1030-9006-.pdf

REVISION HISTORY

S H

REV DESCRIPTION DATE APPROVED

-9

- Initial Release Per ECN-00000006607 7/20/06 Chad Smith

D W

G N

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CONTRACT NO:

CONFIGURATION

IDENTIFIED HEREIN

-001 -_____ -_____ -_____

ORIGINATOR

Chad Smith

DATE

7/7/06

DESIGN

Doug Allen

DATE

7/7/06

ORBITAL SCIENCES CORPORATION

LAUNCH SYSTEMS GROUP

3380 SOUTH PRICE ROAD

CHANDLER, ARIZONA 85248

PROGRAM OFFICE

Jeff Wimble

DATE

7/7/06

QUALITY ASSURANCE

Robin David

DATE

7/12/06

TITLE

GQM-163A MK70 FIN NON-

DESTRUCTIVE ATP

CDRL

MECHANICAL ENGINEER

Jeff Wimble

DATE

7/7/06

INDUSTRIAL SAFETY ENGINEER

Judy Palacio

DATE

7/10/06

DWG NO.

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SIZE

A

CAGE CODE

27555

SHEET

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. Violation 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.

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. Emergency Procedures

2.1.3.1. During Regular Business Hours

2.1.3.2. Before and After Business Hours

2.1.4. Failure and Retest

3. DESCRIPTION OF TEST ITEM

4. TAP ACCEPTANCE TEST

4.1. Test Objectives

4.2. Test Equipment

4.3. Allowable Test Tolerances

5. TEST SETUP ASSEMBLY

5.1. Test Setup Procedure

6. TAP TEST PROCEDURES

6.1. Tap Acceptance Test Fin No. 1

6.2. Tap Acceptance Test Fin No. 2

6.3. Tap Acceptance Test Fin No. 3

6.4. Tap Acceptance Test Fin No. 4

7. DATA COLLECTION AND RESULTS

7.1. Test Report

7.2. Recorded Debonds

7.2.1. Fin No. 1 Debonds

7.2.2. Fin No. 2 Debonds

7.2.3. Fin No. 3 Debonds

7.2.4. Fin No. 4 Debonds

8. PRE ENVIRONMENTAL FUNCTIONAL

9. THERMAL CYCLING

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TABLE OF CONTENTS (CONTINUED)

PAGE

10. TEMPERATURE SHOCK

11. RANDOM VIBRATION

12. SINUSOIDAL VIBRATION

13. SHOCK

14. THERMAL VACUUM

15. BURN-IN

16. POST ENVIRONMENTAL FUNCTIONAL

17. OPEN BOX INSPECTION

LIST OF FIGURES

Figure 2-1. Failure Retest Requirements for LSG Components

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1. INTRODUCTION

1.1. Purpose

The purpose of this document is to perform a tap acceptance test of the GQM MK70 Booster Fin, Drawing

Number 1030-5082 used on the first stage SSST MK70 Booster. This test will verify the workmanship of the

GQM MK70 Booster Fin.

1.2. Scope

This document describes the basic plans to conduct the required tap acceptance test on the GQM MK70 Booster

Fin which includes test setup, the testing sequence, data collection and instrumentation requirements.

1.3. Testing

Fins will be tested for skin/honeycomb debonds by tapping the entire surface on both of its sides using a tap hammer. The tap acceptance test will reveal any debonded areas through a distinct sound alteration created from debond.

1.4. Pass/Fail Criteria

This Tap Acceptance Test will be deemed successful upon completion of the test if the sum of debonded facesheet for each side of fin falls within the total allowable debond of 9 square inches or less per each side of the fin with no single debond having any dimension larger than 3 inches.

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.

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1.6. Applicable Documents

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

1030-5082 Fin, Booster MK70

TM-8251 Standard Operating Procedure Integrity Requirements

TM-14168 Configuration Management Standard

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.

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2.1.3. Emergency Procedures

2.1.3.1. 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.

2.1.3.2. 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:

Cell phone 602-318-6799

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2.1.4. Failure and Retest

If a test discrepancy occurs, the test will be interrupted and a Nonconformance (NC) 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 NC shall be initiated upon isolation of discrepancy.

