Long range aerospace manufacturing developments. Volume III. Surface conditioning and treatment, non-metallic fabrication, and inspection & evaluation techniques. Report (1968)

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66 TITLE POLYTBTRAFLUOROETHYLENE COATING SHEET METAL CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT A low f r i c t i o n coating of polytetrafluoroethylene i s to be applied to sheet metal b a l l -dv«^ !̂r BOcketB These parts are to be used i n the appendage j o i n t s of extra vehicular advanced space s u i t s AARP REFERENCES E ChnrH B Chart . 172a PSFVPS Charts APPLICABLE PROCESS Code FUSION COATING 7 05 04 Polytetrafluoroethylene coated metal parts are being produced by many manufacturers today The process consists of a preliminary surface treatment which includes a primer for adhesion the application of one or more coatings of polytetrafluoroethylene dispersion followed by fusion of the coating at 700 to 750 F The adhesion and general coating q u a l i t y obtainable are judged adequate IiH>roved low f r i c t i o n chemically stable s t r a t i f i e d non s t i c k and se l f l u b r i c a t i n g coatinps are c u r r e n t l y available on an experimental basis One of these Teflon S i s based i n a special fluorocarbon r e s i n and a 450 F heat curing r e s i n Wear resistance I s g r e a t l y liiq>roved I t can be used without a primer and can be applied by a v a r i e t y of conventional methods Additional developments can be anticipated by 1970 Control of dimensions of the coated part may prove to be d i f f i c u l t No manufacturing development program appears necessary CRITICAL PROBLEMS NONE ALTERNATE PROCESSES [NONE Code

67- TITLE HARD FACING OF ALLOY STEEL CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT A hard wear r e s i s t a n t coating s h a l l be applied to a l l o y steel components to be used on an exploratory traverser (wheel) f o r a lunar transport vehicle The coating s h a l l be adequately bonded to withstand the temperature extremes of the lunar day and night and sh a l l r e s i s t abrasion by the lunar surface The components to be coated are 1/2 1 diameter h a l f - b a l l s and 1/4 1 diameter teeth mechanically fastened to pads AARP REFERENCES E rhnrt< B Chort. 169a PAFVPS Chort, APPLICABLE PROCESS Code FLAME SPRAYING 7 14 01 STATE O F THE ART ASSESSMENT The flame spraying process is w e l l developed and understood p a r t i c u l a r l y w i t h respect t o applying wear re s i s t a n t coatinga (e g UC Ni Si B or Ni-Cr Si B) to simple regular shapes of the type involved In the requirement Several companies provide flame spraying on a commercial basis Because the coating substrate bond is p r i m a r i l y mechanical i t is important to prepare the substrate surface to provide maximum int e r l o c k i n g w i t h the coating Also due to the temperature extremes of the lunar environment i t may be necessary to gradate the coating chemistry to provide thermal stress accommodation Off the shelf processing c a p a b i l i t y exists i n both areas No manufacturing development program recommended REFERENCES J A H S Metals Handbook Mock Flame Sprayed Coatings Materials i n Design Engineering pp 89 104 (Feb 66) Ingham and A P Shepard Flame Spray Handbook Vols I I & I I I (1964 1965) pp 507 515 American Society for Metals (1964) Eighth Edition Vol I I CRITICAL PROBLEMS NONE ALTERNATE PROCESSES NONE Code

68 I TITLE COATING OF GRAPHITE FOR OXIDATION PROTECTION CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT , Thin (0 001-0 005 ) uniform defect-free coatings s h a l l be applied to graphite componentsj to be used as noses leading edges heat shields and bearings i n hypersonic cruise hypersonic boost g l i d e and l i f t entry vehicles The coated components i n general s h a l l have an emittance of 0 7 or higher and s h a l l perform w i t h high r e l i a b i l i t y during exposure to high v e l o c i t y a i r to 5000 F and 10'^ Torr - 560 psl f o r cumulative times up to 5 br Involving up to 10 cycles a t 0 5-X hr/cycle I n requirement B126a the coating s h a l l have a c o e f f i c i e n t of f r i c t i o n less than 0 1 at -250 to 3000 F and the surface properties must be maintained f o r 5 cycles Hemispheres and cones have a diameter up to 24 and hemicylinders have a length up to 6 f t AARP REFERENCES 71 100 279 B Chart . 28a. b. 29a. 39b. 40b. 121c. 126a P&FVPS Charts APPLICABLE PROCESS Code PACK CEMENTATION CHEMICAL VAPOR DEPOSITION 7 10 02 STATE-OF THE ART ASSESSMENT The only coating material available now and i n the foreseeable f u t u r e w i t h any p r a c t i c a l u t i l i t y vtth respect to the manufacturing requirement l a SiC The pack cementation chemical vapor deposition process f o r d i f f u s i n g s i l i c o n i n t o the surface of graphite to form the SiC coating i s w e l l developed and understood I n practice the parts to be coated are packed i n a mixture of elemental s i l i c o n and an i n e r t f i l l e r such as TiC or SiC inside a graphite susceptor which i s used f o r induction heating A pack temperature of 3300-3600 F i s maintained f o r 4-8 brs a f t e r which the pack i s cooled disassembled and the coated parts removed Maximum c y c l i c performance I n the AARP applications can be expected to be 10 hrs at 3000 F and a few minutes at 3300 F Coated graphite leading edge segments were successfully f l i g h t tested on ASSET At the high temperature (3000-5000 F) where i t i s most desirable to use graphite there are no p r a c t i c a l coating materials available The inherent oxidation rates of available ma , t e r l a l s coupled w i t h coating-substrate i n t e r d l f f u s i o n rates make nnst of the target AARP time-| temperature requirements unattainable I r i d i u m has been shown i n simple lab tests to provide oxidation protection to graphite at 3600 F However the r e l a t i v e l y high oxidation rate of i r i d i u m (5 mils/hr) under the t e s t condition^v coupled w i t h the short supply and high cost • (about $12S/ft^/mll) l i m i t I t s use to highly c r i t i c a l problem areas The SiC coating would not 1 meet the low c o e f f i c i e n t of f r i c t i o n requirement at elevated temperatures (<1800 P) i f oxidationf products (3102) ere present No coating f o r achieving the low f r i c t i o n c o e f f i c i e n t i s known Although not encompassed by the manufacturing requirement f o r a t h i n coating i t i s ap- propriate to point out that a f u l l scale graphite nose cap was designed b u i l t and successfully q u a l i f i e d bv ground teats f o r the X 20 vehicle The environment included heat fluxes up to 150 BTUs/ft^/sec r e s u l t i n g i n stagnation temperatures near 4000 F I n t h i s design the graphite was given a s i l i c o n carbide coating and then was thermally insulated from the 4000 F environ- ment by t h i c k t i l e s of zirconla Also along t h i s l i n e the t h i c k e r oxide coatings applied by troweling and made mechanically adherent by grooves dovetails etc cut i n t o the graphite surface or by the use of a porous graphite surface could be useful to 5000 F I n t h i s case much of the work discussed i n Chart 516 would apply Continued on next page ALTERNATE PROCESSES VAPOR STREAMING Code 7 10 05

69 STATE-OF-THE-ART ASSESSMENT continued NO S^iiL Materials are not known and none are expected to be found w i t h s u f f i c i e n t l y low d i f f u s i o n rates to provide the required protection I n the form of t h i n ( t o 0 005 ) coatings The 1970 processing st a t e ot the a r t f o r the SIC coating w i l l be adequate f o r the r e - quirement Insofar as the requirement can be f u l f i l l e d w i t h t h i s coating No manufacturing development program i s recomaended Information generated by the programs proposed i n Charts 516 and 521 on coatings f o r r e f r a c t o r y alloys w i l l be useful f o r optimieing the SIC coating process through normal sta t e of the a r t advances REFERENCES 1 USAF Report AFML-TR-6S-29 pp 522-533 on High Temperature Oxidation Resistant Coatings f o r Graphite 2 USAF Contract AF 33(6S7)-11253 High Temperature Protective Coatings f o r Graphite Summary Reports ML-TDR-64-173 Parts I XI and I I I (June 1964 Oct 1964 Oct 1965) also subsequent progress reports 3 USAF Contract AF 33(616)-8106 ASSET Fi n a l Technical Reports AFFDL-TR-65-31 Vols I I I V I I V I I I , X (1965) 4 USAF Contract AF 33(615)-1624 Advances I n the Materials Technology Resulting from the X-20 Program AFML-TR-64-396 (March 1965)

70 TITLE COATING OF WIRE OR FIBERGLASS ROVING FOR FABRICATION OF A CABLE USEFUL IN SPACE CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT A tetrafluoroethylene or equivalent non v o l a t i l e l u b r i c a t i n g coating Is to be applied to wire The wire is to be used to manufacture a cable capable of operating i n the space environment without g a l l i n g or cold welding Cable i s to be rf>r^lpd in n n H rtttt a n n i - n v 4 m a f-A 1 v 100 times = ° '-°"'<= <-apauie ux uperating i n cne space Cable i s to be reeled i n and out approximately Fiberglass i s to be used as the strength member of a p l a s t i c composite from which a cable up to 1 diameter x 100 long w i l l be manufactured The cable must operate i n a lunar environment have low reel out f r i c t i o n and high strength Near complete encapsulation of the i n d i v i d u a l glass filaments i s essential to meet product s p e c i f i c a t i o n AARP REFERENCES E C h n rl< B C h a r l < 167 173 P&FVPS Charts APPLICABLE PROCESS FOLLOWED BY SINTERING t l o n of a polyurethane FLOW COAT WITH TETRAFLUOROETHYLENE DISPERSION Impregnation with l i q u i d epoxy followed by appllca Jacket by melt extrusion using a cross head die Code 7 05 04 Wire is frequently coated commercially for various purposes ethylene coated wire presents no serious problem Manufacturing t e t r a f l u o r o Combining fiberglass w i t h rubber and p l a s t i c has been a subject of considerable research development and production Interest f o r 25 years As a r e s u l t much is known and many products are on the market including a cable material believed to meet the specified requirements (Gastran Cable Packard E l e c t r i c Division General Motors Corp ) Using the t e x t i l e unit for comparing strength on a weight basis fiberglass is available at 4 5 to 6 5 steel at 2 and nylon polyester or Nomex at 3 to 7 depending upon temperature (77 F to 350 F) The most c r i t i c a l problem is that of obtaining adequate penetration of a p l a s t i c to encapsulate each fib e r g l a s s filament i n order to prevent s e l f abrasion and Improve fatigue resistance The r e s u l t i n g product has as i t s p r i n c i p a l v i r t u e s high modulus low growth under load and high strength at 300 F I f high modulus and low growth are not essential rope made from organic t e x t i l e s should be considered fo t h i s a p p l i c a t i o n No manufacturing development program is required CRITICAL PROBLEMS NONE ALTERNATE PROCESSES COAT WIRE WITH DISPERSION OF MOLYBDENUM DISULFIDE IN OIL Code 7 11 02

71 TITLE LUBRICATION OF ANNULAR BEARING FOR A ROTATING SPACE STATION CHART N O PRIORITY RELATED CAMR CHARTS 70 3 MANUFACTURING REQUIREMENT A dry f i l m lubricant such as MoS. or tetrafluoroethylene must be applied to large (2 f t diameter) hub bearings for a r o t a t i n g space s t a t i o n Roller bearings races retainers and I d l e r wheels w i l l probably be Involved The lubricant must be resist a n t to the space environment and useful at 175 to 150 F I t must have a low s t a r t i n g f r i c t i o n low b r l t t l e n e s s and be capable of maintaining c o n c e n t r i c i t y a f t e r shock loads An alternate l u b r i c a t i o n method Involves the a p p l i c a t i o n of o i l or grease to the hub bearing Additional o i l or grease w i l l be contained i n a reservoir for automatic replenishment The l u b r i c a n t must have a low sublimation rate and r e s i s t r a d i a t i o n from nearby nuclear power generators AARP REFERENCES F rhnrtc B Chort, 165a, b PAFVPS Chnrt. APPLICABLE PROCESS SPRAY APPLICATION OF DRY FIIM LUBRICANT or CONVENTIONAL METHODS OF APPLYING OIL OR GREASE TO A BEARING Code 7 05 OA STATE O F THE ART ASSESSMENT Present day dry f i l m lubricants such as tetrafluoroethylene appear to be sa t i s f a c t o r y for t h i s a p p l i c a t i o n Tetrafluoroethylene and molybdenum d i s u l f i d e type dry f i l m lubricants are r o u t i n e l y applied to a v a r i e t y of bearing surfaces w i t h high process r e l i a b i l i t y and effectiveness I f the shock loads are very high g a l l i n g may be a problem i n which case materials development may be required O i l or grease can re a d i l y be applied to bearing surfaces by conventional pressure feed methods The only problem is the a v a i l a b i l i t y of a grease or o i l type lubricant w i t h a s u f f i c i e n t l y low v o l a t i l i t y rate Replenishment may present design problems No manufacturing problems are anticipated Development of an improved non-destructive t e s t c a p a b i l i t y for dry f i l m lubricants Is recommended however as outlined on the following page CRITICAL PROBLEMS NONE ALTERNATE PROCESSES NONE Code

CHART 72 INSPECTION TECHNIQUES SUPPLEMEWTAL RECOMMENDATIONS INSPECTION REQUIREMEWr End Item Inspection of dry f i l m lubricant on hub of large bearings for r o t a t i n g space s t a t i o n OBJECTIVE To develop Inspection techniques to measure (a) s o l i d dry f i l m l u b r i c a n t thickness (b) uniformity of coating thickness and (c) adherence or tenacity of the f i l m The l u b r i c a t i n g and load bearing c h a r a c t e r i s t i c s of the dry f i l m g r e a t l y depend on these three parameters BACKCROUND Dry f i l m lubricants one of the proposed processes are widely used for load bearing applications While the spray process Is considered SOA serious operational problems have been encountered I f the coating Is non uniform i n thickness and/or the coating s l u f f s o f f due to Incomplete surface cleaning p r i o r to f i l m a pplication improper baking of the s o l i d f i l m or other processing variables such as p a r t i c l e sizes These problems could be g r e a t l y minimized by optimizing the NOT methods used to evaluate the coating adequacy Dry f i l m thickness and uniformity (a) and (b) above are amenable to inspection by eddy current l i f t - o f f techniques (CBA) w i t h i n the SOA Microwave short f i e l d probing (COD) can also be used i f part geometry i s reproducible for standardization of the instrument Adherence or tenacity of the f i l m item (c) above is a q u a l i t y c h a r a c t e r i s t i c that can only be evaluated by simulated service wear tests using e i t h e r t e s t coupons designed for standard ASTM wear tests or bearing run i n tests under simulated service conditions on f u l l sized parts A non-destructive test for adherence would be extremely advantageous APPROACH The adherence test method development should be closely coordinated w i t h the development of the dry f i l m lubricant process Tests for i n i t i a l surface cleanliness outlined i n Chart 703 would provide valuable i n process con t r o l information Coupon Samples representing the exact bearing and lubric a n t materials should be prepared under variable processing conditions and tested for wear l i f e using standard ASTM tests Non-destructive tests f o r coating thickness and uniformity should be correlated w i t h adherence r e s u l t s of destructive wear tests Additional NOT tests such as micro-hardness tests and dye penetrant surface examination for mlcrocracks i n the coating would provide data that may be correlated to adherence or tenacity

73 TITLE LUBRICATION OF SLIDING FARTS FOR LONG DURATION USE IN SPACE CHART PRIORITY RELATED CAMR CHARTS 7 0 3 MANUFACTURING REQUIREMENT High strength s t e e l a l l o y l i n k s must be coated to prevent vacuum cold welding The l i n k s are 0 25 x 0 75 and are joined l i k e bicycle chains The coating must be useful f o r 2 years at 175 to -150 F and withstand compressive loads of approximately 2000 p s i The chain i s used i n connection w i t h a remote manipulation arm f o r use on a space s t a t i o n AARP REFERENCES B Charts 16 Id . P&FVPS Charts APPLICABLE PROCESS yjpg APPLICATION OF GREASE or (B) CHEMICAL CONVERSION OF ONE OF TWO CONTACTING SURFACES or (C) APPLICATION OF SOLID FILM LUBRICANTS Code (B) 7 05 03 (C) 7 05 04 STATE O F THE ART ASSESSMENT Silicone greases are available which have s u f f i c i e n t l y low evaporation rates to be use- f u l f o r t h i s requirement Application of the grease to the surface Is simple and could be ac- complished i n space i f necessary The magnitude of the cold welding problem i n space i s not w e l l defined however no evidence of such welding has occurred i n the space f l i g h t s to date An alternate to the use of grease i s to make the contacting surfaces d i s s i m i l a r i n chemistries Surface conversion to provide a very t h i n layer of oxide carbide n i t r i d e or some other compound d i s s i m i l a r to the contacting a l l o y s t e e l can be accomplished w i t h i n the sta t e of the a r t S t i l l another alternate method i s the use of s o l i d f i l m lubricants such as Inorganic bonded MoSo tetrafluoroethylene and s o f t metal films ( s i l v e r gold etc ) Application of these s o l i d f i l m lubricants i s w i t h i n the current state of the a r t An Improved non-destrtictlve Inspection c a p a b i l i t y as out l i n e d f o r charts 503 or 523 would be desirable The alternate methods should be pursued i f s i l i c o n e greases prove unstable (too rapid an evaporation rate) f o r t h i s requirement The use of s i l i c o n e grease would be much more econom- i c a l than the alternate methods CRITICAL PROBLEMS NONE ALTERNATE PROCESSES NONE Code

74 tITLE TROWEL COATING OF REFRACTORY CERAMIC TO METAL STRUCTURE TO FORM A 5000 F OVEN WALL FOR LUNAR WATER RECLAMATION CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT A re f r a c t o r y ceramic coating s h a l l be troweled over supporting metal structure to provide thermal and corrosion protection This s h a l l serve as the w a l l of an oven to be operated at 5000 F for at least 180 days The oven w i l l be 8 cu f t and the w a l l thickness 6 Inches The coated oven w a l l must withstand 8g launch and lOg landing loads The coating must be easily repaired The primary purpose of the oven Is to extract the water of hydration and c r y s t a l l i z a t l o n from lunar rock AARP REFERENCES E Chart* B Char ts . 175 PSFVPS C h a r t s . APPLICABLE PROCESS TROWEL COATING OF CHEMICALLY SETTING CERAMIC INTO REINFORCING METAL MARTIX Code 7 lA OA STATE O F THE ART ASSESSMENT Chemically s e t t i n g r e f r a c t o r y ceramic materials are commonly trowel applied to a l a t h work of expanded metal or metal screen In a v a r i e t y of I n d u s t r i a l applications The repair of f i r e b r i c k furnace l i n e r s i s accomplished with r e f r a c t o r y cements and concretes applied by the trowel or gun process The major problems of t h i s requirement are obtaining a ceramic material useful t o 5000 F and developing a composite ceramic li n e d metal capable of withstanding Sg to lOg loads The need to operate at 5000 F for water ex t r a c t i o n is highly questionable I t should be possible to remove water of hydration and c r y s t a l l i z a t i o n at a much lower temperature p a r t i c u l a r l y i f the pressure i s low I f applicable, assembly operations may be performed at the lunar s i t e a conventional ceramic l i n e r In the form of r e f r a c t o r y f i r e b r i c k may be considered Recommendations are that the required maximum operational temperature be re examined to determine i f I t may be we l l below 5000 F I f t h i s high materials and/or design development may then be required No manufacturing development program i s recommended at t h i s time CRITICAL PROBLEMS NONE ALTERNATE PROCESSES CERAMIC SHAPES ATTACHED TO METAL STRUCTURE BY METAL HANGERS FACED CERAMIC OR GLASS FIBER INSULATION FOR USE TO APPROXIMATELY 2000 F Code 6 11 00 8 02 00

75 TITLE APPLICATION OF ANTI-GALLING COATING TO THIN WALLED TELESCOPING TUBING CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT An a n t i - g a l l i n g coating consisting of a dry lubricant a polytetrafluorethylene cladding or a chemical conversion I s to be applied to telescoping thln-walled tubing of tita n i u m a l l o y s t e e l aluminum or beryllium copper Tubes w i l l vary i n length from 15-20' w i t h diameters of 1 -25 A t i g h t f i t must be maintained to minimize leakage and no cold welding should occur on repeated use over a temperature range of -125 F to +175 F i n a vacuum of 10-5 to 10-13 mm Hg Coating thickness 0 0015 - 0 002 AARP REFERENCES E Charts B C h a r t s . 164 P i F V P S C h a r t s . APPLICABLE PROCESS One of the following (A) SPRAY OF DRY FILM LUBRICANT (B) POLYTBTRAFLUOROETHYLENE CLADDING (C) CHEMICAL CONVERSION - ANODIZING, HARDCOATING (D) FLAME SPRAYING OR PLASMA SPRAYING (A) 6. (B:Fo«'e 7 05 04 (C) 7 05 03 (B) 7 14 01/7 14 02 STATE O F THE ART ASSESSMENT The simplest approach would be the application of a dry lubricant molybdenum d i s u l f i d e by the aerosol spray process This would be applicable to a l l materials l i s t e d The Ti-Hardcoat process developed by the Watervllet Arsenal o f f e r s considerable promise f o r t i t a n i u m as the tube material This process Is s t i l l I n the development stages and scale-up may be ̂ required This anodic coating i s believed to be a Fe-Tl 0 complex I d e n t i f i e d as Fe2Tl40 or F e 3 T l 3 0 and i s accomplished i n an al k a l i n e e l e c t r o l y t e The coating may be used together w i t h a lubric a n t For a l l o y s t e e l tubes a flame or plasma sprayed or electroplated s i l v e r coating would be a l o g i c a l choice No m l s c l b i l i t y exists between s i l v e r and Iron Flame or plasma spraying and e l e c t r o p l a t i n g f a c i l i t i e s would be adequate The polytetrafluoroethylene material could be applied by cladding flame or plasma spraying or spraying and s i n t e r i n g Recent development i n t r e a t i n g polytetrafluoroethylene sheet g r e a t l y enhances I t s bonding properties Cladding w i t h polytetrafluoroethylene on such large pieces would have to be evaluated For aluminum tubes hardcoatlng should also be considered The only major problem w i l l be the handling of such large parts and the scale up of f a c i l i t i e s to handle them No s i g n i f i c a n t process problems can be I d e n t i f i e d however an evaluation of the various coating approaches i s i n order to determine t h e i r performance c a p a b i l i t i e s A dry f i l m l u b r i c a n t appears to be the most applicable material however I t I s not known i f t h i s material or any of the alternates are completely adequate Therefore a materials evaluation program Is In order but not a manufacturing development program CRITICAL PROBLEMS NONE ALTERNATE PROCESSES NONE Code

