GB/T 47445-2026Prevention and control requirements for foreign object debris in launch vehicles (English PDF)

4.1 General Rules

4.1.1 The goal of foreign object prevention and control for launch vehicles is to ensure the normal operation of the development, launch, and flight processes, and to prevent incidents caused by foreign objects. Quality issues must be addressed to ensure the functionality, performance, and reliability of the launch vehicle and to prevent unwanted hazards to the spacecraft.

4.1.2 The prevention and control of extraneous materials on carriers should be based on prevention and the principle of full participation, and should be implemented in a whole-process and all-element control manner.

4.1.3 Both the vehicle development and user units should develop targeted procedures for the prevention and control of unwanted materials, in conjunction with their quality management systems. The preface clarifies the responsibilities and control procedures of relevant departments and personnel, and provides the necessary resources for the prevention and control of excess materials.

4.1.4 The vehicle development and user units should, in conjunction with product characteristics and manufacturing processes, systematically identify products sensitive to particulate matter or pollutants. Identify the types, sources, and generation processes of foreign matter sensitive to products. Based on the identification results, propose foreign matter prevention and control requirements and formulate relevant regulations. And take reasonable and effective measures to prevent and control excess matter. For parts of the product or manufacturing processes sensitive to particulate matter or contaminants, appropriate measures should be implemented. Targeted key controls.

4.1.5 Effective prevention and control measures should be taken during the product manufacturing process, excess materials should be cleaned up in a timely manner, potential hazards should be eliminated, and appropriate inspections should be carried out. Measures should be taken to ensure that the prevention and removal of excess materials meet relevant requirements. The methods used for removing and inspecting excess materials should not lead to the generation of other problems. Remaining items.

4.1.6 When quality problems occur due to foreign matter, zeroing should be carried out in accordance with GB/T 29076, effective corrective measures should be taken, and lessons should be learned. Three in reverse.

4.1.7 Records of the prevention and control of foreign matter on the launch vehicle should be maintained. Areas requiring high cleanliness and difficult to inspect subsequently should be photographed. Or video recording.

4.1.8 The coverage, effectiveness, and implementation status of excess material prevention and control measures should be considered in design reviews, process reviews, and production preparations. One of the contents of inspection and product acceptance review.

4.1.9 Cleanliness or foreign matter control requirements should be specified in the technical agreements for purchased parts, outsourced parts, and accessories.

4.2 Environmental Control

4.2.1 The factory layout and zoning should be reasonable, and the assembly workshop (or area) should be physically separated from the parts processing workshop (or area). isolation.

4.2.2 Production should be carried out in a facility that meets the requirements for the prevention and control of foreign matter. The facility should be conducive to the prevention and control of foreign matter and be reasonably designed. Install facilities such as air showers to prevent potential external objects from entering.

4.2.3 Measures should be taken to control the environment of the production site and storage area to meet the requirements for cleanliness, temperature, humidity, light intensity, pH, and salt spray. The production and storage environment requirements for these products. The manufacturing process for products with special cleanliness requirements should be conducted in a qualified cleanroom. The cleanroom design shall be carried out in accordance with GB 50073.

4.2.4 The production site should be managed by zone and fixed location, with appropriate signage. Items unrelated to production should not be placed there, and restrictions on such items should be imposed. Personnel entering or engaging in activities unrelated to production.

4.2.5 Containers for collecting excess materials should be set up at the production site and cleaned up in a timely manner.

4.2.6 Production areas and work surfaces should be cleaned before and after work to maintain cleanliness and order. Cleaning operations should not move excess materials to other areas. This could lead to excess material entering the product.

4.2.7 Before commencing work, it should be checked whether the production, assembly, and testing environments meet the product requirements.

4.2.8 Regular inspections and maintenance of factory buildings and other facilities are recommended, with timely repairs. Maintenance, upkeep, and repair work on factory buildings and facilities should not result in unnecessary material waste. Hidden dangers.

