1030-9004A.pdf

REVISION HISTORY

S H

REV DESCRIPTION DATE APPROVED

-9

- Initial Release Per ECN 00000000699 7/7/05 Shelby Lee

A Initial Release Per ECN 00000002129 9/21/05 Jeff Wimble

D W

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DISTRIBUTION STATEMENT D: Distribution authorized to Department of Defense and DoD Contractors only; Administrative/Operational Use, June 1999. Other requests for this document shall be referred to the Commander, Naval Air Systems Command, AIR-4.7AD.

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (TITLE 22 U.S.C., Sec 2751 et seq.) or Executive Order 12470. Violations of these export laws is subject to severe criminal penalties.

DESTRUCTION NOTICE: For classified documents, follow the procedures in DoD 5220.22-M, Industrial Security Manual, Section II-19 or DoD 5200.1R, Information Security Program Regulation, Chapter IX. For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the documents.

CONTRACT NO:

CONFIGURATION

IDENTIFIED HEREIN

-001 -_____ -_____ -_____

ORIGINATOR

Shelby Lee

DATE

6/17/05

DESIGN ENGINEERING

Doug Allen

DATE

6/23/05

ORBITAL SCIENCES CORPORATION

LAUNCH SYSTEMS GROUP

3380 SOUTH PRICE ROAD

CHANDLER, ARIZONA 85248

PROGRAM OFFICE

Lee Moralez

DATE

6/20/05

MECHANICAL ENGINEERING

Julia Summers

DATE

6/17/05

TITLE

SSST GQM MK 70 BOOSTER FIN

QUALIFICATION TEST

PROCEDURE

CDRL

QUALITY ASSURANCE

Paul Garland

DATE

6/22/05

SYSTEMS ENGINEERING

Dave Ratynski

DATE

7/7/05

MECHANICAL TEST ENGINEER

Shelby Lee

DATE

6/24/05

INDUSTRIAL SAFETY ENGINEER

Judy Palacio

DATE

6/27/05

MANUFACTURING

Bob Sauer

DATE

6/21/05

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PLANNING AND CONTROL

Robin Hayes

DATE

6/21/05

SIZE

A

CAGE CODE

27555

SHEET

Part No.__________________ MECHANICAL FATIGUE ANALYSIS PERFORMED

Serial No.________________ /

SIGNATURE DATE

Job No.__________________

REVIEWED AND ACCEPTED BY PROJECT LEAD

ENGINEER AFTER COMPLETION

PORTIONS OF THIS PROCEDURE ARE /

HAZARDOUS

ENGINEER DATE

THIS PROCEDURE CONTAINS TEST DATA REVIEWED AND ACCEPTED

STANDARD

HAZARDOUS

OPERATIONS

QA REVIEWER DATE

USE, DUPLICATION AND

DISCLOSURE OF THIS

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TABLE OF CONTENTS

PAGE

1. INTRODUCTION

1.1. Purpose

1.2. Scope

1.3. Testing

1.4. Pass/Fail Criteria

1.5. Procedural Changes

1.6. Applicable Documents

2. TEST PROCEDURE PROVISIONS

2.1. Safety Provisions

2.1.1. References

2.1.2. Safety Precautions

2.1.3. Protective Equipment

2.1.4. Pressurization Safety - Hydraulics

2.1.5. Lifting Safety

2.1.6. Emergency Procedures - Chandler

2.2. Failure and Retest

3. DESCRIPTION OF TEST ITEM

4. STRUCTURAL QUALIFICATION TEST

4.1. Test Objectives

4.2. Test Equipment

4.3. Allowable Test Tolerances

4.4. Test Setup

5. TEST SETUP ASSEMBLY

5.1. Test Setup Build and Assembly Procedure

5.2. Instrumentation Setup and Assembly Procedure

6. STRUCTURAL TEST PROCEDURES

6.1. Quality Test Load Condition

6.1.1. 10% of Quality Test Load Condition

6.1.2. 25% of Quality Test Load Condition

6.1.3. 50% of Quality Test Load Condition

6.1.4. 75% of Quality Test Load Condition

6.1.5. 110% of Quality Test Load Condition

6.1.6. 125% of Quality Test Load Condition

6.2. Reverse Quality Test Load Condition

6.2.1. 10% of Reverse Quality Test Load Condition

6.2.2. 25% of Quality Test Combined Load Condition

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TABLE OF CONTENTS (CONTINUED)