76 TITLE DIFFUSION COATING OF SUPERALLOYS FOR OXIDATION AND EROSION RESISTANCE CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT An oxidation protective coating must be applied to superalloys and TD n i c k e l The coating must be protective at a maximum temperature of 1800 to 2300 F for times of 1 to 25 hours Up to 50 f l i g h t s may be involved The substrate thickness w i l l vary from 0 001 inch to 0 25 inch with the majority being 0 020 inch to 0 10 inch sheet Part size w i l l vary from 1 foot x 1 foot to 6 foot x 12 foot panels Typical parts and assemblies include honeycomb and truss core panels single faced corrugation s t i f f e n e d panels close tolerance complex f i t t i n g s double walled ducts with coolant passages sheet and stringer assemblies and wire rope made from 0 001 inch diameter wire AARP REFERENCES E Chnrt. 70. 99. 259. 306 B Charts 31b, 32b, 41b, 42b c 120c 121b 122b 146 P4FVPS Charts APPLICABLE PROCESS Depending on end item either (1) FLUIDIZED BED VAPOR DEPOSITION (2) PACK CEMENTATION (3) or (4) MELTING SLURRY SLIP PACK 7 10 7 10 01 03 Code 7 10 7 10 02 04 See Chart 515 for a description of the processes and the state of the a r t Compared to the Manufacturing Requirement of Chart 515 t h i s Manufacturing Requirement Involves a shorter coating l i f e and smaller and/or less complex parts and components to be coated The 1970 state of the a r t w i l l be adequate f o r t h i s manufacturing requirement For the shorter time applications the need for an oxidation protective coating should be closely examined From a weight standpoint a coating should be used only when the weight of the coating Is less than the weight of the metal lost ( s t r u c t u r a l l y l o s t ) by oxidation For the case of TD n i c k e l and an alumlnlde coating 0 0015 inch t h i c k the coating weight Is equal to about 0 001 inch of TD nickel At 2000 F i t would require 25 hours before t h i s thickness of TD n i c k e l is oxidized and at 2200 F i t would require about 8 hours For Rene 41 superalloy the time required for a 0 0016 inch depth of oxide penetration is 100 hours st 1800 F and 10 hours at 2000 F Also improvement i n the oxidation resistance of the alloys Is possible For example nickel chrome i s much more oxidation r e s i s t a n t than TD nickel and an a l l o y of Fe Cr Al Y exhi b i t s good oxidation resistance to 2400 F T D Substrate thicknesses of 0 001 inch are not considered p r a c t i c a l for d i f f u s i o n coating currently or i n the foreseeable future The minimum substrate thickness should be 0 006 inch with 0 004 inch a p o s s i b i l i t y for c e r t a i n cases The very t h i n material i s usually associated with the core of honeycomb panels For these cases i t i s suggested that the core be sealed against exposure to a i r as has been done with honeycomb sandwich panels fabricated from refrac tory metals However i n l i g h t of the above discussion of weight and the improved oxidation resistance of newer alloys i t appears that the use of bare metal which is s l i g h t l y thicker than needed s t r u c t u r a l l y to account for oxidation losses would be preferred ALTERNATE PROCESSES NONE Code

77 TITLE APPLICATION OF MOLD RELEASE ACTNTS FOR FOAMED IN PLACE MATERIALS CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Coating surfaces that shape foamed-in-place materials so that the foam does not hold i n tension on parts 10 Inch diameter by 1 foot long The material w i l l be foamed in place In space to provide energy absorption pads f o r spacecraft docking gear AARP REFERENCES c r k « ^ * R Chnrt« 179 • - APPLICABLE PROCESS Code CONVENTIONAL METHODS OF APPLYING MOLD RELEASE COATING SPRAY OR BRUSH APPLIED FOLLOWED BY CURING 7 11 02 STATE O F THE ART ASSESSMENT A large number of mold release agents are available on the market for various foamed In-place materials Aerosol spray ap p l i c a t i o n i s the most widely used method A t y p i c a l material has a fluorocarbon base For wipe-on or brushing a si l i c o n e grease may be used Selection of mold release material i s based on (1) type of foaming material used (2) complexity of part configuration and (3) processing temperatures The unusual aspects of t h i s problem are that the mold release agent must be functional In the space environment and must be reusable Therefore a stable s o l i d reasonably strong and tough surface coating i s required A polytetrafluoroethylene or related coating material w i l l meet these requirements This type of material can be re a d i l y applied by spraying and si n t e r i n g No manufacturing development program i s required CRITICAL PROBLEMS NONE ALTERNATE PROCESSES NONE Code

78 TITLE ELECTRODEPOSITION OF ORGANIC COATINGS CHART PRIORITY RELATED CAMR CHARTS ^ V J AARP REFERENCES F C.hnwt. B Chortl P4FVPS Charts Surface Conditioning No. 2 APPLICABLE PROCESS Code ELECTROPHORETIC DEPOSITION OF ORGANIC COATING 7 08 0 2 MANUFACTURING REQUIREMENT Coatings up to 0 002 t h i c k free from holes and foreign p a r t i c l e s are to be applied to f u e l and oxidizer system components including tubing Coating must protect metal substrate from attack from f u e l and oxidizers^ such as f l u o r i n e The desired service l i f e varies w i t h the component and device (see AARP Vol I I pp 558) up to 500 hours for f u e l containers and ducting for a gaseous f l i g h t power system Maximum service temperature is 500 F for a l l applications STATE O F THE ART ASSESSMENT There is renewed commercial Interest i n t h i s 30 year old process The Crowley Works Pressed Steel Company England is now coating the inside and outside of automobile gasoline tanks a t the rate of 75 tanks per hour by t h i s method After a f i v e year study the Ford Motor Company started a p i l o t l i n e In 1961 and i n 1963 started applying primers by t h i s method to completed bodies Uniform coatings are applied to normally inaccessible areas such as the inside of a tube (See Journal of Paint Technology Vol 38 No A99 August 1966) F a c i l i t i e s are expensive Imperfections must be Incorporated I t i s suggested that before a development program i s started concerning material and/or process development the f e a s i b i l i t y of manufacturing f u e l and oxidizer components from corrosion res i s t a n t metals be reviewed Also depending upon the substrate material e l e c t r o plate chemical conversion and anodic coatings may be useful F i l l and drain methods may be used for organic coating however the coating thickness i s d i f f i c u l t t o c o n t r o l Manufacturing development e f f o r t Is not recommended at t h i s time but e f f o r t t o adapt the process to small volume production with Improved product r e l i a b i l i t y might be warranted at such time as the adequacy of alternate methods has been established for s p e c i f i c fuels and operational conditions ALTERNATE PROCESSES FILL AND DRAIN ELECTROPLATE CHEMICAL CONVERSION OR ANODIC DEPENDING ON EASE METAL Code 7 11 05 7 08 01 7 05 03

79 TITLE PROTECTIVE COATINGS FOR TITANIUM COMPRESSOR DISCS AND BLADES CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Thin (0 0005 0 003 ) uniform defect f r e e coatings s h a l l be applied to titanium base a l l o y s for p r o t e c t i o n against oxidation erosion and foreign object damage and for r e s i s t a n c e to hallde contamination Coatings s h a l l be capable of being applied to leading edges of a i r f o i l s with 0 002 r a d i i P r o t e c t i o n s h a l l be provided for 100 hours at 1200 F AARP REFERENCES E Charts B Charts . P&FVPS r h n r t . Surface Conditioning No 3 APPLICABLE PROCESS one or more of following processes depending on (A) 7 05*fl^® (E) nature of Coating (A) ANODIZING (B) FLUIDIZED BED VAPOR DEPOSITION (B) 7 10 01 J", (C) PACK CEMENTATION (D) SLIP PACK (E) MELTING SLURRY (F) VAPOR (C) 7 10 02 i n O S STREAMING (D) 7 10 03 ' " STATE O F THE ART ASSESSMENT Current titanium a l l o y s used for compressor blades and d i s c s operate i n the 600 700 F range Advanced a l l o y s designed for 800 900 F operation are l i m i t e d by s t r e s s corrosion attack above 800 F Development e f f o r t s toward 1000 F a l l o y s I n d i c a t e production of such a l l o y s to be 3 5 years away A 1200 F a l l o y would be at l e a s t 5 10 years i n the future Since s t r e s s c o rrosion becomes more pronounced with Increasing use temperature i t would be a major concern at 1200 F To date coating development for titanium a l l o y s has been unsuccessful In i d e n t i f y ing high temperature coatings that do not have a detrimental e f f e c t on the base metals Much of the e f f o r t has been d i r e c t e d toward coatings to r e s i s t f r e t t i n g and g a l l i n g A ba s i c problem with coatings for titanium I s that any breaks or flaws In the coating would serve as s i t e s for galvanic a c t i o n which could be more hazardous than no coating Since one must accept the presence of some breaks i n the coating due to impacting p a r t i c l e s the e f f e c t i v e n e s s of coatings i s debatable Thin alumlnlde coatings ( T l A l ^ ) have provided oxidation protection to titanium a l l o y s for over 50 hours at 1500 F The coating was formed by hot dipping or by a p p l i c a t i o n of an aluminum a l l o y s l u r r y followed by a d i f f u s i o n heat treatment at 1500 F Anodizing has a l s o shown promise The e f f e c t s of the coatings on mechanical properties of the base metal r e s i s t a n c e to p a r t i c l e Impact and galvanic corrosion e f f e c t s have not been evaluated For operation at 1200 F the most l i k e l y coatings are the I n t e r m e t a l l i c type s i m i l a r to those used for coating r e f r a c t o r y metals Therefore the processes used for applying coatings to r e f r a c t o r y metals should a l s o be u s e f u l i n t h i s case No manufacturing development program I s recommended at t h i s time because (1) titanium a l l o y s u s e f u l to 1200 F for compressor d i s c s and blades w i l l not be a v a i l a b l e for 5 10 years (2) completely s a t i s f a c t o r y coatings have not been i d e n t i f i e d and (3) the processes for applying coatings to r e f r a c t o r y metals and anodizing appear a p p l i c a b l e Coating development and e v a l u a t i o n should p a r a l l e l the development of titanium a l l o y s CRITICAL PROBLEMS NONE ALTERNATE PROCESSES I Code NONE

80 AARP REFERENCES E Chnrt. B Charts 110a b 120a 121a PAFVPS Chnri< Surface Conditioning No 4 APPLICABLE PROCESS PACK CEMENTATION CHEMICAL VAPOR DEPOSITION OR MELTING SLURRY FOR jaTLTCATTON OF-OXIDATION PHOTF.frrTVF.r.OATTNr.S Code 7 10 02 7 10 04 TITLE COATING OF REFRACTORY METAL TUBING FOR PROTECTION AGAINST LIQUID METALS CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Thin (0 002 ) uniform defect free coatings that are r e s i s t a n t to l i q u i d metals and a i r erosion (by l i q u i d coolant) thermal stress and thermal fatigue s h a l l be applied to r e f r a c t o r y metal tubing Coatings must provide permanent d i f f u s i o n barrier Insulate against galvanic reactions be se l f healing deform e l a s t l c a l l y w i t h base metal and have high thermal conduc t i v i t y Extremely r e l i a b l e coating l i f e for protection against l i q u i d metals of 25 000 hours at 2000 F and 9000 hours at 3000 F are needed however protection against a i r oxidation is required for only a few hours during ground test (Propulsion No 4) Protection against l i q u i d metals and a i r oxidation at 2300 F i s required f o r cooled leading edges (B 120a 121a) Heat exchangers for use i n space require protection against l i q u i d metals only STATE O F THE ART ASSESSMENT Development work w i t h l i q u i d metal systems has demonstrated that columblum a l l o y tubing is not affected by the a l k a l i metals In several thousand hours of operation at temperatures of 2200 to 2300 F Should t h i s hold true for longer times and/or higher operating temperatures protective coatings would be required only for external surfaces that are heated i n a i r In that case current coating processes for r e f r a c t o r y metals (as discussed In CAMR 521) would be applicable or the manufacturing development program covered by CAMR 521 would by establishing better knowledge of the significance of process variables help to extend service l i f e expectancies Should protection agalhst the l i q u i d metal coolant become a necessity for meeting the long time and high temperature requirements of Propulsion No 4 the coating problems could be considered very d i f f i c u l t from both an application process and coating material standpoint There are no known coatings having a resistance to l i q u i d a l k a l i metals superior to the r e f r a c t o r y metals themselves p a r t i c u l a r l y columbium and tantalum A l l present d i f f u s i o n coatings have proven to be harmful impurities i n l i q u i d metal c o m p a t i b i l i t y tests Noble metals of the platinum group may be p o t e n t i a l coating materials No manufacturing development program i s recommended for the a p p l i c a t i o n of coatings to protect against l i q u i d metals because no coating material has been i d e n t i f i e d which is more resist a n t to attack than the r e f r a c t o r y metals themselves CRITICAL PROBLEMS ALTERNATE PROCESSES FLUIDIZED BED VAPOR DEPOSITION SLURRY NON MELTING Code 7 10 01 7 14 06

81 TITLE DIFFUSION COATING OF REFRACTORY ALLOYS FOR OXIDATION RESISTANCE CHART N O S 3 ^ PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Thin (0 001 0 005 ) uniform defect free coatings s h a l l be applied to ref r a c t o r y a l l o y com ponents to be used as skins and substructure In aerodynamic l i f t and control structures a i r i n l e t s and ducting edge members for electromagnetic and o p t i c a l transparencies and heat shields i n hypersonic cruise hypersonic boost g l i d e l i f t entry and drag entry vehicles The coated com ponents In general s h a l l have an emlttance of 0 8 or higher and shall perform with high r e l i a b l l l t ; during exposure to high v e l o c i t y a i r at peak temperatures of 2500 to 3000 F Multiple f l i g h t s required with t o t a l time of 5 to 0 5 hours at the respective peak temperatures The largest component i s a spherical s h e l l about 10 foot diameter A l i f t i n g panel for a missile requires protection at 5000 F f o r 5 seconds This panel i s 5 x 8 inches and of simple design (B 63b) Small thrusters 3 inch dla x 8 Inch long require protection at temperatures of 3000 to 5000 F fo r t o t a l times of 5000 second This t o t a l time may involve a very large number of cycles (B 168b AARP REFERENCES E Charts 7Q. 99. 276. 285 B Charts 30a. 31a. 32a. Ala. 63b. 124. 125. 133c. 168b P4FVPS C h a r t s . APPLICABLE PROCESS One of the following (A) FLUIDIZED BED VAPOR DEPOSITION (B) PACK CEMENTATION VAPOR IKPOSITION (C) SLIP PACK VAPOR DEPOSITION (D) MELTING SLURRY Code 10 01 7 10 02 10 03 7 10 04 STATE O F THE ART ASSESSMENT Chart 521 discussed the applicable processes Depending upon the part size design manu factu r l n g sequence operational requirements base metal and f a c i l i t y a v a i l a b i l i t y each of the above processes i s applicable Selection of the superior process must swalt establishment of the above i n d e t a i l Compared to the manufacturing requirements of Chart 521 these manufacturing requirements Involve a shorter coating l i f e and smaller and/or less complex parts sre to be coated The 1970 state of the a r t w i l l be adequate for t h i s manufacturing requirement Although these requirements can be met by the state of the a r t coatings and processes careful Integration of component design base metal manufacturing sequence coating and process i s mandatory for satisf a c t o r y r e l i a b i l i t y I n the case of the requirement f o r protection of tungsten at 5000 F for 5 seconds no t h i n coatings are available which w i l l withstand t h i s tempe-ature Considering the defined environ ment the oxidation rate of tungsten appears to be s u f f i c i e n t l y low so that i t may be best to use the tungsten without a coating Coated refr a c t o r y metal thrusters of the type required have been q u a l i f i e d for use on space vehicles The peak allowable operating temperature is approximately 3500 F This l i m i t Is due to the coatings available and Is not a process l i m i t a t i o n REFERENCES 1 Report MAB-210-M Coated Refractory Metal Technology 1965 (November 1965) 2 USAF Contract AF33(616) 8106 ASSET Final Technical Reports AFFDL TR 65-31 Vols I I I V I V I I V I I I X (1965) 3 USAF Contract AF33(615) 1624 Advances i n the Materials Technology Resulting from the X 20 Program AFML TR 64-396 (March 1965) ALTERNATE PROCESSES NONE Code

EXPLANATION OF CAMR REFERENCES TO SYSTEMS, COMTONENTS, AND AARP RATING FACTORS CAMR e i M t r N U H U R Set I foe va B-28a, 39b CoivoiMiit 01 01 0 IDSS (or A-3> bypersODlc crulao high «lclciid« or low altltuda v e h U l a for A-]b hyporionlc booat g l U a acrataglc or c a c c l c a l v ahlcla RlIF B-29a 40bi Coopooant 01 OA 0 UADOC BSCS for A-3o and A-3b vahlclea abovo RBP B*121c Cooponanc OB 01 0 RKAT S H I E L D for B-3a l i f t entry v a h u l o BZF B-39b: Coiiionent 01 03 0 KOSB for A-3b byper- aonlc booat gllda acrategle or t a c t i c a l vabicla BBP B-121C Cdnpooaot 08 01 0 (HAT S H I S U ) for B-3a l i f t entry vehicle BBF B-126a b CODiponant 09 01 0 BBARDC for B-3a l i f t entry vehicle BBF B-12St Coopooent 07 03 0 (fftlCAL TBAMffABBNCIBB (IB VIBIBIB, UV) for B-3e l i f t entry vehicle BBF Propulaion Surface CondltlonLng No 5 Coopooant 21 0 4 0 T H B B H O B l E e r B l C - I H B B M I O m c 7 0 I I B B S I S T B M BADMIOB for B-2a (2) near apace operatlona (apace atetion) and B-2e ahuttle (maneuverable) Cc^onant 22 0 4 0 CLOSED CtCLB T U B B O B L B C r B I C POUBB STSTBM BADIATOB for B - l b ( l ) ipece launch ayaten (earth orbit launch) for B-2a(2) near apace operationa (apace atation) for B-2e(3) lunar vehicle, and for B-2c ahuttle (maneuverable) BBF B-13 Coinponont 07 02 0 BLECIRaHACllETIC TRAHS- PARBNCIBS (BAD0NB8 BADAB WDmOBS) for A-2a auparaonic high altitude long range vehicle BBF B-14 Cooponent 08 01 0 AHnmHA UIHDOIIS - HBAT SHIELDS for A-2e vehicle ebove BBP Propulaion Surface Conditioning Ho 1 Cooponant 20 01 0 SOLAB BBFLBCTOR COLLBCTOB SUBFACB for B-2a(2) neer apece operatlona (apace atation) 1 BBF B-124 Conponant 07 02 0 EUCTOOUCNSIIC TBAHS- S06 I FABBHCIES (BADOKBS BADAB WINDOW) for B-3a l i f t entry vehicle BBF B-61d Cooponent 01 03 0 NOSE for A-4a(l) t e c t i c e l ground launched antl-miaaile for A-4a(2) t a c t i c a l — _ I apace launched a n t i - o i a a i l e end for A-4b(4) atrateglc 9 0 y I re-entry o i a a i l e ayacema BEF B-120C Component 01 04 0 LBADINC BDGB for B-3a l i f t entry vehicle BBF B-121b Component 08 01 0 HEAT SHIELD foe B-3a l i f t entry vehicle Hote (x) below denotea not an Air Force ayaten 08.0/ 0 1̂ , SYSTEM PR08ABILIT1 COMtlONENT C R l T I C A U r y FREaUCNCV or m v A t IN SVSTEM D E S I G N A L T E R M / T Q MATCRIAIS IMPUCAnON A A R P SAW SCORCS U S ' ! I t t & S 8 1 1 <1 & 3 T O T A L S e 2 9 « i> 28 AS.i. , z 0 Jt4 . ^ S a , 8 / » t 3 £ 0 3/ 4t 9 & 3 i> 2¥ 83A S /Z 1 6 0 30 U 9 / 3 o 0 /7 8 /Z / 3 0 e S / 3 9^ 0 /9 8 9 / 9 ¥ 0 31 /Z 9 z 6 - 0 33 M l , 8 6 "Z 6 0 2A n 9 1 6 0 'Z ft 9 z a * ¥ 0 33 9 1 e 1? i¥ 8 6 2. c 0 2e /z 6. z c /a 9 2 £ /z a / 3 o 0 zz $ 6 f e M t > 25" A M 3 1 3 & 0 X V . r tz 3 / 3 a 0 X 3 / 2_ 3 6 t) 2S- g z 6 0 2e gJa S /Z 3 & <) SI

