINE | TEST METHODS FOR FLUID RESISTANCE OF GASKET MATERIALS |
| SAE AMS6345D | Steel, Sheet, Strip, and Plate 0.95Cr - 0.20Mo (0.28 - 0.33C) (SAE 4130) Normalized or Otherwise Heat Treated |
| SAE AMS3215M | Acrylonitrile Butadiene (NBR) Rubber Aromatic Fuel Resistant 65 - 75 |
| SAE AS5127/1C | Aerospace Standard Test Methods for Aerospace Sealants Two-Component Synthetic Rubber Compounds |
| SAE ARP1256D | Procedure for the Continuous Sampling and Measurement of Gaseous Emissions from Aircraft Turbine Engines |
| ASTM D 156 : 2015 : REDLINE | Standard Test Method for Saybolt Color of Petroleum Products (Saybolt Chromometer Method) |
| MIL-PRF-32233 Revision B:2015 | Tanks, Collapsible, 3,000, 10,000, 20,000, 50,000 and 210,000 U.S. Gallons, Fuel |
| MIL-T-52983 Revision G:1994 | Tanks, Fabric, Collapsible: 3,000, 10,000, 20,000, AND 50,000 Gallon, Fuel |
| ASTM D 86 : 2017-06 | TEST METHOD FOR DISTILLATION OF PETROLEUM PRODUCTS AND LIQUID FUELS AT ATMOSPHERIC PRESSURE |
| MIL-DTL-24441 Revision D:2009 | Paint, Epoxy-Polyamide, General Specification for |
| ASTM D 3343 : 2016 : REDLINE | Standard Test Method for Estimation of Hydrogen Content of Aviation Fuels |
| API 5L : 2012 | LINE PIPE |
| MIL-PRF-25017 Revision H:2011 | Inhibitor, Corrosion/Lubricity Improver, Fuel Soluble (NATO S-1747) |
| SAE AMS3277J | Sealing Compound, Polythioether Rubber Fast Curing for Integral Fuel Tanks and General Purpose, Intermittent Use to 360 °F (182 °C) |
| MIL-HDBK-515 Base Document:2002 | Weapon System Integrity Guide (WSIG) (No S/S Document) |
| ASTM D 6272 : 2017 : REDLINE | Standard Test Method for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials by Four-Point Bending |
| SAE AMS6415U | Steel, Bars, Forgings, and Tubing 0.80Cr - 1.8Ni - 0.25Mo (0.38 - 0.43C) (SAE 4340) |
| MIL-DTL-5541 Revision F:2006 | Chemical Conversion Coatings on Aluminum and Aluminum Alloys |
| MIL-STD-464 Revision C:2010 | Electromagnetic Environmental Effects Requirements for Systems |
| ASTM D 5363 : 2016 : REDLINE | Standard Specification for Anaerobic Single-Component Adhesives (AN) |
| SAE AMSR25988 | Rubber, Fluorosilicone Elastomer, Oil-and-Fuel-Resistant, Sheets, Strips, Molded Parts, and Extruded Shapes |
| ASTM D 2624 : 2015 : REDLINE | Standard Test Methods for Electrical Conductivity of Aviation and Distillate Fuels |
| SAE AMS7257E | Perfluorocarbon (FFKM) Engine Oil, Fuel and Hydraulic Fluid Resistant 70 to 80 Hardness For High Temperature Seals in Engine Oil Systems, Fuel Systems and Hydraulic Systems |
| SAE AMSS4383B | Sealing Compound, Topcoat, Fuel Tank Buna-N Type |
| SAE AMS5688L | Steel, Corrosion-Resistant, Wire 18Cr - 9.0Ni (SAE 30302) Spring Temper |
| ASTM D 4529 : 2017 : REDLINE | Standard Test Method for Estimation of Net Heat of Combustion of Aviation Fuels |
| JSSG-2001 Revision B:2004 | Air Vehicle |
| SAE AMS3283B | Sealing Compound, Polysulfide Non-Curing, Groove Injection Temperature and Fuel Resistant |
| SAE AMS7271J | Rings, Sealing, Butadiene-Acrylonitrile (NBR) Rubber Fuel and Low Temperature Resistant 60 - 70 |
| DEFSTAN 91-91/7(2011) : 2011 | TURBINE FUEL, KEROSINE TYPE, JET A-1 NATO CODE: F-35 JOINT SERVICE DESIGNATION: AVTUR |
| SAE AMS5613R | Steel, Corrosion and Heat Resistant, Bars, Wire, Forgings, Tubing, and Rings 12.5Cr (SAE 51410) Annealed |
