1 i field joint environmental protection system vibration/ pressurization ... · 2013-08-30 · i i...

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TWR-17245

Field Joint Environmental Protection System Vibration/ Pressurization Qualification Final Test Report

9 March 1989

Prepared for

National Aeronautics and Space Administration George C. Marshall Space Flight Center Marshall Space Flight Center, Alabama 3581 2 Contract No. NAS8-30490 DR No. 5-3, Type 1

ECS No. 600 WBS No. 48 102-1 0-03

Aerospace Group Space Operations P.O. Box 707, Brigham City, Utah 84302-0707 (801) 863-351 1

Publications No 89343

. https://ntrs.nasa.gov/search.jsp?R=19890015078 2020-01-23T09:10:09+00:00Z

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MOITON THIOKOL. INC.

Space Operations

Field Joint Environmental Protection System Vibration/Pressurization Qualification

Final Test Report

Prepared by :

Test Planning and Reporting

Approved by:

Space Systems &f ngineering Test Planning and Reporting

Manager

---ai&- Supervisor

Syskdids Test O G and Support - _ _

Manager

- 311 .)!as Prdbfect hgineer I‘ I : ,; I - 5

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Space Englneerin esign Manager

DatabManagement ECS# 600

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ABSTRACT

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The field joint environmental protection system (herein referred to as the joint protection system (JPS)) vibration/pressurization qualification test consisted of flight-simulating environmental conditioning and dynamic environment testing of a JPS test article. The major purposes of the test were to certify that the flight-designed JPS will withstand the dynamic environmental conditions of flight, and to certify that the cartridge check valve (vent valve) will relieve pressure build-up under the JPS during the initial 120 sec (minimum) of flight.

The vibration test article performed satisfactorily and fulfilled all objectives listed in the test plan. anomalies were evident, and the bondlines showed no evidence of separation or degradation throughout the testing. All requirements for venting and pressure release were met. Also, button pull tests of the extruded cork insulation bondlines yielded acceptable results.

The JPS remained intact, no visual

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1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . 1.1 BRIEF TEST ARTICLE DESCRIPTION . . . . . . . . OBJECTIVES . . . . . . . . . . . . . . . . . . . . . . APPLICABLE DOCUMENTS . . . . . . . . . . . . . . . . . RESULTS SUMMARY. CONCLUSIONS. AND RECOMMENDATIONS . . 4 . 1 RESULTS SUMMARY . . . . . . . . . . . . . . . . 4.2 CONCLUSIONS . . . . . . . . . . . . . . . . . . 4 . 2 . 1 Requirement Traceabi 1 i ty . . . . . . . . . . . 4 .3 RECOMMENDATIONS . . . . . . . . . . . . . . . . INSTRUMENTATION . . . . . . . . . . . . . . . . . . . PHOTOGRAPHY . . . . . . . . . . . . . . . . . . . . . RESULTS AND DISCUSSION . . . . . . . . . . . . . . . . 7 . 1 7 . 1 . 1 7 . 1 . 2 7 .2 7 .2 .1 7 .2 .2 7 .2 .3 7 .2 .4 7 . 3 7 .3 .1 7 .3 .2 7 .3 .3

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TEST ARTICLE DESCRIPTION . . . . . . . . . . . Joint Simulator Fixture . . . . . . . . . . . . Vibration Test Article Assembly . . . . . . . . ACCELERATED ENVIRONMENTAL CONDITIONING . . . . High.Temperature. Hi gh-Humi di ty Conditioning . Salt Spray Conditioning . . . . . . . . . . . . Rain Conditioning . . . . . . . . . . . . . . . Low-Temperature Conditioning . . . . . . . . . TEST RESULTS AND DISCUSSION . . . . . . . . . . F1 ight Random Vibration/Pressurization Test . . Reentry Random Vi bration/Pressurization Test . Vehicle Dynamics Vi bration/Pressuri zation Test . . . . . . . . . . . . . . . . . . . . . Water Impact Shock Test . . . . . . . . . . . . Cork Button Pull Tests . . . . . . . . . . . .

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A DATA FROM SRM FJEPS VIBRATION/PRESSURIZATION T E S T . . A - 1

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B MEMO A 4 0 0 - F Y 8 9 - 1 3 9 , "REDLINE TO C T P - 0 0 5 4 , REV. C , ' Q U A L I F I C A T I O N T E S T PLAN FOR F I E L D J O I N T ENVIRONMENTAL PROTECTION SYSTEM V IBRATION/ PRESSURIZATION TEST"' . . . . . . . . . . . . . . . . B - 1

C DISCREPANCY REPORTS NO. 168169 AND NO. 168188 . . . . C - 1

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FIGURES

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Top View, Field Joint Environmental JPS Vibration/ Pressurization Test Article . . . . . . . . . . . . . 2

Front View, Field Joint Environmental JPS Vibration/ Pressurization Test Article . . . . . . . . . . . . . 3

Side View, Field Joint Environmental JPS Vibration/ Pressurization Test Article . . . . . . . . . . . . . 4

Side View, Close-up, Field Joint Environmental JPS Vibration/Pressurization Test Article . . . . . . . . 5

JPS Test Article Subject to Salt Spray Conditioning . . . . . . . . . . . . . . . . . . . . . 16

JPS Test Article Positioned for Longitudinal Vibration . . . . . . . . . . . . . . . . . . . . . . 17

