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SPAC'E FABRICATION DEMONSTRATION SYSTEM

QUARTERLY PROGRESS REPORT NO. 10

September lo, 1979 - December 15, 1979

NASA-M.SFC Contract MD3 8-32472!r,

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(6ASA-Cit-101704) SPACE rABHICATION N+31-21U95

DEMUNSTRATION SYSTEM Q g cu terly PioyrtssReport, 16 Sep. - 15 Dec. 1979 (Grumman

A:.•rospace Corp.) 11 p HC AOt/NF A01 130CSCL 21A GJ112

2121130

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00ORP MAT 50NmE1TIFwsOt.11^W vOlr^t 177Mi —1

Contract SO-3247$"Mary 3, 1980

National Aeronautics and Space MinistrationGeorge C. Marshall Space Flight CenterMarshall Space Flight hater, Alaboma 338612

Attention. Ericb E. Sngler, CMcode 8P613 SLag. 4610

Subject: SPA FAHRICATmN D- -- -BTRATMN S7BT1K -Quarterly Progress Report No. 20September 16, 1979 - December 15, 1979

References: (a) SFDS Monthly Progress Letter No. 21September 16, 1979 - October 15, 1979

(b) SFDS Monthly Progress Letter No. 22October 16, 1979 - November 15, 1979

Enclosure: (1) SFAS Induction Fastening

During this.reporting period, the Space FabricationDemonstration System (SFDS) program activity included:

o Composite Beam Cap Fabricator - This development effort,conducted at Goldsworthy Engineering Incorporated wascompleted within cost and close to the objectives ofthe abbreviated goals agreed to July 18, 1979 at NASk4WC.The final review meeting was held October 24, 1979. Detailassociated with the above is detailed in previous monthlyand quarterly reports including references (a) and (b).The final report submitted November 30, 1979.

o Flight Experiment Analysis - This effort directed atdesign and analysis of flight weight primary andsecondary beam builder structure has proceeded accordingto plan. The effort has currently been curtailed due tofunding limitations imposed with the authority to proceedAugust 1, 1979. Mechanical and structural preliminary

ANMOM

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VC04FMI-Twol

design layouts and the subsystem requirementsare being completed. Details of these items have beenreported in references (a) and (b). Without addition lfad ing, this effort will be terminated during the actreporting period.

o Induction Fastening - These efforts implemented during thisquarterly reporting period have proceeded satisfactorilywithin cost and schedule. Details are included in references(a) and (b) as well as enclosure (1).

The periodic telecom and meeting& between cognisant programpersonnel have continued to assist in timely problea definition,discussion and resolution. These have definitely been instrumentalin keeping the program on target in achieving process developmentand general beam builder objectives within cost.

DISCUSSMN

WBS 1.1 PROMAK VANA4EtM

Figure .1 remains unchanged from that reported in reference (b).We continue to wait for NASA-MFC direction on final process formingand fastening demonstrations, and structural testing of these oracceptance of the final report on the Composite Beam Cap Fabricatordevelopment effort submitted November 30, 1979.

Figure 2 shows that the efforts associated with the FlightExperiment Analysis is on schedule. As noted above, we havecurtailed this effort at this point and will not proceed beyondthe completion of the preliminary mechanical and structural designlayouts and subsystems requirements document. Any further effortwill be held in abeyance until additional funding is releasedtoward this contract effort. Consequently, the effort completiondate will also slip on a month by month basis.

Figure 3 shows that theeffort is on schedule. Thisand enclosure (1), is within

effort planningeffort, detailedtarget cost.

for the Induction Fastening in references (a) and (b)

PASS._

tSS4WD&LRDD1

WBO 1.2 DEBIW AND DEV=PNMT

The Goldsworthy effort was completed during this quarterlyperiod and will no longer be reported on in this lint item.

The design and analysis effort associated with the Flightexperiment Analysis was reported on during this quarter inreference (a) and (b). Only the preliminary design UWout effortand subsystem requirements document are continuing as required.

The design of the test apparatus associated with theInduction Fastening effort was completed during this quarter andreported in references (a) and (b). No further design or developaenteffort is required at this time. Therefore, this effort will nolonger be reported under this line ites.

WBS 1.3 FAMICATIOe AMD ASS==

The Goldsworthy effort was completed during this quarterlyperiod. it will no longer be reported upon under this line item.

There is no effort associated with the Flight ExperimentAnalysis wader this line item.

The test apparatus associated with the Induction Fasteningk t effort was completed during this quarter and reported upon in

reference (b). Therefore, it will no longer be reported uponunder this line item.

WBS 1.4 TESTS

The Goldsworthy effort was completed during this quarterand reported on in references (a) and (b). This effort will noLonger be reported under this line item.

There is no testing associated with the Flight ExperimentAnalysis under this line item.

Testing associated with Induction Fastening has been reportedin reference (b) during this quarter. Test efforts are continuingand should be completed during the next reporting period. Additionaldata is discussed in enclosure (1).•

GR MMAN PAGE 4^CSS-SFDS-LRO01

CONCLUSIONS

Efforts at Goldsworthy Engineering Incorporated have beencompleted. We wait for further direction on the incompleteitems noted above and in reference (b) or acceptance of the finalreport as noted above.

The Flight Experiment Analysis effort has proceeded satisfact-orily, but will remain curtailed until further funding is madeavailable to complete the effort.

The Induction Fastening effort 1s proceeding satisfactorilyand remains within cost and schedule ::onstraints.

RECOMMENDATION

NASA MSFC respond to request for direction, acceptance and/orconcurrence with the program observations made above in connectionwith:

• Composite Beam Cap Fabricator development effort• Flight Experiment Analysis preliminary design effort

Continued close surveillance of all program elements by allcognizant program and project personnel.

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

Very truly yours,

GRUMMAN AEROSPACE-CORPORATION

jk6.

WKK : kf

cc: Distribution: NASA-MSFCNASA-LaRCGruosna.n

Goldsworthy

Walter K. MuenchSF'DS Program Manager

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DISTRIBUTION: NASA-MSFC

CODE COPIES

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Hill N. Walker 4711

James H. Ehl 4711

Charles N. Irvine 4711

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Erich E. Engler 4610

D. Miller, Grumman,Navy Contracts Plt. 30

DISTRIBUTION: NASA-LaRC

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ENCT;ZURE (1)

INDUCTION FASTENING

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IINDUC':ION FASTENING OF GRAPHITE: REINFORCED COMPOSITES

Test of the IARC prototype induction welder is continuing in an instru-

a.mented test stand. This test stand is comprised of a Dumore drill press (air

over oil feed for variable applied loads) and a dynamometer to measure actual

welding loads. The dynamometer output signal is fed to a Brush strip chart

recorder for permanent record. The supplied L4RC induction welder has typical

operating characteristics of 120 K-Hertz and 60 watts power.

Continued testing has shown that the inter ace screening must be well

impregnated with resin to ensure proper flow when bonding graphite/acrylic lap

shear samples. Specimens have also been prepared from 0.030-inch thick graphite/

polyethersulfone for future induction fastening evaluation. These samples will

differ from the graphite/acrylic in that polyethersulfone film will be ustd

in conjunction with steel screening Lt the lap shear interface.

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