MIL-STD-981 Design, Manufacturing And Quality Standards For Custom Electromagnetic Devices For Space Applications

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MIL-STD-981C

a. Each spool of magnet wire prior to being used shall be subjected to the following tests of MW-

1000 :

(1) Dielectric test.

(2) Visual and mechanical examination.

(3) Check of bare wire size of the magnet wire by a DC resistance measurement.

b. Provisions shall be made to procure and utilize magnet wire not older than five years from the date of its manufacture. Wire older than five years from the date of its manufacture shall not be used. Wire, by design, shall meet the following evaluation tests in accordance with MW-1000.

(1) Visual and dimension.

(2) Adherence and flexibility including mandrel test. (3) Elongation.

(4) Springback.

(5) DWV at rated temperature. (6) Bend (rectangular wire only). (7) Heat shock.

d. Magnet wire shall be stored in protective resealable containers to protect against dust.

e. Magnet wire shall be stored in a controlled environment, at a temperature of +25°C (±7°C), a pressure of no less than one Standard Atmosphere, and a relative humidity of between 30 to

70 percent.

5.6.2.2 Layer insulation. Dielectric strength, tensile strength, volume resistivity and flexibility.

5.6.2.3 Potting and encapsulation materials. (On samples mixed and cured according to the manufacturer's documented process) dielectric strength, volume resistivity, hydrolitic stability and outgassing.

5.6.2.4 Incoming inspection DPA. Incoming inspection shall be in accordance with MIL-STD-1580, except DPA is not required for open construction devices. 100 percent pre-cap inspection with color images of representative samples (see 5.5.8.1.1) in combination with real-time x-ray (per 5.3.1) may be used in lieu of DPA. All metal surfaces shall be verified for the absence of prohibited materials (e.g., pure tin, zinc, or cadmium). Though DPA is not required, open construction magnetic devices require functional electrical tests and visual and mechanical inspection as a minimum.

5.6.3 Calibration. The establishment and maintenance of a calibration system to control accuracy of the measuring and test equipment shall be in accordance with ANSI/NCSL Z540.3, ISO 10012 or equivalent.