MIL 810 Test Method 522 Ballistic Shock Testing

As a MIL-STD-810 certified lab, we realize the importance of ballistic shock environmental testing. Meeting the MIL-810 testing standard requirements can be difficult. Keystone understands the challenges and guides companies through the process.

We have a reputation of helping customers achieve their MIL-STD product certifications. Our accurate test reports are delivered quickly. When products do not meet the requirements, we assist with finding solutions. Our pricing is competitive and we offer volume discounts. We provide comprehensive reports shortly after completion of the MIL-810 standard testing. Keystone Compliance creates an accurate test plan to eliminate expensive over-testing. 

Request a quote and find out first hand about our competitive pricing, timely process, and outstanding reputation. Contact us to receive more information on MIL-STD-810 ballistic shock testing.

The Importance of Ballistic Shock Compliance Testing

This 810-test method includes a set of ballistic shock tests. These tests generally involve momentum exchange of two or more bodies, or momentum exchange between a liquid or gas and a solid.

The MIL-STD-810 test provides a degree of confidence that material can structurally and functionally withstand shock effects. These effects can be caused by high levels of momentum exchange to which the material is mounted. Next, the Ballistic shock is performed to estimate the materials fragility level relative to ballistic shock.

Ballistic shock is defined as a high level shock that generally results from the impact of projectiles or ordnance on armored combat vehicles. These vehicles must survive the shocks resulting from large caliber non-perforating impacts, mine blasts, and overhead artillery attacks while still retaining their combat mission capabilities.

How Ballistic Shock Compliance Testing Affects Products

In general, ballistic shock has the potential for producing various effects on all electronic, mechanical, and electro-mechanical systems. The level of adverse effects increase with the level and duration of the shock, and decrease with the distance from the source. Examples of problems associated with ballistic shock include but are not limited to:

  • System failure as a result of destruction of the structural integrity of micro electronic chips including this mounting configuration.
  • System component failure as a result of relay chatter.
  • System component failure as a result of circuit card malfunction, circuit card damage, and electronic connector failure.
  • Material failure as a result of fracture in crystals, ceramics, epoxies or glass envelopes.
  • System component failure as a result of sudden velocity change of the structural support of the system component. Or, the internal structural configuration of the mechanical electro-mechanical system.

Information on the MIL-STD 810 Test Method

This method includes six ballistic shock test procedures. Unless otherwise identified in the life cycle profile, normally schedule the ballistic shock tests late in the test sequence. In general, these shock tests can be considered independent of other tests because of their unique and specialized nature.

Consider all ballistic shock environments anticipated for the material during its life cycle, both in its logistic and operational mode. In most cases, the MIL-STD-810 standard procedure selected will be dictated by the actual material configuration and noting the structural discontinuities that may serve to mitigate the effects of the ballistic shock material.

Procedure I – Ballistic Hull and Turret (BH&T) – Ballistic shock is applied in its natural form using live fire testing. This expensive procedure requires that an actual vehicle or prototype be available, as well as appropriate threat munitions. Because of these limitations within test method 522, ballistic shock test, a variety of other approaches are pursued. 

Procedure II – Large Scale Ballistic Shock Simulator (LSBSS) – This approach is used for components weighing up to 500 Kg and is considerably less expensive than procedure I. LBSS is a low cost option for producing spectrum ballistic shock without the expense of live fire testing.

Procedure III – Limited Spectrum, Light Weight Shock Machine (LWSM) – Ballistic shock is simulated using a hammer impact. The MIL-810 test item is mounted on an anvil table of the shock machine using the test item’s tactical mount. This military standard test procedure may be appropriate if the specific test item does not respond to high frequency shock. It may also be appropriate if it cannot withstand excessive low frequency response of the drop table. 

Procedure IV – Limited Spectrum, Mechanical Shock Simulator – Ballistic shock is simulated using a metal-to-metal impact. Use of a mechanical shock simulator is less expensive than a full spectrum simulation. This may be appropriate for lightweight items that are sensitive to shock up to 10 kHz.

Procedure V – Limited Spectrum, Medium Weight Shock Machine (MWSM) – Ballistic shock is simulated using a hammer impact. This simulator may be appropriate for heavy components and subsystems that are shock mounted and/or are not sensitive to high frequencies.

Procedure VI – Drop Table – This Ballistic shock lab test is simulated by the impact resulting from a drop. The test item is mounted on the table of a commercial drop machine using the test item’s tactical mount. The vast majority of components that need shock protection on an armored vehicle can be readily shock mounted. The commonly available drop test is the least expensive procedure.

Limitations of the MIL-810 Ballistic Shock Test

After reviewing the purpose and application of ballistic shock tests, there are important limits to note before proceeding with the test. Because of the highly specialized nature of ballistic shock and the substantial sensitivity of ballistic shock to the configuration of the material, apply this method only after considering the information below

  • This military testing method does not include special provisions for performing ballistic shock tests at high or low temperatures. Perform these tests at room temperature unless otherwise specified.
  • The MIL-STD 810 compliance testing method does not address secondary effects such as blast, EMI, and thermal

Keystone Compliance Provides Ballistic Shock Method 522 Testing Services

Keystone Compliance is one of the best MIL-810 standard ballistic shock labs in the country. We employ expert test engineers and properly equip our military testing lab in order to provide MIL-STD-810 ballistic shock test certifications.

Request a quote and learn why so many manufacturers rely on Keystone Compliance to meet their MIL-STD 810 lab compliance testing needs.