R. Schick 1

¶v-c

¶' EP25 (84-49) May 23. 1984

¶TO: EEll/lb. Norton

¶FRon: EP25/*. Miller

¶SUBJECT: E v a l u a t i o n o f TWR-19359, "Program P l a n , R o t e c t i o n o f S p a c e

¶S h u t t l e SIM Primary nDtor Seals"

¶me s u b j e c t Program Plan hrs been e v a l u a t e d as requested and t h e f o l l o w i n g ccmDents a r e s u t m i t t e d f o r yow m s i d u a t i o n :

¶a . Page 3. P a r a g r a p h 3.1.2, Phyaioel R o p r t i o a - This P r o g r a m P l a n m e n t i o n s c o m p r e s s i b i l i t y t e s t i n g of t h e z i n c c h r o m a t e p u t t y , h o w e v e r n o l a b o r a t o r y tests a r e proposed which w i l l determine the extrusion c h a r a c t e r i s t i c s (disDlacement i n a free v o l u m e u n d e r c o m p r e s s i o n l o a d ) of v a r i o u s c a n d i d a t e s . This s h o u l d b e a c c o m p l i s h e d to p r o v i d e a b e t t e r u n d e r s t a n d i n g a s t o why v a r i o u s t y p e s o f p u t t y e x h i b i t u n l i k e e x t r u s i o n p a t t e r n s with i d e n t i c a l layups.

b. Page 4 , P a r a g r a p h 3.1.5, Seoond Solaeo far P u t t y A s e c o n d s o u r c e

¶f o r z i n c c h r o m a t e p u t t y is d e s i r e d and n e e d e d , b u t d u e t o t h e poor w r f o r m a n c e of t h e AandolDh DuttY. a more i m m e d i a t e need e x i s t s f o r development o f a replacement ' f o r the-&sent Randolph putty. Recommendation to t h i s e f f e c t was made i n Memorandum E P 3 (84-35).

¶c. Page 4 , P a r a g r a p h 3 .2.2. 40-Polpd Our Motor The 90-pound c h a r motor should be made a d e f i n i t e put of t h e lest Rogram. It is v i t a l t h a t

¶t h e test a r t i c l e be c a p b l e of s i m u l a t i n g t h e total j o i n t c o n f i g u r a t i o n as close a s p o s s i b l e , which i n c l u d e s z i n c chromate p l t t y . R o v i s l n n s for the i q s t a l l - L i o n of t h e p u t t y tosether w i t h e x t e n d e d b u r n t i m e and i n c r e a s e d vo:umes - . p e ? : l i t i e s a r e a c h i e v a b l e w i t h t h e l a r g e r motor and s h o u l d be included i n the total program.

¶d. Page 5, P a r a g r a p h 3.3, Full-Seal. Joiet T e a t s , R e f e r e n c e : f i r s t p a r a g r a p h f o l l o w i n g "g". P l e a s e e x p l a i n how p o t e n t i a l f i x e s s u c h a s i n d u c i n u p a t h s t h r o u g h t h e p u t t y a t r a g u l v c i r c u m f e r e n t i a l i n t e r v a l s and use o f a soft r u b b e r b a r r i e r b e t w e e n t h e p u t t y and p r i m a r y O-ring w i l l b e v e r i f i e d by hot f i r i n g prior to i n s t a l l a t i o n on Dw-6.

¶e. Page 5, P a r a g r a p h 3.3, Nll-Seel. &lot T e s t a , R e f e r e n c e : Second paragrapn f o l l o w i n g "g". Thc Test Plan should s p c l f y a h u d requirement to v e r i f y a l l p t e n t i a l nozzlelift dome j o i n t chaa.s cm f u l l - s c a l e h a r d w u r .

¶5hc case j o i n t and n o z z l e j o i n t m f i g w a t i o n d i f f e r e n c e s warrant wprate f u l l - s c a l e n o z z l e / a f t scgment assembly tests.

f. GMer.1 - Design changes t o t h e i n s u l a t l o n i n t e r f a c e s u h i z h will p r e v e n t d e g r a d a t i o n of t h e t h e r m a l b a r r i e r due t o j o i n t rounding under p r e s s u r e should be i n v e s t i g a t e d as J p a r t o f t h i s e f f o r t . me p r e s e n t deSip,rI of t h e case j a i n t and nozzle i n t e r f a c e s YlMTc t h e zinc chromate putty is installed are oriented such t h a t the j o i n t gaps can vary Wom minimum to maximum dimensions around the circumference during assembly due to out of romdness and eccentricity. mls fondition which is premt to some dcercc durlng every j o i n t assembly operation, guarantees that some, or almost a l l o f t h e z i n c chromate p u t t y i n c e r t a i n areas w i l l be uiped off when t h e mating surfaces move p a r a l l e l to each o t h e r during mating. This r e s u l t s i n open i n s u l a t i o n g a p s w i t h i n s u f f i c i e n t z i n c c h r o m a t e p u t t y d u r i n g motor operation because t h e j o i n t s tend to become romd and concentric when t h e case is presssurized internally. Qlcstlons concerning t h i s memorandum should be r e f e r r e d to Nr. uilliam L. b y , 3-3809.-

