Attachment_B_Specification_-_Copy.pdf

RRM3-SPEC-001573

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Goddard Space Flight Center

Greenbelt, Maryland

ROBOTIC REFUELING MISSION 3 (RRM3)

XENON DIAPHRAGM ASSEMBLY

SPECIFICATION

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CM FOREWORD

This document is a Satellite Servicing Capabilities Office (SSCO) Configuration Management

(CM)-controlled document. Changes to this document require prior approval of the applicable

Configuration Control Board (CCB) Chairperson or designee. Proposed changes shall be submitted to the SSCO Code 408 CM Office (CMO), along with supportive material justifying the proposed change. Changes to this document will be made by complete revision.

Questions or comments concerning this document should be addressed to:

NASA/Goddard Space Flight Center

SSCO, Code 408

Attention: Configuration Management Office

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SATELLITE SERVICING CAPABILITIES OFFICE

DOCUMENT CHANGE RECORD

Date: June 20, 2016 Sheet 1 of 1

TITLE: Robotic Refueling Mission 3 (RRM3)

Xenon Diaphragm Assembly Specification

REV

LEVEL

DESCRIPTION OF CHANGE AUTHORIZATION

- Initial Release Per Signature Page

SSCO CM RELEASE

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Robotic Refueling Mission 3 (RRM3)

Xenon Diaphragm Assembly Specification

Prepared By:

Approved

Stephen M. Anthony

Gas and Fluid Systems Engineer, KSC:NEF20

6/20/16

Date

Reviewed By:

Approved

Mark A. Neuman

RRM3 Hardware Manager, Orbital ATK/Code 408

Sofia M. Stachel

RRM3 Systems Engineer, Orbital ATK/Code 408

Willliam D. (Dewey) Willis

RRM3 Xenon Transfer Subsystem Lead/Code 597

Joseph C. Joyner

RRM3 Quality Assurance, Orbital ATK/Code 373

Justin Cassidy

RRM3 Office Head, Lockheed Martin/Code 408

Samantha A. Hurley

RRM3 Gas and Fluid Systems Engineer, KSC:NEF20 iii https://sscongin.ndc.nasa.gov

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Table of Contents

1.0 Scope ...................................................................................................................................... 1-1

General Description .......................................................................................................... 1-1

2.0 Applicable Documents ........................................................................................................... 2-1

3.0 Diaphragm Requirements ...................................................................................................... 3-1

AIAA S-080 Certification Requirements .......................................................................... 3-1

Physical Requirements ...................................................................................................... 3-1

3.2.1 Assembly Description ................................................................................................. 3-1

3.2.2 Envelope ..................................................................................................................... 3-2

3.2.3 Mounting Interface...................................................................................................... 3-2

3.2.4 Actuation Force ........................................................................................................... 3-2

3.2.5 Actuator Interface ....................................................................................................... 3-2

3.2.6 Fluid Connections ....................................................................................................... 3-3

3.2.7 Mass ............................................................................................................................ 3-3

3.2.8 Ground and Isolation................................................................................................... 3-3

Functional Requirements .................................................................................................. 3-3

3.3.1 Fluid Media ................................................................................................................. 3-3

3.3.2 Compression Ratio ...................................................................................................... 3-4

3.3.3 Transfer Rate ............................................................................................................... 3-4

3.3.4 Diaphragm Stroke ....................................................................................................... 3-4

3.3.5 Maximum Expected Operating Pressure/Maximum Design Pressure ........................ 3-4

3.3.6 Inlet and Discharge Pressure ....................................................................................... 3-4

3.3.7 Check Valve Crack Pressure ....................................................................................... 3-4

3.3.8 Proof Factor ................................................................................................................ 3-5

3.3.9 Burst Factor ................................................................................................................. 3-5

3.3.10 Allowable Leakage ................................................................................................... 3-5

Lifecycle Requirements .................................................................................................... 3-5

3.4.1 Operational Life .......................................................................................................... 3-5

3.4.2 Storage Life ................................................................................................................. 3-6 iv https://sscongin.ndc.nasa.gov

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Environmental Requirements ............................................................................................ 3-6

3.5.1 Temperature ................................................................................................................ 3-6

3.5.2 Limit Loads ................................................................................................................. 3-6

3.5.3 Random Vibration ....................................................................................................... 3-6

3.5.4 Shock........................................................................................................................... 3-7

3.5.5 On-Orbit Pressure Environment ................................................................................. 3-8

3.5.6 Humidity ..................................................................................................................... 3-8

Mission Assurance Requirements ..................................................................................... 3-8

3.6.1 Materials ..................................................................................................................... 3-8

3.6.2 Fracture Critical Designation .................................................................................... 3-10

3.6.3 Welding ..................................................................................................................... 3-11

3.6.4 Cleanliness ................................................................................................................ 3-13