JPS Test Article Positioned for Tangential Vibration . . . . . . . . . . . . . . . . . . . . . . 18

JPS Test Article Positioned for Radial Vibration . . . 19

JPS Test Article Salt Spray Conditioning--High Temperature and Humidity . . . . . . . . . . . . . . . 23

JPS Test Article Rain and Low-Temperature Conditioning--Chamber and Water Temperature . . . . . 26

TABLES

pjgg

JPS Test Article Salt Fog Conditioning Data . . . . . 24

Cork Button Pull Test Results . . . . . . . . . . . . 30

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ACRONYMS

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CEI . . . . . contract end item FJEPS . . . . field joint environmental protection system grms . . . . gravity root mean square JPS . . . . . joint protection system LSC . . . . . linear-shaped charge PSD . . . . , power spectral density RSRM . . . , redesigned solid rocket motor

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INTRODUCTION

This report documents the procedures used and results obtained from vibration testing the redesigned sol id rocket motor (RSRM) field joint environmenta protection system (FJEPS), hereafter referred to as the joint protection system (JPS), per CTP-0054, "Qualification Test Plan for the Field Joint Environmental Protection System Vi bration/Pressurization Test .'I The JPS installed to protect the RSRM field joints from the exterior environment. The test consisted of fl ight-simulating environmental conditioning and dynamic environment testing of a JPS test article. The major purposes of

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the test were to certify that the flight-designed JPS will withstand the dynamic environmental conditions of the redesigned solid rocket booster, and to certify that the cartridge check valve (vent valve) will relieve pressure build-up under the JPS during the initial 120 sec (minimum) of flight. Also, an evaluation of the extruded cork insulation bonding was performed after the vibration testing.

The test article was assembled and instrumented according to Morton Thiokol drawings 7U76358 (test article assembly) and 211132025 (vi bration fixture). The test article was built using sections of current JPS production components, except that the field joint used was a fixture designed to simulate the external contour of the RSRM field joint. Accelerometer and pressure data were acquired to verify the input and response vibration spectrums and the pressure buildup under the JPS during test i ng .

Testing was conducted at the Morton Thiokol Utah-based test facilities T-3, T-51, T-53, M-15, and M-53 and was completed on 8 Feb 1989.

1.1 BRIEF TEST ARTICLE DESCRIPTION

The test article configuration represented flight hardware, except for the joint simulator fixture (Figures 1 through 4). The test article assembly

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consisted o f an aluminum joint simulator fixture and sections o f pin retainer band, JPS heater, heater thermal barrier, moisture seal, moisture seal retainer straps, instrumented moisture seal retainer strap clips and links, JPS sensor, extruded cork insulation, and K5NA ablation compound. In addition, a cartridge check valve was installed into the center o f the assembly.

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OBJECT I VES

The JPS v i b ra t ion /pressur iza t ion t e s t ob jec t ives were der ived from the ob jec t ives i n TWR-15723, Rev. C, "Redesign D&V Plan," t o s a t i s f y the requirements o f con t rac t end i tem ( C E I ) s p e c i f i c a t i o n CPW1-3600. ob jec t ives are l i s t e d w i t h the C E I paragraph numbers as fo l lows:

The

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b.

C.

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C e r t i f y t h a t the JPS sha l l remain i n t a c t through simulated f l i g h t , postseparation, water impact and, as a goal, through recovery v i b r a t i o n and shock c r i t e r i a . (3.2.1.11.d, 3.2.7.2.2.b)

C e r t i f y t h a t the JPS s t ruc tures and components are designed t o demonstrate the l i f e f a c t o r requirements. (3.3.6.5)

C e r t i f y t h a t the JPS i s designed t o preclude the shedding o f debr is (Debris Prevention) from the elements dur ing prelaunch and f l i g h t operat ions t h a t would jeopardize the f l ightcrew and/or mission success. (3.2.6.5)

C e r t i f y t h a t the vent valve w i l l r e l i e v e the pressure bui ldup under the JPS dur ing the i n i t i a l 120 sec minimum o f both f l i g h t random and veh ic le dynamics v i b r a t i o n c r i t e r i a i n each axis. (3.2.1.11.d, 3.2.7.2.2.b)

Evaluate the JPS bondl i n e performance when subjected t o the prelaunch natural environments as listed:

- - A i r temperature - -Humi d i t y --Rain - -Sa l t a i r

Evaluate the JPS pos t - tes t s t r u c t u r a l i n t e g r i t y (adhesive bondl ines) through but ton p u l l t es ts .


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CPW 1 -3600

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CTP-0054

DPD 400

SE-019-049-2H

STW5-2994

STW5-3 183

STW4-3218

STW 5 -322 5

STW 5 - 32 26

TWR-10163 (CD)

TWR-15671

TWR-15723

TWR- 17230

TWR-19138

GS&HM

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APPLICABLE DOCUMENTS

T i t l e

Prime Equipment Contract End I tem ( C E I ) D e t a i l Spec i f i ca t ions

Q u a l i f i c a t i o n Test Plan f o r the F i e l d J o i n t Environmental Pro tec t ion System V i brat ion/Pressur izat ion Test

Data Procurement Document No. 400

Sol i d Rocket Booster V ibrat ion, Acoust ic and Shock Design and Test C r i t e r i a

Paint, Polyethylene, Chlorosul fonated

Ab1 a t i on Compound, Cork F i 11 ed (K5NA)