¶Q. niller- -- ~ ief, Solid &tor Branch t4 ' cc:

UOl/. m y EEOl/C. 1ittl.s SAIIl/K. Ilrlloy SAW*. w0.s .%Put+. NcIntosh Ell/. mtes a l l / * . Jaws EPOl/. Nc(cco0l E P P l r n . Wccarty EP25/. bw8f-s EPZS/. Ray

275

¶V-D

¶I k c r b e r 6. 1983

¶TO: EE51/&. Horton FRGU: EPWlt. MIller SUBJECT: Replest for Tests by the Contractor t o Obtain Space Shuttle 51111

C l r v l s Joint, Flxrd Houslng/Aft Sepent J o l n t and I g n l t e r Adapter/ Forwrd S q m n t J o l n t L u k Chuk Data

¶I t Is r q u e s t e d that PU take form1 a c t i o n to assure tht the f o l l w i n g t e s t s are porfomrd I n a timely u n w r by the contractor. I b r t o n / l h f o b l . on SR( Hlrdure:

a . Case Clevls J o l n t h a 1 O-Rlng Su - l L u k O I t u t l o n Perfom tests w t ?

¶f u l l scale c l w l s j o l n t hrdurr (short j o i n t s ) t o obtain th. following data IS a mlnlw:

(1) Post assmbly pressure I n the zlnc c h m t e s u l a n t cavlty. (2) M l n l n u and u x l u v o l u e o f the zlm chromate s u l a n t cavity.

¶post a 5 S d l y .

¶.( 3 ) M l n l m u pressure repulred to 8 f f I E t zlnc c k m u t r s w l a n t b l w through

¶( 4 ) Blerdback c a p a b l l l t y o f the p r l u r y 1-1 (fror s u l a n t cavlty to c a v i t y between the p r l u r y and secondary s r l s ) a t a v a r l r t y o f pressure values rrnglng from 10 pslg up to a value h l c h h s born d e t r m l n r d to effect s w l a n t blowttwougr. various types o f p r l u r y s u l lambgo w n d l t l o n s a t p r d r t e m f n d I n l u g e ratas shoui! be s l u l a t r c l .

¶( 5 ) OIterrlne r x 1 . u acceptable l u b g r rates a t 200 pslg which meets the 50 pslg I r k t e s t c r l t e r l a .

¶(6) Daternlnr mlnlmun pressure and tlme r q u l r e d t o p o s l t l o n O-rings for M pslg leak c W k .

¶( 7 ) Datemlne the w o l u o f the c a v i t y h t u a e n thr p r i u r y and srondary O-rlngs by annlysls and f l o w t e s t p r l o r to and followlng the 200 p s i O-ring

' n

¶positloning cycle.

v (a) PC and MTI GsE v o l u e s should be simulated and the r o w f w d t-pm- I I)

¶t u r e range should be d u p l l c r t r d as close as posslble. Type 11 zlnc chmmat. 0 sealant should be usrd for a l l tests.

0 w

276

2 b. lbrrlo C I x d msIng/ACt S-nt Boss Joint - Perfom t e i t s with f u l l

¶m l r h r r d r r o to @ccgmpllshtho o b J c t l v r In Ita 1. rbove. Iho test dosI9ned to d o t a r ~ l mO-ring bloodback r a t e nod not be repeated.

¶c. I s n I t n Mapter/Caso forward Srgwnt Boss JoInt - P r f o t n tests r I t h f u l l r t r l o h r d u r o to reccrpllsh t b l objUtlvos ln Ita 8 . above. T a t s t o d r t m l n e p m s u r e v r l u r r q u f r d t o posltion the s r l i s not r m l r e d . I t 1s hI9hly d r s l r r b l e to c m p t r t e thoso tests prior to strcktng o f STS-12. Questions concerning t h i s r a o r r n d u should be referred to Ic. Leon Ray, 3-3809.