3. DESCRIPTION OF TEST ITEM

The GQM MK70 Booster Fin (Drawing Number 1030-5082) is comprised of a honeycomb structure with Hexcel honeycomb core of ¼-5056.002P (rated at 190 psi) with a bonded .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 tap acceptance test will consist of a fin being tapped with a tap hammer over its entire surface to find debonded areas through distinct sound alteration created from debond.

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Figure 2-1. Failure Retest Requirements for LSG Components

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4. TAP ACCEPTANCE TEST

4.1. Test Objectives

The objective of the tap acceptance test is to verify the workmanship of the GQM MK70 Booster Fin. Each fin to be tested will be tapped over its entire surface on both of its sides using a tap hammer. The tap acceptance test will reveal any debonded areas through a distinct sound alteration created from debond.

4.2. Test Equipment

Test and measuring equipment to be used are listed below.

Part Number Description

SK4858 Tap Hammer

4.3. Allowable Test Tolerances

The maximum allowable tolerances on test conditions during testing, unless otherwise specified, shall be as follows:

Parameter Allowable error

N/A N/A

5. TEST SETUP ASSEMBLY

5.1. Test Setup Procedure

a. Ensure the test is performed in an area where there is minimal noise with the inspector and technician present only.

OPR/DATE /

QA WITNESS/DATE /

b. Obtain required tap hammer to perform test.

OPR/DATE /

L20

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6. TAP TEST PROCEDURES

6.1. Tap Acceptance Test Fin No. 1

a. Clean fin surface so that it is dry and free of oil, grease, and dirt.

Side 1 Side 2

OPR/DATE / /

QA WITNESS/DATE / /

Fin should be gently tapped 2-5 times per second. Slowly move the hammer over the fin surface such that the entire surface is tested.

b. Tap entire area on both sides of structure listening for debonded areas. Debonded areas sound hollow and less dense than bonded. Mark questionable debonded areas using permanent marker.

c. If any questionable areas exist, have a second technician perform the tap test on those questionable areas with a quality witness present.

Side 1 Side 2

d. Once test is completed, sum together debonded areas for each side of fin. Total allowable debonded facesheet is 9 square inches or less per each side of the fin with no single debond having any dimension larger than 3 inches.

Side 1 Side 2

e. Turn fin over and repeat steps a through d above.

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6.2. Tap Acceptance Test Fin No. 2

b. Tap entire area on both sides of structure listening for debonded areas. Debonded areas sound hollow

c. If any questionable areas exist, have a second technician perform the tap test on those questionable

d. Once test is completed, sum together debonded areas for each side of fin. Total allowable debonded facesheet is 9 square inches or less per each side of the fin with no single debond having any dimension larger than 3 inches.

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6.3. Tap Acceptance Test Fin No. 3

b. Tap entire area on both sides of structure listening for debonded areas. Debonded areas sound hollow

c. If any questionable areas exist, have a second technician perform the tap test on those questionable

d. Once test is completed, sum together debonded areas for each side of fin. Total allowable debonded facesheet is 9 square inches or less per each side of the fin with no single debond having any dimension

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6.4. Tap Acceptance Test Fin No. 4

b. Tap entire area on both sides of structure listening for debonded areas. Debonded areas sound hollow

c. If any questionable areas exist, have a second technician perform the tap test on those questionable

d. Once test is completed, sum together debonded areas for each side of fin. Total allowable debonded facesheet is 9 square inches or less per each side of the fin with no single debond having any dimension

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7. DATA COLLECTION AND RESULTS

7.1. Test Report

No test report is required.

7.2. Recorded Debonds

Sketch below the locations and dimensions of debonds found during the acceptance tests performed in

Sections 6.1 through 6.4.

7.2.1. Fin No. 1 Debonds

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7.2.2. Fin No. 2 Debonds

7.2.3. Fin No. 3 Debonds

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7.2.4. Fin No. 4 Debonds

8. PRE ENVIRONMENTAL FUNCTIONAL

Not applicable

9. THERMAL CYCLING

10. TEMPERATURE SHOCK

11. RANDOM VIBRATION

12. SINUSOIDAL VIBRATION

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13. SHOCK

14. THERMAL VACUUM

15. BURN-IN

16. POST ENVIRONMENTAL FUNCTIONAL

17. OPEN BOX INSPECTION