3.6.5 Shipping Requirements ............................................................................................. 3-13

4.0 Verification ............................................................................................................................ 4-1

Qualification Testing ......................................................................................................... 4-1

Acceptance Testing ........................................................................................................... 4-1

Test Requirements ............................................................................................................. 4-2

4.3.1 Dimensional Verification ............................................................................................ 4-2

4.3.2 Proof Test .................................................................................................................... 4-2

4.3.3 Leak Test ..................................................................................................................... 4-2

4.3.4 Fluid Transfer Test ...................................................................................................... 4-2

4.3.5 Test Parameters ........................................................................................................... 4-3

4.3.6 Random Vibration Test ............................................................................................... 4-3

4.3.7 Mechanical Shock Test ............................................................................................... 4-3

4.3.8 Thermal Cycle Test ..................................................................................................... 4-3

4.3.9 Burst Test .................................................................................................................... 4-4

4.3.10 Life Cycle Test .......................................................................................................... 4-4

4.3.11 Post-Test Visual Inspection ...................................................................................... 4-4

4.3.12 Post-Acceptance Test Cleaning Verification ............................................................ 4-4

Verification Matrix............................................................................................................ 4-4 v https://sscongin.ndc.nasa.gov

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5.0 Acronyms ............................................................................................................................... 5-1

List of Figures

Figure 3-1. Diaphragm Assembly Concept ................................................................................. 3-1

Figure 3-2. Diaphragm Assembly Envelope and Interfaces ........................................................ 3-2

Figure 3-3. Random Vibration Environment .............................................................................. 3-7

List of Tables

Table 3-1. Shock Environment ................................................................................................... 3-7

Table 4-1 Qualification Test Matrix ............................................................................................ 4-1

Table 4-2 Acceptance Test Matrix ............................................................................................... 4-1

Table 4-3 Qualification/Acceptance Test Parameters .................................................................. 4-3

Table 4-4. Verification Matrix .................................................................................................... 4-5

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1.0 Scope

This specification establishes the technical, design, fabrication, verification, acceptance, and qualification requirements for the Satellite Servicing Capabilities Office (SSCO) Robotic

Refueling Mission 3 (RRM3) Xenon Diaphragm Assembly as flight-certified hardware for ground testing, and on-orbit operations at the International Space Station (ISS).

This specification contains the assembly’s technical requirements. The programmatic requirements can be found in RRM3-SOW-001571.

General Description

The Xenon Diaphragm Assembly, referred to hereafter as the “diaphragm assembly”, is intended to act as a pump for a xenon transfer demonstration during on-ground and in-space operations.

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2.0 Applicable Documents

Document Number Document Title

541-PG-8072.1.2 GSFC Fastener Integrity Requirements

AIAA S-080 Space Systems - Metallic Pressure Vessels, Pressurized Structures, and Pressure Components

ASTM E-595 Standard Test Method for Total Mass Loss and Collected Volatile Condensable Materials from Outgassing in a Vacuum Environment

AWS C7.4 Process Specification and Operator Qualification for Laser Beam Welding

AWS D17.1 Specification for Fusion Welding for Aerospace Applications

ISO 14952 Space systems -- Surface cleanliness of fluid systems

GSFC-STD-7000A General Environmental Verification Standards (GEVS)

MIL-PRF 27401G Performance Specification Propellant Pressurizing Agent, Nitrogen

MIL-PRF-27407D Performance Specification Propellant Pressurizing Agent, Helium

NASA-HDBK-5010 Fracture Control Implementation Handbook for Payloads, Experiment, and Similar Hardware

NASA-STD-5009 Non Destructive Evaluation Requirements for Fracture-Critical Metallic Components

NASA-STD-5020 Requirements for Threaded Fastening Systems in Spaceflight Hardware

NASA-STD-6001 Flammability, Offgassing, and Compatibility Requirements and Test Procedures

NASA-STD-6016 Standard Materials and Processes Requirements for Spacecraft

RRM3-SOW-001571 Xenon Diaphragm Assembly Statement of Work

SAE AMS 2680 Electron Beam Welding for Fatigue Critical Applications

SSP 52005 Payload Flight Equipment Requirements and Guidelines for Safety-Critical Structures

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3.0 Diaphragm Requirements

AIAA S-080 Certification Requirements

A. The diaphragm assembly shall be designed, fabricated, and tested to meet the requirements for AIAA S-080 flight hardware certification.

B. The vendor shall provide a certificate of conformance that the diaphragm assembly meets the requirements of AIAA S-080.

Physical Requirements

3.2.1 Assembly Description

The diaphragm assembly shall consist of a diaphragm, baseplate, inlet and outlet check valves, fluid connections, and all interconnecting hardware, as shown in Figure 3-1 and

Figure 3-2.

