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  • MIL-HDBK-781 Revision A:1996

    Current The latest, up-to-date edition.

    RELIABILITY TEST METHODS, PLANS, AND ENVIRONMENTS FOR ENGINEERING DEVELOPMENT, QUALIFICATION AND PRODUCTION

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    Publisher:  US Military Specs/Standards/Handbooks

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    Table of Contents - (Show below) - (Hide below)

    1 Scope
    1.1 Purpose
    1.2 Applicability
    1.2.1 Application of handbook
    1.3 Method of references
    1.4 Equipment categories
    2 Applicable documents
    2.1 General
    2.2.1 Specifications, standards, and handbooks
    2.3 Non-government publications
    2.4 Order of precedence
    3 Definitions
    3.1 Terms
    3.1.1 Corrective maintenance (repair)
    3.1.2 Decision risks
    3.1.3 Multiple failures
    3.1.4 Measures of reliability
    3.1.5 Mission profile
    3.1.6 Life-cycle profile
    4 Reliability test methods and test plans
    4.1 Reliability test program
    4.2 Integrated reliability test planning
    4.3 Environmental test conditions
    4.4 Test instrumentation and facilities
    4.5 Performance baselines
    4.6 Failure reporting, analysis and correction action
            system
    4.7 Failure categories
    5 Recommended combined environmental test conditions
    5.1 Purpose
    5.2 Test planning
    5.3 Test methods
    5.4 Test methods and test plan selection factors
    5.5 Reliability development/growth evaluation methods
    5.6 Durability/economic life test
    5.7 ESS monitoring methods
    5.8 MTBF assurance test
    5.9 Sequential test plans
    5.10 Fixed-duration tests
    5.11 All-equipment production reliability acceptance
            test plan
    5.12 Reliability estimates from unit-level results
    6 Test instrumentation and facilities
    6.1 Purpose
    6.2 Thermal and vibration survey
    6.3 Mission and life-cycle environmental profiles
            and test conditions
    6.4 Combined environments for fixed-ground equipment
    6.5 Combined environments for mobile ground equipment
    6.6 Combined environments for shipboard and underwater
            vehicle equipments
    6.7 Combined environments for jet aircraft equipment
    6.8 Combined environments for V/STOL equipment
    6.9 Combined environments for turbopropellor aircraft
            and helicopter equipment
    6.10 Combined environments for air-launched weapons and
            assembled external stores
    6.11 Missile transportation, handling and storage
    7 Test instrumentation and facilities
    7.1 Purpose
    7.2 Test facilities and apparatus
    8 Notes
    8.1 Intended use
    8.2 Supersession
    8.3 Subject term (keyword) listing
    8.4 Changes from previous issue
    NUMEROUS TABLES
    NUMEROUS FIGURES

    Abstract - (Show below) - (Hide below)

    Provides for reliability testing during development, qualification, and production of systems and equipment. Coverage includes: reliability test methods and test plans; combined environmental test conditions; test instrumentation and facilities. Also gives definitions, reference documents, tables and diagrams.

    General Product Information - (Show below) - (Hide below)

    Committee AREA SESS
    Development Note Supersedes MIL STD 781. A NOTICE 1 - Notice of Validation. (02/2015)
    Document Type Standard
    Publisher US Military Specs/Standards/Handbooks
    Status Current
    Supersedes

    Standards Referenced By This Book - (Show below) - (Hide below)

