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NPRD-2LEVEL?NONELECTRONIC PARTSRELIABILITY DATADTICELECTEDC10 19 1 ll DSUMMER 1981Reliability Analysis CenterROME AIR DEVELOPMENT CENTER8112 10 001"THE RELIABILITY ANAL YSIS CENTER IS A DOD INFORMATION ANALYSIS CENTER

THE INFORMATION AND DATA CONTAINED HEREIN HAVE BEEN COMPILED FROM GOVERNMENTAND NONGOVERNMENT TECHNICAL REPORTS AND FROM MATERIAL SUPPLIED BY VARIOUSMANUFACTURERS AND ARE INTENDED TO BE USED FOR REFERENCE PURPOSES. NEITHER THEUNITED STATES GOVERNMENT NOR lIT RESEARCH INSTITUTE WARRANT THE ACCURACY OFTHIS INFORMATION AND DATA. THE USER IS FURTHER CAUTIONED THAT THE DATA CONTAINEDHEREIN MA Y NOT BE USED IN LIEU OF OTHER CONTRACTUALLY CITED REFERENCES ANDSPECIFICA TIONS.PUBLICATION OF THIS INFORMATION IS NOT AN EXPRESSION OF THE OPINION OF THE UNITEDSTATES GOVERNMENT OR OF lIT RESEARCH INSTITUTE AS TO THE QUALITY OR DURABILITYOF ANY PRODUCT MENTIONED HEREIN AND ANY USE FOR ADVERTISING OR PROMOTIONALPURPOSES OF THIS INFORMATION IN CONJUNCTION WITH THE NAME OF THE UNITED STATESGOVERNMENT OR lIT RESEARCH INSTITUTE WITHOUT WRITTEN PERMISSION IS EXPRESSLYPROHIBITED.

OReliability Analysis CenterA DoD Information Analysis CenterNONELECTRONIC PARTSRELIABILITY DATAPrepared by:Robert G. ArnolIT Research InstituteUnder Contract to:Rome Air Development CenterGriffiss AFB, NY13441Ordering No. NPRD-2Approved for Public Releae, Distribution UnlimitedSDTICSELECTEDEC 10 1981D

(Iiiil1 TheRELIABILITY hAmYSISCENER is a DoD information analysisCenter, operated by IIT Research Institute under contract to the Rome Air Development Center, AFSC.The Reliability Analysis Center (RAC) is a Department of Defense Information Analysis Center sponsored by the Defense Logistics Agency, managed by theRome Air Development Center (RADC), and operated at RADC by IIT ResearchInstitute (IITRI). RAC is charged with the collection, analysis and dissemination of reliability information pertaining to parts used in electronic systems.The present scope includes integrated circuits, hybrids, discrete transistorsand diodes, microwave devices, optoelectronics, and selected nonelectronic partsemployed in military, space and commercial applications.In addition, a System/Equipment Reliability Corporate Memory (RCM) is alsooperating under the auspices of the RAC and serves as the focal point for thecollection and analysis of all reliability-related information and data onoperating and planned military systems and equipment.Data are collected on a continuous basis from a broad range of sourcesincluding testing laboratories, device and equipment manufacturers, governmentlaboratories, and equipment users, both government and nongovernment. Automaticdistribution lists, voluntary data submittal, and field failure reportingsystems supplement an intensive data solicitation program.Reliability data documents covering most of the device types mentionedabove are available annually from RAC. Also, RAC provides reliability consultingand technical and bibliographic inquiry services which are fully discussed at theend of this document.REQUESTS FOR TECHNICAL ASSISTANCEAND INFORMATION ON AVAILABLE RACSERVICES AND PUBLICATIONS KAY BEALL OTHER REQUESTS SHOULD BEDIRECTED TO:DIRECTED TO:Charles E. EhrenfriedReliability Analysis CenterRome Air Development Center (RBRAC)Griffiss Air Force Base, NY 13441Telephone: 315/330-4151Autovon:Rome Air Development CenterRBE/Charles F. BoughGriffiss Air Force Base, NY 1311Telephone: 315/330-4920Autovon: 587-4920587-4151(D 1981, IIT Research Institute4. o AllRights Reserved

