ENGINEERING LABORATORY , MONTHLY PROGRESS REPORT For Period September 1, 1967, Through September 30, 1967 FOR INTERNAL USE ONLY NATIONAL AERONAUTICS AND SPACE ADMINISTRATION MSFC - Form 1262 (September 1961) PROPULSION AND VEHICLE ENGINEERING LABORATORY MONTHLY PROGRESS REPORT (September 1, 1967, Through September 30, 1967) Structures Division Advanced Studies Office Materials Division Vehicle Systems Division Propulsicn Division GEORGE C. MARSHALL SPACE FLIGHT CENTER TABLE OF CONTENTS Page 1. STRUCTURES DIVISION ........................... 1 Saturn V ................................... 1 I . S-IC Stage ............................... 1 I1. S-I1 Stage ............................... 2 A . MSFC Test 403 ("C" Structure).............. 2 B . MSFC Test 404 (High Force Thrust Structure).... 3 C . Storage Batteries ....................... 3 D . LH2 Outboard Feed Line .................. 3 E . S-I1 Test Program .................:.... 4 111. S-IVB Stage ............................. 4 A . Tension Testing of S-IVB Structural Joints ...... 4 B . Anti-Flutter Kit Heating Problem ............ 4 C . S-IVB Flutter Panel Testing ................ 4 D . Side Struts ........................... 5 E . Nose Fairing Modification .................. 5 F . Boat Tail ............................ 5 G . CornponentQualification .................. 5 IV . Instrument Unit ........................... 6 A . Swing Arm Testing ...................... 6 B . Panel Testing ......................... 6 V. Saturn V System ........................... 6 A . Damper System ........................ 6 B . Saturn V Sled Test ...................... 7 C . Loads Analysis ........................ 7 VI . Engine ................................. 7 Apollo Application Program ...................... 7 I . Apollo Telescope Mount ...................... 7 I1 . Multiple Docking Adapter ..................... 8 I11 . ~ack/PM............................... 8 IV . Nuclear Ground Test Module .................. 8 V. Voyager ................................ 8 VI . MSFC Flight Experiment # 8 .................. 9 2 . ADVANCED STUDIES OFFICE ....................... 11 Saturn V .................................. 11 Voyager Program ......................... 11 A . Baseline Spacecraft Design ................ 11 1. P&VE Spacecraft Design Status........... 11 2. Voyager Capsule Liaison ............... 11 TAB LE OF CONTENTS (Continued) Page B . Alternate Spacecraft Design Studies .......... 11 C . Voyager 1973 Orbiter Study ................ 12 Apollo Applications Program ..................... 13 I . Advanced S-IVB Workshop .................... 13 I1 . Integration .............................. 14 A. Experiment Catalog ..................... 14 B . EOSS Experiment Accommodation Studies ....... 14 111 . Lunar Systems ............................ 15 A. Mobility Test Program ................... 15 B . LSSM Program ........................ 15 AdvancedPrograms ........................... 15 I . Launch Vehicles .......................... 15 A . Kick Stage Study ....................... 15 B . Liquid Strap-on Pods "660K Launch Vehicle" .... 16 C . Launch Vehicle Handbook ................. 16 D. Stage Design for Personnel Transfer .......... 16 E . Saturn V Uprating Baseline Documents ......... 16 F . Low-Cost 'Launch Vehicle Study ............. 16 G. Saturn Utilization Study ................... 17 I1 . Earth Orbital ............................ 18 A. Long-term Space Station .................. 18 B . Common Mission Module (CMM) ............. 18 1. Requirements ...................... 18 2 . Configuration ...................... 18 I11 . Planetary Systems ......................... 19 A . Integrated Manned Interplanetary Spacecraft Definition .................... 19 B . Manned Planetary Fly-by Study ............. 19 IV . General ................................ 19 A. Development of SRT Requirements . : ......... 19 B . Engineering Support to Integrated Long-range Plan ....................... 20 TABLE OF CONTENTS (Continued) Page 3 . MATERIALS DIVISION ............................ 21 Saturn IB .................................. 21 SaturnV ................................... 21 I . S-IC Stage .............................. 21 A . Evaluation of Commercial Adhesives .......... 21 1. Investigation of Polyurethane Adhesives ..... 21 2 . Investigation of Polyurethane - Epoxy Blends ...................... 23 B . Development and Evaluation of Potting Compounds and C onf or ma1 Coatings ........... 23 1. Development of Epoxysiloxane Embedment Materials ................ 23 2 . Development of Conformal Coating Materials ......................... 24 C . Investigation of Spring Failures in Hydraulic Engine Actuators .............. 24 I1 . Contract Research ......................... 25 A. Polymer Research. Development. and Testing ... 