    MIL-PRF-49316 Revision A:1997 TEST SET, ELECTRONIC SYSTEMS, TS-3895A/UV
    MIL-R-29583 Base Document:1992 RADIO SET
    MIL PRF 62542 : B BALL SCREW LINEAR ACTUATOR (BSLA)
    MIL-PRF-32080 Revision G:2014 TRUCK, AIRCRAFT FUELING-DEFUELING, 6,000 GALLON, A/S32R-11
    GEIA TA HB 0009 : 2013 RELIABILITY PROGRAM HANDBOOK
    DEFSTAN 00-035(PT3)/5(2017) : 2017 ENVIRONMENTAL HANDBOOK FOR DEFENCE MATERIEL - PART 3: ENVIRONMENTAL TEST METHODS
    MIL-DTL-49198 Revision B:2014 HEADSET-MICROPHONE KIT, MK-1564( )/AIC
    MIL-I-25863 Revision D:1990 INDICATOR, ELECTRICAL TACHOMETER 0-110 PERCENT RPM, 2-INCH SIZE, INTEGRALLY LIGHTED
    MIL P 24765 : 0 POWER SUPPLY, UNINTERRUPTIBLE, STATIC
    MIL P 49146 : B POWER SUPPLY 18 MILLIMETER, MICROCHANNEL WAFER
    MIL-DTL-27188 Revision C:2006 INDICATOR, PRESSURE EGU-2/A, OIL, 0-100 PSI
    MIL-DTL-19803 Revision G:2007 CONVERTER, LIQUID OXYGEN, 10-LITER, GCU-24A/A
    MIL-STD-750-3 Base Document:2012 Transistor Electrical Test Methods for Semiconductor Devices Part 3: Test Methods 3000 Through 3999
    MIL-T-83823 Base Document:1991 TRUCK, FIRE FIGHTING (STRUCTURAL OR BRUSH STRUCTURAL)
    MIL-PRF-83419 Revision F:2016 ALTIMETER, SERVO CONTROLLED, AUTOMATIC PRESSURE STANDBY
    MIL-DTL-25949 Revision F:1995 ACCELEROMETER, AIRCRAFT RANGE -5 TO 10G UNITS, INTEGRALLY LIGHTED
    MIL-STD-883 Revision K:2016 TEST METHOD STANDARD - MICROCIRCUITS
    BS EN 50155:2017 Railway applications. Rolling stock. Electronic equipment
    16/30282633 DC : 0 BS EN 50155 - RAILWAY APPLICATIONS - ELECTRONIC EQUIPMENT USED ON ROLLING STOCK
    EN 61124:2012 RELIABILITY TESTING - COMPLIANCE TESTS FOR CONSTANT FAILURE RATE AND CONSTANT FAILURE INTENSITY (IEC 61124:2012)
    DEFSTAN 00-970(PT0)/9(2012) : 2012 DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS
    MIL-DTL-24151 Revision B:2016 DOORS, ROLLER CURTAIN AND HINGED SLAT, AND ASSOCIATED OPERATING EQUIPMENT
    DEFSTAN 00-970(PT0)/17(2016) : 2016 DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS
    DEFSTAN 00-970(PT0)/14(2014) : 2014 DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS
    DEFSTAN 00-970(PT0)/7(2011) : 2011 DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS
    DEFSTAN 00-970(PT0)/15(2015) : 2015 DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS
    DEFSTAN 00-970(PT0)/12(2014) : 2014 DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS
    DEFSTAN 00-970(PT0)/13(2014) : 2014 DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS
    DEFSTAN 00-970(PT0)/11(2013) : 2013 DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS
    DEFSTAN 00-970(PT0)/8(2011) : 2011 DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS
