The USA Materials and Process (M&P) team consists of highly trained and experienced engineers who are established leaders in the design, development, qualification, and implementation of environmentally regulated hardware. They are recognized experts in materials engineering and offer a wide range of validation services. The M&P collective engineering talent and expertise combine to form significant forensic analytical capabilities to appropriately determine material, process, and system failure modes root cause identification, such as could be encountered in the loss of adhering of adhesive, paint film, insulation or other material. The M&P team also performs the full range of comprehensive failure analysis and material characterization evaluations, from simple chemical composition verification to a full array of physical, mechanical and chemical tests.

USA M&P engineers have significant experience in sustaining aging aircraft through advanced corrosion inspection and corrosion control methods. For example, M&P experts have implemented testing on a variety of specialized fasteners in order to qualify torque-tension data and ensure sufficient bolted joint preload. M&P engineers at USA routinely work with corrosion resistant metals, exotics, fiberglass and carbon composites, high heat resistant fabrics, advanced and environmentally friendly solvents, coatings, and adhesives.

As a leader in Non-Destructive Evaluation (NDE) technology, USA offers established inspection capabilities over the full spectrum of equipment required to conduct comprehensive NDE examination of materials, dimensions, bond conformities, coating conformities, and surface and subsurface defects.

USA has highly trained and experienced engineers and technicians who have provided materials engineering support to Marshall Space Flight Center, Kennedy Space Center, and Johnson Space Center for the design, development, and implementation of the M&P used in the production of space flight hardware.

USA laboratory operations are also integrated into other space flight operations such as In-Flight Anomalies (IFAs) and Anomaly Resolution Teams (ARTs).

USA designs and integrates the Thermal Protection System (TPS) involving numerous materials and suppliers. USA is uniquely qualified to apply TPS materials with the environmentally friendly, solvent-free Marshall Convergent Coating process developed jointly by MSFC and USA engineers. USA has also provided TPS design solutions to other SSP Elements, the orbiter, X-38, and the International Space Station.

Additional USA strengths include the development, qualification and implementation of M&P enhancements for new vehicle programs, obsolete material replacement and qualification, internal and vendor critical process control, and analysis of material anomalies.