PAGE

6.2.3. 50% of Reverse Quality Test Load Condition

6.2.4. 75% of Reverse Quality Test Load Condition

6.2.5. 110% of Reverse Quality Test Load Condition

6.2.6. 125% of Reverse Quality Test Load Condition

6.3. Breakdown of Test Equipment

7. DATA COLLECTION AND RESULTS

7.1. Test Report

LIST OF FIGURES

Figure 2-1. Failure Retest Requirements for LSG Components

Figure 4-1. GQM MK 70 Booster Fin Assembly Structural Qualification Test Setup

Figure 4-2. GQM MK 70 Booster Fin Assembly Coordinate System

LIST OF TABLES

TABLE 4-1. STRUCTURAL TEST CONDITIONS

TABLE 4-2. QUALIFICATION TEST LOAD PERCENTAGES

TABLE 4-3. STRAIN GAUGE LOCATIONS

TABLE 4-4. DISPLACEMENT MEASUREMENT LOCATIONS

LIST OF APPENDICES

A. TEST EQUIPMENT LOG

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1. INTRODUCTION

1.1. Purpose

This document defines the method to perform a Qualification Structural Load Test of the GQM MK 70 Booster Fin

(Drawing Number 1030-5082) used on the first stage SSST MK 70 booster. This test will verify the structural integrity of the GQM MK 70 Booster Fin Assembly design.

1.2. Scope

This document describes the basic plans to conduct the required Qualification Structural Load tests on the GQM

MK 70 Booster Fin Assembly which includes test loads, test setup, the testing sequence, data collection and instrumentation requirements.

1.3. Testing

The GQM MK 70 Booster Fin Assembly Qualification Load test setup will utilize a restrained Terrier Rocket Motor or equivalent test fixture to supply the necessary interface and restraint for the Fin Assembly. Fin Analysis from

ME Analysis 041-434 has identified the load condition to subject the GQM MK 70 Booster Fin Assembly.

Loads will be applied with two hydraulic actuators and appropriate test load fixtures on the GQM MK 70 Booster

Fin Assembly. Strain gauges will be mounted on the Fin structure at the Finite Element Model (FEM) predicted peak stress locations. Data collected from this test will be used to verify structural integrity during testing and as necessary, for any model correlation efforts.

Furthermore, displacement devices (i.e., LVDTs or equivalent) will be utilized to measure predicted peak deflections on the GQM MK 70 Booster Fin Assembly during load testing. Displacement data collected will be used to verify structural integrity during testing and as necessary, for any model correlation efforts.

1.4. Pass/Fail Criteria

This structural test will be deemed successful upon completion of the test if:

a. The fin assembly holds the maximum load for 30 seconds minimum.

b. There are no visible signs of permanent deformations or fractures in the Fin Assembly after 30 seconds minimum at maximum load.

c. Sufficient data has been collected to verify and/or update analysis.

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1.5. Procedural Changes

Changes to the text of this document may be accomplished in accordance with TM-14168, Configuration

Management Standards.

WARNING

PROCEDURAL CHANGES TO THIS DOCUMENT WHICH AFFECT THE

SAFETY OF PERSONNEL AND EQUIPMENT SHALL NOT BE IMPLEMENTED

WITHOUT PRIOR WRITTEN APPROVAL BY THE LSG INDUSTRIAL SAFETY

ENGINEER.

1.6. Applicable Documents

The current issue of the following documents applies to the extent specified herein:

Document Number Title

041-415 LRIP Stage 1 Fin Structural Analysis

041-434 LRIP Stage 1 Fin ATP/QTP load levels structural analysis

The following drawings apply to the extent specified herein:

Drawing Number Title

1030-5082 Fin, Booster MK 70

SK 4553 Maximum Hinge Moment Load Pad

SK 4554 Maximum Bending Moment and Maximum Normal Force Load Pad

SK 4555 Hydraulic Jack Stand

SK 4556 Anti-Rotation Fixture

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2. TEST PROCEDURE PROVISIONS

2.1. Safety Provisions

2.1.1. References

The following safety documents, in their current issue, shall be referenced:

a. TM-1617, Safety Manual

b. Safety Definitions:

1. WARNING: OPERATING PROCEDURES, PRACTICES, ETC., WHICH MUST BE STRICTLY

OBSERVED TO PREVENT INJURY TO PERSONNEL.

2. CAUTION: Operating procedures, practices, etc., which must be followed to prevent damage to or destruction of equipment.