EXPLANATION OF CAMR REFERENCES TO SYSTEMS, COMPONENTS, AND AARP RATING FACTORS I CAMR CHARr Sto 513 SIS REF B-85a b c 145b 146 149b 150b Component 01 02 0 AEROOTNAMIC LIFT AND COWTROL STRUCTURE - FLEXIBLE ( f l e x wing shroud lines flex decelerator flex rotor) for B-la earth launch recoverable booater and for B-4a earth landing ayatema tangential and v e r t i c a l Note Flex wing ahroud linea and flex rotor were conaldered very high c r i t i c a l i t y with f l e x decelerator somewhat lesa c r i t i c a l as a component REF B-95a Component 02 04 0 PRESSURE VESSEL for a l l space launch systema Including B - l b ( l ) earth orbit launch REF B-96 Component 02 08 0 HAJOR STRUCTURAL FITTINGS (BULKHEAD ENGINE MOUKI) for B - l b ( l ) above REF B-97b Component 02 07 0 INTERSTAGE AND INTERTANK STRUCTURE for B - l b ( l ) above REF B-98C Componenta 08 01 0/08 04 0 HEAT SHIELD/ EROSION-CORROSION SHIELD for B - l b ( l ) above REF B-lOO Component 08 05 0 PROTECTIVE COATING INCLUDING THERMAL CONTROL for B - l b ( l ) above This i s a general requirement applicable to Interplanetary miaolona for B-lb space launch vehicles B-2b interplanet- ary vehicles and B-4b space landing vehicles and the rcquircmcQt i s not cODsideied applicable to Air Force Systems REF B lb Component 01 07 0 PRESSURE VESSEL for A-la subsonic long endurance chemically fueled a i r c r a f t REF B-lOO Compoi THERMAL CONTROL earth orblc - l b ( l ) spa< REF B 11 Component 01 04 0 LEADING EDGE for A 2 super sonic high altitude long range and t a c t i c a l V/STOL fighter a i r c r a f t REP B-15« b Component 06 01 0 AIR INLETS 4 DUCTING for A-Z supersonic a i r c r a f t REF B-16a b 30b Component 01 01 1 AERODYNAMIC LIFT & CONTROL STRUCTURE - RIGID SKIN for A-2 superaonlc a i r - c r a f t above and for A-3a hypersonic cruise high and low altitude vehicles REF B-17a b 18a b c d 19a b Component 01 08 0 MAJOR STRUCTURAL FITTINGS (BULKHEAD ENGINE MOUNT WING HINGE) for A-2 supersonic a i r c r a f t above REF B-20a Component 08 03 0 RADIATION SHIELD (NUCLEAR & SPACE) for A-2a A-2b supersonic high altitude chemical and nuclear a i r c r a f t REF B-28c 39c Component 01 03 0 NOSE for A-3a hyper- BOnlc high altitude and low altitude cruise vehicle and for A 3b hypersonic boost glide strategic and t a c t i c a l vehlclea REF B-29b 40d Component 01 0^ 0 LEADING EDCX for A 3a and A-3b vehicles above REF Propulsion Surface Conditioning No 7 Component 10 06 0 TURBOJET AFTERBURNER COMBUSTION CHAMBER for A 2a supersonic high altitude long range chemically fueled a i r c r a f t for A-2c supersonic t a c t i c a l V/STOL fighter B - l a ( l ) and B-la(2) earth launch recoverable boosters Component 10 09 0 TURBOJET HOT GAS DUCTING for A-2a A-2c A-3b B - l a ( l ) and B-la(2) systems above Components 13 04 0 RAMJET VARIABLE EXIT NOZZLE and 13 05 0 RAMJET COMBUSTION CHAMBER for A-3a B - l a ( l ) and B-la(2) systems above Components 14 01 0 LIQUID ROCKET MOTOR COQUSTION CHAMBER and 14 02 0 NOZZLE for B - l a ( l ) and B-la(2) earth launch recoverable boostera 3YSTEM P R O B A B I L i n COMPONENT CRtTlCAUir FREaUCKICY OF TOMT IN SYSTewl D E S I G N ALTERNftia MATERIAIS I M P U C A n o N A A R P RAW 3CORES \Z ^ 6> % 3 1 1 q C. 3 -r<»TAL s o/ qto^ ,^-/|« , e 2 & 0 0 3S /Z z 6 0 fi/ei ff. <i>, , 9 2 6 0 0 if /Z <? •3 9 o 0 33 ,pZ,<?g o ,8, l^^l 6 S y 0 0 30 6 3 9 o 0 30 peoip^ ,S, IhO), 9 3 9 e> 0 33 oe^eSo S-lk(i) 6 3 9 0 0 3o 0 0 0./, 0l. <? Al.o-. . 0 / 3 6 0 2<f oe^of.c, ,B,l,b(i) n 6 9 0 0 29 01 l y f ^ ,A Z.. , 9 3 e 6 C) ' 3t /» 3 3 i 0 3o e l pi 1 , 2 ti. 9 3 6 6 t> 36 /Z 3 3 6 O 32 0/ 08.0 AZ / * 9 3 6 6 i> 36 Og 03.0 , ^ 2d /2 9 3 6 t 0 3<i oe eSo A 26 M 9 3 e 6 0 6 1, 0 3 * a 9 3 3 ¥ 0 J7 OlfOia ,/»?^, 9 •2. 3 0 iZ 01 O'l 0 A i f . IZ 3 3 9 0 3c ololo A 3b y _ f _ Z 3 9 10 06.0 A 2 « /z 6 / 3 0 ,IO_oi_o^ A2f /z 9 / 3 0 2 9 /oeio S / t / i ) g £ 7. 3 t> Z3 6 Z 3 i> /9

EXPLANATION OF CAMR REFERENCES TO SYSTEMS, COMPONENTS, AND AARP RATING FACTORS I CAMR OHART N U H U K Continued froo precedlDg pa$Q I RBF B-163b Cooponent 04 07 0 REMOTE MANIPUUTOB A&H Q / 7 I for C-ld a r t i f i c i a l Bpace base (spaca station) r'tA 1 ^-^Ti- Component 08 06 0 FLBXIBLB PBBSSURB SUIT 9/19 I JOIKTS for C-3s extra-vehicular advanced space oult — — — - | REP B-169a Component 05 03 0 SUHTACE COWTACT I CEVICB (SKID) for C-2d lunar exploratory traverser RBF B-28a b 39b Component 01 03 0 NOSE for A-3a hypersonic high and low altitude cruiae vehicles I aiu) for A-3b hypersonic boost glide strategic and t s c c i c a l vehicles REP B-29a 40b Component 01 04 0 LEADING EOGK for A-3fl and A-3b vehicles abcjve REF B-121C Component 08 01 0 HEAT SHIELD for B-3a l i f t entry vehicle REF B-126B Consonant 09 01 0 BEARIHC for B-3a l i f t entry vehicle REF B-28b c 30c d Component 01 03 0 NOSE for A 3a hypersonic high altitude and low altitude cruise vehicles and for A-3b hypersonic boost glide strategic and t a c t i c a l vehicles , , RBF B-29b c d 40c,d 51b 120a Component 01 04 0 S^9 LEADIhC EDGE for A-3a and A-3b vehicles above and ' ' for A-3c hypersonic horizontal takeoff and landing vehicle (HIOL) o r b i t a l vehicle and B-3a l i f t entry vehicle k k / p off e, A 2A, S Y S T E M P R o e A B i L i r COMPONEHI « CRITICAUir FREaUCNCV OF n v i T I N S Y S T E M D E S I G N A L T E R M A T t M A T C R I U S S I M P U C A n O A A R P , RAW S C O R E S I t 8 4 I t 1 6 a 3 1 1 6 4 - 0 T » T A L V /«. 6 z £ y i> 3e / « < j f 0 / ( ie^ / a . 9 2 6 0 33 /oo<te /l'3i 9 a. £ V t> 23" ,/e>,e>9_o /B:/»(i). @ i s i:> 2tf /P.ofl.'. ,5;/*(*J V 6 z £ << i> 7t ,/f ?A 8 9 3 3 0 3o 9 9 2 3 V 0 2£ ¥ 9 z 3 V 0 zz ./3.eS,o, $ 9 3 3 V 0 27 ,/3,»So ,Bja(i), 8 z. 3 9 0 2£ ,/3,eC.o ^ 9 z 3 V 0 7Z 8 9 z 3 0 26 V 9 3. 3 '>_2Z_ 0 24 ftf eto ,S/a</J 8 2 3 9 Z. 3 0 0 2Z 0 28 fZ £ / •3 / c / 6 0 01.0S0 ,^ ?«• . <f 2 3 6 e/,030 AU e f •2. 3 3 6 i> 2V 0'. .^H. / t 2 6 C> 3f « 8 9 2 3 6 0 2¥ et e/ o B3*., •z 3 6 i> 3/ 8 3 2. <S & 0 25- t>lMo 8 9 3 3 6 <) to oyeJe AH. f 9 3 3 3 e, 0 2 f e>/o</o /?,3«. 8 fZ 3 6 0 32 fih'>'fo. <f 9 3 3 6 0 zs- M 9 3 3 & 0 2^ ^.e'/o 8 3tL e 9 _ J 3 6 » 29

EXPLANATION OF CAMR REFERENCES TO SYSTEMS, COMPONENTS, AND AARP RATING FACTORS I CAMR CHAKT S2J_ Continued from precodlng page RSF 123 Component 01 01 2 A E B O D n i A M I C LI7T & CONTROL RIGID SITBSTRUCTURB for, A-3b and B-3a systems above REF B-30a b 12la Component 08 01 0 HEAT SHIELD for A-3c and B-3a systems above REP B-I22a Component 01 01 1/08 01 0 ABRODTOUac L m h COOTROL RIGID 5KIH/HEAT SHQLD for B-3a vehicle above REF B-I26a Component 09 01 0 BEARING for B-3a vehicle above REF Propulsion Surface Conditioning No A Components 18 OS 0 GASEOUS POUBR STSTCH HEAT BXCHANGER and IB 06 0 GASEOUS POUSR SYSTEM DUCTINC-PIPIHC for A-3a hypersonic cru i s e A-3b hypersonic boost glide and A-3c hypersonic HTOL-K)rbital vehicles aitd for B-28(2) near apace operations (space station) REF Propulsion Surface Conditioning Ho 6 Components 10 03 0 TURBOJET TURBINE VANES 10 04 0 TURBOJET TURBINE DISCS 10 OS 0 TURBOJET TURBINE BLADES, 10 06 0 TURBOJET AFTERBURNER COMBUSTION CHAMBER and 10 07 0 TURBOJET AFTERBURNER FLAPS for A-2a supersonic high altitude long range chemically fueled a i r c r a f t A-2c supersonic t a c t l c o l V/STOL fighter A 3b hyper- sonic boost glide strategic and t a c t i c a l vehicles (landing maneuvering system) and B-la earth launch recoverable booster Componenta 13 01 0 RAMJET DIFFUSBR LEADIW EDGES 13 02 0 RAMJET DIFFUSER SKINS 13 03 0 RAMJET COMBUS- TION CHAMBER for A-3a hypersonic cruise vehicle and B-la earth launch recoverable booster Components lA 01 0 LIQUID ROCKET MOTOR CCHBUSTION CHAMBER and lA 02 0 LIQUID ROCKET MOTOR NOZZLE for B-la earth launch recoverable booster Component 15 01 0 NUCLEAR ROCKET MOTOR NOZZLE for A-2b supersonic high altitude long range nuclear a i r c r a f t Component 16 03 0 SOLID ROCKET MOTOR NOZZLE for A-Ab strategic o l s s l l e e and B - l b ( l ) space launch (earth orbit launch) systems 01. Bit .0/0/ I, .69,'/.0. ,f.e,ero. ,/e.o.i.o. .leoso. ./.e.ot.c. /O.oSe. .Ipei.o. ./e>o1e ,/pef/o. /o.e/^,0, . /oo.'/.o. /o QI/D ./o eS,c. ./MS,c. /OffiO /OOi.0 /o c/e /ee'?c. /0070 /.?.ol,o. ,/3i>to, /3.O3 0. .^3 03 0 S Y S T E M P R O B A B I L i n OOMTONEHT CRmCAUTY' FREauENCY OF KQVlT IN S V f S T e M D E S I G N A L T E R N A T Q MATERIAIS IMnjCATION A A R P RAW S C O R E S 11 e 4 11 1 6 3 3 1 1 1 C. 3 ¥ 3 3 6 t> z r 6 ? 3 C 0_ /13c f /Z 3 6 & 0 Z9 8 /z 3 3 i 0 3Z e f i 3 3 6 i> 32 6 3 6 6 0 zi ,'»3<i, , 8 C 3 & Z9 A^it . ¥ 6 i i 0 zs ^3". . 9 3 6 0 2t S 2c.C') n <f z 6 0 3S- .'*-?« , e 6 3 6 . Z9 . ¥ c 3 & e 0 zs ,/)-3e. <f 3 6 0 z% /a. 9 z. e c 0 3'i ./I Za, , /2. 9 3 c 0 3& A . 9 S 6 0 3C ¥ 3 6 0 zs e 9 3 i 3Z , /z 9 3 c c> 3C /2 9 5 6 0 3i ¥ C ? i 0 3S .^(<^ . 8 <f J 6 0 32 /z 3 6 0 39 /! ie /z /z 3 0 39 ¥ 9 3 0 S /z 3 /Z 6 3 i 33 yi .2 '' /z 9 3 c 0 36 . / f 3 i . 3 3 3 & 19 ,B,/o-. e i 3 6 & 0 Z9 /) 2o /t 3 ( 6. i> 33 /tZe /z J i 6 0 33 ,/9?^. // 3 3 3 6 0 /9 g _ 3 6 Z9 , s fZ 3 3\' .8/A , # /z 3 3s' , '?',3;«. t <? 3 3 & 0 Z9 9 3 3 C 0 Z9 ,/«3(i, 9 3 3 c t> t9 g-/A » 9 s 3 0 19

EXPLANATION OF CAMR REFERENCES TO SYSTEMS. COMPONENTS, AND AARP RATING FACTORS CAMR CHA«r NUMQCB, Szl SZi SZ3 Continued from preceding page I REP B-167 Componenta 09 09 0 LAUNCH FACILHT CABLE TIE DOWN for C-le lunar baae aupport eyatem and 02 09 0 SPACECRAFT CEOTRIFUCE COHNECTDB LINKACE for C-3b environmental control externel centrifuge REF B-165a b Component 09 01 0 BEARING for C-lb a r t i f i c i a l apace base support system ^ REF B-163d Component 04 07 0 EXTEBIOR MANIPULATOB Silf for C Id a r t i f i c i a l space base support system REF B 175 Component 09 06 0 ROCK BURNER for C-3d water extraction plant (lunar) REF B-171 Component 07 07 0 ELECTRICAL QUICK I CONNECTOR PINS for C 2d uotk transport device 5Zb I (lunar utch ECS) Rll 11 lot Omponcnt 07 01 0 ANTENNA for C Id 5*27 I a r t i f i c i a l space base support system KEF B 41b Component 01 01 1 AERODYNAMIC LIFT & CDOTROL STRUCTURE - RIGID SKIN for A-3b hypersonic boost glide strategic or t a c t i c a l vehicles HEF B 31b 42b c Component 01 01 2 AERODYNAMIC LIFT i COOTROL STRUCTURE - RIGID SUBSTRUCTURE for A-3a hypersonic cruise high a l t i t u d e or 'o« altitude vehicles end A-3b hypersonic boost glide vehicles REF B-146 Component 01 02 2 A E R O i m i A H I C LIFT A CONTROL STRUCTURE - FLEXIBLE SHROUD LINES for B 4a earth Landing systems REF B 122b Components 01 01 1/08 01 0 AERODYNAMIC LIFT 6i CONTROL STRUCTURE - RIGID SKIN/HEAT SHIELD for B-3a l i f t re-entry vehicles REF 8 120c component 01 04 0 LEADING EDGE for D-3a l i f t re-entry vehicles REF 8 32b Component 06 01 0 AIR INLETS & DUCTING for A-3a hypersonic cruise vehicles REF B-121b Component 08 01 0 KEAT SHIELD for B-3a l i f e re-entry vehicles et o/ o I I REF B-179 Component 05 05 0 DOCKING ATTACHMENT I I fot <:-6e work device spscecraft support system k SYSTEM PROBA&ILir C O M r o N E N I I C R I T I C A U T r FREaUCNCY OF KOVi t IN SYSTEWl D E S I G N A L T E R N A <. MATERimS 3 I M P U C A T i a A A R P , RAW S C O R E S n e 4 I t 1 6 S 3 2 1 1 C. 3 6 4 -o T » T A L S 8 tz 3 3 £ i> 3Z ,^-<'\ 9 3 3 a 0 29 ,/9ZS ¥ 9 / e 6 0 ^ /z 9 / 3 6 0 31 > n 9 / 3 6 0 31 « 1 6 O 0 /7 tt 9 1 3 o /z 9 1 £ e 0 28 /2 6 / 3 e 0 2Z 9 / •3 o 9 / g ¥ 0 z¥ .ci4. . /Z t / 3 o t> 2S- AH. IZ 2 3 o 0 2/ 8 « X 3 O (^ /9 , » 3i V 9 2 3 o (> /8 /< / z 1 6 e> 0 31 s /z •2. 3 0 0 2S . ^ . ^ e 9 2 3 o 3*- 8 9 z 3 o 0 ^^ g 2. S o 0 2S /z <? f a o 0 28

EXPLANATION OF CAMR REFERENCES TO SYSTEMS, COMPONENTS, AND AARP RATING FACTORS CAMR CHART NUHBCR 530 XSSI S32. 33t REP pTOpulaloD Requlrenent Surface Conditioning No 2 Compoiuat 13 07 Oi, FUBI, STSTKM COBHOSIOH PEOTBCTIOH for A-3a hyperaonlc cruise high altitude or low altitude vehicles and B-la earth launch recoverable booster iv vComponent 18 04 0 GASEOUS POWBR STSTSM PROPBUANT- OXIDIZBR TANKS for A-3 hyperaonlc cruise and hyper- sonic boost glide v e h i c l e s , B-la earth launch recov- erable booster, B-2a near spsce operations space- c r a f t , and B-2c spacecraft shuttle Component 18 06 0 GASEOUS FOHBR STSTSM DUCT DC- PIP DIG for B-la, B-2a, and B-2c systems as above REF Propulsion Requirement Surface Conditioning No 3 Components 10 01 0 TURBOJET COHPRESSOS BLADBS and 10 02 0 COMPRESSOR DISCS for A-2a supersonic high altitude long range a i r c r a f t , A-2c supersonic t a c t i c a l V-STOL fighter, and B-la earth launch recoverable booster BF B-100a,b Component 06 04 0 HBAT EXCHANGER (RADIATOR) for B-2a ( 1 ) , B-2a(2}. and B-2a(3) near space operations spacecraft - earth s a t e l l i t e , space station, and lunar vehicle, and B-2c spacecraft shuttle R£F B-120a Component 01 04 0 UADIIC EDGE for B-3a l i f t Te-<ntry vehicle REF B-121a Component 08 01 0 HBAT SHIELD for B-3a l i f t re-entry vehicle REP Propulsion Requirement Surface Conditioning No 4 Components 18 03 0 GASEOUS POUBR SYSTEM HEAT EXCHAHCZR and 18 06 0 DUCTING-PIPING for B-la earth launch recoverable booster, B-2a near space operations spacecraft, and B-2c spacecraft shuttle REP Propulsion Requirements Surface Conditioning No Components 10 01 0 TURBOJET COHPBESSOR BLADBS and 10 02 0 COMPRESSOR DISCS for A-2a supersonic high altitude long range spacecraft, A-2e supersonic t a c t i c a l V/STOL fighter, and B-la earth launch recoverable booster /e.ei.o ./6.of.a. le etc /e ale /e ei.o lo,et.o b SYSTEM PROBABILtrf COMPONENT cBiTicAinr FREaUCNCY or KQMT IN SVST6W\ DESIGN ALTERNA i3 MATCRIAUS IMPUCAnOM A A R P RAW SCORES 11 e <t It '1 & 3 3 1 1 8 2 y 0 7 2 0 zy 0 zy f 2 1 8 Z 9 </ 8 1 9 /z 8 & Z- <> y 0 33 6 Z f 0 gy 8 (• 7, « <? 9 0 Zf 8 6 ¥ ti. 9 c 0 3r A , /z 9 Z e 0 3 f 0 7/ 0 3f e t Z c , < ^ - ^ , /2 z 6 £ /2 z c 0 3S- e f z 6 0 31 11 It / 0 J 7 It. It / V It 1 c 0 SM . 8 It z i $ 9 z 6 6 0 31 e n z i i B 9 z & i 0 31 n 9 z 6 t 3S i z C 0 21 . 8 9 <? C> 31 /t 9 c 0 3S $ C Cr i 6 0 2 ? n <f z 6 0 3S- It <f i c c i) 3r 1 z. 6 c 0 3' A ̂ . It 0 z 6 C 0 ? r A ^f. It z 6 0 t 1 «. 6 6.

