Environmental Test Results

Environmental CMB Test Results

MacSema ButtonMemory, Contact Memory Buttons (CMB’s) have successfully completed rigorous MIL-STD 810F environmental tests conducted by an independent third party. MIL-STD 810F is a US Department of Defense standard for testing the impact of environmental stress on material throughout all phases of its service life.

Fourteen environmental tests were selected from MIL-STD-810F and carried out on MacSema, Inc. ButtonMemory technology. Three additional tests were also conducted; Shear/Impact, Magnetic Field and Gamma radiation. The MIL-STD 810F test parameters were:

500   Low Pressure (Altitude)
501   High Temperature
502   Low Temperature
503   Temperature Shock
504   Contamination by Fluids
506   Rain
507   Humidity

509   Salt Fog
510   Sand and Dust
511   Explosive Atmosphere
512   Immersion
513   Acceleration
516   Shock
518   Acidic Atmosphere
521   Icing/Freezing Rain

Detailed test results are available upon request.

Other Test Results

Altitude: Per Spec. DO-160E Section 4 Category D, Simulated Altitude 50,000 Ft. 2 hours stabilized.

Low Pressure (Altitude): The objective of this test was to assess whether CMBs could withstand both a low-pressure environment and rapid pressure changes. Low–pressure environment was set at 75.3 Kpa (10.0 psia). The pressure of this environment was decreased until it reached 18.8 Kpa (2.73 psia). Lw pressure condition was maintained for at least 10 minutes to allow the test environment to stabilize.

High Temperature (91° F/33° C to 160° F/71° Celsius): CMBs were exposed to at least seven 24-hour temperature cycles consisting of changing the temperature surroundings from 91ºF to 160ºF (33ºC to 71ºC) and back to 91ºF (33ºC) over a 24-hour period. The rate of temperature change did not exceed 6ºF (3ºC) per minute to prevent thermal shock (see temperature shock testing data below).

High Temperature (up to 400 F / 200 Celsius): Additional testing conducted with a Grieve Corporation Model 520 Console oven. CMBs were exposed to 350 F (176 Celsius) and 400 F (204 Celsius). After each temperature exposure of 15 minutes duration, the CMBs were removed from the oven, allowed to cool and operationally checked. The operational checks were all successful.

Low Temperature: CMBs were placed inside the NUAIRE low temperature chamber. After the temperature of the CMBs decreased to -112ºF (-80ºC) at a rate of 1ºC per minute, temperature was maintained for 24 hours. The CMBs were removed from the low temperature chamber and the temperature of CMBs was brought back to ambient temperature at a rate of 1ºC per minute.

Temperature Shock(1): AUTOCLAVE air temperature cell (Model #503 and the NAUAIRE low temperature chamber were the two-celled temperature chambers selected in which test conditions could be established and maintained. The CMBs were placed inside the NUAIRE low temperature chamber. After the temperature of the CMBs was decreased to -112ºF (-80ºC) at a rate of 1ºC per minute, this temperature was maintained for 10 minutes. The CMBs were then transferred to the maximum air temperature cell (160ºF/71ºC) in less than one minute. As soon as the chamber door was closed and the CMBs recovered to peak temperature, the test chamber was cycled through part of the appropriate diurnal cycle until the chamber air temperature reached the CMBs response temperature. This temperature was maintained for 5 minutes. CMBs were then transferred to the lower temperature environment of -112ºF (-80ºC) in less than a minute.

Thermal Shock(2): Additional testing performed with BMA, Model # TA-208CC Thermal Shock Chamber. Cold zone of chamber maintained at -54 degree Celsius and hot zone set at + 160 degree C. Four cycles were completed with the CMBs being transferred within 2 minutes from cold to hot and back again. The CMBs were monitored by thermocouples and the zone transfer took place when the CMBs had reached a stable temperature. All CMBs passed their operational check and the adhesives showed no deterioration.