| ISO 20823:2003 | Petroleum and related products — Determination of the flammability characteristics of fluids in contact with hot surfaces — Manifold ignition test |
| MIL-STD-3004 Revision D:2014 | Quality Assurance/Surveillance for Fuels, Lubricants and Related Products (S/S by MIL-STD-3004-1 and MIL-STD-3004-2) |
| ASTM D 3240 : 2015 : REDLINE | Standard Test Method for Undissolved Water In Aviation Turbine Fuels |
| MIL-STD-882 Revision E:2012 | System Safety |
| ASTM D 4066 : 2013 | Standard Classification System for Nylon Injection and Extrusion Materials (PA) |
| QQ-S-571 Revision F:1994 | SOLDER, ELECTRONIC (96 TO 485 DEG. C) (S/S BY J-STD-004, J-STD-005 AND J-STD-006) |
| SAE AMS3281F | Sealing Compound, Polysulfide (T) Synthetic Rubber for Integral Fuel Tank and Fuel Cell Cavities Low Density for Intermittent Use to 360 °F (182 °C) |
| SAE AMS4750E | Solder, Tin-Lead 45Sn - 55Pb |
| MIL-DTL-5578 Revision D:2008 | Tanks, Fuel, Aircraft, Self-Sealing |
| ASTM D 93 : 2016-07 | TEST METHODS FOR FLASH POINT BY PENSKY-MARTENS CLOSED CUP TESTER |
| MIL A 8625 : F | ANODIC COATINGS FOR ALUMINUM AND ALUMINUM ALLOYS |
| ASTM D 2386 : 2015 | Standard Test Method for Freezing Point of Aviation Fuels |
| SAE AMS6472F | Steel, Bars and Forgings, Nitriding 1.6Cr - 0.35Mo - 1.1Al (0.38 - 0.43C) (135 Mod) Hardened and Tempered, 112 ksi (772 MPa) Tensile Strength |
| MIL-DTL-83133 Revision J:2015 | Turbine Fuel, Aviation, Kerosene Type, JP-8 (NATO F-34) and NATO F-35 |
| SAE ARP1247D | Aircraft Ground Support Equipment — General Requirements |
| SAE AMS6277H | Steel, Bars, Forgings, and Tubing 0.50Cr - 0.55Ni - 0.20Mo (0.18 - 0.23C) (SAE 8620) Vacuum Arc or Electroslag Remelted |
| MIL F 24385 : F | FIRE EXTINGUISHING AGENT, AQUEOUS FILM FORMING FOAM, (AFFF) LIQUID CONCENTRATE, FOR FRESH AND SEA WATER |
| MIL H 17902 : F | HOSE, END FITTINGS AND HOSE ASSEMBLIES, SYNTHETIC RUBBER, AIRCRAFT FUELS |
| JSSG-2009 Revision A:2013 | Air Vehicle Subsystems |
| API 6D :2015 | SPECIFICATION FOR PIPELINE AND PIPING VALVES |
| API 610 : 2010 | CENTRIFUGAL PUMPS FOR PETROLEUM, PETROCHEMICAL AND NATURAL GAS INDUSTRIES |
| ASME B16.21 : 2016 | NONMETALLIC FLAT GASKETS FOR PIPE FLANGES |
| MIL-PRF-87260 Revision B:2006 | Foam Material, Explosion Suppression, Inherently Electrostatically Conductive, for Aircraft Fuel Tanks |
| ASTM D 6379 : 2011 : REDLINE | TEST METHOD FOR DETERMINATION OF AROMATIC HYDROCARBON TYPES IN AVIATION FUELS AND PETROLEUM DISTILLATES - HIGH PERFORMANCE LIQUID CHROMATOGRAPHY METHOD WITH REFRACTIVE INDEX DETECTION |
| MIL F 16884 : J | FUEL, NAVAL DISTILLATE |
| MIL-R-46082 Revision B:1983 | Retaining Compounds, Single Component, Anaerobic (S/S by ASTM-D5363) |
| ASTM D 257 : 2014 : REDLINE | Standard Test Methods for DC Resistance or Conductance of Insulating Materials |
| MIL-DTL-38219 Revision D:1998 | Turbine Fuel, Low Volatility, JP-7 |
| MIL-PRF-8516 Revision G:1997 | Sealing Compound, Synthetic Rubber, Electric Connectors and Electric Systems, Chemically Cured |
| SAE AMS3279D | Sealing Compound, Sprayable For Integral Fuel Tanks and Fuel Cell Cavities, For Intermittent Use to 350 °F (177 °C) |
| MMM-A-132 Revision B:1994 | Adhesives, Heat Resistant, Airframe Structural, Metal to Metal |
| ASTM D 7171 : 2016 : REDLINE | Standard Test Method for Hydrogen Content of Middle Distillate Petroleum Products by Low-Resolution Pulsed Nuclear Magnetic Resonance Spectroscopy |