4.3 Personnel Control

4.3.1 All personnel involved in product research and development and production should receive training on foreign matter prevention and control and pass the assessment. The training recipients include... This includes, but is not limited to, the design, process, production, testing, procurement, and storage of products and their equipment, as well as related management personnel, and those who may come into contact with them. Product personnel.

4.3.2 Personnel entering the production test site shall wear the prescribed attire.

4.3.3 Based on the risk identification results, restrictions should be placed on bringing items unrelated to work into the work area.

4.3.4 Any extraneous items or potential hazards discovered should be reported promptly.

4.3.5 External personnel (such as customers, visitors, suppliers, infrastructure maintenance personnel, etc.) should receive necessary training and briefings on the prevention and control of unwanted materials. They may be informed, or accompanied, guided, and supervised by trained personnel.

4.4 Tool Control

4.4.1 An effective tool management system should be established to ensure clear responsibilities and traceable process records.

4.4.2 The materials and structure of tools should not easily generate or conceal excess material.

4.4.3 Small tools used on site should be equipped with dedicated tool containers, and small-sized tools should be packaged in sets or individually.

4.4.4 Tools should be managed according to their location and condition. Tools should be checked and counted before and after work; their structure should be intact, components complete, and quantities accurate. Consistent.

4.4.5 The use of tools should not create any hidden dangers or risks of generating foreign matter. When working above or inside the product, measures should be taken to avoid this. Tools become superfluous when incorporated into a product.

4.4.6 If a tool is found to be missing or a component is missing that could potentially enter the product, it should be reported immediately, and efforts should be made to locate or remove it from the product. The possibility of [something].

4.4.7 Necessary tools for cleaning and inspecting excess materials should be provided.

Note. The term "tools" in this document refers to production tools in a broad sense, including general tools, measuring tools, instruments, equipment, fixtures, and molds, but excluding factory facilities.

4.5 Material Control

4.5.1 Materials and their heat treatment, surface treatment, and other processing methods should be selected appropriately. Materials that are dense, stable, wear-resistant, have low shedding, and low particle size are preferable. Materials with low particle and fiber content should not be selected, as they are prone to static electricity, have strong adsorption or adhesion properties, and be suitable for use in certain environments and operating conditions. It should not easily produce excess material.

4.5.2 The material shall be compatible with the medium it comes into contact with and shall not react with the medium physically, chemically or electrochemically.

4.5.3 The quality parameters of the gases and liquids used should be controlled according to the characteristics of the product, such as the purity or cleanliness of the gas (solid particles) and dew point. (Moisture content), oil content, pH of the liquid, purity or cleanliness (solid particles), etc.

4.5.4 Materials used for cleaning and wiping the product should not easily generate excess residue. The pH and purity of the cleaning medium should be controlled according to the product's characteristics. Cleanliness or purity (solid particles).

4.5.5 The quantity of small parts and consumables required for assembly should be controlled, and they should be issued according to their matching condition and quantity. Inspections should be conducted before and after installation or use. During the inventory and installation process, measures should be taken to prevent small parts and consumables from falling into the product and forming excess material.

4.5.6 Materials should be used within their expiration date.

4.5.7 Dismantled trial parts, process parts, protective parts, scrapped parts, and remaining selected products should be inventoried and promptly returned to the warehouse or isolated for scrapping.

5.Requirements for prevention and control of foreign matter in product design process

5.1 Excess material should be controlled from the source of the product design, and the ease with which excess material can be prevented and controlled during the manufacturing process should be taken as a guarantee of product quality. One of the design principles is to prevent and control unwanted materials throughout the entire product design process.

5.2 The mutual influence of redundant components, subsystems, between systems, and the entire system should be analyzed.

5.3 Design schemes with strong resistance to extraneous objects should be given priority, or redundant designs should be adopted.

5.4 Structural layouts and materials should be selected that are not prone to generating, introducing, retaining, inspecting, or removing excess matter. Materials that are not prone to generating... To minimize the need for redundant connections, avoid cable crimping and welding during the final assembly process.

5.5 Particulate matter or contaminant-sensitive products should not be located in areas where excess material may be generated during production, testing, or flight.