EXPLANATION OF CAMR REFERENCES TO SYSTEMS, COMPONENTS, AND AARP RATING FACTORS CAMR CHART NUMBCA, HEP B-30., 41a, 63b Component 01 01 1 AERO- DTHAHIC LIFT t COOTSOL STRUCTUKE-RICID SKIN for H-U hypersonic cruise high altitude or lov altitude vehicles A-3b hypersonic boost glide strategic or t s c t l c a l vehicles and A-4a(l} t a c t i c a l ground launched a n t l - n l a a l l e REF B-31a Coiponent 01 01 2 ABROnNAHIC LIFT h COKIROl STRUCTURE - RIGID SUBSTRUCTURE for A-3a hypersonic cruise v s h l c l e s REF B-3Za Coiiponent 06 01 0 AIR IHLBTS & DUCTINC for A-3a hypersonic cru i s e vehlclea REF B-124, 125 Cooponenta 07 02 0 BLECTROMAGIIETIC TRANSPARENCIES (RADOHES, BAMR WINDOHS) and 07 03 0 aPTICAL TRANSPAREKCIES (IR, VISIBLE, UV) for B-3a l i f t re-entry vehlclea REF B-133C CoiDponent 03 01 0 HEAT SHIELD for B-3b drag entry vehlclea REF B-168b Component 14 02 0 LIQUID ROCKET HOTOR NOZZLE for C-2o In-apace personal propulalon unit 97.03 0 ii SYSTEM PRD&ABtLir COMPONENT ( CRITICAUIV FREBUCNCY OF cavit IN SVSTEWl DESIGN ALTERMA C MATEEima ! IMruCATIOl A A R P RAW 3C A S C S I t 8 4 It <)-& 3 3 2-1 3 6 4-0 e 3 3 a 8i n £ 3 o 0 zi A V r /tiit Ant ' 9 A / 3 0 0 X 8 3 3 o ZO A^ , 8 9 3 3 o i> 23 8 a 3 3 o 0 2t) 8 f 3 3 o 0 -23 ft /z 2 3 0 0 t<> /2 9 1 3 o 1 1 0 0 I . , . . 0 J . . . . 0 0 1 , . 1 . 0 0 I I I ) . e> 0 (> 0 0 ' 1 1 1 I 0 0 0 e> 6 0 0 0 0 * 0 •> 0 0 0 l>

-89- PANEL ON NON-METALLIC FABRICATION Members L i a i s o n Dr Robert S Ross, Chairman Mr G K P a r t a i n Mr W M S t e r r y Mr W i l l i a m J R e i l e y Mr W i l l i a m Winters Mr R i c h a r d E Young Mr J J Mattice

-91- 2 2 NON-METALLIC FABRICATION REQUIREMENTS A Sunmiary of Problems and Recommendations The s e v e r i t y of the environment encountered by the v a r i o u s systems considered i n t h i s document, coupled with the numerous f u n c t i o n a l requirements, demands e x t e n s i v e use of n o n - m e t a l l i c m a t e r i a l s i n the c o n s t r u c t i o n of such systems M a t e r i a l s considered m t h i s s e c t i o n are molded p l a s t i c s , r e i n f o r c e d p l a s t i c s , g r a p h i t e s , ceramics and g l a s s , and are u t i l i z e d f o r t h e i r strength-to-weight p r o p e r t i e s or other s p e c i a l c h a r a c t e r i s t i c s i n c l u d i n g e l e c t r i c a l and thermal I n most c a s e s , the combination of p h y s i c a l s i z e and shape, loads, temperature, weight and other requirements p r e s e n t s formidable problems to the d e s i g n e r s and b u i l d e r s of components formed from non- m e t a l l i c s The unique problem c o n f r o n t i n g these f a b r i c a t o r s i s t h a t the b a s i c m a t e r i a l p r o p e r t i e s are imparted at the time of f a b r i c a t i o n of the end a r t i c l e S i n c e the u l t i m a t e i n m a t e r i a l p r o p e r t i e s i s r e q u i r e d f o r most aerospace a p p l i c a t i o n s , the maintenance of u l t i m a t e p r o p e r t i e s and/or property u n i f o r m i t y becomes more c r i t i c a l as l a r g e r s i z e s a re encountered T h i s c o n s t i t u t e s the h e a r t of the n o n - m e t a l l i c f a b r i c a t i o n problem whether i n the organic or i n o r g a n i c a r e a A f u r t h e r problem encountered i s that p h y s i c a l t e s t i n g on n o n - m e t a l l i c components q u i t e often degrades the m a t e r i a l p r o p e r t i e s to such an extent as to render the component unusable T h i s f o r c e s the f a b r i c a t o r to e x e r c i s e i n o r d i n a t e l y s t r i n g e n t and c o s t l y q u a l i t y c o n t r o l over every phase of f a b r i c a t i o n I t p o i n t s up the f a c t that adequate n o n - d e s t r u c t i v e t e s t methods are l a r g e l y l a c k i n g and t h a t they are needed to demonstrate the adequacy of c e r t a i n f a b r i c a t i o n techniques With no n - m e t a l l i c f a b r i c a t e d components i t may be impossible to perform machining o p e r a t i o n s , subsequent to f a b r i c a t i o n , which w i l l b r i n g the components w i t h i n the dimensional t o l e r a n c e s r e q u i r e d f o r operation A good example of t h i s would be a l a r g e woven sandwich radome I f the process used does not keep the e x t e r n a l s k i n spacing w i t h i n c e r t a i n c r i t i c a l dimensions, the radome could not perform i t s e l e c t r i c a l f u n c t i o n although i t might be s t r u c t u r a l l y adequate Another t y p i c a l example i s a tempered p l a t e g l a s s window I f the s u r f a c e f l a t n e s s and p a r a l l e l i s m causes the window to be o p t i c a l l y inadequate a f t e r tempering, there i s no way of r e g r i n d i n g and r e p o l i s h i n g to make i t a c c e p t a b l e I n both of the above examples, the r e s u l t i s a l o s t component Thus, the equipment used f o r f a b r i c a t i n g l a r g e components i s v e r y c r i t i c a l and u s u a l l y expensive, a f a c t which oftentimes n e c e s s i t a t e s funding a s s i s t a n c e

•92- There a r e i n s t a n c e s where a p a r t i c u l a r component i s r e q u i r e d f o r a s p e c i f i c v e h i c l e or m i s s i o n There may be a requirement f o r expensive f a b r i c a t i o n equipment or e x t e n s i v e p r o c e s s development, but no requirement f o r more than a few a r t i c l e s nor any commercial use f o r e - seen f o r e i t h e r s i m i l a r a r t i c l e s or the f a b r i c a t i o n equipment I n such c a s e s , government funding would not only be d e s i r a b l e , but n e c e s s a r y P a r t i c u l a r l y i n the ca s e of n o n - m e t a l l i c f a b r i c a t i o n , t h e r e seems to be a l a c k of confidence i n the use of some p r o c e s s e s due to the absence of experience and data to e s t a b l i s h with c e r t a i n t y the t r u e s t a t e of the a r t Adopting the process f o r a m i s s i o n system would probably be co n s i d e r e d an unacceptable r i s k A c c o r d i n g l y , i t i s suggest- ed that some of the programs that are l i s t e d as s t a t e of the a r t should n e v e r t h e l e s s be government funded and operating experience data accumulated so th a t the n e c e s s a r y confidence l e v e l can be e s t a b l i s h e d I n some a p p l i c a t i o n s , the p h y s i c a l p r o p e r t i e s r e - quired are beyond the c a p a c i t y of e x i s t i n g m a t e r i a l s I n these c a s e s , an e f f o r t should be undertaken to develop a s u i t a b l e m a t e r i a l A manufacturing method f o r these a p p l i c a t i o n s cannot be determined u n t i l the m a t e r i a l i s a v a i l a b l e and i t s handling and forming c h a r a c t e r i s t i c s are known Ceramics The normal r a t e of advancement of the s t a t e of the a r t p r o c e s s e s f o r the production of ceramic and p r i m a r i l y ceramic composites i s s u f f i c i e n t to f i l l the m a j o r i t y of the a n t i c i p a t e d needs Process requirements not expected to be met by the normal r a t e are b r i e f l y d e s c r i b e d below I t should be r e a l i z e d , however, t h a t continuous advances i n m a t e r i a l s s i n c e the time of the o r i g i n a l system s t u d i e s may n e c e s s i t a t e reexamination of m a t e r i a l c a l l - o u t s on the v a r i o u s systems and s p e c i f i c a t i o n of new m a t e r i a l s and r e l a t e d p r o c e s s e s f o r 1970-1985 The f o l l o w i n g process development requirements a r e expected to p e r s i s t r e g a r d l e s s of the s p e c i f i c a t i o n of new m a t e r i a l s Production of l a r g e p a r t s of c o n t r o l l e d p o r o s i t y and pore s i z e w i l l r e q u i r e development of improved methods f o r producing por o s i t y , f o r handling l a r g e f r a g i l e p a r t s i n the u n f i r e d c o n d i t i o n and f o r c o n t r o l l i n g shrinkage during f i r i n g S u i t a b l e equipment i s expected to be a v a i l a b l e so the ta s k w i l l be that of understanding the m a t e r i a l ' s behavior during p r o c e s s i n g , and developing p r e c i s e process c o n t r o l Requirements f o r v e r y high s t r e n g t h r e f r a c t o r y ceramic p a r t s w i l l n e c e s s i t a t e e x p l o i t a t i o n of the c u r r e n t l y new but promising technique of hot working ceramics The p r o c e s s e s are i n t h e i r i n f a n c y but i t appears t h a t c r i t i c a l a s p e c t s of these hot e x t r u s i o n or f o r g i n g type operations w i l l be t o o l s and d i e s s u f f i c i e n t l y strong and r i g i d a t the working temperatures, equipment and procedures f o r manipulating the

-93- blanks and f u r n a c e s or heat sources f o r heating and annealing the p a r t s An a l t e r n a t e procedure f o r producing the r e f r a c t o r y high s t r e n g t h p a r t s i s vapor d e p o s i t i o n Although used s u c c e s s f u l l y to date i n the production of p y r o l y t i c g r a p h i t e and v i t r e o u s Si02» 1970-1985 requirements f o r other r e f r a c t o r y compounds w i l l d i c t a t e the use of more complex gas compositions, r e q u i r i n g e x t e n s i v e s t u d i e s to i d e n t i f y p r o c e s s time-temperature-pressure parameters, flow p a t t e r n s , mandrel m a t e r i a l s and heating techniques Another process r e q u i r i n g development w i l l be t h a t of production of l a r g e low temperature c u r i n g a c i d bonded p a r t s used i n rocket n o z z l e s and vanes The p r i n c i p a l problems w i l l be those of s i z e and a c i d i c nature of the bond M a t e r i a l s and/or c o a t i n g s w i l l have to be developed to p r o t e c t d i e s and t o o l s A c i d r e s i s t a n t bagging m a t e r i a l s w i l l have to be developed, as w i l l ovens capable of handling the a c i d fumes Rei n f o r c e d P l a s t i c s Woven sandwich composites impregnated w i t h r e s i n may be used f o r e i t h e r e lectromagnetic windows or f o r p o r t i o n s of the v e h i c l e s t r u c t u r e Wings, c o n t r o l s u r f a c e s or r o t o r s could be f a b r i c a t e d by t h i s method f o r use i n subsonic and supersonic m i s s i l e s and v e h i c l e s f o r operation i n the e a r t h atmosphere, as w e l l as f o r some space v e h i c l e s s t r u c t u r e s Some woven s t r u c t u r e s have been made of g l a s s and f a b r i c , i n c l u d i n g wings, r o t o r b l a d e s , gangplanks, s t a i r s , e t c However, m e t a l l i c w i r e weaving has been l i m i t e d to experimental t e s t panels The process f o r impregnating woven s t r u c t u r e s with r e s i n has been r e s t r i c t e d to a hand operation w i t h l i m i t e d q u a l i t y c o n t r o l Before t h i s manufacturing method can be a p p l i e d to f a b r i c a t i n g high q u a l i t y p a r t s , development programs must be undertaken to o b t a i n the dimensional t o l e r a n c e s r e q u i r e d and to develop the q u a l i t y c o n t r o l of the impregnation process The a p p l i c a t i o n of sandwich c o n s t r u c t i o n to l a r g e complex shapes w i l l introduce some f a b r i c a t i o n problems, the m a j o r i t y of which are being handled by normal development I t w i l l r e q u i r e the s p l i c i n g of honeycomb cores to maintain s t r u c t u r a l i n t e g r i t y T h i s i s c u r r e n t l y being done by s e v e r a l s u c c e s s f u l methods which r e s u l t i n a s l i g h t weight i n c r e a s e While i t i s t e c h n i c a l l y f e a s i b l e to develop a s p l i c e that does not i n c r e a s e weight or reduce s t r e n g t h , the c o s t of such development might not be warranted Large, high q u a l i t y , f i l a m e n t wound s t r u c t u r e s of unusual shapes w i l l be r e q u i r e d f o r space a p p l i c a t i o n s Research w i l l be r e q u i r e d to l e a r n how to wind these shapes The l a r g e mandrels must

-94- be supported so t h a t t h e i r d e f l e c t i o n s w i l l not a f f e c t the f i n a l s t r u c t u r e The f i l a m e n t s must be l a i d on I n such a manner th a t they do not s l i p during winding or c u r e , but remain i n the design d i r e c t i o n to c a r r y t h e i r apportioned share of the s t r e s s I t has been found t h a t m u l t i p l e l a y e r s of f i l a m e n t s b u i l t up to form t h i c k s e c t i o n s s u f f e r a degradation i n t h e i r c a p a c i t y to work together to develop the s t r e n g t h s a v a i l a b l e i n t h i n s t r u c t u r e s T h i s can be improved to some ex t e n t by v a r y i n g the t e n s i o n as winding ta k e s p l a c e F u r t h e r work i s r e q u i r e d to determine what causes the r e d u c t i o n i n s t r e n g t h and to develop ways to a l l e v i a t e i t There i s a requirement f o r f i l a m e n t wound tanks holding c o r r o s i v e l i q u i d s Some s u c c e s s has been obtained u s i n g an aluminum a l l o y l i n e r When the tank i s p r e s s u r i z e d , the d e f l e c t i o n of the f i l a m e n t wound s t r u c t u r e a l l o w s the aluminum to expand i n t o the p l a s t i c range When the p r e s s u r e i s removed, the l i n e r may encounter some bu c k l i n g away from the f i b e r g l a s s A program i s r e q u i r e d to develop methods of attachment so t h a t l o c a l b u c k l i n g of the l i n e r does not take p l a c e S u b s t i t u t e l i n e r m a t e r i a l s should not be overlooked F o r i n s t a n c e , methods have been found of forming and s e a l i n g p o l y t e t r e f l u o r o - ethylene which might make i t an e x c e l l e n t m a t e r i a l f o r some a p p l i c a t i o n s Large f i l a m e n t wound s t r u c t u r e s might be of such s i z e and shape t h a t i t would be d e s i r a b l e to make them i n s e v e r a l p a r t s and j o i n them permanently a t the assembly a r e a Methods of forming such a strong l i g h t w e i g h t bond are r e q u i r e d and a development program should be considered Thermally P r o t e c t i v e M a t e r i a l s I n the a r e a of a b l a t i v e heat s h i e l d s f o r r e - e n t r y v e h i c l e s , moderately severe environments can be accommodated by u s i n g e x i s t i n g m a t e r i a l s However, manufacturing programs are recommended as a means of o p t i m i z i n g the s t r u c t u r e f o r weight and performance and to I n t e g r a t e the a b l a t i v e s h i e l d w i t h the i n s u l a t i n g s t r a t a and the composite s t r u c t u r a l members For the most severe environments, new m a t e r i a l s w i l l have to be developed before the manufacturing requirement can be e s t a b l i s h e d A s t r u c t u r a l foam t h a t can be formed i n space i s needed f o r temporary s h e l t e r , shock abso r p t i o n pads and emergency p r o t e c t i o n s h i e l d s Methods of forming these i n the shop environment are now a v a i l a b l e Programs must be i n i t i a t e d t o ensure t h a t t h e s e p a r t s may be produced i n the space environment w i t h the degree of r e l i a b i l i t y r e q u i r e d

-95- Other Non-metallic M a t e r i a l s L u b r i c a n t s , b e a r i n g s , s e a l s , adhesives and elastomers w i l l be r e q u i r e d to operate f o r long p e r i o d s without degradation under r a d i a t i o n exposures s e v e r a l o r d e r s of magnitude g r e a t e r than present m a t e r i a l s can w i t h s t a n d T h e r e f o r e , a m a t e r i a l s development program should be i n i t i a t e d to provide the r e q u i r e d p r o p e r t i e s , p o s s i b l y by i n - c l u s i o n of a n t i - r a d s and neutron s h i e l d s I n t h i s review the s p e c i f i c manufacturing requirements have been s t u d i e d and those which a r e s t a t e of the a r t or those which r e - q u i r e new m a t e r i a l s have been s e t a s i d e as beyond the scope of t h i s panel The remaining requirements c o u l d be met w i t h some development of manu- f a c t u r i n g methods S p e c i f i c programs a r e o u t l i n e d i n these a r e a s where development i s recommended and are i n c l u d e d w i t h each CAMR c h a r t B Outlook The use of n o n - m e t a l l i c s i s o f t e n r e l e g a t e d to components where s p e c i a l p r o p e r t i e s such a s thermal, o p t i c a l , e l e c t r o - magnetic, or c o r r o s i o n r e s i s t a n c e a r e r e q u i r e d without f u l l c o n s i d e r a - t i o n to the s t r u c t u r a l c a p a b i l i t i e s of the m a t e r i a l I t i s recommended that more a t t e n t i o n be given to the use of n o n - m e t a l l i c s f o r primary s t r u c t u r a l u s e s , where t h e i r s p e c i a l p r o p e r t i e s may not be an e s s e n t i a l requirement Many uses of n o n - m e t a l l i c s are i n some form of composite s t r u c t u r e where f i l a m e n t s a r e imbedded i n r e s i n s The process technology developed f o r use w i t h c u r r e n t m a t e r i a l s could w e l l lend i t s e l f to the a p p l i c a t i o n s f o r some of the newer f i b e r s , w h i s k e r s , and r e s i n s , f o r s p e c i a l a p p l i c a t i o n s where composite m a t e r i a l p r o p e r t i e s are s u p e r i o r to those now a v a i l a b l e and show promise f o r even f u r t h e r Improvement The e n t i r e f i e l d of n o n - m e t a l l i c s t r u c t u r e s develop- ment i s r e l a t i v e l y new, and i s advancing a t a r a p i d r a t e New m a t e r i a l s are c o n s t a n t l y being developed To take advantage of these i t w i l l be ne c e s s a r y f o r continued p r o c e s s i n g development and demonstration by end-item f a b r i c a t i o n The f i e l d of n o n - m e t a l l i c s can y i e l d s u b s t a n t i a l advances i n the range of i t s a p p l i c a t i o n s , and i n the p r o p e r t i e s achieved w i t h a t t e n t i o n to o p p o r t u n i t i e s presented by m a t e r i a l s develop- ment

96 TITLE IMPREGNATING AND CURING LARGE PLASTIC SANDWICH COMPOSITES CHART PRIORITY RELATED CAMB^JHARTS; MANUFACTURING REQUIREMENT Apply r e s i n I m p r e g n a t i n g agent t o p r e v i o u s l y woven f i b e r s I n sandwich form t o Insure complete and u n i f o r m d i s t r i b u t i o n and ap p l y heat and pre s s u r e I n the range o f 350 F on f l a t s e c t i o n s up t o 20 f e e t x 20 f e e t and h e m i s p h e r i c a l s e c t i o n s up t o 10 f e e t diameter F l a t s e c t i o n s are used f o r s p a c e c r a f t I n t e r n a l s t r u c t u r e (decks and bulkheads) and contoured s e c t i o n f o r radomes AARP REFERENCES E C h a r t s . B C h a r t s . 224 290 108b 112a b 135b 136b P&FVPS Char ts . APPLICABLE PROCESS APPLY LIQUID RESINS BY PRESSURE DIFFERBOTIALS AND HARDEN BY HEAT OR CHEMICAL TRIGGERING AGENT Code 8 03 27 STATE OF THE ART ASSESSMENT The c u r r e n t s t a t e o f the a r t o f f a b r i c a t i o n o f f i b e r g l a s s p a r t s tends toward the use of pre Impregnated m a t e r i a l s and l a r g e a u t o c l a v e s or ovens t o e f f e c t the cure P a r t s up t o 12 f e e t X 16 f e e t have been cured a t 13 p s l by vacuum bagging P a r t s o f c i r c u l a r c r o s s s e c t i o n are being b u i l t by f i l a m e n t w i n d i n g which a p p l i e s the r e s i n by d i p p i n g the yarns d u r i n g w i n d i n g Larger p a r t s can be placed I n the mold and the r e s i n brushed on The pressure can be a p p l i e d by vacuum bagging The necessary heat has been s u c c e s s f u l l y a p p l i e d by r a d i a n t heat lamps There are a l s o r e s i n s which w i l l cure a t room temperature b u t these leave v e r y s h o r t w o r k i n g time I n the shop before s e t t i n g up I t w i l l be d i f f i c u l t t o extend these methods t o h a n d l i n g sandwich c o n s t r u c t i o n A l t h o u g h t h e r e i s c o n s i d e r a b l e i n t e r e s t i n t h i s type o f c o n s t r u c t i o n f o r advanced a p p l i c a t i o n s the r a t e a t which development work I s p r o g r e s s i n g a t the p r e s e n t time does n o t i n d i c a t e t h a t a m a n u f a c t u r i n g method w i l l be achieved by 1970 w i t h o u t a d d i t i o n a l e f f o r t CRITICAL PROBLEMS 1 U n i f o r m i m p r e g n a t i o n o f l a r g e s e c t i o n s and c o n t r o l o f f i n a l t h i c k n e s s t o t o l e r a n c e s of + 0 030 Inches 2 C o n t r o l o f heat and pressure over l a r g e areas t o o b t a i n u n i f o r m and complete c u r i n g 3 C o n t r o l o f ba s i c f i b e r m a t e r i a l o r i e n t a t i o n ALTERNATE PROCESSES APPLY RESIN TO YARNS BEFORE WEAVING APPLY RESIN BY SPRAYING BRUSHING DIP COATING CALENDERING ETC APPLY HEAT AND PRESSURE BY A SUITABLE COMBINATION OF AUTOCLAVES MATCHED MOLDS PLATENS VACUUM BAGS RADIANT LAMPS OVENS ETC Code 7 11 01 8 03 23