SECURITYCLASSIFICATION OF THIS PAGE (When Dot. Enter.d)REPORT DOCUMENTATION PAGEI. REPORT NUMBERREAD INSTRUCTIONSBEFORE COMPLETING FORMRECIPIENT'S CATALOG NUMBER2. G VT ACCESSION NO. 3NPRD-2/cj4. TITLE (inWdSubtitle)S. TYPE OF REPORT & PCRIOD COVEREDNonelectronic Parts Reliability Data - 2N/AS. PERFORMING7.AUTHO:i(.)S.CONTRACT OR GRANT NUMBER(.)Robert G. Arno9.PERFORMING ORGAk'F30602-78-C-0281ATIDN NAME AND ADDRESSI0.PROGRAM ELEMENT. PROJECT. TASKAREA A WORK UNIT NUMBERS12.REPORT DATtReliability Analysis Center (RBRAC)Rome Air Development CenterGriffiss Air Force Base, New York 13441I1.CONTROLLING OeFICE NAMEAND ADDRESSRome Air fevelopment CenterGriffiss Air Force Base, New York14.MONITORING AGESICYO1G. REPORT NUMBERNAME& AODRESS(,/Summer 198113441dif.orr,,nt from Cont-11ina Office)13. NUMBEROFPAGESISSECURITYCLASS. 'of this report)Unclassi fiedIS.IS.DISTRIBUTION STATEMENT (ofOECLASSIFICATION DOWNGRADINGSCHEDULEthis Report)Approved for public release; distribution unlimited.Available from RAC or NTIS.i7.IS.DISTRIBUTION STATEMENT (of the obstrcit entered in Block 20, II different from Report)SUPPLEMENTARY NOTESThis is the second in a series of publications dealing with the nonelectronicparts reliability and supersedes NPRD-1, dated 1978.19. "KEY WORDS (Continue on reverie side if nece**&,, end identify by block number)Nonelectronic Partsfailure RatesReliability InformationFailure Modes and MechanismsElectromechanical ComponentMechanical Parts20. ABSTRACT (Corttlans on reverse side It neceoary end Identify by block number)- -This report, organized in four major sections, presents reliabilityinformation based on field operation, dormant state and test data for morethan 250 major nonelectronic part types. The four sections are Generic Data,Detailed Data, Application Data, and Failure Modes and Mechanisms. Eachdevice type contains reliability information in relation to the specificoperational environments.,.,DD1473EDITION Of I NOV 65 I OOSOLETESECURITY CLASSIFICATION Of THIS PAGE (When Veto Ent-led)Ui

UNCLASSIFIEDsgCUPirY CLA*SI CATION OF THIS PAO6(WUa DNAt*aI.V.E)UNCLASSIFIEDISCURITY CLAGSIPICATION OF'PAoGrVWhe Data Ent@.rE)

PREFACEThis is the second edition of a series of data publications dealing withnonelectronic reliability at the part level. NPRD-Z updates NPRD-1 by expandingthe scope and quality of sareintendedtocompliment such documents as MIL-HDBK-217 and MIL-STD-883. The user iscautioned, however, that the data contained herein may not be used in lieu ofcontractually cited references. It should also be noted that the data contained inthis document is failure data, not part replacement data. Only verified failureswere used in the calculations of the failure rates.hAOesslon ForNTIS GRnt'DTIC TABWffmouned0 DTIC0]IOELIECTEIJustificationD.Distribution/10 19810AvailanG/orIDECAvailability CoGelatspecialDVf

TABLE OF CONTENTSINTRODUCTIONSECTION 1:SECTION Z:SECTION 3:1NONELECTRONIC GENERIC FAILURE RATES3Definitions of Terms5Index for Generic Failure Rates10Generic Failure Rate Tables21NONELECTRONIC PARTS DETAILED DATA117Nonelectronic Parts Detailed Data119Index for Detailed DatalzDetailed Data Tables125NONELECTRONIC PARTS DATA FROM COMMERCIAL209EQUIPMENT APPLICATIONSNonelectronic Parts Data From Commercial211Equipment ApplicationsSECTION 4:Index for Commercial Equipment Application DataZ13Commercial Equipment Application Data Tables215FAILURE MODES AND MECHANISMSZ29Operational Failure Modes and m232BearingsZ33Circuit Breakers234Connectors234Coolant HoseZ35Electron Tubes236Fuses236viiF WEWDAMMLAhE-MOW n1A

TABLE OF CONTENTS (Cont'd)PageSECTION 4:FAILURE MODES AND MECHANISMS (Cont'd)Gaskets and Seals237GyroscopeIC SocketsZ38239Motors241Printed Circuit BoardZ41Pumps243Hydraulic243PneumaticZ44Quick Disconnect CouplingsZ44Relays245ArmatureZ45Reed247Solder Connections248Switches249ValvesZ50Dormant Failure Modes bnd MechanismsBearingsAPPENDIX:z5z25ZConnectors, GeneralZ52Clutches252Gyros252Magnetrons253DC Motors253Relays, Latching253Relays, Nonlatching253Seals253Switches, Sensitive254Transformer254Part Failure Mode Distribution255ADDITIONAL RAC SERVICESZ59viii