Figure 3-1. Diaphragm Assembly Concept

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Figure 3-2. Diaphragm Assembly Envelope and Interfaces

3.2.2 Envelope

The diaphragm assembly shall conform to the envelope dimensions provided in Figure

3-2. Note: this envelope does not include the Inlet/Outlet tubes.

3.2.3 Mounting Interface

The diaphragm assembly will interface to a housing via the perimeter hole pattern shown in Figure 3-2. The housing interface shall be detailed in the ICD between the vendor and

SSCO.

3.2.4 Actuation Force

The diaphragm assembly shall be capable of meeting all performance requirements with a maximum actuation force of 5,000 lbf.

3.2.5 Actuator Interface

A. The diaphragm assembly will include an interface for a shaft from the actuator secured with a transverse pin/screw as shown in Figure 3-2.

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B. Details of the actuator interface shall be defined in an ICD between the vendor and

SSCO.

C. The actuator interface shall be capable of reacting a 7,000 lbs. axial load.

3.2.6 Fluid Connections

A. The diaphragm assembly shall include inlet and outlet fluid connections consisting of welded tubes (ex. check valves) of the material specified in Section 3.6.1.1.

B. The tube-stub interfaces shall have a straight length of 1.5 +0.1/-0.0 inches.

C. The tube-stub interfaces shall have a minimum separation distance of 1.2 inches

(center to center) at their ends

D. The outside diameter of the tube stub ends shall be 0.250 +0.004/-0 inch.

E. The wall thickness of the tube stub ends shall be 0.028 +0.003/-0 inch.

3.2.7 Mass

A. The diaphragm assembly shall have a mass of no more than 3.0 lbm.

B. The vendor shall define the diaphragm assembly center of mass to within 0.01 inch relative to external references.

3.2.8 Ground and Isolation

A. The diaphragm assembly shall be designed and fabricated to ensure that all external parts, shields, and surfaces are at ground potential.

B. The diaphragm assembly shall have a ground point to provide ground to the system.

C. The diaphragm assembly shall achieve an electrical bonding value of <2.5 milliohms

(complies with SSP 57003 Class R) to the diaphragm assembly mount.

Functional Requirements

3.3.1 Fluid Media

3.3.1.1 Flight Service Medium

The diaphragm assembly shall be designed, fabricated, and tested to operate with gaseous or supercritical xenon of purity of at least 99.99% as the flight service medium.

3.3.1.2 Test Media

A. For all testing where gaseous helium (GHe) is required, clean dry GHe that meets

MIL-PRF-27407D, Type 1, Grade A, or an SSCO-approved equivalent with a moisture content of no more than 6 ppm water and filtered through a stainless steel filter with a 10 micro-m absolute rating, shall be used.

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B. For all testing where gaseous nitrogen (GN2) is required, clean dry GN2 that meets

MIL-PRF-27401G, or an SSCO-approved equivalent with a moisture content of no more than 6 ppm water and filtered through a stainless steel filter with a 10 micro-m absolute rating, shall be used.

3.3.2 Compression Ratio

The diaphragm assembly shall have a volumetric compression ratio of at least 10:1 using the flight service medium specified in Section 3.3.1.1.

3.3.3 Transfer Rate

The diaphragm assembly shall be capable of transferring 1 kg of the flight service medium specified in Section 3.3.1.1 in no more than 3 hours at the pressures specified in

Section 3.3.6.

For the purposes of this specification, the transfer of 1 kg of xenon in no more than 3 hours is considered a ‘fluid transfer’.

3.3.4 Diaphragm Stroke

A. The diaphragm assembly shall be capable of meeting all performance requirements with a diaphragm stroke rate of 2.5 +0/-1 Hz.

B. The diaphragm assembly shall be capable of meeting all performance requirements with a diaphragm stroke length of 0.006 ± 0.002 inch.

3.3.5 Maximum Expected Operating Pressure/Maximum Design Pressure

For the purposes of this specification, the MEOP is also the Maximum Design Pressure

(MDP) of the assembly.

A. The diaphragm assembly shall be designed, fabricated, and tested for a maximum expected operating pressure (MEOP) of at least 3,000 psia.

B. The diaphragm assembly design shall account for flight ambient (vacuum) pressures, thus test pressures may need to be increased by the ambient test pressure.

3.3.6 Inlet and Discharge Pressure

A. The diaphragm assembly shall be capable of meeting all performance requirements in this specification with an inlet pressure range of 200 to 1,400 psia.

B. The diaphragm assembly shall be capable of discharging the flight service medium specified in Section 3.3.1.1 at a density of at least 1.65 kg/L.

C. The diaphragm assembly shall be capable of discharging the flight service medium specified in Section 3.3.1.1 at a pressure of at least 2,100 psia.

3.3.7 Check Valve Crack Pressure

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The diaphragm assembly check valves shall have a differential crack pressure of no more than 10 psid.