3. NOTE: Highlights an operating procedure, condition, etc. which is essential.

2.1.2. Safety Precautions

Testing shall be performed at LSG, Chandler. Measures shall be taken to prevent, or reduce to a minimum, personnel exposure to hazardous conditions and environments (e.g., explosives, voltage, sound levels, pressure, lifting, etc.). A safe testing area shall be maintained during testing and inspection. The following personnel and facility safety precautions shall be observed:

a. A test conductor shall be designated and be responsible for the safety of personnel and equipment during conduct of the test.

b. Secure the area from unnecessary traffic (signs shall be posted and hazardous areas roped off as required).

c. Protective equipment shall be worn as required by testing procedures or established safety practices.

d. Prior to working with electrical circuits (e.g., battery box) personnel shall remove jewelry, watches, rings, and metal objects.

e. Personnel shall read and understand safety precautions outlined in reference documents and MSDS.

2.1.3. Protective Equipment

The following items are required Personal Protective Equipment (PPE) for each person:

X Hard Hats X Safety Toe Shoes

X Eye Protection Respiratory Protection

Faceshield and Eye Protection SCAPE

X Hearing Protection Fall Protection Arrest System

Ordnance Wrist Stat X Hand Protection/Gloves

Ordnance Jackets/Coveralls Other

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2.1.4. Pressurization Safety - Hydraulics

Ensure the following safety precautions are observed:

ABSOLUTELY NO MAINTENANCE SHALL BE PERFORMED ON A

PRESSURIZED SYSTEM.

THIS IS A DANGEROUS OPERATION. DO NOT CHECK FOR LEAKS WITH

BARE HANDS. AIR/FLUID CAN BE INJECTED THROUGH SKIN. FAILURE

TO COMPLY MAY RESULT IN INJURY TO PERSONNEL. USE LIQUID LEAK

DETECTOR METHOD.

a. Filling hoses shall be secured utilizing rope or hose tethers to prevent whipping of the line if the fitting should fail. Hose tethers shall be secured tightly to hoses. Long lengths of hose shall be secured every 6 feet with sand bags or hose tethers.

b. The following PPE shall be worn during hydraulic pressure operations:

1. Eye protection (ANSI-STD-Z87.1).

2. Ear protection (ANSI S3, 19-1974).

c. Area shall be marked with "DANGER - HIGH PRESSURE" signs and roped off.

1. Under no circumstances shall pressurization be performed exceeding the vendor rated MOP of any component.

d. Each hose assembly shall have a tag attached identifying certification dates.

e. All safety line attachments shall be in place at all times while the hose is pressurized.

f. Make a final check before applying pressure to determine that all lines are connected and that all fittings are tight.

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2.1.5. Lifting Safety

PERSONNEL SHALL KEEP CLEAR OF SUSPENDED LOADS DURING

CRANE/LIFT OPERATIONS. FAILURE TO COMPLY MAY RESULT IN INJURY

TO PERSONNEL.

ALL LIFTING OPERATIONS SHALL BE CLASSIFIED AS A HAZARDOUS

OPERATION. LIFTING OPERATIONS REQUIRE A TEST CONDUCTOR AS

THE DESIGNATED MOVE DIRECTOR. ALL LIFTING OPERATIONS SHALL

BE REVIEWED WITH ALL PERSONNEL PRIOR TO A MOVE TO INSURE

MINIMAL RISK TO THE STRUCTURE. A SPOTTER TO WATCH THE CRANE

AND POSSIBLE CONTACT WITH THE STRUCTURE IS REQUIRED FOR ALL

LIFTING OPERATIONS. LIFTING OPERATIONS SHALL PROCEED TO

COMPLETION BEFORE STOPPING OPERATIONS. VERIFY THE LOAD

MEETS REQUIREMENTS OF THE CRANE AND LIFTING STRAPS.

NOTE

The crane operator shall be current in certification training.

Ensure the following safety precautions are followed:

a. The test conductor shall inspect the crane, rigging (e.g., slings, wire ropes, chains), and test dates to ensure they are serviceable prior to the lift operation.

CRANE OPR/DATE /

b. Personnel shall wear the following PPE during crane operations:

1. Hard hats

2. Steel toe shoes

3. Leather gloves shall be worn if tag lines are used.

c. The crane operator and the test conductor shall ensure personnel keep clear of suspended loads during lift operations.

d. The crane operator shall not exceed the cranes rated load capacity during lift operations.

e. Only one person will give hand signals to the crane operator.