PROPOSED DEVELOPMENT PROGRAM OBJECTIVE E s t a b l i s h a process f o r i m p r e g n a t i n g and c u r i n g l a r g e woven sandwich panels i n f l a t s e c t i o n s 20 f e e t x 20 f e e t and h e m i s p h e r i c a l s e c t i o n s 10 f e e t I n diameter w i t h s u r f a c e t o l e r a n c e s o f + 0 030 inches U n i f o r m s u r f a c e d e n s i t y i s i m p o r t a n t The completed s e c t i o n must~be ab l e t o w i t h s t a n d a space environment and temperatures up t o 300 F R e p r o d u c i b i l i t y i s t o be a f u t u r e p o t e n t i a l BACKGROUND P r e s e n t l y sandwich components are being made us i n g form o r pre cured honeycomb as the core I n these cases the c o r e remains a p a r t o f the f i n a l sandwich The face c l o t h s can e i t h e r be prepreg m a t e r i a l or the i m p r e g n a t i n g agent can be brushed on I n sandwich m a t e r i a l where the core i s composed o f web or threads the agent may be calendered and the h o l e s open b e f o r e d r y i n g Prepreg m a t e r i a l i s t o o s t i c k y t o sew w i t h any degree o f success Some o f the agent w i l l w i c k down the t h r e a d s i f the d i s t a n c e i s not g r e a t and the v i s c o s i t y i s low I n any o f these methods the c u r i n g i s done w i t h removable cores i n s e r t e d i n the spaces between webs APPROACH An at t e m p t should be made t o automate the process i n order t o o b t a i n u n i f o r m i t y over l a r g e areas p a r t i c u l a r l y i f spray c o a t i n g i s c o n s i d e r e d Methods f o r t e s t i n g the u n i f o r m i t y o f the s e c t i o n s w i l l be r e q u i r e d Develop method o f i m p r e g n a t i o n o f l i ^ i d r e s i n by pressure d i f f e r e n t i a l A l s o c o n s i d e r a t i o n should be g i v e n t o d e v e l o p i n g the process i n a phased manner w i t h spray c o a t i n g and a u t o c l a v e p r e s s u r e and heat a p p l i c a t i o n However o t h e r methods such as u s i n g matched nx>ld d i e s r a d i a n t lamps d i p c o a t i n g e t c should a l s o be c o n s i d e r e d I f p o s s i b l e the same process should be used f o r the f l a t panels as the curved s e c t i o n s However i f d e s i r a b l e two d i f f e r e n t methods may be employed I n some cases p r o v i d e means f o r the v o l a t i l e s t o escape Consider the adhesive problems between the f i b e r s and the i m p r e g n a t i n g m a t e r i a l s Consider i n s p e c t i o n and q u a l i t y c o n t r o l as w e l l as means f o r e n v i r o n m e n t a l l y t e s t i n g the completed components R e p r e s e n t a t i v e samples should be f a b r i c a t e d and t e s t e d t o work ou t d e t a i l s of the process and t o v e r i f y the r e s u l t s o b t a i n e d

98 PRIORITY RATING WORKSHEET PffgqP^M FACTORS PROaRAM PROBABILITV Of S U C C E S S D L O W • M O D E B A T E >t, HiaH CRITICAL PROBLEMS TO B E SOLVED • F e > ^ / N O T TOO PIFFltfUUT S O M E / D I F F I C U L T • MANY/ VERV DIFFjCUtr PROCeSS fiROWTH P O T E N T ( A L D L I T T L E OR UNDEFINAQV.C yt, KeeofiNaABLE P O T B U T I A L APPLICATIONS OTHER THAN AIR FORCE • NONE n SOME "% MANY NECESSITY FOR AIR FORCe FUNDIWa n Law H>6» iNiuSTEV/'snicA 6mr srr ar 4 > ( iA<nit4AT» - SOME E F R H L T ermx •SpuMCS s n ttuui'stte AIR F»(iet F U M P M * UI£6L<( W . z 5 8 Z s 6 o 4 o 4 e NEED FACTORS P a CHART 8 0 s _22_ S Y S T E M S P R O B A B I L I T Y H\a» PeoBAB ITY IZ FAIB. PROBABILITY S LOW P R O B A B I L I T Y 4 COMPONENT CRIT ICALITY VERY HICH HIAH 9 FAIR 6 L e w 3 F R E a U E N C Y OF REQUIREMENT IN S Y S T E M MORE THAN 3 CotAVnitHTa 3 Z 3 C«MP»NENrS 2 SINGLE (JOMPONENT I DESIGN ALTERMATES No ALTERNATe R n E G E E H 1 ONC ALTERNATE 6 SEVEILAL A L T E R N A T E * 3 MATERIALS IMPLICATION New MATERIAL peyfLoFHeNT c e o o 6 (VWTtBIAL IMPaCVEMCMT KEfi D 4 NO PRooLeM F a e s E e i J o CALCULATE PRIORITY STEP I CIRCLE HIGHEST A A R P S C O R E S T E P Z IN EACH OTHER S Y S T E M C I R C L E IF WITHIN 4 POINTS OF TOP NUMBER OF -SViTEWS M i d H ^ U O W RAW Scopes FOR EACH gtrtieneiv CoMFMcirr M TABceS AT tND or PAllEL Vtpetr VWITH tJAlO TOTALS ENTERCP IN •SUMUAtV K eiSMT s v s r M . -"̂ ABP SCOWS (5y[ l i ] [ I i ]aCZlCD 8 Ze ^ [ 2 ^ 1 1 II 1̂ I 3o NEXT HIGMEST S C O R E lr» L SCORE S T E P 3 C I R C L E FREQUENCY DISTRIBUTION FACTOR I 2. 3 e M«u f B E L O W t NUNieeR OF SYSTEMS Low 0 I 1 0 1 a 1 4 1 1 1 3 1 z 1 H- 1 4 i n a n • • • • • I C Z I I TOTAL PRIORITY

99 TITLE WEAVING METALLIC AND NON METALLIC SANDWICH COMPOSITES CHART PRIORITY NO 4.13 ^ RELATED CAMR CHARTS ^ / A MANUFACTURING REQUIREMENT Weave sandwich components o f non m e t a l l i c s t r u c t u r a l f i b e r s t o form radomes up t o 10 f e e t i n diameter and o f m e t a l l i c and non m e t a l l i c f i b e r s t o form f l a t s e c t i o n s up t o 20 f e e t m a i n t a i n i n g a t o t a l t h i c k n e s s accuracy o f + 0 030 inches I n a d d i t i o n t o radomes a p p l i c a t i o n s are f o r s p a c e c r a f t i n t e r n a l s t r u c t u r e (deck and bulkheads) I n f l a t a b l e f l e x i b l e wings f l e x r o t o r s and f l e x d e c e l e r a t o r s AARP REFERENCES E C h a r t s . B Char ts . 223 289 300 108b 112a b 135b 136b lA5a b lA9a 150a b P4FVPS Char ts . APPLICABLE PROCESS WEAVE TWO FACE CLOTHS AND A CORE SIMULTANEOUSLY ON A PLUSH LOOM TO FORM A SANDWICH COMPONENT Code 8 04 03 STATE OF THE ART ASSESSMENT S p e c i a l looms have been used t o weave A l r m a t c l o t h up t o 8 f e e t t h i c k and 20 f e e t wide T h i s c o n s i s t s o f two s i m u l t a n e o u s l y woven c l o t h s i n t e r c o n n e c t e d w i t h yarns dropped between the c l o t h s a t programmed I n t e r v a l s The l e n g t h o f these are v a r i e d t o c o n t r o l the contour o f the completed p a r t C y l i n d r i c a l s e c t i o n s have been made by weaving one face c l o t h longer than the o t h e r P a r t s w i t h double c u r v a t u r e have been heat formed i n n y l o n a f t e r weaving S p e c i a l shapes t h a t do not lend themselves t o machine weaving have been formed by hand sewing the drop threads between the face c l o t h s A machine has been developed f o r weaving d i a g o n a l webs between woven face c l o t h s C u r r e n t t o l e r a n c e o f + 0 12 inches i s n o t adequate f o r t h i s a p p l i c a t i o n A program must be developed t o o b t a i n the t o l e r a n c e r e q u i r e d T h i s would p r o b a b l y I n c l u d e a means f o r l o c k i n g the weave t o prev e n t s l i p p a g e d u r i n g the m a n u f a c t u r i n g process and a means f o r p r e d i c t i n g m a t e r i a l s t r e t c h so t h a t the f i n i s h e d p r o d u c t dimensions c o u l d be p r e d i c t e d more a c c u r a t e l y CRITICAL PROBLEMS 1 M a i n t a i n i n g f i n a l t h i c k n e s s t o l e r a n c e s w i t h i n + 0 030 inches o f s p e c i f i e d v a l u e 2 M a i n t a i n i n g f i l a m e n t o r i e n t a t i o n u n t i l locked i n p l a c e by im p r e g n a t i n g agent 3 C o n t r o l l i n g t e n s i o n o f each f i b e r U I n c o r p o r a t i n g openings attachments and r e i n f o r c e m e n t s f o r l o c a l s t r e s s c o n c e n t r a t i o n s 5 Ha n d l i n g low de n i e r s y n t h e t i c h i g h modulus f i b e r s 6 Means o f h a n d l i n g and t r a n s p o r t i n g l a r g e s t r u c t u r e s w i t h o u t damage 7 I n s p e c t i o n and q u a l i t y c o n t r o l as w e l l as means f o r p e r f o r m i n g e n v i r o n m e n t a l t e s t s ALTERNATE PROCESSES FABRICATE THE SANDWICH BY APPROPRUTELY SEWING TOGETHER FLAT CLOTH HONEYCOMB HAND LAYUP BAG MOLDED REINFORCED PLASTIC Code 8 04 08 8 03 22

100 CHART NO b/o PROPOSED DEVELOPMENT PROGRAM OBJECTIVE BACKGROUND APPROACH E s t a b l i s h a weaving t e c h n i q u e which w i l l p e r m i t the f a b r i c a t i o n o f f l a t s e c t i o n s 20 f e e t X 20 f e e t from m e t a l l i c and n o n - m e t a l l i c f i b e r s and contoured 10 f e e t i n diameter h e m i s p h e r i c a l shaped sandwich m a t e r i a l u s i n g non m e t a l l i c f i b e r s and y i e l d i n g d i m e n s i o n a l t h i c k n e s s t o l e r a n c e w i t h i n + 0 030 inches S t r u c t u r a l i n t e g r i t y i s e s s e n t i a l so t h a t o r i e n t a t i o n and t e n s i o n o f the f i b e r s must be main t a l n e d u n t i l locked i n p l a c e by the c o a t i n g agent N o n - m e t a l l i c f i b e r s o f low d e n i e r and p o s s i b l y h i g h modulus should be co n s i d e r e d f o r use A non seam component i s d e s i r a b l e f o r s t r u c t u r a l i n t e g r i t y and u n i f o r m i t y o f e l e c t r i c a l p r o p e r t i e s Large s e c t i o n s o f woven sandwich have been made i n sym m e t r i c a l s e c t i o n s up t o 20 f e e t wide and 8 f e e C t h i c k When these are handled i n removing them from the loom some of the f i b e r s s l i p and r e s u l t i n a non u n i f o r m or warped s e c t i o n Some work has been done t o a n t i c i p a t e crimp and s t r e t c h a f t e r weaving so t h a t the f i n a l dimensions may be met t o a t o l e r a n c e o f + 0 12 Inches A phased program which d e f i n e s steps o f progress toward the s i z e and t o l e r a n c e s o f the d e s i r e d sandwich i s suggested I t should I n c l u d e the v a r i o u s f i b e r c o a t i n g s or t r e a t m e n t s necessary f o r ease i n h a n d l i n g t h r o u g h the loom d u r i n g the weaving process as w e l l as a means f o r removal i f necessary a f t e r w a r d s C o m p a t i b i l i t y o f the f i b e r s w i t h the e v e n t u a l bonding m a t e r i a l should be co n s i d e r e d i n s e l e c t i n g the f i n a l c l o t h f i n i s h Whether or n o t the same equipment can be used on f l a t and curved panels should be determined I f p o s s i b l e w i t h o u t major c o m p l e x i t y c o n s i d e r a weaving c a p a b i l i t y t h a t p e r m i t s programming r e i n f o r c e d areas i n t o t h e sandwich f o r attachments c u t o u t s and o t h e r p o i n t s o f s t r e s s c o n c e n t r a t i o n I t may be a d v i s a b l e t o co n s i d e r I n s p e c t i o n c l e a n i n g t r e a t i n g and c o a t i n g o f the woven p r o d u c t w h i l e s t i l l on the loom i n or d e r t o m a i n t a i n the r e q u i r e d t o l e r a n c e s A l s o c o n s i d e r a t i o n should be g i v e n t o removal and st o r a g e o f the f i n i s h e d p r o d u c t as t o whether i t should be spooled f o l d e d or handled i n a d e f i n e d c o n f i g u r a t i o n The program should i n c l u d e the f a b r i c a t i o n o f t y p i c a l p a r t s t o work o u t the p r o d u c t i o n d e t a i l s and t o v e r i f y the c a p a b i l i t y developed

PRIORITY RATING WORKSHEET CHART P R Q g R A M FACTORS PROSRAM PROBABILITV OF S U C C E S S n LOW 2 • M O D E R A T E 5 HICH 8 CRITICAL PROBLEMS TO B E SOLVED X FEN^/NOT TOO DIFFUJULT 2 • SOME/DIFFICULT 3 a MANY/ VERY DIFFICULT 8 P R O C E S S GROWTH P O T E N T I A L • LITTLE OR yNOEFINAOLE O X eeSOUNaABLE POTEMTIAL 4 APPLICATIONS OTHER TXAN AIR FORCE • NONE O a SOME 4 K MANY 8 NECESSITY FOR AIR FORCE FUNDINO • LOW HisK imus ev/OTHf* Gtwr I F F tr l^ MeotdATS - Some SFfotr erHte •SouMes e • ttteuisive AlR FfA^t IZ. NEED FACTORS e 3o S Y S T E M S P R O B A B I L I T Y HIQH PEOBAB ITY 12 FAIR PROBABILITY 8 LOW P R O B A B I L I T Y 4 COMPONENT CRITICALITY l/ERY H l fH l i H I«H 9 FAIR 6 LOW 3 FREaUENCY OF REQUIREMENT IN S Y S T E M MOW THAM 3 CeMP»xleMT9 3 a 3 CAMreUENTS 2 SIHiaLE CeMPeniENT 1 DESIGN ALTERWATES No ALTERNATE RMEOEEN '> one ALTERNATE 6 SevEILflL ALTERUATEC 3 MATERIALS IMPLICATION NEW MATERIflL PeV lOtUtHT CCll O 6 IVWTtBlAl IMPMVEMCNT E E l B P 4 NO PRe&LEM Fo«.csceia o CALCULATE PRIORITY STEP I CIRCLE HIGHEST A A R P RAW S C O R E n n S T E P 2 IN EACH CTTHER S Y S T E M C I R C L E NEXT HI<SM£ST IF WITHIN 4 POINTS OF T O P S C O R E W NUMBER flF sysTeiws HlAH ^ LOW ^ RAW scooes FOR E/^M REFCKEHetP CoMFfNCMT IN TABLtS AT t u n OF PANEL PtPatT WITH 12AW TcTTftLS ENTECEP IN W KlSUT S Y . . M S AARP SCOWS 32a Qj Yu][3^\ I I ^ 1 I B2cCti V3o\ r?e"| I 1 1 1 1 I gU&)\Ti\V^\ I I ^ 1 I Bze \2a'\ I 1 1 1 1 I S T E P 3 C I R C L E FREOOENCY DISTRIBUTION FACTOR SCORE B £ L O W i 3 KMMLC IMUMaCR OF SYSTEMS LOW 0 I 2 R Mau 1 0 1 a I 4 1 1 1 3 1 *f 1 «t- 1 4 39 1 8 • • • • • • • • • • • • • • • • • • • • • • • • • TOTAL PRIORITY

102 TITLE FILAMENT WINDING OF SPACECRAFT HULLS WITH APPROPRIATE OPENINGS CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT F i l a m e n t w i n d i n g o f h i g h s t r e n g t h g l a s s f i b e r s s y n t h e t i c f i b e r s or m e t a l w i r e s bonded w i t h s u i t a b l e r e s i n s i n s i z e s up t o 20 f e e t 0 D and AO f e e t long The d e s i g n o f a p p r o p r i a t e openings and J o i n t s f o r h a t c h covers and assembly i n space i s t o be c o n s i d e r e d p a r t o f t h i s requirement AARP REFERENCES B C h a r t . 107b. C P A F V P S C h a r t . APPUCABLE PROCESS Code FILAMENT WINDING 8 03 21 STATE O F THE ART ASSESSMENT I t i s w i t h i n the s t a t e o f the a r t t o f a b r i c a t e c y l i n d r i c a l p ressure v e s s e l s of g l a s s f i l a ments w i t h a s t r e n g t h t o d e n s i t y v a l u e w e l l i n excess o f 1 x 10^ Organic f i b e r s t r u c t u r e s w i t h e l a s t o m e r i c r e s i n s have shown s t r e n g t h t o d e n s i t y v a l u e s g r e a t e r t h a n 9 5 x 10^ A l i m i t e d amount o f w i r e w i n d i n g has a l s o been performed R i g i d s p a c e c r a f t h u l l s may be s u b j e c t e d t o compression d u r i n g the launch phase and thus c o u l d be b u c k l i n g c r i t i c a l T o r o i d a l segments ( p i p e elbows) are being s u c c e s s f u l l y wound as such meaning t h a t h u l l segments c o u l d be c o n s t r u c t e d on a curved a x i s C o l l a p s i b l e rubber bonded s t r u c t u r e s which c o u l d be i n f l a t e d i n space are a l r e a d y s t a t e o f the a r t These can be produced i n c y l i n d r i c a l or t o r o i d a l shapes f o l l o w i n g l i m i t e d development Openings have been made i n sm a l l pressure v e s s e l s through b u i l d u p s o f the s e c t i o n s where they are t o occur CRITICAL PROBLEMS The r e i n f o r c e m e n t of openings i n s t r u c t u r e s h a v i n g a s t r e n g t h t o d e n s i t y v a l u e o f 1 x 106 i s a r e q u i r e d development f o r l a r g e diameter elements The e v e n t u a l method o f c l o s i n g the opening w i l l a f f e c t t h e m a n u f a c t u r i n g method used ALTERNATE PROCESSES NONE Code