25 B . Development of Cryogenic and High Temperature Insulation Material ............ 25 C . Analytical Methods Development ............. 25 D . Assessment and Evaluation of Blast Hazards .... 25 E . Nondestructive Testing Techniques ........... 25 111. S-11 Stage ............................... 26 A . Investigation of Fracture Toughness of 20 14-T6 Aluminum Alloy Weldments ........ 26 B . Evaluation of Spray Foams for Applicability as S-I1 Liquid Hydrogen Tank Insulation ....... 26 C . Evaluation of Nondestructive Techniques for Examining Composite Materials .......... 26 D . Investigation of Failure of S-I1 Interstage Fasteners ........................... 27 E . S-I1 Stage. Project Management. Materials ..... 27 1. Investigation of Applicability of MIG Pulsed-Arc Welding Process for Cylinder - Bulkhead Joints ............. 27 2 . Spray Foam Insulation Test Tank ......... 27 TABLE OF CONTENTS (Continued) Page 3. Testing and Evaluation of 1. 6-Inch Insulation ......................... 28 4 . Investigation of Weld Cracks in S-11-7 ...... 28 IV . S-IVB Stage .............................. 29 A . Study of Materials Problems Attendant to the S-IVB Workshop Program ............. 29 1. Study of Flammability of Materials ........ 29 2 . Study of the Outgassing Characteristics of Orbital Workshop Materials ........... 30 B . Investigation of Passive Thermal Control Coating . 30 C . S-IVB Stage. Project Management. Materials .... 30 1. Thermal Insulation of Flutter Kits onS-IVB-501and-503 ................ 30 2 . Defective Liquid Hydrogen Tank Insulation ... 31 3 . Stress Corrosion .................... 31 4 . Orbital Workshop .................... 31 a . Emissivity of Workshop Interior ....... 31 b . Fire Retardant Liner of Aluminum Foil . 3 1 c . Storage ....................... 32 d . Long-Term Storage of Materials in Earth Orbit (ECP-247) ............ 32 e . Study of Insulation of Hydrogen Tank and Micrometeoroid Bumper ......... 32 f . Study of Outgassing of Liquid Hydrogen Tank Insulation ........... 32 V . F-1 Engine .............................. 33 Investigation of Insulations for Use on F - 1 Engine Components ................... 33 VI . Instrument Unit ........................... 34 A . Study of Possible Gas Evolution in the Environmental Control System .............. 34 B . Evaluation of Diffusion-B onded Tube Joints for Use in the Environmental Control System of the Instrument Unit ........................ 34 VII . Apollo Telescope Mount (ATM) ................. 34 A . Investigation of Contamination and Contamination Sources ................... 34 TABLE OF CONTENTS (Continued) Page B . Investigation of the Cleanliness of the Space Environment Simulation Chamber ........ 35 C . Evaluation of Direct Current Motors for Use on ATM ........................ 36 1. Brushes .......................... 36 2. Potting Compound .................... 36 3. Magnet Corrosion Protection ............ 36 D. Investigation of ATM Bearing Lubrication ...... 36 E . Thermal Control Materials for the ATM ........ 37 VIII . Nuclear Ground Test Module .................. 37 Advanced Research and Technology ................. 40 I . Contract Research ......................... 40 A . Polymer Development and Characterization ..... 41 B . Adhesive Development ................... 41 C . Developmental Welding ................... 41 D . Thermal Control Coatings ................. 41 E . Physical and Mechanical Metallurgy .......... 41 F . Composite Material Development and Testing .... 41 G . Lubricants and Lubricity ................. 41 H. CorrosioninAluminumandSteel ............ 41 I . Explosion Hazards and Sensitivity of Fuels ...... 41 J . Synergistic Effects of Nuclear Radiation. Vacuum. and Temperature on Materials .............. 41 K . Instrument Development .................. 42 I1 . General - In-House ........................ 42 A . Development of High Temperature Resistant Polymers ............................ 42 B . Development and Characterization of Phosphonitrilic Polymers ................ 43 C . Investigation of Metallic Composites .......... 44 D. Investigation of Stress Corrosion Characteristics of Various Alloys ............ 45 E . Investigation of Organic Semi-conductor Materials ............................ 46 F . Development and Evaluation of Light Weight Ceramic Foams ........................ 46 G . Evaluation of the "Alstan 70" Process ......... 47 H . Investigation of Thin Film Dielectrics ......... 47 TABLE OF CONTENTS (Continued) Page I . Development and Evaluation of Nondestructive Techniques for Assessing Stress Corrosion Damage ............................. 48 J . Documentation Review. ................... 48 K . Literature Survey ...................... 49 Monthly Production Report ...................... 50