Contamination by Fluids: Immersed the CMBs in the specified test fluid for 24 hours. Allowed CMBs to drain naturally. Exposed the CMBs to ambient temperature conditions for 8 hours. Performed visual and read checks. Repeated this procedure for another 16 hours and performed the visual and read checks again. Repeated for two additional 24-hour periods. Performed visual and read checks again. The contaminant fluids used in this test were: Diesel, Gasoline, Mineral Based –NATO H515-Mobile Aero, Hydraulic Fluid, Mineral Based –NATO 0-1176-SAE 10W/30, Isopropyl Alcohol, Gun Cleaning Oil (Breakthrough Solvent), Ethylene Glycol, 25% Ethylene Glycol and 75% Water, Commercial Insecticide (Permethrin), Phenol (88% pure Phenol 12% water.

Rain: Placed the CMBs in the rain facility and adjusted the rainfall rate to about 2mm/min. The nozzle pressure was at least 276 KPa. Initiated the wind at a velocity of about 20 m/s and maintained it for about 40 minutes. Flipped the CMBs upside down to expose the lower face to the rain and blowing wind source.

Humidity: Placed the CMBs in a humidity chamber and adjusted the chamber’s temperature to 23+ 2ºC and 50 + 5% RH. Maintained these conditions for 24 hours. Adjusted the humidity chamber’s temperature to 30ºC and RH to 95%. Exposed the CMBs to 5 repeating 48-hour temperature and humidity cycles. Performed readability checks. During temperature change, used a tolerance not greater than 3ºC. Maintained the relative humidity at 95 + 4% at all times, except during the descending temperature periods when the relative humidity might drop as low as 85%.

Humidity: The test conducted was the 10 day aggravated profile per MIL-STD-810E. 5% to 95% non-condensing. Tenny Environmental Model #TH-27-8200 Chamber.

Salt Fog: Adjusted the salt fog test chamber’s temperature to 95ºF (35ºC) and exposed the CMBs to this temperature for at least two hours before introducing the salt fog. Continuously atomized a 5 + 1% salt solution into the salt fog test chamber for a period of 24 hours. During this period the salt fog fallout rate and pH of the fallout solution was between 1 and 3 ml/80cm²/hr. Let the CMBs dry at a standard ambient temperature and at a relative humidity of 50% or less for 24 hours. At end of drying period replaced CMBs into salt fog chamber for total of two wet and two dry 24-hour periods.

Sand and Dust: Settling Dust Procedure: Placed the CMBs inside the Abrasive Blasting Cabinet at standard ambient condition (Temperature = 77ºF + 18ºF), and relative humidity no greater than 30%. Kept the air velocity lower than 0.2m/s above CMBs. Used different small dust particles such as quartz, silica, salt, fertilizers, organic fibers, etc. Used a basic deposition rate of 6g/m²/day for three days.

Sand-Blasting Procedure: Placed CMBs inside the Abrasive Blasting Cabinet at standard ambient condition (Temperature =77ºF + 18ºF), and humidity not greater than 30%. Kept the air velocity at 18m/s. Used particles of silica sand (at least 95% by weight SiO₂). Maintained the sand concentrations at 2.2 + 0.5 g/m3, for 90 minutes.

Immersion: Immersed the CMBs in water so that the uppermost point of the CMBs was 1 + 0.1m below the surface of the water for 60-minute period.

Acceleration: Installed CMBs onto a lathe in its operational orientation. Brought the lathe to a speed of 135 RPM. This is the speed required to induce a g level of 2.0 on the CMBs according to MIL-STD-810F.

Shock(1): Testing done per Spec. DO-160E Section 7. X,Y, Z orientation at 6 G’s.

Shock(2): Installed the CMBs in its transit or combination case. Dropped the case on each face, edge and corner (total of 26 drops) from a test height of 48 inches.

Vibration(1): Vibration/Shaker Table:Unholtz-Dickie T1000W IAR-17/MA145A150IAR-E per Spec. DO-160E Section 8 Category S, DO-160E Section 8.2 Category U2, and DO-160E Section 8.2. Sinusoidal: Per DO-160E, Section 8 Category S, X,Y,Z orientation at 10-2000hz@ 0.5 g

Vibration(2): Vibration/shaker: Lingo Model # V860. A random vibration profile taken from US DoD MIL-STD-810E representing vibration found in the fuselage area of a jet aircraft was applied for 15 minutes at low and high temperature cycles. A total of 10 cycles were conducted.