3.3.8 Proof Factor

The diaphragm assembly shall be designed and tested for a minimum proof factor of 1.5.

3.3.9 Burst Factor

The diaphragm assembly shall be designed and tested for a minimum burst factor of 2.5.

3.3.10 Structural Factors

Positive margins of safety shall be confirmed when using the following factors of safety:

1.25 yield and 1.4 ultimate for tested structure.

3.3.11 Allowable Leakage

3.3.11.1 Internal Leakage

A. The internal leak rate of the diaphragm assembly shall be defined by the vendor such that it meets all performance requirements in this specification.

B. Internal leakage shall be verified to meet the defined value by testing at the minimum and maximum qualification and acceptance test temperatures specified in Section

3.5.1.

3.3.11.2 External Leakage

A. The external leak rate of the diaphragm assembly shall not exceed 1 x 10-6 sccs GHe at the MEOP defined in Section 3.3.5.

B. External leakage shall be verified by testing at the minimum and maximum qualification and acceptance test temperatures specified in Section 3.5.1.

Lifecycle Requirements

3.4.1 Operational Life

A fluid transfer is defined in Section 3.3.3.

A. The diaphragm assembly shall be designed, fabricated, and tested for an operational life in LEO of at least 2 years.

B. The diaphragm assembly shall be designed for a minimum of 40 fluid transfers. The

Operational Life is 10 fluid transfers, but the diaphragm needs to be tested/analyzed for 4x the Operational Life. See Section 4.3.10.

C. The diaphragm assembly design shall have positive margins when subjected to the analysis for cyclic fatigue in accordance with AIAA S-080 Paragraph 4.2.6, using limit loads specified in Section 3.5.2 for the number of cycles equivalent to 40 fluid transfer cycles.

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D. Positive margins of safety as specified in Section 3.5.2 shall be confirmed for cyclic fatigue.

3.4.2 Storage Life

A. The diaphragm assembly shall be designed, fabricated, and tested for a storage life of

2 years from acceptance to first mission use.

B. The diaphragm assembly shall be designed, fabricated, and tested for a pressurized storage life of 10 years in LEO after operations are complete, with no degradation causing external leakage that exceeds the requirement in Section 3.3.11.2, or failure of the diaphragm assembly.

Environmental Requirements

3.5.1 Temperature

A. The qualification test temperature range shall be -60 to +70°C.

B. The acceptance test temperature range shall be -55 to +65°C.

3.5.2 Limit Loads

A. The diaphragm assembly shall be designed to withstand quasi-static launch loads of

15.5 g.

B. The diaphragm assembly shall be designed to withstand an on-orbit load of 0.4 g in any direction combined with loads imposed by the MEOP specified in Section 3.3.5, and at the qualification temperatures specified in Section 3.5.1.

C. The diaphragm assembly shall be capable of withstanding a transportation load in its shipping container of 5 g in any direction.

D. At the subjected limit loads specified above, positive margins of safety shall be confirmed when using the following factors of safety: 2.0 yield and 2.6 ultimate for analyzed structure.

3.5.3 Random Vibration

The diaphragm assembly shall remain functional after exposure to the random vibration spectrum shown in Figure 3-3 for components of 50 lbs or less. (Source: NASA-STD-

7000, GEVS)

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Frequency ASD Level (g2/Hz)

(Hz) Qualification Acceptance

20-50 50-800

800-2000

0.026 +6 dB/oct

0.16 -6 dB/oct

0.026

0.013 +6 dB/oct

0.08 -6 dB/oct

0.013

Overall 14.1 Grms 10.0 Grms

Figure 3-3. Random Vibration Environment

3.5.4 Shock

An assessment of diaphragm assembly shock sensitivity shall be performed based on the levels specified in Table 3-1 at the MEOP defined in Section 3.3.5. This assessment will be accomplished through inspection methods including similarity, documentation, and/or engineering assessment.

Table 3-1. Shock Environment

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Frequency

(Hz)

Shock Response Spectrum (G peak)

(G Peak) 100 80

611 500

10000 500

3.5.5 On-Orbit Pressure Environment

The diaphragm assembly shall operate in a minimum pressure environment of 5.5x10-12 psia (2.7x10-10 Torr).

3.5.6 Humidity

The diaphragm assembly shall be able to meet the requirements herein during and after exposure up to 70% relative humidity for the duration of the shelf life specified in

Section 3.4.2.

Mission Assurance Requirements

3.6.1 Materials

3.6.1.1 General Material Requirements

A. The vendor shall select materials and processes in accordance with NASA-STD-

6016.

B. The vendor shall provide a list of all materials, including inorganic materials, lubricants, and material processes to the SSCO.