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2.1.6. Emergency Procedures - Chandler

During Regular Business Hours

In the event an employee is seriously injured or is in need of medical attention, the following procedure shall be adhered to:

Dial "0" for the Security Officer(s) and let them know you have a medical emergency. Inform the Security

Officer(s) of the area or Module where the emergency is located.

The Security Officer(s) shall page the Emergency Response Team.

Announce loud and clear, "Can I have your attention please? The Emergency Response Team is needed in ____________."

Repeat the announcement two times.

Activity shall be discontinued until an investigation is made by the LSG Industrial Safety Engineer and it is determined safe to continue.

Non-emergency situations shall be reported immediately to the Safety Engineer.

Before and After Business Hours

In the event of an injury or illness before or after business hours:

Call 911

Give the 911 Operator the following information:

Location

Nature of Emergency

Condition of victim (conscious, unconscious, bleeding, breathing, etc.)

Other information the operator may require

Have someone (employee, guard, etc.) wait outside to escort the Fire Department and Paramedics to the scene

Notify Judy Palacio as soon as possible at:

Pager No. 602-356-2704

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2.2. Failure and Retest

If a test discrepancy occurs, the test will be interrupted and a DR will be generated. The test configuration will not be disturbed without the approval of the test engineer. If the discrepancy is determined to be due to the test setup, software, or to a failure in the test equipment, the test being conducted at the time of the failure may be continued after repairs are completed. If the discrepancy is determined to be a failure in the item under test, the appropriate disposition shall be approved by Engineering and QA and completed before testing resumes.

The degree of retest will be determined for each case by the test engineer, based on the nature of the failure, and shall be accomplished per the requirements of the test procedure and Figure 2-1. Retesting at the failed environment is mandatory following completion of the approved disposition, unless disposition is “USE AS IS”.

Retesting at the other environments shall depend on the type of failure and approved disposition.

NOTE

For Integration Operations, System Level troubleshooting may be accomplished per TM-8251, a System Level DR shall be initiated upon isolation of discrepancy.

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Figure 2-1. Failure Retest Requirements for LSG Components

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3. DESCRIPTION OF TEST ITEM

The GQM MK 70 Booster Fin is comprised of a honeycomb structure with Hexcel honeycomb core of ¼-

5056.002P (rated at 190 psi) with a bonded 0.063 inch thick 2024-T3 aluminum skin. The fillet plate, channel and bottom fitting are made of 6061-T6 aluminum; and the leading edge is made of stainless steel. The fin shaft is made of 4140 steel heat treated to yield strength of 132 ksi and ultimate strength of 150 ksi.

The Fin Assembly qualification load test will consists of a 1030-5082 fin assembled in a Terrier Rocket Motor or equivalent test fixture. The fin shaft is engaged in the motor or equivalent test fixture and retained by a snap ring and an aft adjustment screw is engaged into an aft bracket on the rocket motor or test fixture.

ME Analysis from 041-434 has identified the load condition to subject the GQM MK 70 Booster Fin Assembly for

Qualification Load test.

Two load trains will be used to apply loading to the fin assembly as described in 041-434. A compressive load train will apply a normal load to the fin to create the required moment loads and another load train will utilize a nylon strap to apply the inertia/drag load on the leading edge of the GQM MK 70 Booster Fin Assembly. The load condition will be tested for normal and reverse bending moment load.

Instrumentation requirements will involve strain gauges and displacement measurements of the Fin Assembly at the FEM predicted peak stress locations and displacements. Data collected from this test will be used to verify structural integrity during testing and as necessary, for any model correlation efforts.

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4. STRUCTURAL QUALIFICATION TEST

4.1. Test Objectives

The objective of the Structural Qualification Load Tests is to verify that the GQM MK 70 Booster Fin will withstand

125% of the expected flight loads. One (1) test load condition will be run utilizing a normal compressive load train

(NF) to simulate the Hinge Moment (HM) and Bending Moment (BM) loads and another load train to simulate the

Inertia/Viscous Axial (IVA) load (see Table 4-1).

4.2. Test Equipment

Test and measuring equipment to be used are listed below.