Epoxy Resin Adhesive, Nonasbestos, S t ruc tu ra l Bonding (EA 934NA)

Coatings, Epoxy-Polyamide

Primer, Z i nc- R i ch , Epoxy- Polyamide

Safety Plan for Space Shut t le S o l i d Rocket Motor Pro jec t

Q u a l i t y Plan f o r the SRM Redesign Program

Redesign D&V Plan

Cork Extrusion Mechanical Character izat ion F ina l Test Report

FJEPS V i brat ion/Pressur izat ion Test F1 ash Report

Morton Thiokol/Wasatch Operations General Safety and Health Manual

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MIL-STD-810C Environmental Test Methods

MIL-STD-810D

MIL-S-8802 Type I C1 B-2 Sealant (PR1422 Polysulfide)

Environmental Test Methods and Engineering Guidelines

MI L - STD- 45662 Calibration System Requirements

Drawins No.

211132025 Vibration Fixture RSRM Field Joint

71176358 Test Assembly, Vi bration/Pressure

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RESULTS SUMMARY, CONCLUSIONS, AND RECOMMENDATIONS

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4.1 RESULTS SUMMARY

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This sect ion contains an execut ive summary o f the key r e s u l t s from the t e s t data evaluat ion and pos t - tes t inspect ion. Addi t ional in fo rmat ion and d e t a i l s can be found i n Section 7 o f t h i s repor t .

The v i b r a t i o n t e s t a r t i c l e performed s a t i s f a c t o r i l y and f u l f i l l e d a l l o f the ob jec t ives l i s t e d i n CTP-0054. anomalies were evident, and the EA 934NA adhesive and K5NA ab la t i on compound bond1 ines showed no evidence o f separat ion o r degradation throughout the tes t i ng . The ca r t r i dge check valve performed as expected. A l l requirements f o r vent ing and pressure release were met and the c a r t r i d g e check valve remained securely bonded i n place. the extruded cork i n s u l a t i o n and the aluminum j o i n t s imulator f i x t u r e , moisture seal, and moisture seal r e t a i n e r s t raps y ie lded s a t i s f a c t o r y resu l t s .

The JPS remained i n t a c t , no v isua l

Button p u l l t e s t s o f the bonds between

Throughout the v i b r a t i o n environment t e s t s there was no drop o r change i n the moisture seal r e t a i n e r s t rap tension. During a l l o f the f l i g h t random and veh ic le dynamics pressur iza t ion t e s t s there was no i n t e r n a l pressure drop.

For the water impact shock tes t , the impact-s imulat ing pulse dura t ion c r i t e r i o n was changed from 0.050 t o 0.010 sec t o accommodate the c a p a b i l i t i e s o f the t e s t equipment. Longi tud ina l ax is shock No. 1 was run w i t h a loose lead on the cont ro l accelerometer, and thus the a r t i c l e was over- tested t o 70.23 g ( t e s t c r i t e r i a peak l e v e l was 20 9). run t o 19.77 g ( t e s t c r i t e r i a peak l e v e l was 8 9). The cause of t he tangen- t i a l over - tes t i s unknown. a r t i c l e i n each over- test , both t e s t runs were acceptable.

Tangential ax i s shock No. 1 was

Since no v i sua l damage was done t o the t e s t

Based on the r e s u l t s o f these tes ts , i t can be concluded t h a t the t e s t was successful.

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4.2 CONCLUSIONS

Overa l l , the r e s u l t s o f t h i s t e s t were sa t i s fac to ry . t h a t when proper i n s t a l l a t i o n procedures are fo l lowed the JPS w i l l remain i n t a c t throughout the f l i g h t environment. d i d no t come free from the j o i n t s imulator f i x t u r e . No evidence of debr is was present and the c a r t r i d g e check valve re l i eved the pressure b u i l t up under the JPS as needed. A l l o f the bondlines were i n exce l len t cond i t ion and pos t - tes t p u l l t e s t s showed greater- than-ant ic ipated bondl i ne strengths.

4.2.1

L i s t e d fo l l ow ing are the conclusions as they correspond t o the ob jec t ives and C E I paragraphs. Addi t ional in format ion t o support these conclusions can be found i n Sections 7.2 and 7.3 o f t h i s repor t .

Test r e s u l t s i nd i ca te

The JPS tes ted remained i n t a c t and

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C e r t i f y t h a t the JPS s h a l l remain i n t a c t through simulated f l i g h t , post - separation, water impact and, as a goal, through recovery v i b r a t i o n and shock c r i t e r i a .

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C e r t i f y t h a t the JPS s t ruc tu res and components are designed t o demonstrate the l i f e fac to r requ i rements .

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3.3.1. l l d . The f i e l d j o i n t p ro tec t i on system sha l l remain i n t a c t through f l i g h t and, as a goal, through recovery.

3.2.7.2.2b: Induced Environment Loads. The RSRM sha l l be designed t o wi thstand postseparation- through-recovery loads as specif ied.. . 3.3.6.5: Life Factors. The RSRM sha l l be designed t o wi thstand fa t i gue and f r a c t u r e mechanics requ i rement s as speci f ied. . .

Concl usions

Cert i f i ed . Throughout tes t i ng , a l l o f the bondl i nes and components o f the t e s t a r t i c l e remained i n t a c t and d i d no t degrade i n any way.