5.6 The migration area of excess material should be controlled. In systems with gas or liquid lines, on critical components, or in ground-connected pipelines, [measures should be taken]. Filtering devices that meet accuracy requirements.

7.1 Parts Machining

7.1.1 The amount of excess material that may be generated during the part manufacturing process (such as residual working medium, byproducts, residues, or substrate that may fall off later) should be considered. Targeted prevention and control measures should be taken for the materials.

7.1.2 Excess material generated during parts manufacturing operations should be removed promptly. Contaminants should not be introduced during product processing, installation, and cleaning. Apply to other clean product surfaces.

7.1.3 Appropriate methods should be selected to remove and inspect excess materials from parts, especially in cavities, holes, grooves, gaps, and interlayers where excess materials are prone to accumulate. The structure or part of an object.

7.1.4 During and after the machining of parts, non-surface-treated areas and exposed openings should be covered or sealed. Or add temporary packaging or other protective measures.

7.1.5 After the parts are processed, they should be cleaned before packaging and delivery until the cleanliness requirements are met.

7.1.6 After the parts are processed, they should be packaged as required. The packaging materials should be cleaned before use and no excess material should be introduced.

7.2.1 Structural Products

7.2.1.1 During welding and other operations, the product should be protected to prevent spatter from remaining or entering its internal cavity. The product should be cleaned before welding. Effective protective measures should be taken during processing, welding, and grinding, and the area should be cleaned promptly.

7.2.1.2 After rinsing and drying, the storage tank should be rotated, inspected, and any excess material inside should be removed, especially from seams, interlayers, and joints. Delivery Beforehand, replace the air inside the chamber with clean, dry air and seal it promptly.

7.2.1.3 During catheter welding, the catheter lumen should be protected from oxidative contamination. After welding, acid pickling is generally used to remove oxidation products. After catheter testing, Clean and dry the tube and check for any foreign objects. After checking the lumen of the small-diameter catheter with an endoscope to ensure there are no foreign objects, seal the opening promptly.

7.2.1.4 After the gas cylinder has passed the test, dried, and the nozzle has been assembled, an endoscope should be used to check to ensure that the inner surface is clean and free of foreign matter, and the cylinder should be sealed in a timely manner. Bottle neck.

7.2.1.5 During riveting assembly, measures should be taken to remove metal shavings or powder generated during drilling. For sections with high cleanliness requirements (such as...), For areas of the spacecraft fairing that cannot be cleaned, protective measures such as sealing or coating should be taken; for areas where sealing or coating measures are not taken, disassembly-cleaning should be used. The secondary assembly method of resetting the body.

7.2.1.6 Products made of laminated composite materials should have burrs removed, and after sanding, they should be vacuumed and wiped clean. Composite materials and non-metallic materials... Dust generated during drilling and riveting assembly should be collected using a vacuum cleaner. For sandwich-structure composite products, extruded residue should be removed. Remove the glue, vacuum and wipe clean, and avoid rain or moisture.

7.2.2 Valves and Servo Mechanisms

7.2.2.1 Before assembling the valve, the parts should be cleaned and dried, and then inspected visually and endoscopically. The dynamic seal should be inspected with a microscope. Use a magnifying glass to check the moving guide surface, static sealing surface, etc., and there should be no excess material.

7.2.2.2 Measures should be taken during valve assembly to prevent external foreign matter from entering or leaving foreign matter.

7.2.2.3 Valves should be dried after assembly and vacuum-sealed after passing acceptance.

7.2.2.4 Servo mechanism parts should be cleaned before assembly, and moving mating parts should be cleaned and checked again after the break-in test to ensure there are no foreign objects. Hole parts should be cleaned and inspected under a microscope and light to ensure there are no foreign objects.

7.2.2.5 During the commissioning and testing of the servo mechanism, the cleanliness of the oil should be ensured, and the test system should be equipped with and the filter device should be replaced regularly.

7.2.3 Electronic Products

7.2.3.1 For electronic products, the assembly process should control foreign objects. Before closing the cover, a visual inspection should be conducted to ensure there are no foreign objects. After closing the cover, an audible inspection and displacement signal detection should be performed. There should be no moving or excess material.