C. The vendor shall obtain written concurrence from SSCO for all materials and processes lists.

D. A Materials Usage Agreement (MUA) shall be submitted for each non-compliant material usage.

E. The vendor shall obtain written approval of all Materials Usage Agreements.

F. A copy of any process shall be submitted for review upon request.

G. Materials shall be compatible with high purity xenon as specified in Section 3.3.1.1, and test media specified in Section 3.3.1.2.

H. All tubing material shall be dual-grade, seamless, type 304/304L or 316/316L stainless steel per ASTM A269, or other materials approved by SSCO.

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3.6.1.2 Flammability and Toxic Offgassing

SSCO will review the submitted material list for flammability and toxic offgassing in accordance with the test methods described in NASA-STD-6001. Noncompliant materials will be documented in a MUA.

3.6.1.3 Vacuum Outgassing

SSCO will review the submitted material list for vacuum outgassing in accordance with

American Society for Testing of Materials (ASTM) E-595. In general only materials that have a total mass loss (TML) less than1.00% and a collected volatile condensable mass

(CVCM) less than 0.10% will be approved for use in a vacuum environment.

Noncompliant materials will be documented in a MUA.

3.6.1.4 Shelf-Life-Controlled Materials

A. Polymeric materials that have a limited shelf-life shall be controlled by a process that identifies the start date (manufacturer’s processing, shipment date, or date of receipt, etc.), the storage conditions associated with a specified shelf-life, and expiration date.

B. Materials such as O-rings, rubber seals, tape, uncured polymers, and paints shall be included.

C. All shelf life controlled materials must have 75% of their usable shelf life left when procured for this task. Any deviation from this policy must be approved in writing by

SSCO.

3.6.1.5 Platings

The use of tin, zinc, cadmium, and silver platings in any flight application shall require a

MUA prior to use of that material. Alloys of solder containing less 97% tin do not require a MUA.

3.6.1.6 Fasteners

A. A list of flight fasteners shall be submitted as part of the materials and processes list.

B. All fasteners shall be classified as either “critical” or “controlled” per the definitions of 541-PG-8072.1.2.

C. All fasteners shall be approved by SSCO.

D. The vendor shall comply with the procurement documentation and test requirements for flight hardware and critical ground support equipment fasteners contained in 541-

PG-8072.1.2.

See Section 3.6.2.1.2 for fastener locking features requirements.

3.6.1.7 Material Procurement Requirements

3.6.1.7.1 Purchased Raw Materials

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Raw Materials purchased by the vendor shall be accompanied by the results of nondestructive, chemical, and physical tests, and a Certificate of Compliance. This information need only be provided to the SSCO when there is a direct question concerning the material’s flight-worthiness.

3.6.1.7.2 Raw Materials Used in Purchased Products

The vendor shall require that their suppliers meet the requirements of Section 3.6.1.7.1 and provide, upon request, the results of acceptance tests and analyses performed on raw materials.

3.6.2 Fracture Critical Designation

Per SSP 52005, the diaphragm assembly is considered fracture critical, and classified as

Lines, Fittings, and Other Pressurized Components.

A. All drawings of pressure-containing parts shall include a note that specifies the part is fracture critical (this applies to all parts on the diaphragm assembly).

B. Material certifications for all parts used in the assembly will be provided. See

Section 3.6.1 and subsections.

C. A pressurization log, documenting every time the diaphragm assembly is put through a pressure cycle, to what level, and for how long, shall accompany the assembly as part of the end item data package (EIDP).

D. The diaphragm assembly shall comply with requirements of SSP 52005 section

5.3.2.1.4 or equivalently NASA-STD-5019 Section 4.1.2.1.4. Note, a Damage

Tolerance Assessment is not required.

3.6.2.1 Fracture Critical Designation Considerations

A. The part minimum thickness as shown in the drawing shall be used for stress calculations. Actual as–built dimensions may be used in stress calculations when available.

B. Thermal stresses/loads shall be combined with mechanical and pressure stresses/loads when they are additive, but not when they are relieving.

C. Pressure integrity shall be verified at the unit level by performing a leak check. The leak test will be performed at 1.0 x MDP (MDP defined in Section 3.3.5) as a minimum.

D. The diaphragm assembly shall be proof-tested to a minimum proof-factor of 1.5 x

MDP and subsequently leak checked at a minimum pressure of 1.0 x MDP (MDP defined in Section 3.3.5).

3.6.2.1.1 Non-Destructive Evaluation (NDE)

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A. Volumetric inspection of the unit’s fracture-critical fusion joints shall be made after proof-testing to determine acceptable conditions both on the surface and within the fusion joint.

B. In instances where NDE is not feasible, the manufacturer may employ a process-control program that assures the quality of the un-inspectable welds as coordinated with SSCO. Section 5.2.1.4 of NASA-HDBK-5010 contains an outline and guidance for building an acceptable process-control program for specific components.

C. NDE inspections for Fracture Control shall be performed in accordance with NASA-

STD-5009 for metallic components.