C e r t i f i e d . The t e s t a r t i c l e was subjected t o accelerated environmental cond i t ion ing p r i o r t o successful compl e t i on o f v i b r a t i o n and pressur iza t ion tes t i ng .

MORTON THIOI(OL. JNC Space Operations

Objec t ive

C e r t i f y t h a t t he JPS i s designed t o p rec l ude the s heddi ng o f debr is (Debris Prevention) from the e l ements dur ing prelaunch and f l i g h t operations t h a t would jeopard ize the f l i g h t crew and/or mission success.

C e r t i f y t h a t the vent va lve w i l l r e l i e v e the pressure bu i ldup under the JPS dur ing the i n i t i a l 120 sec minimum o f both f l i g h t random and veh ic le dynamics v i b r a t i o n c r i t e r i a i n each ax is .

Evaluate the JPS bondl i ne performance when subjected t o the prelaunch na tu ra l environments as 1 i sted: - - A i r temperature --Humidity --Rain - - S a l t a i r

Evaluate the JPS post - t e s t s t r u c t u r a l i n t e g r i t y (adhesive bondl ines) through bu t ton p u l l t es ts .

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3.2.6.5: Debr is Prevention. The SRM s h a l l be designed t o preclude the shedding o f debr is from the elements dur ing p r e l aunch and f l i g h t operations.. .

3.3.1. l l d . The f i e l d j o i n t p ro tec t i on system s h a l l remain i n t a c t through f l i g h t and, as a goal, through recovery.

3.2.7.2.2b : Induced Environment Loads. The RSRM sha l l be designed t o wi thstand postseparat ion- through - recovery 1 oads as spec i f ied . . .

None

None

Conclusions

Cer t i f i ed . Throughout tes t i ng , a l l components o f t he t e s t a r t i c l e remained i n t a c t and d i d n o t degrade i n any way.

C e r t i f i e d . The vent va lve performed as designed and re1 i eved the JPS i n t e r n a l pressure dur ing the i n i t i a l 120 sec minimum o f each f l i g h t random and veh ic le dynamics v i b r a t i o n t e s t . S a l t deposi ts were present on the vent va lve from the environmental condi - t i on ing , bu t the deposi ts d i d no t impact va lve performance.

The t e s t a r t i c l e was subjected t o the spec i f i ed simulated prelaunch environments and a l l bondlines remained i n t a c t and d i d n o t degrade i n any way.

Cork i n s u l a t i o n p u l l t e s t s y i e l d e d r e s u l t s as expected, and a l l brea k i ng s t rength values were h igher than expected.

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4 .3 RECOMMENDATIONS

Based on the r e s u l t s o f t h i s t e s t , i t i s recommended t h a t the use o f the f l i g h t configuration JPS, as documented i n t h i s r e p o r t , should be continued.

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INSTRUMENTATION

Vibration test instrumentation consisted of a triaxial accelerometer (A002-A004) mounted on the joint simulator fixture to measure response frequencies, and a single accelerometer (A001) mounted to the shaker table input plate to control input frequencies (Figure 1 ) . flowmeter controlled air flowing into the cavity under the JPS, and a pressure gage (Pool) monitored the pressure buildup (Figure 2).

In addition, a mass

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Pretest and post-test photographs o f the test article were taken. through 8 show the test setup and post-test condition o f the test article.

Figures 5

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Prior to the vibration/pressurization testing, the test article was assembled and subjected to accelerated environmental conditioning.

7.1 TEST ARTICLE DESCRIPTION

The test article configuration was designed to certify the JPS. configuration represented flight hardware, except for the joint simulator fixture (Figures 1 through 4). The test article assembly consisted of an aluminum joint simulator fixture and sections of pin retainer band, JPS heater, heater thermal barrier, moisture seal, moisture seal retainer straps, instrumented moisture seal retainer strap clips and links, JPS sensor, extruded cork insulation, and K5NA ablation compound. In addition, a cartridge check valve was installed into the center of the assembly.

Test article

7.1.1 Joint Simulator Fixture

Drawing 2U132025 defined the joint simulator fixture configuration, which was designed to simulate the external profile of an assembled RSRM fi'eld joint and allow for the installation of the JPS. The fixture was machined from aluminum to be 32 in. long by 20 in. wide by 6.2 in. high. The 32-in. test article length was selected using the following criteria:

a. Similarity to the test article length used in the nozzle linear-shaped charge (LSC) and the systems tunnel qualification tests (approximately 30-to-40-in. length).

b. As close to the maximum length possible to achieve the 35.2-grms level required for reentry random vibration.

(Analysis shows that vibration modes which cause element lifting, separation, debonding, etc., are relatively high in frequency and pure radial, tangential, or longitudinal modes. Although 32 in. is only about 15 percent of the JPS circumference, test article length for the lifting, separation, debonding, etc., modes is not a factor.)

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A requirement of the JPS vibration fixture was to simulate and monitor pressure buildup under and venting through the cartridge check valve in the JPS. simulator fixture: and one to monitor the pressure directly under the cartridge check valve in the JPS (Figure 2).

To accomplish this, two pressure ports were drilled into the joint one to allow an airflow into the volume under the JPS,

To ensure that tension in the moisture seal retainer straps could be monitored and verified to be within the 1,300-to-3,000-lb range during assembly, two cavities were machined into the joint simulator fixture to accommodate two turnbuckle/load cell assemblies to which the straps were attached and tightened (Figure 3).

