3.0 APPROACH

¶The program approach vill consist of analysis. aubrcale (hot) teats, full-acale joint taata. and final varification in motor atatic taating.

¶The analysis vill attampt to identify the cauae of o-rini aroaion. its acceptability, and juatification. It vill idmtify apecific daaign or procaaa changaa vhich vill eliminate further o-rins charring. Studlea vill be parformod ahwint the affacta of utarial variation charactariatica, putty layup confiprationr. and froah utariala varaua anvirowntally axpoaad putty. In conjunction vith tbaaa analyaaa. a thorough 8tudy will be performed on utarial from altarnata amrcaa.

¶Tearing vill include laboratory material characterization, -11 motor hot teat. aimulmtin~affacts on cavity v o l u v veriationa. f l a patternr. axpoaura of O-ring and lubrication effects. T he burn t i w of

l motora vill ba in tho range of 3 30 aaconda dopanding on the

¶a ~ l hot results of pravioua amall rcala motor taat result.. Norton Thiokol alao racomandr that actual full-acala a a p n t joint taata ba uaad to evaluate prarrurization affect. on putty layup arrangounta and flar changaa due to final aaaembly of the j oint.. It la further a u U a a t d that a group of exparianced paopla from WSFC and ItTI be selected to vitnaaa the antira joint praparation. aaaembly. leak tamti-, and poatfire taardovn at KSC and MTIIClaarfiald facilitiaa. h i e team vill also r a v i w a11 anslpraa. laboratory taata. aubacala hot teat, and aupport team raviava.

,, . I , 1.

¶m-14359

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3.1 Analyria The following teat. s h a l l be p e r f o r u d on tb vacuum putty m a a

¶m i n i m . If furchar t e s t i n g is r e q u i r d . i t a b l l be p e r f o r u d and documented. Sow of t h e t e s t a are c u r r e n t l y bein# porforwd on t h e a x l e t i n s putty, but are l i s t e d t o amsure t h a t presently e r a i l a b l e d a t a ara e-rised in th. a n s u i w report. These teat. v i l l h a t o k repeated on any p o t m t i a l now putty. (See s e c t i o n 3.1.5)

3.1.1 Chomical Composition An e n a l ~ s i . v i l l be performod on tb. putty t o deternine a o l i d s

¶content, u b e e t o a f i b e r (or other f i l l e r ) content. chromate c o n t m t . binder u b u p , and a11 other applicable tests d e a c r i b d in SN4-2847, h t W . Vacuum Seal.

3.1.2 Physical Properties Taets a h a l l be developod .ad conducted t o datermine dheeive

¶atrength of t h e putty ( t a c t i m s a ) , s t r a i n capability. c a p r e a a i b i l i t y . and r e a i s t e s c e t o heat. eroaion. d pnaeure .hock ( a t 8111 m i t i o n ) .

3.1.2.1 hvirormental Effectr The putty v i l l be coeditioned in controlled temperature end

¶humidity m v i r o n w n t e , i n c l u d i w nb1-t conditjocu et Utah d N o r i d a . then t e e t d f o r a11 physical propertiee and appropriate c h d u l prop.rt1.e such aa ann-voletila contont and water s o l u b i l i t y .

3.1.3 4iw An aging program v i l l b. conductad on putt? in Utah and Florid..

¶The p r o g r r ahould run for five y u r s with p a r t i c u l a r . p b . a i s duriw tho f i r s t y u r a t 3, 6, 9, and 12 months. Chric.1 end physical t e s t a dull be performod a t each r t a g e of agiw. The putty w i l l a l s o bo checked f o r shrinkage and e i l i c o n e m i r a t i o n from t h e p e p r backin# u u d ae a separator i n the r o l l f o r r .

¶3.1.4 Competihility of h t t y With Other Materiala

¶The putty v i l l b . t e a t e d t o deternine e f f e c t s of it. miring with Conoco UD-2 sreeee. cured W B R rubber. and both freah and a a l m t e r . I f the u t e r i e l s r e a c t . propertiee of t h e r a s u l t m t u t e t i a l v i l l be eetabliehed. T u t a .hell a l e o determine whothor tho r e e u l t a n t u t e r i a l ie corrorive t o the D6AC came.

264

¶3.1.5 Second Soutce for Putty

¶A aecond (or third) aource of putty l a demirable to prevat further supply probluu. which could merioumly impact the Space Shuttle pro8r.r. A d e v e l o p ~ n tprogram will be i.pl.wnted to C e l t eltenate W t t Y cendidatea per the precedin8 requirmanta ea a minimum. Subacele ffrfnl temta ehall ume the alternate putty to eetabliah confldmce to ineta11 the new putty in RIC-SIII mtatic firing DU-6 for putty qUdifiCAtiW.

¶Iherm are three alternate mource candidetma mt thie time: Plastic Sealer 579.6 from Inrout Corporation of Georgetown. Oatario. with mmbemtom end Plamtic Seelez S79.6 from I l l ~ m tCorporetion. St. L o u i m . without aabemtoa. General Sealant. l a developing a high temperature putty that will elno be mcreened.