Part Number Description

BJ1125F61-1060 Pump and Hydraulic Cylinder (5k lbf minimum capacity)

Load Cell (5k lbf minimum capacities)

Data Acquisition System or Equivalent

LVDTs or Equivalent

4.3. Allowable Test Tolerances

The maximum allowable tolerances (exclusive of instrumentation tolerances) on test conditions during testing, unless otherwise specified, shall be as follows:

Parameter Allowable Error

Layout Dimensions on decimal dimensions ±0.02

Pressure +5%, -0% psi

Test Duration Time +5%

Force (Load) Load at 10%: + 20%, -5%

Load at 25%: + 10%, -5%

Load at 50%: + 10%, -5%

Load at 75%: + 10%, -5%

Load at 100%: + 10%, -5%

Load at 125%: + 10%, -0%

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4.4. Test Setup

An illustration of the Qualification Structural Test setup for the GQM MK 70 Booster Fin Assembly is shown in

Figure 4-1.

Figure 4-1. GQM MK 70 Booster Fin Assembly Structural Qualification Test Setup

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Two loads are applied simultaneously to the fin. The NF is applied through a hydraulic jack assembly at the specified fin center of pressure; while the IVA load is applied though a nylon strap at the fin leading edge. The NF applied at the fin center of pressure will provide the correct BM and HM loads on the fin. See Figure 4-2 and

Table 4-1. The test normal and axial loads will be incrementally applied to the fin assembly as a percentage of their maximum value for the Quality Test Load Condition. Steps of 10%, 25%, 50%, 75%, 110% and 125% will be utilized. Finally, the quality test load condition will be tested for normal and reverse bending moment loads.

Figure 4-2. GQM MK 70 Booster Fin Assembly Coordinate System

TABLE 4-1. STRUCTURAL TEST CONDITIONS

Case Xcp

(inches fwd of hinge line)

Ycp (inches from root chord)

Normal Force

(NF)

(lbs) 125%

Bending Moment (BM)

(in-lbs)

Hinge Moment (HM)

(in-lbs)

Inertia/Viscous Axial Load (IVA)

(lbs) 125%

Quality Test Load

Condition

7.5 12.0 1795 20,712 13,142 986

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TABLE 4-2. QUALIFICATION TEST LOAD PERCENTAGES

Load Condition Load 10% 25% 50% 75% 110% 125%

Quality Test Load

NF 144 359 718 1077 1580 1795

IVA 79 197 394 592 868 986

During testing, strain gauges and LVDTs or equivalent will be mounted on the Fin structure at the FEM predicted peak stress locations and displacements. Data collected from them will be used to verify structural integrity of the fin during testing and as necessary, for any model correlation efforts. See Table 4-3 for strain gauge locations.

See Table 4-4 for displacement measurement locations and see Figure 4-2 for graphical locations of strain gages and displacement measurements on Fin.

TABLE 4-3. STRAIN GAUGE LOCATIONS

Gauge Description Type Orient X Y Surface

SG1A Base of Hinge Line (NS) Uniaxial Y dir -.50 +1.0 Skin

SG1B Base of Hinge Line (NS) Uniaxial X dir -.50 +1.0 Skin

SG2A Base of Hinge Line (FS) Uniaxial Y dir -.50 +1.0 Skin

SG2B Base of Hinge Line (NS) Uniaxial X dir -.50 +1.0 Skin

SG3 Leading Edge (NS) Uniaxial Y dir +17.0 +1.50 Skin

SG4 Leading Edge (FS) Uniaxial Y dir +17.0 +1.50 Skin

SG5 Center of Fin (NS) Uniaxial Y dir -.50 +11.3 Skin

SG6 Center of Fin (FS) Uniaxial Y dir -.50 +11.3 Skin

Strain Gauge P/Ns: CEA-13-250UW-120

TABLE 4-4. DISPLACEMENT MEASUREMENT LOCATIONS

Gauge Description Type Orientation X Y

L1 Lower Left Corner LVDT* Normal +17.5 +1.5

L2 Upper Left Corner LVDT* Normal +8.5 +25.0

L3 Upper Right Corner LVDT* Normal -8.5 +25.0

L4 Lower Right Corner LVDT* Normal -17.0 +3.0

L5 LVDT* X-DIR

*Permissible to substitute with string potentiometer or equivalent.

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5. TEST SETUP ASSEMBLY

BEGIN HAZARDOUS OPERATION

5.1. Test Setup Build and Assembly Procedure

NOTES

1. Steps can be performed out of sequence if necessary.

2. The crane operator shall be current in certification overhead crane training.

a. Ensure the following safety precautions are followed: Crane operator shall inspect the crane, rigging (e.g., slings, wire ropes, chains, and test dates), to ensure they are serviceable prior to lift operation.