21 PAGE

Prior to installing the JPS, the fixture was grit blasted, vapor degreased, and spray painted with STW5-3226 zinc-rich primer and STW5-3225 top coat.

7.1.2 Vibration Test Article Assembly

Assembly and instrumentation of the JPS vibration fixture was conducted at the Morton Thiokol M-15 facility and was defined by drawing 71176358. The assembly consisted of sections of the pin retainer band, JPS heater, heater thermal barrier, moisture seal, moisture seal retainer straps, instrumented moisture seal retainer strap clips and 1 inks, JPS sensor, extruded cork insulation, and K5NA ablation compound installed on the joint simulator fixture. o f the JPS assembly.

In addition, a cartridge check valve was installed into the center

To obtain an assembly which was capable o f holding pressure, the moisture seal was trimmed 0.75 to 2.0 in. on either end and sealed in place using polysulfide sealant (MIL-S-8802). The cartridge check valve was then bonded to the moisture seal with polysulfide sealant (MIL-S-8802).

Once the seal was verified, the moisture seal retainer straps were installed and tightened to 2,990 k10 lb tension. To monitor and record the tension in the straps, the straps were installed using two specially modified retainer strap clip and link assemblies (the modification to the strap clip and link assemblies consisted of instrumenting them to measure load) and two

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89656-1.18

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Space Operations

turnbuckle/load cell assemblies. relaxation and then retightened, after which the heater sensor was put in pl ace.

The straps were allowed a 30-min period of

Finally, EA 934NA adhesive was applied to both the joint simulator fixture and the extruded cork insulation. The cork was positioned in place and cured inside a vacuum bag for 8 hr. After cure, the adhesive surrounding the upper 0.25 in. of the cartridge check valve was removed and replaced with K5NA (Figure 4). cork and K5NA were painted with white polyethylene paint (STW5-2994). Assembled, the test article weighed 171.4 lb.

K5NA was applied at the aft end of the cork, and all the

7.2 ACCELERATED ENVIRONMENTAL CONDITIONING

Prior to vibration testing, the test article was subjected to temperature, humidity, salt spray, and rain conditioning per CTP-0054 and MIL-STD-810D to simulate the prelaunch natural environment. from 29 Nov to 12 Dec 1988.

This conditioning took place

7.2.1 Hi q h -TernDerature, Hi qh-Humi di tv Condi ti on i nq

Initially, the test article was placed in the Morton Thiokol T-51 test facility and subjected to an environment of 120' +lo-O'F and 90 +lo-0 percent relative humidity for 48 hr minimum (Figure 9). conditioning, the test article was placed in a 75' k1O'F environment for 24 hr minimum and allowed to return to ambient condition.

Upon completion of this

7.2.2 S a l t S w a y Conditioninq

Following the high-temperature, high-humidity, and return-to-ambient conditioning cycle, the test article was placed in the Morton Thiokol T-3 test facility and subjected to a 95' k1O'F salt spray conditioning for 48 hr (Table 1 and Figure 5). article was placed in a 75' k1O'F environment for 48 hr and allowed to return to ambient conditions. showed salt deposits accumulated in and around the vent valve.

Upon completion of this conditioning, the test

Postconditioning inspection of the test article

REVISION -

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REVISION -

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MOWON THIOKOL. INC.

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Space Operations

Table 1 . JPS Test Article Salt Fog Conditioning Data

Reau i red

DH Gravi tv TemDerature Fa1 1 out Speci f i c

6 . 5 to 7 .2 1.023 to 1.037 95 210'F 0 . 5 to 3 .0 mL per hr o f solution

Actual (Pretest1 Fa1 1 out

Speci f i c ReceDtacle RecePtacle - Date DH Gravi tv TemDerature No. 1 No. 2

1 Dec 1988 6 . 9 1.028 96'F 25 70

Actual [Test) Fa1 1 out

Speci f i c ReceDtacle ReceDtacle - Date DH Gravi tv TemDerature No. 1 No. 2

2 Dec 1988 6 . 5 1.026 95'F 25 70 3 Dec 1988 7 . 1 1.029 95'F 30 50 4 Dec 1988 6 . 5 1.025 95'F 50 50

REVISION __

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MOWON THIOKOL. INC.

SEC

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25 PAGE

7.2.3 Rain Conditioninq

Simulated rain conditioning was conducted after completion of the salt spray conditioning. The test article was subjected to a water spray for a minimum of 1 hr. facility and met the following conditions:

The conditioning was conducted at the Morton Thiokol T-3 test

Water pressure: 40 psig Water temperature: 45'F Chamber temperature: 73'F Rain duration: 1 hr minimum Rain droplet size: Distance from nozzle: 19 k1 in.

2 to 4.5 mm diameter

7.2.4 Low-TemDerature Conditioning

Low-temperature conditioning was conducted after completing the rain conditioning. The test article was towel dried, immediately placed in the Morton Thiokol T-3 test facility, and subjected to a 20' to-1O'F environment for a minimum of 48 hr (Figure 10). Upon completion of this conditioning, the test article was placed in a 75' t1O'F environment for a minimum o f 24 hr and allowed to return to ambient conditions. Postinspection of the test article showed salt deposits accumulated in the bottom of the vent valve.

