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(NASA-CR-161705) SPACE FARRICATIon - 981-21t^93ulanwoSTBATION S?STan Qear"way progressB-Nport, 16 Sep. - 15 Dec. 1978 (6rayaAtirospace Corp.) 20 p H . AO2/al AO1 Rwl.as

CSCL 22A x3112 21128

SPACE FASRIMTION DE ONSTFLATIO SYSTEN

QUA.rGEMY PROGPI S REPOPT NO. 5

September-16, 1978 - December 15, 1978

NASA-MF-C Contract NAS8-324*72

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QUARTERLY PROGRESS REPOP,T No. 6

' September 26, 1978 - December 15, 1978

NASA-Wan Contract XAS8-32472

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&aT1-+PAG$.N$WrCrAK1^,714

NSS-SF1)S-LR069Contract NAS8-32472

December 30, 1978

National Aeronautics and Space AdministrationGeorge C. Marshall Space Flight CenterMarshall Space Flight Center, Alabama 35812

Attention: Erich E. Engler, CORCode EP-13 Bldg. 4610

Subject: SPACE FABRICATION DEMONSTRATION SYSTEM - QuarterlyProgress Report No. 6, September 16, 1978 -Deeember 15, 1978

Enclosures: (1) SFDS Engineering Support at NASA-MS:(1.(2) Goldsworthy Engineering Incorporated, Monthly

Progress Letter No. 2

References: ( a) SFDS Monthly Progress Letter No. 13, September 16-October 15, 1978

(b) SFDS Monthly Progress Letter No. 14, October 16-November 15, 1978

SUh4•!AAY

This Space Fabrication Demonstration System program quarterlyreporting period witnessed the completion of the aluminum beam buildereffort at Gr=, man, Bethpage, Pier York under the base contract and theinitiation of continued contract efforts in two distinct areas, i.e.-

o Engineering surport of the aluminum beam builder at ITASA-USFC,see enclosure (1)

o Design development of a composite beam cap fabricator, seeenclosure (2)

Both areas have proceeded satisfactorily during this reportingperiod, though the beau cap flange rippling problem has reappearedin the third rolling mill after its installation in the beam builder.Tbis problem will . be subject to intensive investigation and resolutionduring the next monthly reporting period.

S.

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GRUMMAN Petit 9A58-UDS-LRO69

The bi-weekly telcon review and the periodic meetings of alla ssociated.program manement personnel at NASA-P3FC, Gnman andGoldsworthy, referencesta), has been of assistance in keeping allinformed on program progress, problems and their resolution. Atthis time we see no difficulties in meeting air program goals andobjectives during the next reporting period.

DISCUSSION

WBS 1.1 PROGRAM MANAGEMENT

Figure 1, SFW Master Program Schedule which outlines progressmade with regard to the aluminum beam builder and Figure 2, SFDSComposite Beam Cap Fabricator Schedule show program efforts to date.The former shags that while we are on schedule with our hardwareeffort, which is described in more detail below, we are behind sched-ule in supplying a final report on the base contract effort. Thisreport is being prepared and will be submitted during the next report-ing period. The latter schedule shows excellent progress being madein the com_mosite program, described in more detail below.

WBS 1.2 DESIGN AND DEJELCPINIENT

The composite beam cap fabricator orientation meeting was heldat Goldsworthy Engineering, Incorporated on December 7, 1978. NASA

-MSFC and Gruen program management representatives were briefed byGoldsworthy on their progress to date (they had been under contractsix weeks at the time) and their project plan. Included in theirinformal working presentation were the following:

• Pultrusion Dies - they have completed the design for processingboth open and closed beam caps of thermoset materials. Theyplan to modify these dies experimentally for thermoplasticmaterial processing. The prepreg tape layup mandrel designfor both cap configurations and both materials was also shown.These, the dies and the mandrel have been ordered.

• 'Pultrusion Machine - they are setting up an experimentalmachine to perform the process development effort associatedwith this project. It was shown to us during a tour of theirfacility.

133q̂UU MAN Paat 3_NSS -SrM -LRO69

o •Materials - they have gone through an extensive review ofavailable graphite reinforced thermoset and thermoplasticmaterials with several suppliers, reference (b), and are inthe process of making their final selection for demobstrationpurposes based upon price and availability. Review of andavailability of those not selected will continue as the processdevelopment efforts proceed. It should be noted that effortsassociated with fberaas,at process development will precedethose for thermoplastics, the reverse of that shown in figure 2,in order to min3mtze pultrusion die expense.