7.2.3.2 For inertial devices forming air and oil circuits, the air bearings and float assemblies, and the welding of key components of hydrostatic air (liquid) float inertial instruments, should be done with ventilation. Positive pressure clean gas protection. For enclosed products such as motors and screw pumps, check for foreign objects by observing startup performance parameters. For enclosed components such as floats and instruments... The product can be inspected for excess material using X-ray imaging.

7.2.3.3 There should be no objects inside or at the interfaces of power supply and distribution system instruments (such as batteries, distributors, and relays) that could cause short circuits or movement. Stuck or excess material.

7.2.3.4 There should be no [illegible] inside the antennas and front-end control instruments of the flight control computer, satellite navigation (GNSS) receiver, or their interfaces. Foreign objects (such as metal shavings or wire ends) that could cause a short circuit or grounding.

7.2.3.5 Electronic products should have their plugs (sockets) inspected internally to avoid any conductive foreign objects (such as metal shavings or solder balls) or potential sources that could cause wire breakage. Deliver broken or high-resistance insulating materials (such as fibers or plastics) and seal them for protection.

7.2.3.6 Manufacturing processes that are sensitive to contamination (such as adhesive bonding) should be cleaned and protected.

7.2.3.7 The amount of liquid materials injected or lubricants, sealants, adhesives, etc., applied during assembly should be controlled to avoid exceeding product requirements. Used in certain areas or in excessive amounts.

7.2.4 Engine

7.2.4.1 Before assembling the engine, the parts should be cleaned.

7.2.4.2 During solid rocket motor assembly, the internal cavities of the solid rocket motor (such as the nozzle throat, the inside of the flexible nozzle, and the propellant charge) should be controlled, inspected, and cleaned. (Internal cavity) extraneous material.

7.2.4.3 Control any excess material (such as metal shavings, tools, hard particles) between the propellant grain of the solid rocket motor and the insulation layer or casing before bonding. The bonding surfaces should be inspected and cleaned to remove excess adhesive.

7.2.4.4 There should be no extraneous objects on the mating surfaces and in the channels of the ignition system passage and safety ignition mechanism.

7.2.4.5 The greases, sealing greases, and adhesives used in liquid engines should be compatible with the working medium of the product, especially for dynamic seals in cryogenic systems. Do not apply to areas where adhesive has not hardened. When insulating cryogenic components during engine assembly, measures should be taken to prevent uncured adhesive from dripping onto other surfaces. The product may be on the surface or inside the engine.

7.2.4.6 Before grinding the sealing surface of liquid engine connectors, the inner cavity should be sealed, the interface to be ground should be facing downwards, and after completion, clean and remove. Sealing material. Before installation, the conduit should be blew out and checked for any foreign objects. Before assembly, the joints should be checked for any foreign objects. When filing or repairing engine conduits, the cut-off point... The inner and outer edges of the pipe opening should be sharpened or chamfered and burrs removed.

7.2.4.7 Seal and protect the engine and its components from any openings during disassembly, assembly, or storage. Use a vacuum cleaner to clean the hydraulic engine piping during disassembly. Remove any excess material. After disconnecting the engine ball joint flared end conduit, ensure the conduit ball joint is in full contact with the connector flared end before cleaning is complete. Before cleaning the graphite seal ring, the product opening should be sealed and protected. For disassembled threaded products, the interface should be vertically downward during cleaning.

7.2.4.8 When disconnecting the adhesive-coated pipe joint, all adhesive debris should be thoroughly cleaned from the threads before disconnecting the joint, and the joint should be properly cleaned. Protect it.

7.2.4.9 During the disassembly and assembly of liquid and gas system pipelines, burrs should be removed in a timely manner and cleaned in accordance with regulations.

7.3.1 Overall assembly inside the storage tank

7.3.1.1 Personnel entering the storage tank should wear dedicated one-piece clean suits.

7.3.1.2 All items entering and leaving the storage tank shall be counted and registered.

7.3.1.3 Before the products are placed into the box, they should be cleaned and checked to ensure there are no extra items.