    MIL-DTL-5099 Revision C:2011 INDICATOR, CABIN AIR PRESSURE, 1-7/8 INCH DIAL, TYPE MA-1
    DEFSTAN 00-970(PT0)/10(2013) : 2013 DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS
    DEFSTAN 00-970(PT0)/16(2015) : 2015 DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS
    MIL-DTL-6162 Revision C:2000 GENERATORS AND STARTER-GENERATORS, ELECTRICAL DIRECT CURRENT, NOMINAL 30 VOLTS, AIRCRAFT GENERAL SPECIFICATION FOR
    MIL-P-49452 Base Document:1989 POWER SUPPLY 18 MM, MICROCHANNEL WAFER, GEN III, MX-10130()/UV
    MIL-E-29581 Base Document:1991 EARCUP, UNIT ACTIVE NOISE REDUCTION SYSTEM
    MIL-DTL-25867 Revision D:2006 GAGE, PRESSURE, DIAL INDICATING, PNEUMATIC
    MIL-PRF-49404 Revision A:1997 Bias Voltage Regulator, CN-1559/UA (No S/S Document)
    MIL-DTL-24765 Revision B:2016 POWER SUPPLY, UNINTERRUPTIBLE, STATIC (NAVAL SHIPBOARD)
    MIL-PRF-49434 Revision A:1997 AIMING LIGHT, INFRARED, AN/PAQ-4C
    MIL-A-24233 Revision B:1989 ANTENNA, AS-1735( )/SRC
    IEEE 1332-2012 IEEE Standard Reliability Program for the Development and Production of Electronic Products
    MIL-F-51536 Base Document:1988 FILTER UNIT, GAS-PARTICULATE, 200 CFM, 208V, 400 HZ, M56
    MIL-PRF-49177 Revision B:1997 SCAN-INTERLACE, PL-1408/UA
    MIL-DTL-38195 Revision D:2000 GENERATOR SET, GAS TURBINE ENGINE, 60 KW 400 HZ, GENERAL PURPOSE
    MIL-DTL-52872 Revision D:1998 SENSOR GROUP, ULTRASONIC MOTION: TRANSCEIVER RT-1161/FSS-9(V) AND PROCESSOR MX-9444/FSS-9(V)
    MIL-F-24713 Base Document:1989 FREQUENCY CHANGER, STATIC, AIR COOLED (NAVAL SHIPBOARD)
    DEFSTAN 00-42(PT7)/1(2014) : 2014 RELIABILITY AND MAINTAINABILITY - PART 7: RELIABILITY TESTING
    MIL-DTL-25469 Revision J:2014 VALVES, FILLER, LIQUID OXYGEN, AIRCRAFT TYPE
    SAE ARP 81490 : 2016 TRANSMISSION LINES, TRANSVERSE ELECTROMAGNETIC MODE
    SAE ARP 94910 : 2012 AEROSPACE - VEHICLE MANAGEMENT SYSTEMS - FLIGHT CONTROL DESIGN, INSTALLATION AND TEST OF, MILITARY UNMANNED AIRCRAFT, SPECIFICATION GUIDE FOR
    I.S. EN 50155:2017-11 RAILWAY APPLICATIONS - ROLLING STOCK - ELECTRONIC EQUIPMENT
    MIL-HDBK-115 Revision C:2016 U.S. ARMY REVERSE ENGINEERING HANDBOOK (GUIDELINES AND PROCEDURES)
    MIL-PRF-38230 Revision D:2008 TRANSMITTER, PRESSURE, OIL, VARIABLE RELUCTANCE
    MIL-DTL-52876 Revision D:1997 CABINETS, MONITOR, CY-7359/FSS-9(V) CY-7360/FSS-9(V), AND CY-7361/FSS-9(V)
    MIL-A-28865 Revision A:1987 ANTENNA GROUP, OE-82()/WSC-1(V)
    MIL-PRF-26139 Revision E:2015 TESTER, PRESSURIZED CABIN LEAKAGE, AIRCRAFT, (AF/M24T-3 AND AF/M32T-1)
    IEEE 1633-2016 REDLINE IEEE Recommended Practice on Software Reliability