CRANE OPR/DATE /

b. Mount Rocket Motor or equivalent test fixture to the test bay ground floor using rubber pads, chains, and

¾-10 cap-head screws and washers as required. Torque 3/4-10 screws to 150 ±5 ft-lb. Refer to

Figure 4-1.

OPR/DATE /

WITNESS/DATE /

c. Position the load trains for quality test load condition. See Table 4-1.

5.2. Instrumentation Setup and Assembly Procedure

a. Install strain gauges on fin per locations in Table 4-3. Measure and record their actual positions and gage factors in Table A-2.

TC/DATE /

L20

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b. Attach the Fin assembly to the motor or test fixture and verify the snap ring has engaged. Attach aft set screw.

c. Attach cables wires to the appropriate strain gauges in test assembly and then connect to the Data

Acquisition system.

d. Assemble displacement transducers per locations in Table 4-4. Measure and record their actual positions in Table A-3.

e. Setup and verify that the data acquisition system is functional. Print out device and channel setup information.

f. Establish alarms on the data acquisition system per engineering direction.

ENG/DATE /

g. Check each strain gauge and displacement measurement channel for the correct direction and scale factor settings.

h. Verify and re-position the load trains as required for Quality Test Load Condition. See Table 4-1.

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i. Take baseline photographs of entire test setup. Establish convenient reference frames for subsequent photographs.

j. Perform Test Readiness Review to ensure compliance with all test requirements.

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6. STRUCTURAL TEST PROCEDURES

6.1. Quality Test Load Condition

a. Verify that the Quality Test Load Condition is properly setup.

b. Take still pictures of test item and test assembly setup.

c. Immediately before testing, place a gage of known thickness under displacement transducer and confirm data acquisition system agrees with known value.

6.1.1. 10% of Quality Test Load Condition

a. Zero all gauges.

b. Clear all personnel from test bay area. Secure bay area by posting signs and blocking doors. If applicable, install safety barriers around test assembly and personnel barriers outside the test bay.

c. Using video recorders, video tape the test assembly for the duration of the test.

d. Start logging data using data acquisition system. Print screen.

e. Begin load test case by applying 10% of the loads listed in Table 4-2 for Quality Test Load Condition.

Hold for 30 seconds minimum. Print data acquisition screen at end of the hold period.

f. Gradually release the load to 0%. Print screen.

g. Stop logging data.

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h. Inspect hardware for signs of shifting, yielding or cracking. Note any anomalies.

QA/DATE /

i. Review logged data and compare with FEM analysis to ensure reasonable values before proceeding to next step.

j. Inspect instrumentation.

6.1.2. 25% of Quality Test Load Condition

a. Zero instrumentation at the discretion of the test conductor.

applicable, install safety barriers around test assembly and personnel barriers outside the test bay.

c. Using video recorders, video tape the test assembly for the duration of the test.

e. Ramp up to 10% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

f. Ramp up to 25% of the loads listed in Table 4-2. Hold for 30 seconds minimum. Print screen.

g. Ramp down to 10% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

h. Ramp down to zero load. Print screen.

i. Stop logging data.

j. Inspect hardware for signs of shifting, yielding or cracking. Note any anomalies.

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k. Review logged data and compare with FEM analysis to ensure reasonable values before proceeding to

l. Inspect instrumentation.

6.1.3. 50% of Quality Test Load Condition applicable, install safety barriers around test assembly and personnel barriers outside the test bay.

c. Using video recorders, video tape the test assembly for the duration of the test.

e. Ramp up to 25% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

f. Ramp up to 50% of the loads listed in Table 4-2. Hold for 30 seconds minimum. Print screen.

g. Ramp down to 25% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

h. Ramp down to zero load. Print screen.

OPR/DATE /

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6.1.4. 75% of Quality Test Load Condition applicable, install safety barriers around test assembly and personnel barriers outside the test bay.

c. Using video recorders, video tape the test assembly for the duration of the test.

f. Ramp up to 50% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

g. Ramp up to 75% of the loads listed in Table 4-2. Hold for 30 seconds minimum. Print screen.

h. Ramp down to 50% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

i. Ramp down to 25% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

j. Ramp down to zero load. Print screen.

k. Stop logging data.

l. Inspect hardware for signs of shifting, yielding or cracking. Note any anomalies.

m. Review logged data and compare with FEM analysis to ensure reasonable values before proceeding to

n. Inspect instrumentation.