¶cc : SMZ/IC. U w r S M Z / l t . Denton EEll/Mr. mtn E M l / l k . &Cool EPZl/n. W a r t y EPZS/Mr. Powers EPZWlk. Ray

277

¶V-E a r c h 7 , 1485

¶TOY SAUl/nr. n u l l o y THRU: EEllNr. H o r t o n k

¶FROM: EPOlNr. M c C o o l

¶SUBJECT: Roquost f o r I n i t i a t i o n of T o s t i n g to P m v i d o Data for R o w i v i n g t h o &mod 0-Ring Sul P r o b l r On t h o S F C O S h u t t l e S M

¶L o t t o r EPZS (83-119). f r a Wr. H i l l o r (EP25)a ,t Wr. Borton (EEll), subjoct: "Roquoat for T e s t s by th* Contractor to Obtain Spa00 S h u t t l e S M Clovia J o i n t , F i e l d Housin&Vlft S e p o n t J o i n t and Imitian Ad.ptrr/Forurd 5.p-t Joint Leak Chock Data' is Nf0NIlC.d. On Docombor 6, 1983, t h i s office roquoatod ria t h o I r f 0 N n o . d letter t h t tho contractor obtain available f u l l scalo d 1 w t . r . a h o r t a t m k hrdwrr and conduct t o a t a to provide d a t a on rim ahrout. p u t t y bohavior u mlated to a f f o c t on j o i n t loak chocks. Fourtoon montha h a m 0lapa.d a d IY) v i . i b l o a c t i o n has boon taken t o o b t a i n and e q u i p t h o s h o r t a t a o k h.m~ althwh .(lNOmOtlt baa mad. to porfom t h e t o a t at t h o t L . Of NqUu.at. Tho only p o s i t i v e rosponao by t h o contractor n a t h o a u b m i t t a l of TUlLlU359 on h y U, 1983. which contained a pmgru plan f o l l o w d by 5 4 m h CP motor t o a t a . which W N not d e a l m o d to provido 0 a o l u t i o n to t h o burned O-ring p r o b l r . Tho a c q u i s i t i o n of j o i n t p u t t y layup and l w k chock d a t a on a h i @ p r i o r i t y bas is has bocmo vary lmportant i n v i w of t h o nood to Nrolw t h o burned 0- ring p r o b l e u i accordinaly, it is Nqu0at.d that You take t h o n m o a s a r y a c t i o n t o d i m t t h a t t h e follouin# t a s k s 50 0 X p . d i t i O U ~ l Y p.Pf0mr.d by t h e contractr-r a. Subscalo and f u l l acalo teats to detomiru o f f o c t a of u k a t o a f i l l a d . cotton and t a l c f i l l a d , and non-fil1.d sim c h r a a t e p u t t y on O-riq sealing intrp-lty.

b. Full acalo t o a t i t 0 :1 ) P u t t y layup t e s t a uaiw c u r r o n t layup d o a i m . n ( 2 ) Putty layup tests Usin# t h o attachod fi@N 1 layup EonCopt. 0 (3) P u t t y layup t e s t a wiry t h o attached f i y N 2 layup Eonc*pt. w 01 8 w W

¶.. .

¶( u ' Pepeat tests ( 1 ) and ( 2 ) except w i t h v e n t s l o t s l o c a t e d a t I?$- degree i n t e r v a l around t h e c i r c u m f e r e n c e as shown by a t t a c h e d f i g r e s ? and 4. The s l o t s am designed to prevent a i r entrapment and r e s \ r l t l n g volcanoes. E v a l u a t i o n of l a y u p e f f e c t i v e n e b s should be p e r f o m e d w i t h f l m meter3 to d e t e r m i n e c a v i t y v o l m e s .

¶The above t a s k s a r e intended to complement TUR-14359 r a t h e r t h a n r e p l a c e t h e tests d e f i n e d t h e r e i n . W e w i l l be happy to assist t h e c o n t r a c t o r i n working o u t t h e d - t a i l s f o r t h e above p r o p o s a l s .

¶h%G C-CE, 1.1. nocoo1 Director S t r u c t u r e s and P r o p u l s i o n L a b o r a t o r y

¶Enclosures: As stated cc: SA42/nessrs. Mcfntosh/Donton EEllR(r. Coat03 EE11 Rlr. Jonoa E P 2 1 m . UcCarty EP2SAossrs. M l l l e r / P a v s r s / R a y EEOI/Dr. Little.