    MIL-HDBK-338 Revision B:1998 ELECTRONIC RELIABILITY DESIGN HANDBOOK
    MIL-DTL-16392 Revision D:2015 BRAKE, ELECTRO-MECHANICAL, NAVAL SHIPBOARD
    MIL-PRF-49293 Revision B:2011 RADIAC SET, AN/PDR-75
    MIL-PRF-49168 Revision C:1997 SCAN-INTERLACE, PL-1403/UA, PL-1403A/UA
    ABS 0272 : 2017 GUIDANCE NOTES ON QUALIFYING NEW TECHNOLOGIES
    DEFSTAN 00-41/3(1993) : 1993 RELIABILITY AND MAINTAINABILITY MOD GUIDE TO PRACTICES AND PROCEDURES
    MIL-DTL-25308 Revision C:2010 GAGE, PRESSURE, DIAL INDICATING, HYDRAULIC, TYPE ME-1
    SAE AS 19692 : 2016 Aerospace – Military Type Variable Delivery, Pressure Compensated Hydraulic Pump
    SAE AIR 1277 : 2005 COOLING OF MILITARY AVIONIC EQUIPMENT
    IEC TR 62866:2014 Electrochemical migration in printed wiring boards and assemblies - Mechanisms and testing
    MIL-STD-750-1 Revision A:2015 Environmental Test Methods for Semiconductor Devices Part 1: Test Methods 1000 Through 1999
    EN 50155:2017 Railway applications - Rolling stock - Electronic equipment
    MIL-HDBK-344 Revision A:1993 ENVIRONMENTAL STRESS SCREENING (ESS) OF ELECTRONIC EQUIPMENT
    MIL-DTL-38394 Revision E:2009 Transmitter, Pressure TRU-81/A, Oil, 0-500 PSI
    MIL-PRF-49163 Revision B:1997 VIDEO PREAMPLIFIER, AM-6923/UA
    MIL-HDBK-2164 Revision A:1996 ENVIRONMENTAL STRESS SCREENING PROCESS FOR ELECTRONIC EQUIPMENT
    MIL-PRF-49318 Revision A:1997 TEST SET, ELECTRONIC SYSTEMS, TS-4348/UV
    UNE-EN 61124:2014 Reliability testing - Compliance tests for constant failure rate and constant failure intensity
    DEFSTAN 00-35(PT3)/4(2006) : 2006 ENVIRONMENTAL HANDBOOK FOR DEFENCE MATERIEL - PART 3: ENVIRONMENTAL TEST METHODS
    CEI EN 61124 : 2013 RELIABILITY TESTING - COMPLIANCE TESTS FOR CONSTANT FAILURE RATE AND CONSTANT FAILURE INTENSITY
    MIL-DTL-5882 Revision E:2013 TRANSMITTER, PRESSURE, MULTIPURPOSE, 0-50 PSI, MS28005-1
    DEFSTAN 00-40(PT7)/1(2003) : 2003 RELIABILITY AND MAINTAINABILITY (R&M) - PART 7: (ARMP-7) NATO R&M TERMINOLOGY APPLICABLE TO ARMP'S
    MIL-DTL-5790 Revision H:2008 Transmitter, Pressure, Oil, Synchro, 0-200 PSI 320-Degree Movement, 26V, Single Phase, 400 Cycles
    MIL-A-52879 Revision C:1992 Alarm, Audible, BZ-204/FSS-9(V) (No S/S Document)
    MIL-DTL-7627 Revision G:2010 INDICATOR, TURN AND SLIP, 28 V DC
    MIL-DTL-52869 Revision C:1997 SENSOR GROUP, PASSIVE ULTRASONIC: RECEIVER R-1860/FSS-9(V) AND PROCESSOR MX-9443/FSS-9(V)
    ADS-63-SP : 2001 AERONAUTICAL DESIGN STANDARD - STANDARD PRACTICE - RADAR SYSTEM AIRWORTHINESS QUALIFICATION AND VERIFICATION REQUIREMENTS
    MIL-PRF-49185 Revision B:1997 RADIO SET AN/GRC-103(V)3
    RE.AERO 70306 : 2001 GUIDELINES FOR RELIABILITY GROWTH CONTROL