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6.1.5. 110% of Quality Test Load Condition

a. Zero all instrumentation at the discretion of the test conductor.

applicable, install safety barriers around test assembly and personnel barriers outside the test bay.

c. Using video recorders, video tape the test assembly for the duration of the test.

f. Ramp up to 50% of the loads listed in Table 4.2. Hold for 10 seconds minimum. Print screen.

g. Ramp up to 75% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

h. Ramp up to 110% of the loads listed in Table 4-2. Hold for 30 seconds minimum. Print screen.

i. Ramp down to 75% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

j. Ramp down to 50% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

k. Ramp down to 25% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

l. Ramp down to zero load. Print screen.

m. Stop logging data.

n. Inspect hardware for signs of shifting, yielding or cracking. Note any anomalies.

o. Review logged data and compare with FEM analysis to ensure reasonable values before proceeding to

p. Inspect instrumentation.

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6.1.6. 125% of Quality Test Load Condition applicable, install safety barriers around test assembly and personnel barriers outside the test bay.

c. Using video recorders, video tape the test assembly for the duration of the test.

g. Ramp up to 75% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

h. Ramp up to 110% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

i. Ramp up to 125% of the loads listed in Table 4-2. Hold for 30 seconds minimum. Print screen.

j. Ramp down to 110% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

k. Ramp down to 75% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

l. Ramp down to 50% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

m. Ramp down to 25% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

n. Ramp down to zero load. Print screen.

OPR/DATE /

o. Stop logging data.

p. Inspect hardware for signs of shifting, yielding or cracking. Note any anomalies.

q. Review logged data and compare with FEM analysis to ensure reasonable values before proceeding to

r. Engineering approval of test data is required before next test.

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6.2. Reverse Quality Test Load Condition

a. Rotate Fin Assembly 180 degrees to perform the Reverse Quality Test Load Condition test (i.e., load test the other side of the fin).

b. Reposition the load trains for Reverse Quality Test Load condition.

c. Re-install displacement transducers per locations in Table 4-3. Measure and record their actual positions in Table A-3.

d. Immediately before testing, place gage of known thickness under displacement transducer and confirm data acquisition system agrees with known value.

6.2.1. 10% of Reverse Quality Test Load Condition

a. Zero all gauges.

applicable, install safety barriers around test assembly and personnel barriers outside the test bay.

c. Using video recorders, video tape the test assembly for the duration of the test.

e. Begin load test case by applying 10% of the loads listed in Table 4-2 for Quality Test Load Condition.

Hold for 30 seconds minimum. Print data acquisition screen at end of the hold period.

f. Gradually release the load to 0%. Print screen.

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g. Stop logging data.

h. Inspect hardware for signs of shifting, yielding or cracking. Note any anomalies.

i. Review logged data and compare with FEM analysis to ensure reasonable values before proceeding to

ENG/DATE /

j. Inspect instrumentation.

6.2.2. 25% of Quality Test Combined Load Condition applicable, install safety barriers around test assembly and personnel barriers outside the test bay.

c. Using video recorders, video tape the test assembly for the duration of the test.

e. Ramp up to 10% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

f. Ramp up to 25% of the loads listed in Table 4-2. Hold for 30 seconds minimum. Print screen.

g. Ramp down to 10% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

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6.2.3. 50% of Reverse Quality Test Load Condition applicable, install safety barriers around test assembly and personnel barriers outside the test bay.

c. Using video recorders, video tape the test assembly for the duration of the test.

f. Ramp up to 50% of the loads listed in Table 4-2. Hold for 30 seconds minimum. Print screen.

g. Ramp down to 25% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

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6.2.4. 75% of Reverse Quality Test Load Condition applicable, install safety barriers around test assembly and personnel barriers outside the test bay.

c. Using video recorders, video tape the test assembly for the duration of the test.

g. Ramp up to 75% of the loads listed in Table 4-2. Hold for 30 seconds minimum. Print screen.

h. Ramp down to 50% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

i. Ramp down to 25% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

j. Ramp down to zero load. Print screen.

k. Stop logging data.

l. Inspect hardware for signs of shifting, yielding or cracking. Note any anomalies.

m. Review logged data and compare with FEM analysis to ensure reasonable values before proceeding to

n. Inspect instrumentation.