7.3 TEST RESULTS AND DISCUSSION

The vi bration/pressurization test was conducted in the Morton Thiokol T-53 shaker facility from 19 Dec 1988 to 6 Jan 1989. Two Ling A340 shakers were used to conduct the test. The longitudinal and tangential axes tests were conducted using a shaker which was configured horizontally and bolted to a shaker plate (Figures 6 and 7). for the radial test (Figure 8). accelerometer power spectral density (PSD) plots and time history plots) are included in Appendix A.

The other shaker was configured vertically Test results (control and response

The test setup included an internal pressurization pretest of the test article per paragraph 8.1.2 of CTP-0054. All requirements for air flow (3.2 k0.5 in. /sec for 160 sec) and pressure (1.0 t0.5-0 psig) were met. The cartridge check valve (vent valve) performed as designed and relieved the JPS

3

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DOC NO. T W R- 1 72 45 REVISION - VOL

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27 PAGE

internal pressure during the initial 120 sec (minimum) of each flight random and vehi cl e dynamics vi brat i on test.

7.3.1 F1 iqht Random Vibration/Pressurization Test

The equipment armature and head expander exhibited a natural resonance in the 1,000-to-2,000-Hz range. accelerometers which measure motion o f the shaker plate, and response accelerometers which measure motion on the test article. Control accelerometer PSD plots show that the test article was subject to motion within tolerances specified by CTP-0054 (Table 11). PSD plots, however, show the equipment resonance as a data spike which exceeds the to1 erance criteria o f CTP-0054. The resonance/spi ke was a1 1 owed per MIL-STD-810C (Method 514.2, para 4.5.2) and upon receipt of a redline copy of CTP-0054 and a memo from the vice president of Space Operations (Memo A400-FY89-139, included in Appendix B ) . (The test changes specified in Memo A400-FY89-139 have been incorporated into CTP-0054, Rev. C.) Control and response accelerometer PSD plots are included in Appendix A.

Two types o f accelerometers were used: control

Response accelerometer

The test article was pressurized (1.0 t0.5-0 psig) during the initial 160 sec of the vibration test. drop throughout this test. Instrumented moisture seal retainer strap clips and links were monitored with a portable data acquisition system to detect any change in strap tension. throughout this test. article were found.

Pressure gages indicated no internal pressure

No change in strap tension was indicated

The test article met the requirements o f CTP-0054. Upon test completion, no visual anomalies on the test

7.3.2 Reentry Random Vibration Test

Radial axis test levels could only be met by using two control accelerometers and averaging the two outputs for a solid control. of equipment armature and head expander natural resonance in the 1,000-to- 2,000-Hz range. As in the Flight Random Test, control motion was within test criteria, while response motion exhibited a data spike due to equipment resonance. redline version of CTP-0054 and Memo A400-FY89-139, both included in Appendix B.

This setup was a result

The resonance/spi ke was allowed per MIL-STD-810C, and per the

REVISION -

89656-1.21

MORTON THIOICOL. INC

Space Operations

Instrumented moisture

SEC

ea1 ret

28 PAGE

i ner trap clip and 1 inks were monitored, and no change in the strap tension was indicated. completion, no visual anomalies on the test article were found. article met the requirements of CTP-0054.

7.3.3 Vehicl e Dynamics Vi bration/Pressurization Test

The test article was pressurized (1.0 t0.5-0 psig) during the initial 160 sec of the vibration test. throughout this test. links were monitored, and no change in the strap tension was indicated. test completion, no visual anomalies on the test article were found. test article met the requirements of CTP-0054.

7.3.4 Water Imoact Shock Test

The test criteria required an impact-simulating, half-sine pulse duration of 0.050 sec. 0.010 sec. redline version of CTP-0054 and Memo A400-FY89-139, included in Appendix B. Time history data for the shock tests are included in Appendix A.

Upon test The test

Pressure gages indicated no internal pressure drop Instrumented moisture seal retainer strap clips and

Upon The

However, the computerized equipment could only give a duration of The pulse duration criterion was changed to 0.010 sec per the

Longitudinal axis shock No. 1t was run with a loose lead on the control accelerometer, and thus the article was over-tested (70.23 g at 100 Hz on the shock spectrum and test criteria peak level at 20 9). No. 168169 was written to cover the over-test, and is included in Appendix C. Since no visual damage was done to the test article, the over-test was acceptable. Shock No. 2t was run to 31.14 g.

Discrepancy Report

Tangential axis shock No. 1t was run to 19.77 g. (Test criteria peak level was 8 9). Discrepancy Report No. 168188 was written to cover the over-test, and is included in Appendix C. Since no visual damage was done to the test article, it met or exceeded the test requirements and was acceptable. No. 1- to 13.49 g, and No. 2- to 13.43 g.

The cause of the over-test is unknown.

Shock No. 2t was run to 16.68 g,

Radial axis shock testing was satisfactory. Shock No. 1- was run to 12.96 g, No. 2- to 12.98 g, No. 1t to 13.44 g, and No. 2t to 13.44 g.

REVISION -

89656-1.22

MORTON THIOKOL. INC

DOC NO. T WR- 1 72 45

Space Operations

VOL

7.3.5 Cork Button Pull Tests

Cork but ton p u l l t e s t i n g was conducted on 8 Feb 1989 i n the Morton Thiokol M-53 Development Lab (Table 2). t o - j o i n t f i x t u r e bond f a i l e d 100 percent i n the cork and f a i l e d a t h igher s t ress than cork t e n s i l e dog bone t e s t s (documented i n TWR-17230, "Cork Extrusion Mechanical Character izat ion F ina l Test Report"). Two other p u l l t e s t l oca t i ons (moisture seal - to-cork ext rus ion bondl i n e and Kevlar s t rap

and K5NA-to-cork ex t rus ion bondl ine) a lso y ie lded acceptable r e s u l t s .