279

¶PC 026415

c c

280

¶PC 026416

¶N

1 W Y, c

¶0 2 6 4 x 7

J ' I -. A W b m a & r(

Y ;e

¶64-420 0 - 86 - 10

282

¶PC 026418

il 'JY %- I

¶A

283

¶V-F

¶To: €Ell/*. Hotton FRCN: EP25/W. Miller

¶SUBJECT: Inspection of Fired SRM Ressure Joint k t n g Disassembly

¶Please take t h e necessary a c t i o n t o r e i n s t a t e d e t a i l post f l i g h t and post s t a t i c firing inspection of specific pressure j o i n t s on the SRM which incor- porate the thermal barrier and O-ring seal design concept. Ih. inspection must be conducted at the time of disassembly to preclude d e s t r u c t i o n of data. I b task should be performed by experienced, q u a l i f i e d e n ~ i n e e r l n g personnel and should be continued m t l l the burned Wiry p b l e m is under- - stood and resolved. me incidence of heat damaged O-rings on STS-2. 911-4 and on t h e r e c e n t f l i g h t of STS-11 warrants close surveillance of the= areas to ensure that 5uspcted anomalies are detected and properly recorded for assessment pr- pses. Recent discovery that the new type I1 zinc chromate saalant (thermal b a r r i e r m a t e r i a l ) would not adhere t o t h e nozzle surface to uhich it was being applied, has opened up several mansuered questions, the m ost impor- t a n t being dhesion l i f e of the sealant after installation on UU SRn. ryp I1 zinc chromate sealant was installed on a l l SRH's beginning w i t h STs-8. Areas of concern uhich warrant inspection are:

¶a. SRW case field joints.

b. SRX case nozzle boss to nozzle f i x a d housing joint, C. SRM igniter to SW case igniter boss. L

¶d. HDzzle field splice joint.

284

¶cc : EEOl/W. Hardy SA41/W. t b l l o y SA42/W. Wear SA42/W. HcIntosh EPOl/W. H c ~ l EP21/W. nfCsrty EPWW. mwrs EP25/W. Ray

285

¶V-G

.. .~. .._ - . , ._.. . .. . ..-' -

¶-- - . .

. .._ . ... .- .. . . .. ' ., . . - . . .

286

¶V-H

THIOKOL MORTON

¶Wasatch Division -I-

¶InIeroflice Memo

1 October 1985 E150/RVE-86-47

TO : A. J. McDonald, Director Solid Rocket Motor Project FROM : Manager, SRM I g n i t i o n System, Final Assembly. Special Projects and Ground Test CC: B. McDougall, B. Russell, J. McCluskey. D. Cooper, J. Kilmlnster. B. Brinton. T. O'Grady, D. HagBeth. J. Sutton. J. Elmll. I. Adans, F. Call. J. Lanere. P. Ross, D. Fullmer. E. Bailey, D. Smlth, L. Bailey,

Kuchek, Q. Eskelsen. P. Petty, J. McCall

SUBJECT: Weekly A c t i v i t y Report 1 October 1985

EXECUTWE SUPWARY

. .. - HELP! The seal task force I s constantly being delayed by every possible means. People are quoting policy and systems without work-around. HSFC i s correct i n stating t h a t we do not know how t o run a development program.

The two (2) GTH center sepnents were recelved a t T-24 l a s t week.

¶Optical measurements are being taken. Slgnlficant work has t o be done t o clean up the j o l n t s . I t should be noted t h a t when necessary SICBH takes p r l o r i ty.

The On-6 t e s t report less composite section was released l a s t week.

ELECTRICAL

¶As a r e s u l t of the l a t e s t engineering analysis o f the V - I case I t appears t h a t high-stress r i s e r s t o the case are created by the phenolic

¶OF1 housings and fairings. As I t presently stands. these w i l l probably '

¶have t o be modified o r rmoved and i f rclloved w i l l have t o be replaced. n

¶This could have an Impact on the launch schedule. c.

a N \n u! E

J. McDonald, Director

¶1 October 1985 E!SO/RVE-86-47 Page 2

FINAL ASSEMBLY

¶One SRM 25 and two SRH 26 segments along with two SRW 24 exit cones were completed during this period. Only three segments are presently in work. Availability o f igniter cunponents. nozzles and systems tunnel tooling are the present constraining factors in the final assembly area.

IGNITION SYSTEM

Engineering is currently rewriting igniter gask-o-seal coating requirements to allow minor flaws and scratches. Bare metal areas will be coated with a thin film of HD-2 grease. Approval is expected within the week. 2. Safe and A m Device component deliveries i s beginning to cause concern. There are five S M ' s at KSC on the shelf. Procurement, Program Office representatives visited Consolidated Controls to discuss accelerating scheduled deliveries. CCC has promised 10 Am's and 30 B-8's no later than 31 October 1985.