INTRODUCTIONThis nonelectronic reliability data publication e rate andelectromechanical,electrical,pneumatic, hydraulic and rotating parts. The data utilized in the development ofthis publicationexperienceunderwere collectedfieldby the RAC and represent mmercialapplications.Ithas been necessaryto acceptthe assumptionthatthe failuresofnonelectronic parts follow the exponential distribution; that is, such parts display aconstant failure rate. This assumption is necessary due to the virtual absence ofdata containing individual times or cycles to failure.Section 1 of this publication provides summarized generic part level failurerates. Section 2 consists of detailed entries by part type and environmentalapplication in unsummarized form. In Section 3, failure rates for parts unique to orfrequently used in computer peripherals, pointof sale equipment,and testinstruments are tabulated. Section 4 presents the distribution of failure modes fora number of major nonelectronic part families.

NONELECTRONIC PARTS RELIABILITY DATASECTION 1NONELECTRONIC GENERIC FAILURE RATES.

Section IDEFINITIONS OF yexperiencefornonelectronic parts. The summaries are presented in alphabetical order by majorfamily classes and alphabetically by type within each family class.A careful reading of the description of the presentation format and entrycodes employed will aid the user of this publication. The circled numbers shown inthe tabulation form below are referenced to the explanatory text which follows.rAtIURF MAI[ /10'Nit.OMIONOMIrNl0o YT vPEILOWEPRLFFOPAI.1GppraRFcot' s FAI IF"M(otPART CLASSA major family of parts having orproviding the same function.TYPE:The identification of the part type.ENVIRONMENT:The coded entries are as follows:DOR - DormantThe state wherein a component orequipment is connected to a systern in the normal operational configuration and experiences belownormal and/or periodic operationalstresses and environmental stresses. The system may be in a dormant state for prolonged periods(up to five years or more) beforebeing used in a mission.5

DEFINITION OF TERMS (Cont'd)SAT-SatelliteEarthorbital, approaches benignaccesswithoutconditionsformaintenance. Vehicle neither underpowered flight nor in atmospherere-entry.GRF - Ground FixedConditionslessthanidealtoinclude installation in permanentracks with adequatecoolingair,maintenance by military personnelandpossibleinstallationunheated buildings.GRM - Ground MobileinConditions more severe than GRF,mostly for vibrationCooling air supplyandshock.may also bemore limited, and maintenance nditions.Al - Airborne InhabitedGeneralconditionsareas rne Inhabited TransportConditions in inhabitedareas ofsubsonic aircraft such as transport,cargo, heavy bomber, and patrol.AlF - Airborne Inhabited FighterThe conditions to be found in thecockpitareainterceptors.6offightersand

DEFINITIONS OF TERMS (Cont'd)AU - Airborne UninhabitedGeneral conditions typical of suchareas as cargo storage areas, e pressure,vibration cycling exist; also, meybebyaggravatedcontaminationfrom oil, hydraulic fluid and engineexhaust.AUT - Airborne Uninhabited TransportConditions in uninhabited areas ofsubsonic aircraft such as transport,cargo, heavy bomber, and patrol.AUF - Airborne Uninhabited FighterConditions in uninhabited areas offighters and interceptors.HEL-HelicopterConditions most severe for vibration, temperature and humidity.SHS - Ship ShelteredSurface conditions similar to GRFbutsubjecttooccasionalhighshock and vibration.SHU - Ship etitivehighwithlevels of shock and vibration.SUB - SubmarineConditionsnormaltooperationaboard a submerged vessel.Tem-perature and humidity controlled.

DEFINITIONS OF TERMS (Cont'd)MIS - Missile LaunchconditionsSeverenoise,ofvibration and other and armainlaunchduringoperations.( APPLICATION:MIL. (Military)Data resulting from a military orsatellite application.COML. (Commercial)Data resulting from a commercialor industrial application.N/ANot applicable.The nature of thehardware application is unknown.The maximum likelihood estimatorwhen the exponential distributionis assumed. 60% UPPER SINGLE-SIDEDThe 60% upper single-sided con-CONFIDENCEfidencelimitestimatefailure rate, computedofthefrom theChi-square distribution, is providedfor those entries for which zerofailures have been recorded.8