WBS 1.3 FABRICATION AND ASSE16 Y,-

The lager right alumim m beam cap roll forming mill was deliveredto NASA-^MFC and instal!!!- in the beam builder on December 8, 1978.The beam }+wilder was 1 ,.c ght to full operational status and beams ofone to six bay lengths were prcduced to demonstrate full system capa-bility. The problem. encountered with the lower right mill while thebeam builder was still at Grumman, that of cap flange waviness, re-appeared. A Yoder Company field service represe_3tative was called into adjust the machine. He had moderate success. See enclosure (1)for more detail on this problem as well as beam builder operation atNASA-YZFC in general. Further testing and evaluation of the lowerright mill during the next reporting period is planned in order tosolve the waviness problem.

QQP= IO

With the exception of the persistant flange waviness problm theSM program is progressing satisfactorily within cost and schedule.Resolution of this outstanding problem is forthcoming.

RECON 7-TDATION

Continued close surveillance of all program elements by ?^LQ.SA-MSFC, Grumman and Goldsworthy program management personnel to assuresuccess.

Should you have any question with regard to the above, the enclosedor the program in general, please contact us.

Very truly yours,

GRUI,YWI AEROSPACE CORPORATION

r Walter K. MfuenchSFDS Program h:azegerC-e

WM/drcc: Pistributicn: NASA-.C-_--C, Grumman, Goldsworthy _

4GRUMMAN PA06

NSS-SFDS-LRO69

DISTRIBUTION: NASA-MSFC

CODE COPIES ATTENTION BLDG.

EH 43 1 Hill M. Walker 4711

EH 44 1 James H. Ehl 4711

EH 44 1 Charles N. Irvine 4711

EP 12 1 W. Prasthofer 4610EP 13 11 Erich E. Engler 4610

_EM 34-13 1

AS 24D 3

AP 25G 1

AT Ol 1

NAVPRO 1 D. Miller, Grumman,Navy Contracts Plt. 30

DISTRIBUTION: GRLN11L%ialT MAIL STOP

T. A. Guarino 1 Bll-25

D. A. Imgrsm 1 A13-25

R. W. Jonnson 1 A13-25

A. Alberi 1 A09-25

J. Huber 2 A04-12

P. Jacknis 1 CO3-25

L. Junen 1 ---

A. Wey'nreter 1 A01-10

H. Morfin 1 A09-25

W. Muench 4 A09-25

R. Panza 2 ---

L. Rooney 1 A02-25

DISTRIBMCN: GOLDSWOR1TIrl

W. E. Haynes 2

SFDS PIASTER PRGGRANI SCHEDULE

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MONTNLY)u MORTSI 1 1 13 4=A 9130 7/29120

QUARTERLY REPORTS 013 4130

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ENCLOSURE (1)

SETS LliGrAMRMG SUIPMRT

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WBS 1.2 DESIGN ALM DEVTWPME11T

A competitive award to develop a composite beam cap fabricator wasgiven to Goldsworthy Engineering I:rcorporated. A program orientationmeeting was held at Goldsworthy arl the following progress was reported.Suppliers of both thermoset and thermoplastic candidate laminates withgraphite reinforcement have been surveyed and final material selectionsare in progress. The final la►ninate layup is anticipated to be a 0',345% 0' orientation. The tool designs for fabricating both open andclosed sections (as shown in Figure 1) have been completed and fabricationis underway.

WBS 1.3 FABRICATIO:i ACID ASSDIBLY

Disassembly and shipment of the aluminum bean builder less the lowerright rolling mill was accomplished. The maciaine was delivered to MMM3FC and reassembled by MPC personnel under the direction of a team oftwo Grumman engineers. All installed subsystems,,were runctionally checkedout and found to be operating satisfactorily.

The lower right altunintun beam cap forming mill removed from the beenbuilder was shipped to the Yoder Company for modification and/or adjustmentto eliminate flange rippling. At the cimpleation of work at Yoder, the millwas sent to rSrC and installed in the beam builder. Retesting of this millin the beam builder showed flange ripples still apparent. Interchangingthe tooling of the last three stations of this mill with anon-affected millshowed the problem to follow the tooling. Returning the tooling to theiroriginal positions it was found that cap sections of minimal flange wavinesscould be produced from the left mill through increasing Fart deformationthroughass number one, and using oversize width material (6.375-inch in lieuof 6.360. A final deteirdnation on the apparent tooling discrepancy willbe undertaken.

Once the final Yoder mill was installed, all subsystems were operationallychecked out threuih the fabrication of several cne-bay beaM3 and one, six-baybeam.

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ENCLOSURE (2)

GOLDSI•IORTF.Y MGME- E.R."'IG ZICORDOP,aTED-

MDVM'l PROGRESS LETTZID NO. 2

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DESIGNERS AND -i MANUFACTURERS OF

ADVANCED PRODUCTIONDEVELOPMENT OF A COMPOSITE CAP

SYSTEMS FOR COMPOSITES FORMING MACHIN F0!(. SPACE CONSTRUCTION

Monthly Progress Letter

No. 2

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W. E. HAYNES

Development of a Composite Cap

Forming Machine for

Space Construction

Monthly Progress Letter No. 2

Gtumman Purchase Order No.