D. Except for translucent material (e.g., glass), visual inspection shall not be used for the purpose of detecting flaws to be used in damage-tolerant assessments without documented rationale and specific approval by the SSCO.

E. Each inspection report shall contain a record of the inspection results identifying the part name; part number; serial number; material and condition; NDE type and sensitivity level; a sketch of the part showing the area inspected and type of flaws inspected for; the results of the inspection; and the inspector’s signature, date, and stamp.

3.6.2.1.2 Fastener Locking Features

A. Threaded fasteners that perform a safety critical function shall incorporate two separate verifiable locking features. SSCO preferred method is use of locking inserts and verifiable final torque.

B. Threaded fastening systems shall meet or exceed the requirements in NASA-STD-

5020. Fasteners that are not safety critical, are internal to the diaphragm assembly, and are shown to be contained, are excluded from this requirement.

3.6.3 Welding

A. The processing and quality assurance requirements for manual, automatic, and semiautomatic fusion welding for space flight applications shall meet the requirements of AWS D17.1 with the following modifications/additions:

a. Fracture critical welds and welds classified as “low risk fracture” shall comply with AWS D17.1, Class A requirements.

b. Other non-fracture critical structural welds shall comply with AWS D17.1, Class B requirements.

c. Non-fracture critical, non-structural welds (including seal welds) shall comply with AWS D17.1, Class C requirements.

d. Laser welding shall comply with AWS C7.4, Process Specification and

Operator Qualification for Laser Beam Welding

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e. Electron beam welding shall comply with SAE AMS 2680, Electron Beam

Welding for Fatigue Critical Applications

f. The following welding practices shall not be used:

o Welding from both sides if full penetration of the first pass is not verified

(either by inspection of the back side or by grinding prior to welding on the opposite side).

o Partial weld penetration in Class A or Class B welds.

o Straightening operation after welding.

o Lap welds in Class A or Class B applications.

g. The Welding Procedure Specification (WPS) shall include the following content in addition to that required by AWS D17.1:

o Prequalified rework welds in accordance with AWS D17.1.

o Testing and documentation of allowable parameter variations for automatic and semi-automatic welds.

o Manual welding parameters. Show Class A manual welds are qualified.

o Qualification strength requirements. Class A and Class B weld procedure qualification require tensile testing per AWS B2.1, Specification for

Welding Procedure and Performance Qualification, special test weldments. Class A and B weld procedure qualification require macro-examination and NDE testing per acceptance criteria defined in AWS

D17.1 section 7. Qualification strength values are not the same as materials design allowables.

o Electrode diameter and shape.

o Verification of strength values used in design

h. Material Review Board disposition shall be required for weld repair/rework/processing activities that are not covered by the weld qualification. Examples include:

o Wrong filler metal used o More than two attempts performed at the same location on heat sensitive materials o More than five attempts performed at the same location on materials that are not heat sensitive o Repair weld required after the weldment has been post weld heat treated o Repair weld required after final machining has been completed o Repair extends outside the original weld zone

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Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this o Weldment has been direct aged o Repairs following proof or leak test

B. A continuous audit of weldment production quality shall be maintained.

C. Resulting records shall include the location of repairs, type of defects repaired, procedures used, and inches of repair per total inches of weld.

D. These records shall be made available to SSCO upon request.

E. Personnel training certifications for welding shall be made available upon request.

3.6.4 Cleanliness

3.6.4.1 External Cleanliness

The diaphragm assembly external surfaces shall be 500A clean in accordance with ISO

14952, or by using an equivalent method approved by SSCO.

3.6.4.2 Internal Cleanliness

The diaphragm assembly internal surfaces shall be 100A clean in accordance with ISO

14952, or by using an equivalent method approved by SSCO.

3.6.5 Shipping Requirements

A. The diaphragm assembly shall be capped and double-bagged with a nitrogen purge for shipping to maintain cleanliness.

B. A label shall be affixed to the outer bag to document the cleanliness level.

C. A label shall be affixed to the inner bag to document the part number and serial number of the device.

D. The diaphragm assembly shall be secured during shipping to ensure no damage occurs that would prevent the assembly from meeting any of the requirements of this specification.

E. Alternate methods of packaging must be approved by SSCO.

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4.0 Verification

A. Any proposed deviations from the test sequence shown in Table 4-1 and Table 4-2 shall be approved by SSCO prior to implementation.

B. Test documentation (plans, procedures, and reports) for all testing shall be submitted per the terms in RRM3-SOW-001571.

Qualification Testing

Qualification testing shall be performed on a vendor test article diaphragm assembly in accordance with Table 4-1 to verify that the diaphragm assembly meets the design, fabrication, and reliability requirements of this specification and AIAA S-080.