    MIL-PRF-52955 Revision D:2009 IMPROVED POSITION AND AZIMUTH DETERMINING SYSTEM (IPADS)
    MIL F 51544 : A FILTER UNIT, GAS-PARTICULATE, 200 CFM, 208 VAC, M84
    MIL-A-0083216 Revision C:1976 AIR CONDITIONER, HORIZONTAL, 54,000 BTUH, 208/230 V
    MIL-DTL-27189 Revision E:2008 INDICATOR, PRESSURE, OIL
    I.S. EN 61124:2012 RELIABILITY TESTING - COMPLIANCE TESTS FOR CONSTANT FAILURE RATE AND CONSTANT FAILURE INTENSITY
    SAE AS 94900 : 2007 AEROSPACE - FLIGHT CONTROL SYSTEMS - DESIGN, INSTALLATION AND TEST OF PILOTED MILITARY AIRCRAFT, GENERAL SPECIFICATION FOR
    PD IEC/TR 62866:2014 Electrochemical migration in printed wiring boards and assemblies. Mechanisms and testing
    IEC 61124:2012 Reliability testing - Compliance tests for constant failure rate and constant failure intensity
    MIL-DTL-9398 Revision D:2007 GENERATOR, TACHOMETER, TWO-POLE, HIGH TEMPERATURE, AIRCRAFT
    ARMP-7 : 2008 NATO R&M TERMINOLOGY APPLICABLE TO ARMPS
    AECTP-400 : 2006 MECHANICAL ENVIRONMENTAL TESTS
    10/30238858 DC : 0 BS EN 62506 - METHODS FOR PRODUCT ACCELERATED TESTING
    SAE ARP 6461 : 2013 GUIDELINES FOR IMPLEMENTATION OF STRUCTURAL HEALTH MONITORING ON FIXED WING AIRCRAFT
    MIL-A-53129 Base Document:1992 ALARM-MONITOR GROUP OA-9431/FSS-9(V)
    MIL-DTL-24347 Revision C:2015 MONITOR, AVAILABLE LOAD, 60 AND 400 HERTZ, A.C., 1 PHASE, ELECTRICAL POWER (NAVAL SHIPBOARD USE)
    MIL B 62542 : A BALL SCREW LINEAR ACTUATOR
    MIL-P-49090 Revision D:1992 POWER SUPPLY 25 MILLIMETER, MICROCHANNEL INVERTER
    MIL-L-85314 Revision A:1983 LIGHT SYSTEMS, AIRCRAFT, ANTI COLLISION, STROBE, GENERAL SPECIFICATION FOR
    MIL-O-52374 Revision E:2013 Oscillator: High Voltage General Specification for
    MIL-T-23752 Revision E:1992 TRITIUM AIR MONITOR, PORTABLE OR FIXED
    ADS-65-HDBK : 2004 AERONAUTICAL DESIGN STANDARD - HANDBOOK - AIRWORTHINESS QUALIFICATION AND VERIFICATION GUIDANCE FOR ELECTRO-OPTICAL AND SENSOR SYSTEMS
    MIL-A-29521 Base Document:1988 ANTENNA GROUP, AN/BRA-34(V), AN/BRA-34A(V), AN/BRA-34B(V)
    MIL-C-85283 Revision B:1994 CONTROL MONITOR SET, GUIDED WEAPON, AN/AWW-9
    MIL-DTL-27190 Revision C:2006 INDICATOR, PRESSURE AGU-3/A, HYDRAULIC, 0-4,000 PSI
    RE.AERO 70305 : A2000 GUIDE FOR RELIABILITY CONTROL
    MIL-STD-781 Revision D:1986 RELIABILITY TESTING FOR ENGINEERING DEVELOPMENT, QUALIFICATION AND PRODUCTION
    MIL T 49318 : 1991-11-21 TEST SET, ELECTRONIC SYSTEMS
    MIL-PRF-49320 Revision A:1997 LASER INFRARED OBSERVATION SET, AN/PVS-6
    BS EN 61124:2012 Reliability testing. Compliance tests for constant failure rate and constant failure intensity
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