14-14284

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23930 MADISON STREET • TORRANCE. CA. • 90505 PHONE (213) 373.037

December 20, 1978

Grumman Aerospace Corp.Mail Stop A 09-25Bethpage, N. Y. 11714•

Attention: Mr. Walter K. Muench, Program Mgr.

Subject: Composite Cap Forming Machine - Monthly ProgresP Letter No. 2Reporting period 20 November thru 20 December 1978.

Enclosures: I Master Schedule StatusII Materials S-catusIII Program Review Agenda and Attendees

Summary:

Activities during the current reporting period centered around theselection and ordering of materials (ref. Enclosure II) and the firstjoint NASA/GAC review at GEI, which occurred on 7 December, 1978.(ref. Enclosure III).

Results of the NASA/GAC review were favorable and all participantsexpressed satisfaction with the start-up efforts and program objectives.

Mr. Muench indicated that current planning is for the next review tooccur at GEI during the 4th week of February, 1979.

Discussion:

All activities were completed on or ahead of schedule during thereporting period (ref. Enclosure I).

WBS 1.1.1.1.0, 1.1.1.2.0 - CompletedWBS 1.1.1.3.0 Select and order materials

Selection process continuing; ordering begun (ref. Enclosure II)This activity will continue until satisfactory quantities of allselected candidate naterials are on hand.

GAC provided GEI with background information on a list of materialsin response to GEI request.

DESIGNERS AND MANUFACTURERS OF ADVANCED PRODUCTION SYSTEMS FOR COMPOSITES

2-3

Grumman Aerospace CorpMonthly Progress Letter No. 2December 20, 1978 Page 2

WBS 1.1.2.1.1. Set up Tool -IngWood mandrel parts (pre-prep lay-up tooling) have beenreceived. Metal tension members, heating elementsand thermocouples delivery awaited shortly. Diesstill expected end of January 1979.

WBS 1.1.3.0.1 Design ReviewAccomplished on 7 December 1978 (ref. Enclosure III)Next review expected in February, 1979.

L Conclusions: r -

The Composite Cap Development Program progressed satisfactorily duringthe reporting period.

Recommendations:

As recommended by Mr. Muench, GEI will coordinate the next review withon-going fabrication activities to provide NASA and GAC the opportunityto see the process in action.

I will take this opportunity to wish all of you a very merry holidayseason.

Respectfully,

William E. HaynesGoldswothy Engineering, Inc.Program Manager

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DISTRIBUTION:

GAC

Mr. Walter Muench'- Original plus 1 copy

Mr. Robert Panza - 1 copy

GEI

W. Brandt Goldsworthy - 1 copy

G.W. Ewald - 1 copy

R. Sjostedt - l.copy

W. Haynes - 1 copy

File - 1 copy

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2-6

Enclosure I

Composite Cap Development Program

Master Schedule Status a/o 20 Dec. 78

ACTIVITY OCT. NOV. DEC. JAN.— Go

Ahead

Progress Report

Design Dies (2)

71 4-n--

Order Dies

Receive Dies

Design Fittings & Prep.Guidance Tooling

Select & Order Materials

Feb. Prep. Tooling ..

Enclosure II

WBS 1.1.1.3.0 Select & Order Materials

The following describes activities to the dateof this report.

A. Materials ordered for January '79 delivery:

1) Two vinyl ester resin pre-preg tapes - 10 lbs. total

2) One high temperature polyester - 5 lbs. total

3) All above purchased from Celanese Research Lab.Summit, N.J. Total Cost: $500.

B. Materials ordered for late January delivery:

1) 15$ polyimide pre-preg from Iiexcell Corp.Dublin, Ca. Total cost: $1470.

7 December 1978

First NASA/GAC Program Review of the Composite Beam Cap Project

at GEI.

09:30 Convene

Opening Statement - Introductions Johnson/Haynes

09:40 Status Review:

Dies ....................................Haynes

Materials ...............................Sjostedt

Fabrication of Caps .....................Sjostedt

Scheduled vs Actual ... ..................Haynes

Summary .................................Haynes

10:40 Technical Discussion ....................All

Background information on pultrusion

(Film)

Application to composite beam cap

11:40 Tour of GEI facilities ..................All

. . I

Z-S

COMPOSITE BEAM CAP PROJECT

PARTICIPANTS

NASA Marshall Space Flight Center

Mr. Clyde Nevins

Mr. Hugh Dudley

GRUM.'KAN Aerospace Corporation

Dr. Roger Johnson

Mr. Walter K. Muench

Mr. P. Layton

Mr. L. Poveromo

Mr. R. Panza

Mr. Warren Marx

GOLDSIIORTHY Engineering Inc.

Mr. W. Brandt Goldsworthy

Mr. W. E. Haynes

Mr. Rob Sjostedt

Mr. David Beck

Z-9

1-

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