Table 4-1 Qualification Test Matrix

Test Sequence of Tests Section

Dimensional Verification 1 4.3.1

Proof Test 2 4.3.2

Leak Test 3, 5, 7, 9, 11 4.3.3

Fluid Transfer Test 4 4.3.4

Random Vibration Test 6 4.3.6

Thermal Cycle Test 8 4.3.8

Life Test 10 4.3.10

Burst Test 12 4.3.9

Acceptance Testing

A. Acceptance testing shall be performed on the flight diaphragm assembly in accordance with Table 4-2 to verify that the diaphragm assembly is fabricated in accordance with this specification and AIAA S-080.

B. Once acceptance testing begins, any changes to the diaphragm assembly design, materials, or processes will result in invalidating the acceptance testing already performed.

C. If such changes are made, the vendor shall repeat acceptance testing unless the change is approved without additional testing by SSCO.

Table 4-2 Acceptance Test Matrix

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Test Sequence of Tests Section

Dimensional Verification 1 4.3.1

Proof Test 2 4.3.2

Leak Test 3, 5, 7, 9 4.3.3

Fluid Transfer Test 4 4.3.4

Random Vibration Test 6 4.3.6

Thermal Cycle Test 8 4.3.8

Test Requirements

4.3.1 Dimensional Verification

A. The vendor fabrication drawings shall be verified to meet the requirements of this specification and approved by SSCO before the start of fabrication.

B. Cross-sectional assembly details shall be shown in the vendor fabrication drawings.

C. The diaphragm assembly dimensions shall be verified to be in accordance with the vendor fabrication drawings.

4.3.2 Proof Test

A. The diaphragm assembly shall be hydrostatically or pneumatically proof tested to the proof factor (Section 3.3.8) times the MDP (Section 3.3.5) for a minimum of 5 minutes.

B. Visual inspection shall be performed to verify no external deformation, deterioration, or damage after completion of proof testing.

C. When proof tests are conducted at temperatures other than design temperatures, the change in material properties at the proof temperature shall be accounted for in determining proof pressure.

4.3.3 Leak Test

A. The diaphragm assembly shall be tested for internal and external leakage (Section

3.3.11) with GHe as specified in Section 3.3.1.2, at MEOP specified in Section 3.3.5, for a minimum of 30 minutes.

B. The leak rates shall be measured by mass spectrometer with a detection level of 1 x

10-7 sccs GHe or better.

4.3.4 Fluid Transfer Test

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A. The qualification diaphragm assembly shall be tested for three fluid transfers using the flight service medium as specified in Section 3.3.1.2.

B. The acceptance diaphragm assembly shall be tested for one fluid transfer using the flight service medium as specified in Section 3.3.1.2.

C. The fluid transfer test shall demonstrate compliance with the requirements in Sections

3.3.2, 3.3.3, 3.3.4, 3.3.6, and 3.3.7.

D. The vendor shall record all data related to the diaphragm assembly performance as a function of time, including inlet pressure and temperature, discharge pressure and temperature, actuation force, actuation frequency, and actuation stroke length.

4.3.5 Test Parameters

The parameters in Table 4-3 shall be applied.

Table 4-3 Qualification/Acceptance Test Parameters

Test Qualification Acceptance

Random Vibration

Level

Duration

Figure 3-3 + 3dB

3 minutes/axis

Figure 3-3

1 minute/axis

4.3.6 Random Vibration Test

A. For qualification testing, the diaphragm assembly shall be subjected to a random vibration test along three orthogonal axes in accordance with Table 4-3.

B. For acceptance testing, the diaphragm assembly shall be subjected to a random vibration test along three orthogonal axes in accordance with Table 4-3.

C. A leak test shall be performed before and after random vibration testing in accordance with Section 4.3.3.

D. Prior to the random vibration test, the test fixture/exciter combination shall be surveyed to evaluate the fixture dynamics and the proposed choice of control accelerometers.

4.3.7 Mechanical Shock Test

Mechanical shock testing is not required. See Section 3.5.4.

4.3.8 Thermal Cycle Test

A. A fluid transfer, as defined in Section 3.3.3, shall be performed at the first and last hot and cold plateaus.

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B. After completion of thermal cycle testing, each diaphragm assembly shall be subjected to leak testing in accordance with Section 4.3.3.

C. The diaphragm assembly shall be exposed for a minimum of 1 hour at each temperature extreme for each thermal cycle.

4.3.8.1 Qualification Thermal Cycle Test

For qualification testing, the diaphragm assembly shall be exposed to 4 thermal cycles at the minimum and maximum qualification temperatures specified in Section 3.5.1.

4.3.8.2 Acceptance Thermal Cycle Test

For acceptance testing, the diaphragm assembly shall be exposed to 4 thermal cycles at the minimum and maximum acceptance temperatures specified in Section 3.5.1.

4.3.9 Burst Test

A. The qualification diaphragm assembly shall be subjected to a hydrostatic burst test to the burst factor specified in Section 3.3.9.