| SAE AMS2410K | Plating, Silver Nickel Strike, High Bake |
| ASTM D 1322 : 2015-06 | TEST METHOD FOR SMOKE POINT OF KEROSINE AND AVIATION TURBINE FUEL |
| EI 1570 : 2012 | HANDBOOK ON ELECTRONIC SENSORS FOR THE DETECTION OF PARTICULATE MATTER AND/OR FREE WATER DURING AIRCRAFT REFUELLING |
| SAE AMSP5315B | Acrylonitrile-butadiene (NBR) Rubber For Fuel-Resistant Seals 60 to 70 |
| SAE AMS3376C | Sealing Compound, Non-Curing, Fluorosilicone Groove Injection Temperature and Fuel Resistant |
| ASTM D 240 : 2017 : REDLINE | Standard Test Method for Heat of Combustion of Liquid Hydrocarbon Fuels by Bomb Calorimeter |
| FED-STD-791 Revision D:2007 | Testing Method of Lubricants, Liquid Fuels, and Related Products |
| ASTM E 659 : 2015 : REDLINE | Standard Test Method for Autoignition Temperature of Chemicals |
| MIL-HDBK-516 Revision C:2014 | Airworthiness Certification Criteria |
| MIL-DTL-25988 Revision C:2006 | Rubber, Fluorosilicone Elastomer, Oil - and Fuel-Resistant, Sheets, Strips, Molded Parts, and Extruded Shapes |
| MIL-DTL-27422 Revision F:2014 | Tank, Fuel, Crash-Resistant, Ballistic-Tolerant, Aircraft |
| ASTM D 2622 : 2016 : REDLINE | Standard Test Method for Sulfur in Petroleum Products by Wavelength Dispersive X-ray Fluorescence Spectrometry |
| SAE AMS4107F | Aluminum Alloy Die Forgings (7050-T74) Solution Heat Treated and Overaged |
| MIL-S-85334 Base Document:1980 | Sealing Compound, Noncuring, Low Consistency, Silicone, Groove Injection, for Integral Fuel Tanks |
| EI 1598 : 2012 | DESIGN, FUNCTIONAL REQUIREMENTS AND LABORATORY TESTING PROTOCOLS FOR ELECTRONIC SENSORS TO MONITOR FREE WATER AND/OR PARTICULATE MATTER IN AVIATION FUEL |
| FED-STD-141 Revision D:2001 | Paint, Varnish, Lacquer and Related Materials: Methods of Inspection, Sampling and Testing |
| SAE AMS5604H | Steel, Corrosion Resistant, Sheet, Strip, and Plate 16.5Cr - 4.0Ni - 4.0Cu - 0.30Cb Solution Heat Treated, Precipitation Hardenable |
| MIL-H-4495 Revision D:1985 | Hose Assembly, Rubber, Aerial Refueling |
| ASTM D 471 : 2016-02 | TEST METHOD FOR RUBBER PROPERTY - EFFECT OF LIQUIDS |
| JSSG-2006 Base Document:1998 | Aircraft Structures |
| ASTM D 3359 : 2017 : REDLINE | Standard Test Methods for Rating Adhesion by Tape Test |
| SAE AMS6444M | Steel, Bars, Forgings, and Tubing 1.45Cr (0.93 – 1.05C) (SAE 52100) Premium Aircraft-Quality, Consumable Electrode Vacuum Remelted |
| EI 1540 : 2014 | DESIGN, CONSTRUCTION, COMMISSIONING, MAINTENANCE AND TESTING OF AVIATION FUELLING FACILITIES |
| SAE AMS7902G | Beryllium Sheet and Plate 98Be |
| DOD-L-85645 Revision A:1988 | LUBRICANT, DRY THIN FILM, MOLECULAR BONDED (METRIC) |
| SAE AMS3265E | Sealing Compound, Polysulfide (T) Rubber, Fuel Resistant, Non-Chromated Corrosion Inhibiting For Intermittent Use to 360 °F (182 °C) |
| A-A-3097 Base Document:1997 | Adhesives, Cyanoacrylate, Rapid Room Temperature-Curing, Solventless |
| MIL-PRF-46010 Revision H:2013 | Lubricant, Solid Film, Heat Cured, Corrosion Inhibiting NATO Code - S-1738 |
| SAE AMS3278B | Sealing and Coating Compound, Polyurethane (PUR) Fuel Resistant High Tensile Strength / Elongation For Integral Fuel Tanks / Fuel Cavities / General Purpose |
| ASTM D 5191 : 2015-10 | TEST METHOD FOR VAPOR PRESSURE OF PETROLEUM PRODUCTS (MINI METHOD) |
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