F ive specimens located on the extruded cork-

8

SEC REVISION __

89656-1.23

29 PAGE

MOWON THIOKOL. INC.

DOC NO. T WR- 1 7245

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MORTON THIOKOL. JNC.

Space Operations I

DOC NO. TWR- 17245

Appendix A

DATA FROM SRM FJEPS VIBRATION/PRESSURIZATION TEST

VOL REVISION -

89656- 1 .27

SEC A- 1 PAGE

MORTON THIOKOL, INC. Aerospace Group Support Services

TEST REPORT

PREPARED BY

Rick Baird Test Cn2ineer

r 2 APPROVED BY’

firuck3 0. Tams, bianager I C S ~ Engineering -

DISTRIBUTION:

FORM TC 7166 (REV 10-87)

A- 2

?IOliTO!i THIZKOi W.ASATCII OPERXTi OS5

?.ABLE OF L'OKTEKTS

S i.'?I?iARY

TEST RESCiTS

TEST L4T.A

A-3

1.0

2.0

2 . 1

2 . 2

2 . 3

2.3.1

2.3.2

MORTON THIOKOL, IEC. IV’ASATCH OPERATIONS

This report contains the results of the Vibration Testing conducted on the 7U76358 Field Joint Test Assembly. Testing met or exceeded the requirements contained in the CTP-0054 test plan. Testing was run per Shop Travelers 7A052 and 7A053,

TEST RESULTS

Test Configuration

The following test tools were used:

2U105664 Vibration Slip Plate 6021ST Drive Bar X-M19506-6 Head Expander 7U76358 Test Assembly

Test Set-Lip

The test article was received at T-53 on 12 December 1988. Visual inspection showed rust and corrosion on all exposed metal (non-painted or non-plated). Test article was stored at T-$3 til 19 December 1988 when test set-up could be scheduled.

Test set-up included an internal pressurization pretest per paragraph 8.1.2 of CTP-0054. All requirements f o r air flow ( 3 . 2 t/- . 5 in 3/sec for 160 sec) and pressure (1.0 t . 3 -0 psig) were met.

Testing was conducted using the Ling .4340 shakers. Longitudinal and radial axes were run on the slip plate. Radial axis was run on the vertical shaker.

T e s t Pe A o rmance

Flight Random Vibration

Test was run per requirements listed in CTP-0054 table I1 Flight Random Vibration. Test article was pressurized during initial 160 seconds visually monitoring pressure gages. FN Tape i42295i contains flight random vibration levels and pressure levels. No visual ancmalies were noticed. Article met requirements of Test Plan.

Re-Entry Random

Test was run per requirements listed in CTP-0031 Table I1 Re-entry Random Vibration. FM Tape 822957 contains the longitudinal and tangential axes data. F?i Tape ii22959 contains the radial axis data. Article met requirements of test plan. Radiai axis test levels could only >e met by using two control accelerometers and averaging between their two outputs for a solid control. PSD plots show resonance between 1000-2000 HI. This is due to armature and Head Expander set-up natural resonance.

A-4

2.3.3

2 . 3 . 4

2.3.5

2.3.6

3.0

MORTON THI OKOL WASATCH OPERATIONS

Vehicle Dynamics

Test was run per requirement listed in CTP-0054 Table I1 Vehicle Dynamics Criteria. Test article was pressurized during initial 160 seconds of the vibration. So drop in pressure was seen by visually monitoring pressure gages. FM tape #22958 contains vehicle dynamics data. Article met requirements of test plan.

SRM Water Impact Shock

Test was run per requirements listed in CTP-0054 Table I1 under SRY Water Impact Shock Criteria.

Test criteria required a duration of ,050 seconds. Computerized equipment can only give aduration of ,010 seconds. Traveler was changed to .010 seconds upon receipt of a "red-lined'' test plan and memo from J. D. Thirkill.

Longitudinal axis shock t l was run with a loose lead on the control accelerometer and thus an overtest level of 70.23 G's wa seen. DR a168169 was written to cover this. Disposition was that data was acceptable.

Tangential axis shock was run to a 19,iiG level. Cause was unknown. DR ii168188 was written and dispositioned that data was acceptable.

Test Monitoring of Clip Gages

During the Flight Random, Re-entry and Vehicle Dynamics Vibration, Clip Gages were monitored by C/C 5618. This consisted of a FDXS set-up to inonitor "clip-gages", The clip gages were installed on the straps during Fieid Joint Build-up, No loosening or change in the straps Kas noticed during testing.

Post Test

Post test inspection showed no visual ancmalies to the test article.

TEST DAT.l

A . Photographs

8 . PSD Plots

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MOWON THIOKOL. INC

Space Operations ‘I

DOC NO. TWR-17245 REVISION - VOL

Appendix B

SEC

MEMO A400-FY89-139, “REDLINE TO CTP-0054, REV. C, ‘QUALIFICATION TEST PLAN FOR FIELD JOINT ENVIRONMENTAL

PROTECTION SYSTEM VIBRATION/PRESSURIZATION TEST”’

B- 1 PAGE

Note: The r e d l i n e changes s p e c i f i e d i n t h i s memo have been i n c o r p o r a t e d i n t o CTP-0054, Rev. C. Rev is ion C was accepted by NASA on 16 Feb 1989.