103 C H A R T PROPOSED DEVELOPMENT PROGRAM OBJECTIVE The f i l a m e n t w i n d i n g o f l a r g e s p a c e c r a f t h u l l s 20 f e e t diameter 40 f e e t long w i t h a p p r o p r i a t e openings u s i n g g l a s s s y n t h e t i c f i b e r s or metal w i r e s so as t o achieve s t r a i g h t or curved c y l i n d r i c a l forms w i t h an u l t i m a t e s t r e n g t h t o d e n s i t y r a t i o o f 1 x 10* or y i e l d s t r e n g t h t o d e n s i t y r a t i o o f 9 5 x 10^ BACKGROUND ATPROACH I t I s s t a t e o f the a r t t o wind r i g i d or c o l l a p s i b l e s t r a i g h t and curved c y l i n d r i c a l p r e s s u r e v e s s e l s u s i n g h i g h s t r e n g t h g l a s s f i l a m e n t s s y n t h e t i c f i b e r s and m e t a l w i r e s however do i n g so i n the s i z e s and w i t h the s t r u c t u r a l e f f i c i e n c y d e s i r e d I s s t i l l t o be done I n c l u d i n g openings i n f i l a m e n t wound v e s s e l s has always been a problem area p a r t i c u l a r l y i f they are needed o f f the a x i s f o r some reason B u i l d ups e i t h e r wound or hand I n s e r t e d are used t o handle s t r e s s c o n c e n t r a t i o n s To e f f i c i e n t l y d e s i g n and f a b r i c a t e l a r g e s t r u c t u r e s would t h e r e f o r e be a development t h a t I s needed The major problem r e l a t e s t o the bonding and w i n d i n g process I t appears t h a t c u r i n g whether u s i n g room or h i g h temperature r e s i n s can be handled through the use o f ovens which w i l l produce the c i r c u l a t i o n r e q u i r e d When l a r g e s i z e ovens have n o t been a v a i l a b l e temporary ovens have been f a b r i c a t e d T h i s technique has been employed s a t i s f a c t o r i l y f o r r a i l r o a d tank c a r s where a i r was c i r c u l a t e d both I n s i d e and o u t s i d e the wound s t r u c t u r e s S e l e c t the t y p i c a l shapes and s i z e s both s t r a i g h t and curved t h a t would be f u n c t i o n a l l y r e q u i r e d f o r a s p a c e c r a f t m i s s i o n Determine what type o f openings are needed and the s i z e and l o c a t i o n t h a t would be c h a r a c t e r i z e d by t h e i r use Develop or modify e x i s t i n g machinery t o manufacture these t y p i c a l s e c t i o n s i n f u l l s cale b e i n g sure t o i n c l u d e w e l l designed openings t h a t can p e r f o r m f u n c t i o n a l l y Since the same w i n d i n g machinery can be used f o r both c o l l a p s i b l e or r i g i d components make a t l e a s t one o f each i l l u s t r a t i n g how the d i f f e r e n t b i n d i n g r e s i n s should be employed I f i t i s consi d e r e d economical t o f a b r i c a t e model s e c t i o n s b e f o r e s t a r t i n g the f u l l s c a l e components t h i s can be done S e l e c t i n g one sample type component s e v e r a l d u p l i c a t e u n i t s should be made and t h o r o u g h l y t e s t e d t o assure t h a t q u a l i t y c o n t r o l and i n s p e c t i o n techniques used are adequate t o p e r m i t p r e d i c t i o n o f s t r u c t u r a l performance and r e p e a t a b i l i t y INSPECTION TECHNIQUES SUPPLEMENTAL RECOMMENDATIONS OBJECTIVES I n s p e c t i o n o f r e s i n bonded f i b e r ( g l a s s or s y n t h e t i c ) s p a c e c r a f t h u l l BACKGROUND S o l i d p r o p e l l e n t m i s s i l e chambers from 44 i n c h t o 56 i n c h diameter and up t o t e n f e e t long were made i n p r o d u c t i o n q u a n t i t i e s i n the time p e r i o d 1961 t o 1967 A chamber 23 f e e t diameter by 60 f e e t long has a l s o been made These i n c l u d e t h r u s t attachments and bonded i n s e r t s f o r nozzles i g n i t e r s and t h r u s t t e r m i n a t i o n p a r t s Rovings The l a y o f the r o v i n g s and the occurrence o f r e l a x e d r o v l n g s has been s u c c e s s f u l l y e v a l u a t e d w i t h r a d i o g r a p h i c I n s p e c t i o n (BAA) De l a m l n a t i o n Through t r a n s m i s s i o n u l t r a s o u n d (DAB) and microwave techniques (CDD) have been used t o d e t e c t t h i s c h a r a c t e r i s t i c d u r i n g the f a b r i c a t i o n process development program T a n g e n t i a l r a d i o g r a p h i c i n s p e c t i o n (BAA) has been used t o d e t e c t d e l a m l n a t i o n between composite r e i n f o r c i n g I n s e r t s i n the a f t end o f the Stage I A3 P o l a r i s motor Continued on next page

104 CHART INSPECTION TECHNIQUES SUPPLEMENTAL BECOMMENDATIONS c o n t i n u e d > Bonding o f M e t a l l i c I n s e r t s Pulse-echo u l t r a s o u n d (DAA) and t h r o u g h t r a n s m i s s i o n u l t r a s o u n d (DAB) have been used f o r composite/metal I n s u l a t i n g r u b b e r / m e t a l and c o m p o s i t e / I n s u l a t i n g rubber bond i n t e g r i t y S p e c i a l techniques u s i n g frequency modulated c o n t i n u o u s wave and pu l s e d methods d e t e c t i n g phase I n v e r s i o n have a l s o been used f o r t h i s c h a r a c t e r i s t i c APPROACH No new tec h n i q u e development I s recommended because the I n s p e c t i o n methods should be s t a t e o f t h e a r t by 1970 The normal c h a r a c t e r i z a t i o n and d e f i n i n g o f q u a l i t y l i m i t s w i l l be r e q u i r e d f o r each c o m b i n a t i o n o f m a t e r i a l s i z e and c o n f i g u r a t i o n

PRIORITY RATING WORKSHEET CHART P R O S R A M FACTORS PR06RAM PROBABILITY OF SUCCESS • LOW Z • MODEBATe 5 )g, HI&H 8 CRITICAL PROBLEMS TO BE SOLVED a FevtytioT T O O P I F F U J U L T Z • SOME/DIFFICULT S a MANY/ VERY DIFFICULT 8 PROCESS GROWTH POTENTIAL D L I T T L E O R U N D E F I N A C L E O ^ eeco6HizikeLe porEMTiAL 4 APPLICATIONS OTXER THAN AIR FORCE • NONE O • S O M E 4 X MAMv e NECESSITY FOR AIR fORCt FUNOIWa • L w Hifix INt s e ' f /orHeft 6 o « r S F F t r 4 • M̂ OCSATC - Smc EFFCDLT OTHCA 'Seu8<!eS s ^ EKfLiJsiyE AlK PollCt F U M V M a UKCL>( 12. NEED FACTORS SYSTEMS PROBABILITY HIQH PBOBAei ITY FAIR. PROBABILITY LOW PROBADILTY COMPONENT CRITICALITY V E R Y H I C H F A I R L O W FREauENCY OF REQUIREMENT IN SYSTEM MORE THAM 3 C 0 M P m < E N T 9 2. 3 C « M P e M E N r 3 S l w a L E CeMPONENT DES\GN ALTERMATES No ALTERNATE R»ESEEN ONE ALTERNATE SEVERAL ALTERUATCC MATERIALS IMPLICATION NEW MATERIAL tJeveu><>IH£NT RCd O MATERIAL IMPflCVEMENT R£(S V NO PeosLEM FoftcseEia IZ 8 4 l i 9 e> 3 3 2 CALCULATE P R I O R I T Y e 3 ¥ RAW SCoOCS FOR EACM REFceeMirtP CoMrONCNT IN TABLES AT tND or PAtlEl IZtPOtT WITH 13AI0 TcrTttLS ENTEREP ru ^UMUAtV w A A R P RANM Seooes SYS MS [ m • • o • • • • • • • • • • [ = ] STEP 1 CIRCLE HIGHEST A A R P RAW S C O R E n = S T E P 2 IN EACM CTTHER S Y S T E M C I R C L E NEXT H I G H E S T IF WITHIN if POINTS OF T O P S C O R E H NUMBER OF 5VSTE(W3 HidH ^ UOW L 3 / S T E P 3 C I R C L E FREQUENCY DISTRIBUTION FACTOR I 2. 3 K M O U NUMBER OF SYSTEMS LOW 0 I 2 BMoee 1 0 1 a 1 4 1 1 1 3 1 & 1 1 4 • • • • • • • • • • • • • • • • • • • • SCORE B£UOWi TOTAL PRIORITY

106 TITLE FABRICATION OF A LARGE FIAT HIGH TEMPERATURE ELECTROMAGNETIC TRANSPARENCY FROM SLIP CAST FUSED SILICA CHART PRIORITY N O J Z L R E U T E D CAMR CHARTS MANUFACTURING REQUIREMENT P r o v i d e l a r g e h i g h temperature e l e c t r o m a g n e t i c t r a n s m i s s i o n windows ( g l a s s or ceramic) w e i g h i n g 10 t o AO l b s maximum dimensions i n f l a t or s l i g h t l y curved m o n o l i t h i c panels up t o 60 Inches S t r e s s r u p t u r e s t r e n g t h d e s i r e d equal t o or g r e a t e r t h a n 1500 p s l a t 2300 F f o r 30 minutes w i t h good e r o s i o n c h a r a c t e r i s t i c s AARP REFERENCES B Charts P«FVPS Charts. APPLICABLE PROCESS EITHER (A) SLIP CASTING AND SINTERING or (B) SECONDARY BONDING OF SMALL HIGH QUALITY SEGMENTS INTO LARGER COMPONENTS Code (A) 8 02 01 (B) 7 08 04 STATE O F THE ART ASSESSMENT M a t e r i a l s are c u r r e n t l y a v a i l a b l e which possess m a r g i n a l or adequate p r o p e r t i e s but have never been made i n the s i z e s r e q u i r e d Alumina f o r example has been made I n o g l v a l shapes o f a p p r o x i m a t e l y e i g h t e e n Inches diameter and up t o f o r t y e i g h t inches i n l e n g t h The problem I s t h a t h i g h f o r m i n g pressures and m a t e r i a l weakness d u r i n g the f o r m i n g s t a t e make the f a b r i c a t i o n o f l a r g e r s i z e s most d i f f i c u l t The same problem h o l d s t r u e f o r o t h e r ceramics Fused s i l i c a i s p o s s i b l y m a r g i n a l f r o m a temperature s t a n d p o i n t b u t I t s t h e r m a l shock r e s i s t a n c e makes i t a most l i k e l y c a n d i d a t e f o r t h i s case S l i p c a s t i n g t e c h n i q u e s have been developed which a l l o w the f a b r i c a t i o n o f f a i r l y l a r g e components but the s i z e s s p e c i f i e d would r e q u i r e the i m p l e m e n t a t i o n o f l a r g e r equipment capable o f s t r i n g e n t c o n t r o l t o l e r a n c e s and process parameters would have t o be i n v e s t i g a t e d which would a l l o w the h a n d l i n g o f green s l i p c a s t m a t e r i a l o f s i z e s up t o s i x t y Inches maximum dimension O g l v a l s e c t i o n s up t o f o u r f e e t long and e i g h t e e n Inches base diameter have been success f u l l y f a b r i c a t e d However f l a t t o s l i g h t l y curved s e c t i o n s approaching the r e q u i r e d s i z e have not been attempted The t o o l i n g and h a n d l i n g are unique f o r each s i z e and shape and would r e q u i r e f u r t h e r process development and t o o l i n g and equipment i m p l e m e n t a t i o n An a l t e r n a t e process w o r t h y o f mention i s the f a i r l y r e c e n t development o f bonding pre f i r e d and ground s m a l l ceramic segments i n t o a l a r g e component w i t h a ceramic or g l a s s type adhesive T h i s method was i n v e s t i g a t e d on an alumina component but the technique should be e q u a l l y a p p l i c a b l e t o o t h e r ceramics where an e f f e c t i v e bonding agent I s a v a i l a b l e C o l l o i d a l s i l i c a cements appear t o be e f f e c t i v e and have been w i d e l y used i n bonding t o o l i n g m a t e r i a l I n t o l a r g e masses w i t h s u r p r i s i n g l y rugged j o i n t s CRITICAL PROBLEMS 1 T o o l i n g capable o f h a n d l i n g s i z e s r e q u i r e d 2 C o n t r o l o f m a t e r i a l d e n s i t y 3 C o n t r o l l i n g dimensions a f t e r f i r i n g 4 M a i n t a i n i n g adequate u n i f o r m bonding temperature and pressure d u r i n g the bonding c y c l e ALTERNATE PROCESSES j Code NONE

107 CHART PROPOSED DEVELOPMENT PROGRAM OBJECTIVE APPROACH Develop m a n u f a c t u r i n g methods f o r the f a b r i c a t i o n o f l a r g e f l a t ceramic e l e c t r o - magnetic windows up t o 60 Inches maximum dimension w i t h good e r o s i o n c h a r a c t e r i s t i c s and s t r e s s r u p t u r e p r o p e r t i e s I n excess o f 1500 p s l a t 2300 F 1 Conduct f u r t h e r s t u d i e s I n the pr o c e s s i n g o f s l i p c a s t fused s i l i c a which w i l l p e r m i t the h a n d l i n g o f f l a t or n e a r l y f l a t specimens up t o 60 Inches maximum dimensions 2 Using p r e v i o u s developments as a base make a study o f the a d a p t a t i o n o f segment bonding techniques t o l a r g e f l a t or s l i g h t l y curved e l e c t r o m a g n e t i c window com ponents and c o n t r a s t w i t h l a r g e s i n g l e p i e c e c o n s t r u c t i o n 3 Implement t o o l i n g and equipment which w i l l p r o v i d e the r e q u i r e d p r o c e s s i n g c o n d i t i o n s f o r the process which appears most f e a s i b l e A F a b r i c a t e t y p i c a l a r t i c l e s and e v a l u a t e e l e t r l c a l s t r u c t u r a l and thermal performance c h a r a c t e r i s t i c s INSPECTION TECHNIQUES SUPPLEMEWIAL RECOMMENDATIONS INSPECTION REQUIREMENT Process c o n t r o l and end i t e m I n s p e c t i o n f o r l a r g e s l i p - c a s e t r a n s p a r e n c i e s or bonded s m a l l s l i p case segments OBJECTIVE To develop or s e l e c t I n s p e c t i o n techniques f o r measurement o f (a) s l i p c a s t i n g t h i c k n e s s w h i l e i n mold (b) S i02 phase d u r i n g s i n t e r i n g ( c ) d e n s i t y / p o r o s i t y o f green c a s t i n g and f i n i s h e d transparency (d) st r e n g t h / h a r d n e s s ( e ) segment bonding ( f ) c r a c k s v o i d s and o t h e r f l a w s Acceptance l i m i t s r e l a t e d t o performance o f the transparency must be e s t a b l i s h e d and d e t a i l e d i n s p e c t i o n procedures w r i t t e n f o r s p e c i f i c hardware designs BACKGROUND While d e s i r e d i t i s not regarded as p r a c t i c a l t o attempt techniques f o r NDT m o n i t o r i n g o f t h i c k n e s s d u r i n g s l i p c a s t i n g except by v i s u a l m o n i t o r i n g through g l a s s window a t edge of c a s t i n g Formation o f c r y s t a l l i n e S102 d u r i n g s i n t e r i n g i s a l s o regarded as i m p r a c t i c a l and b e t t e r l e f t t o s i n t e r i n g c o n t r o l p l u s I n s p e c t i o n a f t e r s i n t e r i n g The f o l l o w i n g background i s o f f e r e d f o r each a t t r i b u t e o f s i g n i f i c a n c e For t h i c k e r measurement c o n v e n t i o n a l techniques should s u f f i c e a f t e r machining w i t h o u t f u r t h e r development For S102 phase measurement s e v e r a l techniques should be e v a l u a t e d f o r a p p l i c a t i o n a f t e r s i n t e r i n g polarscope (AAB) x-ray d i f f r a c t i o n (BCA) f o r near s u r f a c e s t r u c t u r e d i e l e c t r i c a n a l y s i s a t low f r e q u e n c i e s (CDD) u l t r a s o n i c v e l o c i t y measurement (DA) and I n f r a r e d thermal techniques (ECM) The most responsive technique f o r d e t e c t i n g c r y s t o b o l i t e cannot be p r e s e l e c t e d Since the problem i s a s s o c i a t e d w i t h r e s i d u a l s t r e s s caused by thermal expansion d i f f e r e n c e s between c r y s t a l l i n e and amorphous forms o f SIO2 and p o s s i b l e v o l u m e t r i c changes o c c u r r i n g on t r a n s f o r m a t i o n (so as t o reduce thermal shock r e s i s t a n c e ] ^ the a l l o w a b l e l e v e l s o f c r y s t a l l i n l t y must be e s t a b l i s h e d as a t a r g e t f o r NDT development For d e n s i t y / p o r o s i t y and str e n g t h / h a r d n e s s measurements techniques are a v a i l a b l e but must be q u a n t i t a t i v e l y c o r r e l a t e d w i t h m i c r o s t r u c t u r e b u l k d e n s i t y f r o m the same l o c a l areas and w i t h strength/hardness as I n f l u e n c e d by m l c r o p o r o s i t y Since s t a r t i n g p a r t i c l e s i z e and shape and pr o c e s s i n g parameters ( s l i p c a s t i n g and s i n t e r i n g ) a l s o I n f l u e n c e s t r e n g t h the p r o c e s s i n g should be h e l d c o n s t a n t d u r i n g Continued on next page

108 INSPECTION TECHNIQUES SUPPLEMENTAL RECOMMENDATIONS c o n t i n u e d CHART, ^ , these s t u d i e s o f NDT vs p o r o s i t y vs s t r e n g t h Recent work shows t h a t d e n s i t y v a l u e s o b t a i n e d from r a d i a t i o n gauging (BBA) can be combined w i t h u l t r a s o n i c v e l o c i t y measurements (DA) t o y i e l d a V^p pr o d u c t T h i s p r o d u c t can be r e l a t e d t o modulus and t e n s i l e s t r e n g t h by e m p i r i c a l c o r r e l a t i o n (1) Low frequency d i e l e c t r i c a n a l y s i s (CDD) may a l s o be r e q u i r e d Co take account o f the per c e n t c r y s t o b o l i t e i f i t s i g n i f i c a n t l y i n f l u e n c e s s t r e n g t h / h a r d n e s s (1) REF Non d e s t r u c t i v e D e t e r m i n a t i o n o f Mechanical P r o p e r t i e s o f R e f r a c t o r y M a t e r i a l s Lockyer G E and Pr o u d f o o t E A paper presented b e f o r e American Ceramic S o c i e t y Annual Meeting May 9 1966 t o be p u b l i s h e d For segment bond e v a l u a t i o n u l t r a s o n i c techniques (DA) should be e v a l u a t e d f o r optimum response t o unbonds C o n v e n t i o n a l u l t r a s o n i c bond t e s t s are a p p l i c a b l e but the t e s t techniques must be v e r i f i e d on the b a s i s o f the geometry o f the hardware segment s i z e s t y p e o f adhesive e t c Cracks, v o i d s and o t h e r f l a w s are d e t e c t a b l e by o p t i c a l (AA) f l u i d p e n e t r a n t (ABA ABB) f i l t e r e d p a r t i c l e (ABD) ra d i o g r a p h y (BA) e l e c t r i f i e d p a r t i c l e (CDB) d i e l e c t r i c a n a l y s t s (CDD) u l t r a s o n i c (DA) and i n f r a r e d (ECB) tech n i q u e s S e l e c t i o n o f s i g n i f i c a n t optimum te c h n i q u e s w i l l depend upon the e s t a b l i s h m e n t o f a l l o w a b l e types and s i z e s o f f l a w s APPROACH The NDT development and technique s e l e c t i o n e f f o r t roust be c l o s e l y c o o r d i n a t e d w i t h t h e d e s i g n e n g i n e e r i n g and m a t e r i a l s i n t e r e s t s concerned w i t h s e t t i n g acceptance l i m i t s on f l a w s i z e s p r o p e r t i e s and performance requirements T e s t techniques capable o f p e r f o r m i n g as r e q u i r e d are b e l i e v e d t o be a v a i l a b l e They must be v e r i f i e d c a l i b r a t e d and d e t a i l procedures w r i t t e n f o r s p e c i f i c t r a n s p a r e n c y hardware The proposed program i s summarized 1 Screen s l i p c a s t bodies t o s e l e c t specimens c o v e r i n g a range o f c r y s t o b o l i t e d e n s i t y / p o r o s i t y and t y p i c a l f l a w types and s e v e r i t i e s 2 C o r r e l a t e NDT responses f o r t h e above v a r i a b l e s w i t h d e s t r u c t i v e t e s t s t o develop q u a n t i t a t i v e NOT c a l i b r a t i o n 3 Work w i t h d e s i g n and m a t e r i a l s engineers t o develop acceptance l e v e l s f o r d e f e c t s and p r o p e r t i e s A S e l e c t optimum NDT techniques 5 Prepare unambiguous w r i t t e n t e s t procedures f o r s p e c i f i c t r a n s p a r e n c i e s hardware so as t o c o n t r o l t e s t s e n s i t i v i t y r e s o l u t i o n and c a l i b r a t i o n check procedures