Acidic Atmosphere: A test chamber capable of maintaining temperatures in the exposure zone at 95ºF + 4ºF (35 + 2ºC) was purged with clean air. A test solution containing 11.9mg (6 ul) of sulfuric acid (95-98%) per 4 liters of solution and 8.8mg (6 ul) nitric acid (68-71%) per 4 liters of solution in distilled or deionized water was prepared. The acidic atmosphere test chamber was adjusted to 95ºF (35ºC) and the CMBs were exposed to this environment for at least 2 hours before introducing the acid solution. CMBs were exposed to a 2-hour spraying period followed by a 22-hour storage period. This process was repeated two more times.

Icing/Freezing Rain: A test chamber capable of maintaining temperatures in the exposure zone at -10ºC. was used for this test. CMBs were installed into the test chamber. The temperature inside the chamber for the test was (32ºF+ 4ºF (0ºC+2ºC). Pre-cooled water (32-37ºF (0-3ºC) was sprayed onto the CMBs for 1 hour. The test chamber was adjusted to 14ºF (-10ºC) and the water spray rate was maintained until the required thickness of ice had accumulated on the CMB surface. The test chamber temperature was maintained for 4 hours and then the CMBs were removed from chamber to stabilize at standard ambient condition.

Additional Tests

EMI: No degradation when exposed to electric field strengths of 200 Volts/meter over the frequency ranges of 2.0 MHz to 4.0 GHz, as well as 18.5 to 19.5 GHz. CMBs were classified as not susceptible to RF signals of 200 Volts/meter Continuous Wave (CW) over the frequency of 2.0 MHz to 4.0 MHz and 18.5 GHz to 19.5 GHz.

EMP: 5.8, 26.7 and 55.0 kV/m.

ESD: 15 kV, 20 pulses per second, human model

Temperature/Vibration: Temperature cycling from -65°C (-85°F) to 135°C (275°F). A random vibration profile taken from MIL-STD-810E representing vibration found in the fuselage area of a jet aircraft was applied for 15 minutes at the low and high temperatures each cycle (10 cycles). Post op checks showed no apparent discrepancies. Tenny Mfg. Combined Environmental Chamber Model #AG-64CAS and Lingo, model #V860 vibration shaker.

As a matter of information regarding temperature survivability, CMBs were satisfactorily tested at the Yuma Proving Grounds on an M1 Tank engine (Allied Signal AGT 1500 Gas Turbine) to temperatures above 350 F. The testing covered 214 hours of vehicle operation. As a result of this evaluation, Honeywell Engines and Systems "determined that MacSema, Inc. 32K mini-button is a viable solution for accurately and reliably tracking major components of the AGT1500 gas turbine engine."

Ford Motor Company uses 2K MiniButtons on an electrical assembly line that routinely requires temperatures of 125° C (257°F). Prior to Ford’s acceptance of the technology they subjected CMBs to temperature shock of –40°C (–40°F), to 150°C (302°F) in 30 minute increments for over 1500 cycles.

Shear/Impact: The objective of this test was to assess the integrity of the CMBs and the strength of the epoxy after these were exposed to shear and impact forces. When affixed with epoxies Hysol EA 9394 and Hysol EA 9359.3 the flanged CMBs were able to withstand several impacts with shear loads of up to 15lb.

Gamma Radiation: Irradiated CMBs in the ⁶⁰Co Irradiator to the highest non-failure dose and tested for function. The maximum gamma radiation levels(in Krad) that each CMB category was able to withstand are as follows: Mini - 75.0 Krads, Micro-205.0 Krads.

Magnetic fields: CMBs were tested in a VARIAN Magnetic field generator, Model # V-3800. In this test the ButtonMemory® technology products were exposed to a 8000-Gauss magnetic flux density field without losing the data stored in memory.

Acid Bath: CMBs were subjected to a 30% phosphoric acid bath to etch prior to painting and passed.

Paint Removal: CMBs have been painted, chipped by hammer, read/updated and performed normally. CMBs have been blasted with glass beads and aluminum hydroxide at 80 psi and performed normally.

Salt Water: Submerged in saltwater for over a month

Gunfire: April 2000. CMBs were bonded to HK33 5.56mm Assault Rifle in close proximity to the barrel extension. 10,000 rounds were fired from the shoulder in series of 200 (fired in three minutes with a mixture of single shot and full auto). At the end of each series, the weapon was immersed in cold water to rapid cool. No failures.