89656- 1.28

MORTON THIOKOL. I N C 1-

4 January 1989 A400-FY89-139

TO: D i s t r i b u t i o n

FROM : J . D. T h i r k i l l

SUBJECT: Red1 i ne t o CTP-0054, Rev. C, "Qual i f i c a t i o n Test Plan f o r F i e l d J o i n t Environmental P ro tec t i on System V i brat ion/Pressur izat ion Test"

NASA has a l ready approved the r e d l i n e change. However, t he re i s one area t h a t was not marked up. Sheets 15 and 16 t h a t are i n quest ion are at tached.

These changes are requ i red t o f i n i s h the v i b r a t i o n t e s t on the j o i n t p r o t e c t i o n system hardware a t T-53.

The Test Plan w i l l be corrected f o r engineer ing t r a c e a b i l i t y .

W Attachments: a/s

8-2

TABLE I1

-~

TEST

LIGHT RANDOM [BRATION

.EENTRY RANDOM 'I BRAT I ON Radial Axis)

-~

(Tangential & Longitudinal A x i s )

Revision C

FJEPS TEST CRITERIA

SPECTRUM & TOLERANCES

20 - 50 -

50 HZ @ 0.020 g3/HZ

500 HZ @ 0.060 gZ/HZ

2000 HZ @ 0.0038 gr/HZ

150 HZ @ +3 dB/oCt.

500 - 2000 HZ @ -6 dB/oct. 150

Composite =,6.9 g e m s Duration = 360 seconds/axis

Tolerances

Composite Amplitude f 10% PSD Amplitude +loo%, -30% 1 Frequency Dura ti on

20 Hz @ 0.036 g2/hz

e0 - 2000 Hz @ -6 dB/oc4>

+ 5% + lo%, - 0% - -

20 - 180 HZ @ +6 dB/oct 80 Hz @ z 3.13 g 2 / h

00 H 4 2 /hz z 8 U.Ub9

-

Composite = 35.2 grm, Duration = 90 seconda/axis

For test tolerances, see Flight Random Vibration ( above ) . 20 Hz @ 0.0039 gz/hz 20 - 80 HZ @ +6 dB/OCt 80 - 275 HZ @ 0.063 gz/hZ 275 - 560 HZ @ -9 dB/oCt 560 - 2000 HZ @ 0.0075 g2/hz

Composite = 5.6 g r m m Duration = 90 seconds/axis

For test tolerances, see Flight Random Vibration (above).

NOTES

Por the initial 160 seconds of :he vibration :est, .

xessurize the zest article PS noted in the internal ?res suri z a ti on test (section 5.1.2 A-E).

-

None.

None.

' , . ;

CTP - 005 4 Page 15

. . . . . ...

NOTES 1 -.= For the 160 seconds of the vibration testing, pressurize the t e s t article( 8) as noted in the internal pressurization test (section 8.1.2 A - E ) .

TABLE I1

limit). Since the majority 0: the test artic response lies the higher frequency rang (compared to these lower frequency pulses) the pulse duration

FJEPS TEST CRITERIA (cont.) -7 ’ SPECTRUM & TOLERANCES

2 shocks in each direction.

Tolerances (for both1 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Amplitude: +40%, -20% Pulse Overshoot: +20% Duration: 2 10%

TERIA ngitudinal ,xis)

tteral Axis)

LB WATER IPACT SHOCK UTERIA

(Longitudinal Axis)

3.5 - 5 HZ @ 1.0 G ’ a peak * 5 - 40 Hz @ 1.0 G ’ s peak

2 - 5 - 10 Hz @ 0.6 G ’ s peak 10 - 40 Hz @ 1.7 G ’ s peak

5 Hz e 1.7 G ’ s peak *

Sweep Rate = 3 Oct./Min. (1 Sweep from low to high frequency).

Tolerances

Peak Amplitude +20%, -10% Frequency + 5% Duration +1?A9 -0%

I-- I e OJO

20 G’s peak, 0.050 second 1 % - sin= 2 shocks in flight directior

(Radial and Tangential

Axis)

r Design Criteria Only.

I effect. ._

Revlsion C CTP-0054 Page 16

8-4


Space Operations

DOC NO. TWR- 1 72 45

Appendix C

VOL

DISCREPANCY REPORTS NO. 168169 AND NO. 168188

SEC

REVISION -

89656-1.29

PAGE

ORIGINAL PAGE IS OF POOR QUALITY

8

O W W L PAGE IS of POOR QUALITY I

U I I I

-r

IY3S3U

'.- - / ..' I 5< 4 :I* 'ON U W O

3

c - 3

MORTON THIOICOL. INC. I Space Operations

DOC NO. TWR- 17245

DISTRIBUTION

VOL

No. o f Reci D i en t CoDies

SEC

M. Cook N. Black M. Wi l l iams M. Cox G. Stephens J. S e i l e r R . Hyer R . Pa l iga J. Oostyen J. Kapp D. Mason T. Olsen J. Chaffee B. Tams R . Larsen S . West F. C a l l P r i n t C r i b Data Management

PAGE

4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

45 5 5

Ma i l StoD

136

136 136 136 E12 110 110 123 123 120

122 134 122 56 1 851 85 1 E05 282 123e

REVISION -

89656-1.24