109 PRIORITY RATING WORKSHEET CHART P R O f i R A M FACTORS P R O S R A M CRITICAL P R O C E S S APPLICATIONS n NECESSITY P R O B A B I L I T V O F S U C C E S S D LOW Z • MODERATE 5 X man 8 P R O B L E M S TO B E S O L V E D • F E N ^ / N O T T O O P I F F U U L T Z Jg S O M E / D I F F I C U L T S a M A N V / VERV OlFFICUtT 8 GROWTH POTENTIAL X L I T T L E O B . U N D E F I N A e L E O a fseconminBLe P O F B U T I A L 4 OTHER THAN AIK FORCE N O N E O S O M E 4 M A N Y 0 FOR AIR FORCE FUNDIWa ^ MdOKATE - scnc E F R D L T OTHce 'SouC/:es e • tlC£UiSlVe Am F Ait F U N P M 6 UKELM | t N E E D F A C T O R S SYSTEMS PROBABILITY HiaH P B O B A B I T Y FAIR. P R O B A B l L i r y LOW P R O B A B I L I T Y C O M P O N E N T C R I T l C A L I T Y V E R Y H I C H H I « H F A I R L o w F R E Q U E N C Y OF R E Q U I R E M E N T IN S Y S T E M Mens THAN 3 COMPeNEIUTS 2 3 C « M P e M E N r s SIWeLE C e M P O N E N T D E S I G N A L T E R M A T E S No A L T E R N A T E R » E e E E N ONE A L T E R N A T E S e v E H A L A L T E R U A r e S M A T E R I A L S I M P L I C A T I O N New M A T E e i « L VtStLOtUtMT BCO O PWTtRlAL I M P A O V E M C N T E E S r No P R O B L E M F o K C ^ E e N C A L C U L A T E P R I O R I T Y STEP I S T t P 2 e ^ 5 - R A W SCOU.S roe. EACM CEFCREMfU) COMPCNCMT I N T A B L M AT t N B o r P A N E l R t P e t T W I T H 12AI0 T O T > L S E N T E R C P IN AT ClSMT S Y S A A R P RA>N SCOWS z ; ? ^ rigii 1̂ II II I • • • • • n = CIRCLE HIGHCST A A R P RAW S C O R E IN EACH Cn-HER S Y S T E M C I R C L E NEXT H I G H E S T IF WITHIN 4 FOUNTS OF TOP S C O R E r» / 1 m » j O Z 8 SCORE if N U M B E R OF ^ V S T E M S HIdlH LOW • • • [ • • • • • • • • • • • • • • • • • • • ] [ S T E P 3 C I R C L E FREQUENCY DISTRIBUTION FACTOR f B E L O W i N U M B E R OF S Y S T E M S L O W 0 2 £ > 1 a 1 4 1 11 1 3 1 «f 2 n Msec 1 7. 1 *f 1 4 TOTAL PRIORITY

110 TITLE FABRICATION OF FOAM IN SPACE CHART AIL PRIORITY R E U T E D CAMR CHARTS MANUFACTURING REQUIREMENT P r o v i d e a usthod o f m a n u f a c t u r i n g foam i n space under z e r o g and 8 g s which can be used t o c o n s t r u c t temporary s h e l t e r s shock a b s o r b i n g pads and emergency a b o r t r e - e n t r y p r o t e c t i v e s h i e l d s AARP REFERENCES E Charts B Charts 166. 174c. 179 P&FVPS Charts. APPLICABLE PROCESS USE SPRAY MIX NOZZLES TO CONTROL FOAM ARTIFICIAL ATMOSPHERE MAY HAVE TO BE PROVIDED Code 8 03 14 STATE OF THE ART ASSESSMENT Foam s p r a y i n g machines are a v a i l a b l e which w i l l mix the chemicals i n t h e nozzle and for m foam as i t i s used These operate w e l l i n a shop environment and can c o n t r o l the d e n s i t y o f the foam The foam I s g e n e r a l l y c l o s e d c e l l and forms a g a i n s t the atmospheric pressure a t room temperature Some foam has been formed I n a vacuum by p r o v i d i n g a p l a s t i c bag i n t o which the foam I s formed and which p r o v i d e s an a r t i f i c i a l atmospheric pressure t o c o n t r o l i t I n t h i s case the chemicals were mixed and f o r c e d i n t o the chamber through a s h o r t p i p e Cold foaming I n g r e d i e n t s have been mixed and a p p l i e d t o the s u r f a c e o f a p l a s t i c sheet No a c t i o n t o o k p l a c e as long as i t was r e f r i g e r a t e d but on h e a t i n g an open c e l l foam formed d i r e c t l y i n the vacuum No foaming t e s t s have been made a t 0 or 8 g s CRITICAL PROBLEMS 1 F o r m u l a t i n g a foam system which w i l l meet the requirements 2 C o n t r o l o f foam d e n s i t y and d e n s i t y d i s t r i b u t i o n 3 C o n t r o l o f foaming over range o f a c c e l e r a t i o n 0 t o 8 g s 4 C o n t r o l foam f o r m a t i o n over temperature range 5 Heat o f f o r m a t i o n must be d i s s i p a t e d or e l i m i n a t e d ALTERNATE PROCESSES MIX FOAMING MATERIALS AND INJECT INTO PRE SHAPED BAG or COAT BAG WITH "FROZEN MIX WHICH WILL FOAM WHEN TRIGGERED Code 8 03 14 8 03 14

I l l CHART PROPOSED DEVELOPMENT PROGRAM OBJECTIVE P r o v i d e a m a n u f a c t u r i n g method o f foaming i n space t o form temporary l u n a r s h e l t e r s r e p l a c a b l e shock a b s o r p t i o n pads and i n s t a n t emergency p r o t e c t i o n s h i e l d s BACKGROUND There I s c u r r e n t c a p a b i l i t y f o r m i x i n g foam i n a n o z z l e Two chemical are spray mixed I n s i d e t h e no z z l e Foaming I s Instantaneous I t f l o w s i n t o whatever con t a l n e r I s t o be f i l l e d and s e t s up I n s e v e r a l hours Some c o n t r o l o f foam d e n s i t y i s p o s s i b l e T h i s a c t i o n takes p l a c e a g a i n s t a standard back p r e s s u r e o f one atmosphere and u n i f o r m room temperature T h i c k foam c o u l d not be b u i l t up r a p i d l y as the heat o f f o r m a t i o n must escape The foaming chemicals have been mixed I n s i d e a c l o s e d c o n t a i n e r i n a vacuum chamber As foaming t o o k p l a c e i t was allowed t o f i l l a connected p l a s t i c con t a l n e r which p r o v i d e d an a r t i f i c i a l back pressure u n t i l the foam hardened Mixed f r o z e n foam I n g r e d i e n t s have been kept r e f r i g e r a t e d f o r as lo n g as a year When r a i s e d t o room temperature foaming was i n i t i a t e d The a c t i o n was s e l f s u s t a i n i n g I n t h a t the heat r e l e a s e d I n s u r e d t h a t the e n t i r e batch foamed Some temperature problems were encountered i n t h a t normal p l a s t i c f i l m was overheated T h i s system has been foamed uncontalned I n a vacuum chamber and forms an open c e l l foam APPROACH The f i r s t phase of the program should I n c l u d e the development o f a technique where a foam can be sprayed over a form t o harden I n a vacuum chamber The f i n a l p r o d u c t must be capable o f w i t h s t a n d i n g a 2 p s i compresslan load The second phase r e q u i r e s o p e r a t i o n under 0 g s and 8 g's and t e s t s may be made on a c e n t r i f u g e i n a vacuum chamber f o r the h i g h g c o n d i t i o n and a t l u n a r g or zero g I n a vacuum chamber i n a h i g h speed a i r c r a f t such as the KC 135 T y p i c a l p a r t s f i t t i n g s and attachments should be f a b r i c a t e d and t e s t e d t o In s u r e the adequacy of the m a n u f a c t u r i n g technique Both spray mixed foams and some t h a t are premixed b u t a r r e s t e d i n t h e i r development should be e v a l u a t e d A separate program may be r e q u i r e d f o r f a s t s e t t i n g foams (15 sec ) INSPECTION TECHNIQUES SUPPLEMENTAL RECOMMENDATIONS INSPECTION REQUIREMENTS Process c o n t r o l and end i t e m e v a l u a t i o n o f f a b r i c a t i o n s foamed i n space OBJECTIVE I n view o f the r e l a t i v e d i f f i c u l t y o f I n s p e c t i n g r e j e c t i n g and r e p l a c i n g d i s crep a n t hardware i n space the o b j e c t i v e should be t o develop on the ground a process which i s as f o o l p r o o f as p o s s i b l e l e a v i n g a minimum o f necessary e v a l u a t i o n t o In-space i n s p e c t i o n The o b j e c t o f the proposed e f f o r t should be t o d e f i n e whether i n space i n s p e c t i o n i s necessary and how i t might be accomplished BACKGROUND I t I s expected t h a t each o f the foam a p p l i c a t i o n s I n c l u d i n g temporary s h e l t e r s shock absorbing pads and emergency a b o r t p r o t e c t i v e s h i e l d s w i l l i n v o l v e i t s own unique q u a l i t y requirements Neither the I n s p e c t i o n techniques r e q u i r e d nor t h e i r s t a t e o f the a r t can be judged c l e a r l y u n t i l these problems are q u a n t i t a t i v e l y d e f i n e d Continued on next page

CHART 112 INSPECTION TECHNIQUES SUPPLEMENTAL RECCTIMENIIATIONS. c o n t i n u e d APPROACH A c o o r d i n a t e d program o f foam process development and I n s p e c t i o n development should be conducted t o p r o v i d e a q u a n t i t a t i v e d e f i n i t i o n o f I n space e v a l u a t i o n problems The program should h i g h l i g h t many problems w h i c h can be s o l v e d d u r i n g process development so as t o minimize space I n s p e c t i o n The suggested program should a p p l y SOA I n s p e c t i o n techniques t o screen process steps and end I t e m foams f o r f a i l u r e - c o n t r o l l i n g v a r i a b i l i t y aa demonstrated by ground e n v i r o n m e n t a l t e s t I n s p e c t i o n t e c h n i q u e s and equipment should t h e n be s e l e c t e d / o p t i m i z e d based upon these f i n d i n g s G e n e r a l l y speaking r a d i o m e t r i c gauging (BB) I s a p p l i c a b l e t o d e n s i t y / t h i c k n e s s m o n i t o r i n g The program i s summarized 1 Produce foams by can d i d a t e processes 2 Submit r e p r e s e n t a t i v e samples o f hardware t o NOT v a r i a b i l i t y s c r e e n i n g 3 Submit samples c o n t a i n i n g observed v a r i a b i l i t y t o e n v i r o n m e n t a l t e s t t o sepa r a t e r e l e v a n t f r o n n o n r e l e v a n t v a r i a b i l i t y A Optimize foaming processes t o minimize r e s i d u a l r e l i a b i l i t y problems 5 S e l e c t / o p t i m i z e q u a n t i t a t i v e NOT techniques and equipment f o r r e s i d u a l i n space i n s p e c t i o n problems 6 C a l i b r a t e NDT and w r i t e i n s p e c t i o n procedures

113 PRIORITY RATING WORKSHEET CHART P R 0 6 R A M P R O B A B I L I T V O F S U C C E S S D LOW 2 • MODERATE S ma» 8 CRITICAL PROBLEMS TO B£ SOLVED U F E W / N O T TOO D IFFICULT Z >ff 30M£/0IFFIC1)LT S D M A N Y / V E R Y D I F F I C U L T S G R O W T H P O T E N T I A L yH L I T T L E OR U N D E F I N A B L E O • K e C 0 6 N I Z A B L E p o r e U T I A L 4 O T H E R THAN AIR FORCE NONE O S O M E 4 MANY g FOR m FORCE FUNOIMO PRocess APPLICATIONS • NECESSITY n L w »\6X itiPttSTdV/crHfa G O V T E F F «.r 4 P a N E E D FACTORS S Y S T E M S P R O B A B I L I T Y HI<3H F ^ B A B ITY IZ FAIR. P R O B A B I L I T Y g LOW P R O B A B I L I T V 4 C O M P O N E N T C R I T I C A L I T Y V E R Y men IZ HIAH 9 FAIR e> L o w 3 F R E O U E N C V OF R E Q U I R E M E N T IM S Y S T E M MSRE THAW 3 COMPeUEUTS 3 z 3 c e M P e H E u r g 2 S l N f l L E OOMPe iMENT I D E S I G N A L T E R M A T E S No A L T E R N A T E R M E B E E N <9 ONE A L T E B N A r e 6 S e v E H A L A L T E R M A T E C 3 M A T E R I A L S I M P L I C A T I O N New MATEfelflL PevttoFMtNT Reo O 6 IVWTtBIAL IMPRCVEMCMT EEffl D 4 No P R O B L E M F o R e ^ e e i d o CALCULATE PRIORITY STEP I CIRCLE UIGHCST A A R P PAW S C O R E e 8 2S R A W S C O R E S F O R E A C H REFceeMftD CoMFOMctrr W TABceS AT tND or PAklEL f J tpOtT WITH 1JA10 TOT M i ENTEt tCP IM AT ei6MT S V S M S 11 = Z 9 S T E P 2 IN EACH OTHER S V S T 6 M C I R C L E NEXT HICSHEST SCORE IF WITHIN 4 POINTS OF T O P S C O R E n 2- 1 « v » . / NUMBER OF ^ySTElMS HlAH LOW S T E P 3 C I R C L E NUMfSER. O F S Y S T t M S L O W FREOOENCY DISTRIBUTION FACTOR MUMBEB. o SYST«>1S H S l l I 2. 3 R MMU B E L O W l 0 I 2 RMo«e 1 0 1 2. I 4 1 1 1 *f 1 z 1 «f 1 4 2 f A A R P RA>N Se«ReS • • • • • • • • • • ] • ] C Z 1 • • • • [ • • • • • • • • • • • • • • • ] • • [ ICZ] TOTAL PRIORITY

l U TITLE FABRICATION OF HETEROGENEOUS NON METALLIC MATRIX RADIATION SHIELDS CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Mold heterogeneous s h i e l d s c o n t a i n i n g elements w i t h h i g h m o d e r a t i n g v a l u e s f o r f a s t neutrons and w i t h h i g h cross s e c t i o n s f o r gamma and the r m a l neutrons I n a n o n - m e t a l l i c m a t r i x i n the form o f s t r u c t u r a l f l a t s e c t i o n s up t o a p p r o x i m a t e l y 12 f t across and s h e l l s up t o 10 f t diameter f o r use a t 1800 F f o r 30 000 hours AARP REFERENCES E r h n r t . 9. 35 B C h a r t . 2 20b P A F V P $ C h a r t t APPLICABLE PROCESS Code HYDROSTATIC PRESSING 8 02 03 STATE OF THE ART ASSESSMENT The requirements f o r 30 000 hours l i f e a t 1800 F negates any p l a s t i c known today or i n the f o r e s e e a b l e f u t u r e The best a l t e r n a t i v e appears t o be a ceramic m a t e r i a l w i t h s e l e c t e d a d d i t i v e s t o accomplish the r e q u i r e d s h i e l d i n g A l t e r n a t e l y one o f the f o l l o w i n g paths may be f o l l o w e d 1 Develop new n i g h temperature r e s i n s (beyond our scope) 2 Develop new d e s i g n concepts t o I n c l u d e I n t e g r a l c o o l i n g 3 Replace the s h i e l d a t I n t e r v a l s A new l i g h t w e i g h t m a t e r i a l would be r e q u i r e d f o r the time and temperature d e s i r e d C o n t r o l s i z e and d e n s i t y o f c o m p o s i t i n g elements t o achieve proper d i s t r i b u t i o n s t r u c t u r e J o i n t I n t e g r i t y between s e c t i o n s or i n d i v i d u a l s h i n g l e s depending on f i n a l d e s i g n c h o i c e Cure c y c l e c o n t r o l Attachment methods f o r r e p l a c e a b l e s h i e l d s Non d e s t r u c t i v e t e s t methods t o i n s u r e m a t e r i a l and j o i n t I n t e g r i t y ALTERNATE PROCESSES SLIP CASTING Code 8 02 01

115 CHART PROPOSED DEVELOPMENT PROGRAM OBJECTIVE To develop m a n u f a c t u r i n g methods f o r the f a b r i c a t i o n o f heterogeneous m i x t u r e non m e t a l l i c m a t r i x r a d i a t i o n s h i e l d s i n the form o f bulkheads up t o 12 f e e t across and s p h e r i c a l s h e l l s up t o 10 f e e t I n diameter f o r use a t 1800 F BACKGROUND The m a t e r i a l s c u r r e n t l y u t i l i z e d f o r ground based r e a c t o r s impose tremendous w e i g h t p e n a l t y on the use o f a i r b o r n e r e a c t o r s T h e r e f o r e l i g h t w e i g h t s u b s t i t u t e s must be developed The optimum w e i g h t savings would be o b t a i n e d by a p l a s t i c m a t r i x composite s t r u c t u r e however the l o n g time exposure t o 1800 F would negate any known or contemplated p l a s t i c m a t e r i a l s T h e r e f o r e a l t h o u g h m a t e r i a l s development I s beyond t h e scope o f t h i s s t u d y I t i s recommended t h a t e f f o r t b e g i n I n development o f bo t h a ceramic based composite and a d e s i g n concept program t o f u l f i l l the needs s t a t e d APPROACH 1 I n i t i a t e a program t o o p t i m i z e a m a t e r i a l c o m p o s i t i o n f o r s t r e n g t h d e n s i t y and s h i e l d i n g c a p a b i l i t y ( 1 e a ceramic m a t r i x w i t h boron t u n g s t e n e t c r e i n f o r c e m e n t s ) 2 Conduct d e s i g n s t u d i e s f o r optimum c o n f i g u r a t i o n ( 1 e i n t e r l o c k i n g s h i n g l e s v e r s u s hemispheres) 3 Ev a l u a t e J o i n i n g techniques ( 1 e f i r e d ceramic cements c e r a m i C ' t o - m e t a l s e a l s tape wound o v e r l a y s ) 4 C o n s t r u c t p r o t o t y p e models f o r f a b r i c a t i o n e v a l u a t i o n and t e s t i n g

116 PRIORITY RATING WORKSHEET CHART PRftqpAM FACTPR8. P R 0 6 R A M P R O B A B I L I T V O F S U C C E S S O L O W 2 >C M O O E R A T E 5 • HISH fl CRITICAL PROBLEMS TO B E SOLVED D FtW/NCT TOO PIFFUJULT Z > t SOME/DIFFICULT » • MANY/ VERY P I F F I C U L T S P R O C E S S GROWTH P O T E N T I A L L I T T L E OR U N D E F I N A O L E O • Kei:<XiNIUBLE POTEMTIAL 4 APPLICATIONS OTHER THAN AIR FORCE • NONE O J< SOME ^ • MANY e MECESSITY FOR AIR FORCE FUNOIMQ • LOW HlfiH l«IPUSTItV/«rrH£A S W T E F F tX 1^ O MOOEHATE - SOME eFfoitr OTHtR ^m9Ct% 8 ^ E K f l d S l f E A l * FoWt FUMPWCi U K C L W 14. N E E D FACTORS S Y S T E M S P R O B A B I L I T Y H I Q H F ^ B A B I T Y F A I R P R O B A B I L I T Y LOW P R O B A i 3 I L I T Y C O M P O N E N T C R I T l C A L I T Y V E R Y H I C H Kiei t F A I R L o w F R E f l U E N C Y OF R E Q U I R E W E N T IN S Y S T E M MORE THAN 3 C O M P e N E N T S 2. 3 C O M P e N E N T S S l W a L E C d M P O N E M T O e S l S N A L T E R M A T E S No A L T E R N A T E R M E S C E N ONE A L T E R N A T E ; S E V E R A L A L T E R M A T E C M A T E R I A L S I M P L I C A T I O N NEW M A T E R I A L pevcuifMENT eea o M A T E R I A L I M P R O V E M E N T R £ ( B P No P R O B L E M f n e s e e i d RAW S C O R E S FOR EACH REFceENfEP C O M P O N E N T I N T A B L E S A T L N D or P A N t t RtPOtT W I T H B A M T O T > L S E N T E R C P IN «r C I S W T A A R P RANM SCOOeS A Zh • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • I • • • • • • • • CALCULATE PRIORITY- STEP I S T E P 2 S T E P 3 CIRCLE HIGHEST A A R P RAW S C O R E H e IN EACH OTHER S Y S T E M C I R C L E NEXT HIOMEST IF WITHIN 4 POINTS OF T O P S C O R E n 3S- N U M S E R OF SViTEMS HIAH C I R C L E FREQUENCY LOW DISTRIBUTION FACTOR H a n 3 « R M M E NuMQei). o c sysrCMf I X N U M B E R OF SYSTEMS L O W 0 1 Z R.MOCE 1 0 1 z. 1 4 ) 1 1 3 1 f 1 *f 1 4 SCORE B E L O W t TOTAL PRIORITY

117 TITLE SPLICING OF LARGE SANDWICH CORE SECTIONS CHART PRIORITY RELATED CAMR CHARTS 701 MANUFACTURING REQUIREMENT F a b r i c a t i o n o f v e r y l a r g e (up t o 70 f t l o n g and w i t h r a d i i 60 inches t o 600 Inches) c y l i n d r i c a l and e l l i p s o i d a l assemblies o f honeycomb sandwich i n which m u l t i p l e s e c t i o n s o f core are Joined t o g e t h e r by s p l i c i n g F u l l s t r e n g t h core s p l i c e s are d e s i r e d i n f l a t or curved panels w i t h minimum weight p e n a l t y i n view o f the l a r g e number I n v o l v e d i n components o f these s i z e s A p p l i c a t i o n s are f o r pressure v e s s e l bulkheads and m e t o r o i d / t h e r m a l s h i e l d i n g f o r space launch systems AARP REFERENCES E Charts B Charts 175 95a 96 98c P&FVPS Charts. APPLICABLE PROCESS ADHESIVE BONDING Code 6 08 00 STATE OF THE ART ASSESSMENT I t i s c u r r e n t p r a c t i c e t o s p l i c e core by o v e r l a p c r u s h i n g adhesive bonding p o t t i n g or merely i n t e r l e a v i n g the d i s c o n t i n u o u s c e l l s a t the edge o f the s e c t i o n s t o be j o i n e d A l l o f these methods cause r e d u c t i o n o f core s t r e n g t h and/or s u f f e r w e i g h t p e n a l t y The d e s i r e d e f f e c t c o u l d be achieved by c a r e f u l l y a l i g n i n g the c e l l s and i n d i v i d u a l l y bonding or j o i n i n g each node However unless o p t i m i z a t i o n i s r e q u i r e d and the p a r t i c u l a r a p p l l c a t l o n w a r r a n t s the extreme c o s t the method i s eco n o m i c a l l y u n f e a s i b l e A l s o the mismatch o f core t h i c k n e s s may cause v o i d s or inadequate adhesion o f the core t o s k i n bond Techniques are c u r r e n t l y a v a i l a b l e however f o r machining or o t h e r w i s e removing s t o c k on core t o m a i n t a i n the necessary t o l e r a n c e s CRITICAL PROBLEMS J o i n i n g core s e c t i o n s w i t h comparable s t r e n g t h t o parent m a t e r i a l w i t h l i t t l e or no weig h t p e n a l t y ALTERNATE PROCESSES NONE Code