¶3.1.6 Vicon Cheraceerimtice

¶To aid the accuracy of the hot gar jet malymim. temtm will b. IUIL to determine the eromion rate of Piton. Theme date, along vfth remslte from other teats described in chi* plan, will be uaed when the enalyaim l a redone.

3.2 Subacele Firing Temta 3.2.1 Five Inch CP &tor 8 jet. through the putty opaninea i m correct. To verify that hot 6 .

¶teats will be conducted which induce gea jet i r p i n g u n t 011 .

¶I) o-tin# uming five inch CP motor8 ea teat beds. Under tightly controlled conditions (environmental and mechanical). this data will b . usemmed to more fully underitand whet 1s happening in the SIIl epplicatiom.

¶If s meaningful mubmcale joint t e a t can be davimed with putty in i t , it will a l s o be pcrformd uaina the five inch CP ae the hot g u source.

3.2.2 40 Lb. Char Motor Depending on the reoulta of the five inch CP hot teeting. it u y be

¶deoirable to include larger mcale teat motor. hnving putty inete1l.d. norton Thiokol 1s investigating the 40 Ib. char wtorm. If roquirad, much testa ehall be performed to further verify the change in putty leyup. type. andlor other filler uterialm.

3.3 Full-Scale Joint Temtm Tests ahall be performed using full-mcele SW field j o i n t to

¶verify the mubrcale reaulta of the candidate putty l a p p configurmtioar $1: as affected by the actual joint aaaembly and leek teat procdurw. The "mhort mtack" herduarc IS preferred for uae instead of SIll cam rep.ntr ( 8 for eeme of aaawblv and inspection. The follovlng qwmtioam aha11 b . , , snmwred as mininm requirements of this test sequence:

a. What ia p o s t u s e a b l y p r e i a u r e i n t h e c a v i t y b t t v a s n t h e p u t t y and t h e p r l o a r y O-ring?

b. What la t h e mlnimum p r e s a u r e r e q u i r e d t o blow through t h e putty?

C. What la t h e maximum a c c e p t a b l e l e a k a g e rate a t 200 p s i g v h i c h meets t h e 50 p a i g l e a k t e a t c r i t e r i o n ?

¶d. How ir O-ring s e a t i n g a f f e c t e d by p r e a a u r c and t i m e ?

e. What la t h e p r o p e r amount of HD-2 grease to be a p p l i e d t o t h e j o i n t metal surface. t o r i n i m i z e t h o free volrw b e t v e e n t h e vacuum p u t t y and t h e p r i u r y O-ring?

f. What is t h e e f f e c t of c u e e c c e n t r i c i t y d u r i n g a e p c n t u t i n g on t h e flow of vacuum p u t t y i n t h e j o i n t ?

What dimension and weight control. are r e q u i r e d t o a s s u r e t h e vacuum p u t t y layup i a c o n a i a t e n t and adequate?

¶P o t e n t i a l f i x e s w i l l be i n v e a t i g a t e d such a0 i n d u c i n g p a t h s through t h e vacuum p u t t y a t r e g u l a r c i r c u m f e r e n t i a l l n t c r v a l a t o p r e v e n t l o c a l i z e d O-ring daauge f a m e d by smnll. Supersonic 9.8 jets. concept of a s o f t r u b b e r b a r r i e r between t h e p u t t y and p r i u r y O-ring w i l l also be i n v e s t i g a t e d . I n a d d i t i o n . l e a k check procadurea. p a r t i c u l a r l y t h o s e employing t h e rue o f a flow meter, v i l l be examined with a c c e p t a b l e and non-acceptable ( l e a k i n g ) O-rings. I n a11 i n a t a n c e s t h e behavior of t h e p u t t y s h a l l be c l o i e l y monitored.

¶R e s u l t s of t h e above d e s c r i b e d t e s t s w i l l be e x t r a p o l a t e d t o t h e n o z z l e t o c a s e joint and t e s t s r u i n g a f u l l - s c a l e n o z z l e f i x e d h o m i n g and a f t d o w w i l l be conducted, if neceasary. t o v e r i f y t h e adequacy o f any change r e s u l t i n g from t h e f i e l d j o i n t t e s t a .

¶A plan. 'IVR-13983, h a s been prepared t o check t h e p u t t y c o n i i g u r n t i o n o f t h e igniter t o caaa j o i n t . Theme t e s t a w i l l a l s o b e conducted and t h e r e s u l t s w i l l be a-rized in t h e f i n a l r e p o r t .

¶3.4 Full-Scnle S t a t i c T e s t

¶A l l p o t e n t i a l d e s i g n changes w i l l be a d e q u a t e l y t e s t e d on t h e s u b s c a l e l e v e l and s h a l l be i n c o r p o r a t e d i n t o t h s SIW-PUC s t a t i c f i r i n g Dn-6 f o r q u a l i f i c a t i o n . A c r i t i c a l p o s t f i r e I n s p e c t i o n w i l l be performed on t h e new c o n f i g u r a t i o n u w e l l as t h e b a r e l i n e d p o r t l o n e o f t h e DM-6 j o i n t s .