B. Following completion of the burst test, the vendor shall verify that there is no rupture or failure of the diaphragm assembly.

4.3.10 Life Cycle Test

This test is only performed on the qualification unit.

The diaphragm assembly shall be tested to 4x the number of fluid transfers defined in

Section 3.4.1 at the MDP defined in Section 3.3.5.

A fluid transfer is defined in Section 3.3.3.

4.3.11 Post-Test Visual Inspection

Upon completion of acceptance testing and prior to delivery, the vendor shall verify that there is no deformation of the diaphragm assembly, and that the diaphragm assembly meets the dimensions specified in the vendor fabrication drawings.

4.3.12 Post-Acceptance Test Cleaning Verification

Upon completion of acceptance testing, the cleanliness of the diaphragm assembly shall be verified in accordance with Section 3.6.4.

Verification Matrix

The verification matrix in Table 4-4 provides the minimum activities needed to verify that the diaphragm assembly design meets the requirements specified in Section 3.0. The content of each column in Table 4-4 is defined as follows:

Requirement: Requirement to be verified.

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Verification Method: “I” indicates that inspection is required; “T” indicates that testing is required; “A” indicates that analysis is required. Shaded columns indicate the paragraph is a header, not applicable for a certain phase, is for information only, is a target guideline, or is a statement of fact signified by a

“will.”

Unless otherwise noted, it should be assumed all subsections of a requirement can be verified the same way.

Table 4-4. Verification Matrix

Requirement Verification Method

1.0 Scope

2.0 Applicable Documents

3.0 Diaphragm Requirements

3.1 AIAA S-080 Certification Requirements I, T, A

3.2 Physical Requirements

3.2.1 Assembly Description I

3.2.2 Envelope I

3.2.3 Mounting Interface T

3.2.4 Actuator Force T

3.2.5 Actuator Interface A: I

B: I C: A

3.2.6 Fluid Connections I

3.2.7 Mass A: T

B: I

3.2.8 Ground Isolation A: I

B: I C: T

3.3 Functional Requirements

3.3.1 Fluid Media

3.3.1.1 Flight Service Medium T

3.3.1.2 Test Media I

3.3.2 Compression Ratio T

3.3.3 Transfer Rate T

3.3.4 Diaphragm Stroke T

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Requirement Verification Method

3.3.5 Maximum Expected Operating Pressure/Maximum

Design Pressure

T

3.3.6 Inlet and Discharge Pressure T

3.3.7 Check Valve Crack Pressure T

3.3.8 Proof Factor A, T

3.3.9 Burst Factor A, T

3.3.10 Allowable Leakage

3.3.10.1 Internal Leakage T

3.3.10.2 External Leakage T

3.4 Lifecycle Requirements

3.4.1 Operational Life A, T

3.4.2 Storage Life A, T

3.5 Environmental Requirements

3.5.1 Temperature T

3.5.2 Limit Loads A

3.5.3 Random Vibration T

3.5.4 Shock A

3.5.5 On-Orbit Pressure Environment A

3.5.6 Humidity A

3.6 Mission Assurance Requirements

3.6.1 Materials

3.6.1.1 General Material Requirements I

3.6.1.2 Flammability and Toxic Outgassing

3.6.1.3 Vacuum Outgassing

3.6.1.4 Shelf-Life-Controlled Materials I

3.6.1.5 Platings I

3.6.1.6 Fasteners I

3.6.1.7 Material Procurement Requirements

3.6.1.7.1 Purchased Raw Materials I

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Requirement Verification Method

3.6.1.7.2 Raw Materials Used in Purchased Products I

3.6.2 Fracture Critical Designation I

3.6.2.1 Fracture Critical Designation Considerations A: I

B: (Statement)

C: I D: T

3.6.2.1.1 Non-Destructive Evaluation (NDE) I

3.6.2.1.2 Fastener Locking Features I

3.6.3 Welding I

3.6.4 Cleanliness

3.6.4.1 External Cleanliness I

3.6.4.2 Internal Cleanliness I

3.6.5 Shipping Requirements I

4.0 Verification

5.0 Acronyms

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5.0 Acronyms

°C degree Celsius

ASME American Society for Mechanical Engineers

ASTM ASTM International (formerly American Society for Testing Materials)

AWS American Welding Society

CVCM collected volatile condensable materials g gravity

GEVS General Environmental Evaluation Standard

GHe gaseous helium

GN2 gaseous nitrogen

Hz hertz

ISO International Organization for Standardization kg kilogram lbm pound-mass min minute

NASA National Aeronautics and Space Administration

NDE nondestructive evaluation psia pound per square inch absolute psid pound per square inch differential sccs standard cubic centimeters per second

SOW Statement of Work

SSCO Satellite Servicing Capabilities Office

TBD to be determined

TBR to be resolved

TML total mass loss