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6.2.5. 110% of Reverse Quality Test Load Condition applicable, install safety barriers around test assembly and personnel barriers outside the test bay.

c. Using video recorders, video tape the test assembly for the duration of the test.

f. Ramp up to 50% of the loads listed in Table 4.2. Hold for 10 seconds minimum. Print screen.

g. Ramp up to 75% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

h. Ramp up to 110% of the loads listed in Table 4-2. Hold for 30 seconds minimum. Print screen.

i. Ramp down to 75% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

j. Ramp down to 50% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

k. Ramp down to 25% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

l. Ramp down to zero load. Print screen.

m. Stop logging data.

n. Inspect hardware for signs of shifting, yielding or cracking. Note any anomalies.

o. Review logged data and compare with FEM analysis to ensure reasonable values before proceeding to

p. Inspect instrumentation.

6.2.6. 125% of Reverse Quality Test Load Condition

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c. Using video recorders, video tape the test assembly for the duration of the test.

g. Ramp up to 75% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

h. Ramp up to 110% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

i. Ramp up to 125% of the loads listed in Table 4-2. Hold for 30 seconds minimum. Print screen.

j. Ramp down to 110% of the loads listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

k. Ramp down to 75% of the load listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

l. Ramp down to 50% of the load listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

m. Ramp down to 25% of the load listed in Table 4-2. Hold for 10 seconds minimum. Print screen.

n. Ramp down to zero load. Print screen.

o. Stop logging data.

p. Inspect hardware for signs of shifting, yielding or cracking. Note any anomalies.

q. Review logged data and compare with FEM analysis to ensure reasonable values before proceeding to

r. Engineering approval of test data is required before next test.

END HAZARDOUS OPERATION

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6.3. Breakdown of Test Equipment

a. Disassemble LVDTs and cables.

b. Remove load trains.

c. Inspect all test structures for signs of fatigue, yielding, or fractures.

d. Remove GQM MK 70 Booster Fin Assembly.

e. Identify Fin has been “Qual tested to per 1030-9004” and date of test completion with permanent marker.

7. DATA COLLECTION AND RESULTS

7.1. Test Report

The Qualification Load Tests are conducted to obtain information to validate design concepts, verify design criteria, determine design margins, identify failure modes, and to verify manufacturing processes. The results of this test will be presented in a test report, along with a presentation of the data and the completed procedure.

a. Copy the following items onto a CD and attach to this document:

1. Raw data files

2. Data plot files

3. Photos

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APPENDIX A

TEST EQUIPMENT LOG

USE OR DISCLOSURE OF

INFORMATION ON THIS SHEET IS

SUBJECT TO THE RESTRICTIONS ON

THE FIRST SHEET OF THIS

DOCUMENT

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TABLE A-1. SUPPORTING EQUIPMENT, PARTS, MATERIALS OR SOFTWARE

(AND/OR COMPUTER PRINTOUT)

UNIT UNDER TEST DESCRIPTION: P/N: S/N:

PART NUMBER MANUFACTURER PART NAME PART BAR CODE QTY DATE CAL DATE CAL DUE

FM35-047

Rev. B, 13 September 2001

USE OR DISCLOSURE OF

INFORMATION ON THIS SHEET

IS SUBJECT TO THE

RESTRICTIONS ON THE FIRST

SHEET OF THIS DOCUMENT

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TABLE A-2. ACTUAL STRAIN GAUGE LOCATIONS

Gauge Description Type Orient X Y Surface

SG1A Base of Hinge Line (NS) Uniaxial Y dir Skin

SG1B Base of Hinge Line (NS) Uniaxial X dir Skin

SG2A Base of Hinge Line (FS) Uniaxial Y dir Skin

SG2B Base of Hinge Line (FS) Uniaxial X dir Skin

SG3 Leading Edge (NS) Uniaxial Y dir Skin

SG4 Leading Edge (FS) Uniaxial Y dir Skin

SG5 Center of Fin (NS) Uniaxial Y dir Skin

SG6 Center of Fin (FS) Uniaxial Y dir Skin

Strain Gauge P/Ns: CEA-13-250UW-120

TABLE A-3. ACTUAL DISPLACEMENT MEASUREMENT LOCATIONS

Gauge Description Type Orientation X Y

Combined Load Condition

L1 Lower Left Corner LVDT* Normal

L2 Upper Left Corner LVDT* Normal

L3 Upper Right Corner LVDT* Normal

L4 Lower Right Corner LVDT* Normal

L5 LVDT* X-DIR

Reverse Combined Load Condition

L1 Lower Left Corner LVDT* Normal

L2 Upper Left Corner LVDT* Normal

L3 Upper Right Corner LVDT* Normal

L4 Lower Right Corner LVDT* Normal

L5 LVDT* X-DIR

*Permissible to substitute with string potentiometer or equivalent.