7.3.1.4 When installing products inside the container, any assembly work that can be completed outside the container should be completed before the product is placed inside the container.

7.3.1.5 When entering the storage tank for final assembly, the inside of the storage tank should be inspected, and there should be no extraneous objects.

7.3.1.6 When performing operations such as cutting off excess material inside the box, measures should be taken to prevent it from falling off.

7.3.1.7 After the products inside the box are installed, any excess material should be removed from the inside out. After cleaning, the excess material inside the storage box should be inspected, preferably using [method/method]. When collecting items using the tape method, visual inspection should be conducted to ensure there are no excess items.

7.3.1.8 Before sealing the storage tank, the excess material samples and audio-visual records inside the storage tank should be checked and confirmed.

7.3.1.9 After sealing the box, use dry compressed gas to replace the gas inside the box to prevent subsequent condensation or icing.

7.3.2 Assembly of the booster conveying system

7.3.2.1 During the final assembly and storage period, all open openings of flanges, conduits, etc., shall be sealed with protective devices.

7.3.2.2 Before final assembly, the visible parts such as sealing surfaces, sealing grooves, sealing rings, and outer nuts should be inspected and cleaned. For through-hole type parts, they can be immersed in water.

7.3.2.3 Before installation, the inner cavity of the arrow guide tube and other similar parts should be purged with clean gas for inspection.

7.3.2.4 When using catheters for coordinated sampling, protective measures should be taken to prevent foreign matter from entering the system.

7.3.2.5 When heat protection treatment is performed before the conduit is installed, the pipe joint should be protected against excess material before heat protection.

7.3.2.6 The lubricant for mechanical joints should not enter the internal cavity or critical surfaces, nor should it come into contact with the propellant. The installation of seals should not allow the lubricant to enter the internal cavity or critical surfaces. Lubricants and other additives are introduced into the system.

7.3.3 Airtightness Check

7.3.3.1 The gas medium used for airtightness testing shall meet the cleanliness requirements.

7.3.3.2 The ground air supply system should meet the cleanliness requirements, and filters should be installed at the product interfaces (including pressure test ports) of the ground pipeline. The filter accuracy should be no less than the accuracy specified in the design.

7.3.3.3 Adapters in the ground air distribution system (especially adapters between filters and products), airtight plugs on the carrier, etc., should be clean and dry. Clean; visual inspection revealed no visible foreign matter.

7.3.3.4 Before use, ground gas distribution platforms, joints, high and low pressure pipelines, etc., should be purged with clean gas. The gas should be collected and inspected for any visually visible defects. Remaining items.

7.3.3.5 During the airtightness test, the inflation and deflation rates should be controlled to avoid excessive speed, which could lead to condensation, frost, or ice formation on the product surface. Phenomenon.

7.3.3.6 When using the soap bubble method for leak detection, measures should be taken to prevent the leak detection solution (soap solution) from dripping onto instruments, cables, or other products. After the leak detection is completed, the affected area should be wiped dry. Areas that have been coated with leak detection solution (soap solution).

7.3.3.7 After helium mass spectrometry leak detection, the leak detection encapsulation material, sealing putty and other auxiliary materials should be cleaned up in a timely manner.

7.3.3.8 After the airtightness test is completed, all protective components (such as covers, plugs, etc.) on the product and ground pipelines should be promptly reset and installed.

7.3.4 Instrument cable installation

7.3.4.1 Before installing instrument cables, check and remove any foreign objects. There should be no foreign objects inside the electrical connector interfaces. Cables with thermal protection coatings should be properly sealed. The coating should be intact, clean, and free of rough edges or exposed threads.

7.3.4.2 Protective components at electrical connectors, pressure testing ports, etc., should not be removed during instrument cable installation. If it is necessary to remove the protective components for inspection, they should be... Store it properly, keep it clean, and reinstall it promptly after inspection.