¶An a n a l y s i r w i l l be p e r f o m e d t o sssean t h e r e s u l t s o f t h e IVC-SRn f i e l d j o i n t s es they compare t o t h e HPM-SRPI f i e l d j o i n t . The f i e l d

¶I , j o i n t a are a h w n i n f i g u r e r 1 and 2 f o r HPn-SRH and Tvc-SRII, respectively.

¶1VR-14359

266

3.S hviou and Witnear T e u A n v i w md u i t n r r r toam ahall bo eatobl1rh.d corraiating of

¶uporionced onginearr from Norton T h i o b l and RA8A t o inopect .nd aa0e.a a l l toat roaulta. ~ n o u l o u aeoaditionr of joint. f m f l o r a motor. s h a l l bo c r i t i c a l l y 1nap.cc.d wrb.ra of thia to-. fbo t o u w i l l dotornin* tho courao of oction t o bo t a b n om intenwdiato md firm1 rom~lto becaw avallablo.

¶The attaehod achodulo reflaeta tho tin ~ v a i l o b l et o caplet. the taotin# and qualification of tho preeodlng i t a h

¶A coqrehenaiva roport ahall bo propmod by hginmring d o e r r a t i n @ tho toata ud r o w l t a . The original ohall bo r e l u r a d e f t o r the developrat toating, but prior t o DKb. A rowlaion ahall k nloaaod aftor &I-6 and J mocondmd ficul ro~laiorrahall be pab1iah.d a f t e r tho wing program.

¶--SRY-HPM Fiold Joint

¶FIBure 1

¶-- NBR Insulation NBR Insulation

-_ FWC-SRY Fioid Joint Ply?.²² Rogers Commission Report, Volume I, p. 199. o bid., Chart SRB-4. 2 1 Larry Mulloy, NASA, Marshall Space Fli ht Center, "STS-51L Level I1 Flight Readiness Review,'' January 14,1986. See Appendix VIII-g. 2 2 Discussion with Allan McDonald, September 4, 1986. Z3 Rogers Commission Report, Volume 11. See Chart 15 (p. H-10) and Chart 19 (p. H-12). s Ibid., Chart 30 (p. H-18).

270

8 .²⁷²⁷ bid., p. 201. Rogers Commission Report, Volume 11, p. F-2. 1

272

IAW WmIR MIL STDI

¶J. C. K i h l n 8 t e r I COO

J. McDoMld 1 COO

¶x. v. m i i n 8 1 111 t. c.IJai1.y 1 El 1 I?. 8. k I n t o 8 h 1 w3 J. 1. Llwll 1 112 8 . 0. busell 1 L1 1

I?. Kdler 1 El2

C. Braafield 1

C. Brinton 1

¶P. c. P8tt.Y 1 250 R . n. B O ~ ~ J O I Y I 250 S. B. P m d h t o n 1 20 1 0 . J.¹¹ For the purpose of this report, a procedure is a formal set of instructions designed to guide and assist in the performance of a technical or management function. g8 mid., July 24, 1986, p. 11. 1 9 9 Ibid., June 25, 1986, p. 52. 280 1. 8. b78r 1 281 K. 1. Cekhardt 281

C. Bunhr 20 I

L. Uollmh8UPt

¶c. C. Gorun 281

S. Sh.dl88k.Y

¶A. 1. ThhapSOU 1 287

D. Bnm?~ I

B. D.*h 1

¶P. 0. lurr.11 1 2421

L. Bar..¹¹ For the purpose of this report, a procedure is a formal set of instructions designed to guide and assist in the performance of a technical or management function. g8 mid., July 24, 1986, p. 11. 1 9 9 Ibid., June 25, 1986, p. 52.

¶s. U. Cardall 1 242B U.¹¹ For the purpose of this report, a procedure is a formal set of instructions designed to guide and assist in the performance of a technical or management function. g8 mid., July 24, 1986, p. 11. 1 9 9 Ibid., June 25, 1986, p. 52. . JohMon I 514 D. w. l u l l r r I 514 J . U. Calbrafth 1 9131

M. Pu8kadra 1

J. Burka I

¶J . Tr811kl.¹¹ For the purpose of this report, a procedure is a formal set of instructions designed to guide and assist in the performance of a technical or management function. g8 mid., July 24, 1986, p. 11. 1 9 9 Ibid., June 25, 1986, p. 52. 166

Coiner I

¶?. Y. C e l l 25 114 n. L. P8rk.r I mlc D. H.¹¹ For the purpose of this report, a procedure is a formal set of instructions designed to guide and assist in the performance of a technical or management function. g8 mid., July 24, 1986, p. 11. 1 9 9 Ibid., June 25, 1986, p. 52. mlc