7.3.4.3 When assembling instruments with optical components and sealing surfaces, the caps should not be removed except during inspection, and the optical components should not be touched with bare hands or cleaned without authorization. When cleaning is required for the surfaces of components or other sensitive devices containing particulate matter or contaminants, it should be done in accordance with the technical requirements.

7.3.4.4 During cable installation, when removing excess materials such as cable ties and wire ends, measures should be taken to prevent splashing.

7.3.4.5 Before plugging in the electrical connector, remove the protective cover from the connector, visually inspect the inside of the plug (socket) for any foreign objects, and clean it if necessary. The plug (socket) should be inspected and photographed. Removed plug (socket) protective components should be promptly inventoried and properly stored.

7.3.4.6 After disconnecting the electrical connector, check that the internal visible parts are clean and free of debris. Electrical connectors not currently being connected should be replaced with the provided replacement parts promptly. Use a protective cap for protection.

7.3.4.7 Before use, flexible materials should be clean and free of debris. During cutting, fabrication, and installation, rough edges, debris, and loose threads should be removed. Etc., to avoid contaminating the product.

7.3.5 Internal assembly and sealing

7.3.5.1 The work surfaces, sealing surfaces, datum surfaces, locating surfaces, and fixtures of the parts and components involved in the assembly should be carefully inspected. Clean the planes.

7.3.5.2 Before section docking, check and remove any excess material inside the compartment, and confirm that the docking surfaces, docking holes, sealing grooves, and seals are clean. The process components and protective parts that needed to be removed from the cabin have been removed as required.

7.3.5.3 Tools, parts, auxiliary materials, etc. should not be placed directly inside the cabin, and documents or other materials should not be placed inside the product cavity.

7.3.5.4 For parts that cannot be inspected after assembly, a dual-shift system should be implemented, with inspection personnel present, to jointly confirm that there are no extraneous materials. Assembly can only proceed after this, and photographs or videos should be taken to record the process.

7.3.5.5 All process components, protective parts, nameplates, labels, gaskets, fuses, and lead seals that need to be removed should be inventoried and checked after assembly is completed. examine.

7.3.5.6 Before the final sealing of the product, all excess materials in the designated areas should be inspected and removed, and it should be confirmed that the process components and protective components have been removed as required.

7.3.6 Lifting, flipping, parking, and transferring

7.3.6.1 Before hoisting, overturning, parking, or transferring the carrier, the surfaces of the crane and ground support equipment should be clean and free from oil leaks and peeling.

7.3.6.2 Before the carrier is placed on ground support equipment such as a support vehicle or bracket, the relevant support surfaces and docking holes should be cleaned.

7.3.6.3 Before hoisting or overturning the carrier, check that all moving parts and unconnected electrical connectors on the carrier are securely fixed.

7.3.7 Testing and Experimentation

7.3.7.1 Upon receiving the product, its appearance and any excess items should be inspected.

7.3.7.2 The control of foreign matter in electrical connectors shall be performed in accordance with the provisions of

7.3.4.5 and 7.3.4.6.

7.3.7.3 Before the test, the cleanliness of the test area environment, test system and medium shall be checked or tested to ensure that the requirements are met.

7.3.7.4 The ground pipelines for the test medium and auxiliary system pipelines should be thoroughly cleaned and purged. A filter device should be installed between the test equipment and the product. Regular inspection and replacement.

7.3.7.5 When testing and troubleshooting electrical connectors, a white, lint-free cloth should be placed under the disconnected connector to catch any loose parts. Excess material.

7.3.7.6 During the test and withdrawal process, the interior of each compartment should be cleaned and any excess materials removed.

8.Requirements for controlling excess material during packaging, storage and transportation

8.1 Before transportation and storage, effective sealing or protective measures should be taken for open parts of the product and precision products.

8.2 Products shall be protected, packaged, and sealed in accordance with the prescribed product protection and packing levels.

8.3 Products that are sensitive to environmental humidity or high-precision products should be packaged in a vacuum-sealed manner, protected by gas filling, or with desiccants.

8.4 Reliable dust and pollution prevention measures should be taken during product transportation. 8.5...