118 CHART PROPOSED DEVELOPMENT PROGRAM OBJECTIVE To f a b r i c a t e honeycomb sandwich assemblies up t o 70 f e e t long I n which m u l t i p l e s e c t i o n s o f core are j o i n e d t o g e t h e r by s p l i c i n g S p l i c e s are t o have e q u i v a l e n t s t r e n g t h o f p a r e n t core a t l i t t l e or no Increase i n w e i g h t APPROACH Develop mechanical d e v i c e f o r a l i g n i n g and bonding c e l l s a t nodes f o r s p l i c e s i n the L d i r e c t i o n o f the core For s p l i c e s i n the V d i r e c t i o n a s i m i l a r mechanical device might be used f o r p r o d u c i n g an I n t e r l o c k s p l i c e i n t o which a f i l m adhesive or prepreg tape can be I n c o r p o r a t e d f o r bonding o f the l i m i t e d w e i g h t Because o f the h i g h c o s t o f development and because o f the l i m i t e d w e i g h t p e n a l t y i n u s i n g c o n v e n t i o n a l s p l i c i n g techniques i t would be recommended t h a t t h e proposed developmental program be i n i t i a t e d o n l y i f a p a r t i c u l a r a p p l l c a t i o n w a r r a nted an u l t i m a t e o p t i m i z a t i o n o f the system w e i g h t I n the event an economical and p r a c t i c a l s o l u t i o n i s conceived I t s a p p l i c a t i o n c o u l d be e x t e n s i v e

119 PRIORITY RATING WORKSHEET CHART P R 0 6 R A M PACTORS P R 0 6 R A M P B O B A B I L I T y O F S U C C E S S • LOW 2. 'yt. M O D E R A T E 5 • R I C H 8 CRITICAL PROBieMS TO BE SOCVeO • F C W / N O T TOO DIFFICULT 2 ^ a o M E / o i F F i c u t r a D M A N V / V E R V P I F F I C U J . T 8 P R O C e S S G R O W T H R O T E N T ( A ( . X U T T L E OR U N D E F I N A O L B O • K K O f i N I U t B L E P o r e M T I A L 4. O T H E R -mAN AIR FORCE NONE O S O M E 4 MANY g FOR AIR rORCE FUNDIMQ • LOW HlfiH INtUStcy/cTHCA CFFVCT 4- O MeoteATs - Seine SFMCT o r H « 'SMCt ies 8 t t t U I S I I ' E AlR FoftCfc F U M S u a UKBW 14. A P P L I C A T I O N S n NECESSITY P a N E E D FACTORS SYSTEMS P R O B A B I L I T Y HiaH P B O B A e i l - l T Y F A I R P R O B A B I L I T Y LOW P R O B A B I L I T V C O M P O N E N T C R I T l C A L I T Y veity H i c H H I A H F A I R L O W FBEaUENCy OF R E Q U I R E M E N T IN S Y S T E M M e u THAW 3 CoMPen '^MTS Z 3 C e M P M J E M T S S I M f l L E O e M P e W E N T D E S \ G N A L T E R M A T E S No A L T E R N A T e R M E S E E N ONE A i r e B N A T e SeVEB -AL A L T E R M A T E C M A T E R I A L S I M P L I C A T I O N NEW MATE(! . |« l . P£V£U) f l i l£NT RCD O nMteClAL I M P W V E M C W T R E S P NO P R o & u E M F o c e ^ e e k i CALCULATE P R I O R I T Y . 24> RAW S c o « e s F O R E A C H R E F c e E M O V CoMWNtMT IN T A B L C i AT t N B o r PAMEL V^POlT W I T H pAlk) T O T A L S E N T t a e p IM ^UiuiuAtV AT E I G M T S V . T . . S A A B P RA>N S C O W S • • • • • • • • • • • • • • • • • • • • STEP I S T E P 2 2& CIRCLE HIGHEST A A R P RAW S C O R E IN EACH OTHER S Y S T E M C I R C L E NEXT HI«aHEST SCORE IF WITHIN if POINTS O F TOP S C O R E n 1 t o w — L — N U M B E R OF S f S T E I V I S HIAH N U M S E R O F S Y S T E M S L O W NUMOeO. 0 1 £ H at4 3 K MMLC 0 1 0 1 a 1 4 1 1 3 1 R. Moce 1 z 1 *f 1 4 2 r 6 oHHS ] [ • • • • • • • • • • S T E P 3 C I R C L E FREOUENCY DISTRIBUTION FACTOR f B E L O W i TOTAL P R I O R I T Y

120 TITLE FABRICATION OF LARGE POROUS CERAMIC PARTS AARP REFERENCES E Cher . . 73 268 B Charts 28e 30d 41d 121b c 120c P4FVPS Charts APPLICABLE PROCESS Code SLIP CAST AND SINTER (SLIP CONTAINING FUGITIVE BURNOUT MATERIAL) 8 02 01 STATE OF THE ART ASSESSMENT MANUFACTURING REQUIREMENT CHART PRIORITY RELATED CAMR CHARTS: P r o d u c t i o n o f porous i n s u l a t i n g ceramic p a r t s (permeable and/or c l o s e d pores p o s s i b l y m e t a l r e i n f o r c e d ) o f h e m l c y l i n d e r or compound curved shape up t o 12 inches x 60 inches w i t h t hermal c o n d u c t i v i t y as low as k< 0 05Btu/Ft2 Hr °F/Ft and usable t o 5000 F hot face Size 2 i n c h x 12 i n c h x 12 Inch f e a s i b l e now but 60 inches l o n g porous p a r t s have n o t been made Porous p a r t s are made by whi p p i n g or gas blowing o f s l i p s or s l u r r i e s which are designed t o se t i n the foamed c o n d i t i o n These may then be f i r e d or i n some c a s e S ; may be s t r o n g enough f o r d i r e c t use as a r e s u l t o f the type o f bond formed d u r i n g the s e t t i n g A l t e r n a t i v e l y f u g i t i v e ( b u r n o u t ) m a t e r i a l s o f p a r t i c l e shape d e s i r e d i n the pores may be added t o s l u r r i e s or d r y mixes f o r p r e s s i n g i n t o shape T h i s process r e q u i r e s f i r i n g t o burn out the pore formers A l l o f the above processes e n t a i l use of f i n e l y d i v i d e d powders which are c h e m i c a l l y bonded d u r i n g the s e t t i n g process or which s i n t e r d u r i n g f i r i n g H e a t i n g a f t e r s e t t i n g d u r i n g f i r i n g or a f t e r f i r i n g causes f u r t h e r s i n t e r i n g and shr i n k a g e o f the a r t i c l e T h i s i s almost i n e v i t a b l e and can be minimized o n l y by v e r y p r e c i s e c o n t r o l o f p a r t i c l e s i z e d i s t r i b u t i o n and p a r t i c l e shape The p r o d u c t i o n o f cont i n u o u s pores i n permeable bodies has been l i t t l e s t u d i e d and w i l l be v e r y d i f f i c u l t f o r l a r g e p a r t s s i n c e i t may e n t a i l o r i e n t a t i o n o f f i b r o u s or s t r i n g type burnout elements P e r m e a b i l i t y o b t a i n e d s i m p l y by u s i n g a l o o s e l y bonded body o f l a r g e p a r t i c l e s i z e s w i t h c o n t i n u i t y between i n t e r s t i t i a l pores r e s u l t s i n heavy and weak bodies Maximum s t r e n g t h and p o r o s i t y r e s u l t s from s m a l l c l o s e d s p h e r i c a l pores i n a dense impermeable body F i r i n g o f l a r g e porous p a r t s i s d i f f i c u l t because t h e i r low the r m a l c o n d u c t i v i t y makes i t d i f f i c u l t t o m a i n t a i n temperature u n i f o r m i t y t hroughout the p a r t A common r e s u l t i s o v e r f i r i n g o f the e x t e r i o r and u n d e r f i r i n g o f the i n t e r i o r o f the p a r t T h i s w i l l be p a r t i c u l a r l y d i f f i c u l t w i t h p a r t s f r o m 3000 F usage s i n c e these w i l l have t o be f i r e d t o a t l e a s t t h i s t e m p e r a t u r e t o minimize s h r i n k a g e d u r i n g use F i r i n g processes are f u r t h e r c o m p l i c a t e d by the need f o r long slow burnout c y c l e s f o r removal o f pore f o r m i n g a d d i t i v e s which t i e up expensive h i g h tempera- t u r e f u r n a c e s Use o f two separate f u r n a c e s i s c o m p l i c a t e d by the f r a g i l i t y o f the p a r t i a l l y f i r e d foams w h i c h makes t r a n s f e r d i f f i c u l t A l l o f the above i n t e r a c t i o n s and problems i n d i c a t e t h a t i t w i l l be d i f f i c u l t U> produce porous permeable p a r t s o f the s i z e and f o r use a t the temperature r e q u i r e d Continued on next page ALTERNATE PROCESSES PRESS AND SINTER (body c o n t a i n i n g f u g i t i v e burnout m a t e r i a l s ) EXTRUDE SINTER (body c o n t a i n i n g f u g i t i v e burnout m a t e r i a l s ) WHIP FLUID WITH SETTING AGENT AND CAST ISOSTATIC PRESS AND SINTER (body c o n t a i n i n g f u g i t i v e burnout m a t e r i a l ) Code 8 02 OA 8 02 10 8 02 12 8 02 03

CHART 121 STATE-OF-THE ART ASSESSMEWT. c o n t i n u e d C u r r e n t l y a v a i l a b l e foamed alumina and z l r c o n l a I n common b r i c k s i z e s a r e s u i t a b l e f o r f u r n a c e I n s u l a t i o n but p r o p e r t i e s are I n c o n s i s t e n t s t r e n g t h I s low th e y are g e n e r a l l y o f c l o s e d pore t y p e and are n o t d l m e n s l o n a l l y s t a b l e above 3000 F Alumina foamis have been developed f o r co r e m a t e r i a l I n sandwich radomes h a v i n g r e a s o n a b l y c o n s t a n t p h y s i c a l and e l e c t r i c a l p r o p e r t i e s b u t work t o develop c o n t r o l l e d pore shape f o r t r a n s p i r a t i o n c o o l i n g I s r e q u i r e d Furnaces o f adequate s i z e and c o n t r o l a r e expected Co be a v a i l a b l e I n mid 1970 CRITICAL PROBLEMS M a n i p u l a t i o n o f m a t e r i a l d u r i n g f o r m i n g t o m a i n t a i n c o n t r o l o f pore shape s i z e and d i s t r i b u t i o n H a n d l i n g o f u n f l r e d p a r t s w i t h dimensions up t o 60 Inches Development o f time - t e m p e r a t u r e parameters e n a b l i n g burnout o f f u g i t i v e m a t e r i a l and c o n t r o l o f f i r i n g s h r i n k a g e and f i n a l p r o p e r t i e s o f r e s u l t a n t m a t e r i a l PROPOSED DEVELOPMENT PROGRAM OBJECTIVE Develop most p r o m i s i n g technique f o r f o r m i n g porous permeable and/or c l o s e d pore p o s s i b l y m e t a l r e i n f o r c e d ceramic bodies i n s i z e s up t o 12 In c h diameter cones and 60 In c h diameter t i l e s usable t o 5000 F hot face and w i t h k<0 05 Btu/Ft2 Hr "F/Ft f o r 5 f l i g h t s o f 30 minutes BACKGROUND High temperature (5000 F) the r m a l I n s u l a t i o n panels are needed f o r e x t e r i o r usage on boost g l i d e and l i f t i n g r e - e n t r y v e h i c l e l e a d i n g edges nose cones and e x t e r i o r s k i n panels Processes a r e a v a i l a b l e f o r p r o d u c i n g foams but n o t w i t h t h e d e s i r e d c o n t r o l or u t i l i t y t o 5000 F While foams can be produced by wh i p p i n g and blo w i n g o f s l i p s and s l u r r i e s these methods p r o v i d e i n s u f f i c i e n t c o n t r o l o f pore s i z e and d i s t r i b u t i o n p a r t i c u l a r l y where p e r m e a b i l i t y i s d e s i r e d Optimum c o n t r o l o f p o r o s i t y I s o b t a i n e d f r o m use of burnout pore p r o d u c i n g m a t e r i a l s The best process t h e n depends upon a s e l e c t i o n f r o m s l i p c a s t i n g p r e s s i n g or e x t r u s i o n as f o r m i n g methods O b v i o u s l y the l a t t e r two are more s i z e or shape l i m i t e d than s l i p c a s t i n g APPROACH Ev a l u a t e burnout media and develop techniques f o r p r o d u c i n g media w i t h d e s i r e d s i z e and shape Develop methods f o r d i s t r i b u t i n g the burnout media u n i f o r m l y i n the ceramic body and coiiq>are d i s t r i b u t i o n m a i n t a i n e d when f o r m i n g body by s l i p c a s t i n g d r y p r e s s i n g i s o s t a t i c p r e s s i n g and e x t r u s i o n E v a l u a t e foaming techniques t o p r o v i d e a b a s i s o f comparison w i t h above techniques Compare each o f the above processes f o r p r o d u c i n g d e n s i t y g r a d a t i o n s i n components Develop f u g i t i v e burnout and f i r i n g time temperature parameters Develop NOT techniques and f u r n a c e support designs p e r m i t t i n g escape of burnout media gases (Furnaces o f adequate s i z e w i l l be a v a i l a b l e i n t h e mld-1907's) F a b r i c a t e t y p i c a l p a r t determine p r o p e r t i e s and check o u t NDT techniques

122 PRIORITY RATING WORKSHEET CHART P R O G R A M FACTOttfi. PROflR/VM PBOBABILITV OF S U C C E S S D LOW • MODERATe TX HIGH CRITICAL PROBtEMS TO B E SOtVeO • FCW/NOT TOO OlFFXCUir yl 3<3M£/OIFFICUtT • MANY/ VERY PIFPICULT P R O C E S S fiROWTH P O T E N T I A L y6 LITTLE OR UNDEFINAOLE • geco&HattBte poreuTiAL OT«ER TWAN AIR FORCE NONE SOME MANY Z 5 8 Z a 6 o 4 APPLICATIONS • NONE O ^ SOME 4 n MANY g NECESSITY FOR AIR FORCE FUNDIWa • I w HiSH mtusTiv/'orHtft <SMT trrotr <^ K MeocAATi - sme Bratx aruat •souece^ 8 • tX£LiJsiyE AIR fcdet F U M C M A UKELW I S . N E E D FACTORS S Y S T E M S P R O B A B I L I T Y HiaH PSo&Aei t r y FAIR. PROBABILITY LOW P R O B A B I L I T Y COMPONENT CRITICALITY V/ERY HIi'H HIAH FAIR Low F R E Q U E N C Y O F R E Q U I R E M E N T IN S Y S T E M Mew THAU 3 CoMPei'eiilTS 4 3 COMPeHENTS SINGLE COMPONCMT D E S I G N A L T E R M A T E S No A L T E B N A T e R m E S E E N ONE ALTERNATE SEVEdf lL ALTEBMATEC MATERIALS IMPLICATION NEW MA ce. AL t>e.veu>fUCNT RCO D IVUTCeiAL IMPlU>V£MeNT REra D No PROBLEM f o t e S E E H 8 2S- RAW SCoOCS FOR EACK REFCRetMXP CCMPDNCMT IN TABLt* AT t*ll> or PANEL WITH IJAM T»r«LS ENTEOEP IM ^UMUAEV AT gIGMT s v s « M S a 5^ A A R P R A ^ I SeoftCS 2 < 2 9 ^ [ z F l l II II I • • • • • • • • CALCULATE PRIORITY STEP t CIRCLE HIGHEST A A R P T2AW S C O R E n : S T E P 2 IN EACH OTHER S Y S T E M C I R C L E N E X T H I G H E S T 3f IF WITHIN NUM&ER OF 4 POINTS SysTtiws HISH O F T O P S C O R E LOW S T E P 3 C I R C L E FREOUENCY DISTRIBUTION FACTOR uuMQen. o SYSTEMS H at* I 2. 3 «s t*e*i SCORE S £ L O W t NUMBER, OF SYSTEMS LOW 0 I 2 RMoce 1 0 1 a I 4 1 1 1 f 1 £ 1 *f 1 1 •HSH • c z i n i • • • • • • l : TOTAL PRIORITY

123 TITLE FABRICATE ABLATIVE STRUCTURAL SHAPES FOR MODERATE TO LOW HEAT FLUX RE-ENTRY VEHICLE ENVIRONMENT CHART PRIORITY RELATED C A / l ^ ^ y R T S MANUFACTURING REQUIREMENT Produce 6 12 s p h e r i c a l nose or C and D shaped l e a d i n g edge a b l a t i v e s t r u c t u r e s h a v i n g g r a d i e n t p r o p e r t i e s t o p r o v i d e predetermined d i m e n s i o n a l r e c e s s i o n r a t e s i n a maximum heat f l u x environment o f 200 B t u / f t ^ sec and maximum exposure time o f 30 minutes Heat s h i e l d w i l l be bonded w i t h or w i t h o u t mechanical f a s t e n e r s t o h i g h temperature or r e f r a c t o r y s u b s t r u c t u r e AARP REFERENCES E Charts. B Charts. 104 39a 40a P8FVPS Charts. APPLICABLE PROCESS HAND LAY UP WITH MATCHED METAL MOLD CURING OR BAG MOLDING Code 8 03 02 8 03 22 8 03 23 STATE OF THE ART ASSESSMENT Heat s h i e l d s t o date have been e s s e n t i a l l y homogeneous composites throughout the t h i c k n e s s and area a f f e c t e d by a b l a t i o n M a t e r i a l s capable of w i t h s t a n d i n g the environment have been developed However techniques f o r f a b r i c a t i o n o f these m a t e r i a l s i n t o shapes h a v i n g the d e s i r e d v a r i a b l e p r o p e r t i e s t h r o u g h the c r o s s s e c t i o n and along the s u r f a c e have not been developed P o s i t i v e f i b e r o r i e n t a t i o n i s a necessary c r i t e r i o n f o r any o p t i m i z e d a b l a t i v e s t r u c t u r e and i s i n c l u d e d as a p a r t o f the process Most s u c c e s s f u l methods used t o date have I n c l u d e d tape wrapping and hand l a y up o f prepreg g l a s s or h i g h s i l i c a f a b r i c U niform d e n s i t y i s achieved by the a p p l i c a t i o n o f h i g h pressure molding techniques Some success i s a l s o being achieved w i t h low d e n s i t y o p t i m i z e d a b l a t i v e s t r u c t u r e s and these c o u l d a l s o be co n s i d e r e d as a p p l i c a b l e depending on the s p e c i f i c l o c a t i o n on the heat s h i e l d CRITICAL PROBLEMS 1 Development o f p r e d i c t a b l e p r o p e r t i e s such as t h e r m o p h y s l c a l p r o p e r t i e s o f the basic m a t e r i a l s employed and maintenance o f d e s i r e d r e i n f o r c e m e n t o r i e n t a t i o n t h r o u g h s e c t i o n w a l l and along t h e s u r f a c e 2 Non d e s t r u c t i v e t e s t methods are e s s e n t i a l 3 Dimensional c o n t r o l and s t a b i l i t y must be ma i n t a i n e d 4 Chemical c o m p a t i b i l i t y o f s u b s t r u c t u r e and a b l a t o r should be co n s i d e r e d ALTERNATE PROCESSES NONE Code

124 CHART PROPOSED DEVELOPMENT PROGRAM OBJEgTIVE To produce 6 12 s p h e r i c a l nose or C and D shaped l e a d i n g edge a b l a t i v e s t r u c t u r e s having g r a d i e n t p r o p e r t i e s t o p r o v i d e predetermined r e c e s s i o n r a t e s a t v a r i o u s a x i a l s t a t i o n s so as t o p r o v i d e c o n s t a n t aerodynamic c h a r a c t e r i s t i c s i n a 200 B t u / f t ^ sec maximum heat f l u x environment BACKGROUND Advanced v e h i c l e s w i l l r e q u i r e c l o s e d i m e n s i o n a l c o n t r o l o f nose t i p s and l e a d i n g edges Because o f the non u n i f o r m e r o s i v e environment f r o m the s t a g n a t i o n p o i n t a f t t h e r e i s a need t o v a r y performance c h a r a c t e r i s t i c s o f the heat s h i e l d along i t s c o n t o u r Heat s h i e l d s t o date have e s s e n t i a l l y been homogeneous composites t h r o u g h o u t t h e i r t h i c k n e s s and area a f f e c t e d Techniques f o r f a b r i c a t i o n o f a b l a t i v e m a t e r i a l s w i t h g r a d i e n t p r o p e r t i e s must thus be developed Before any m a n u f a c t u r i n g development program can b e g i n a c a r e f u l a n a l y s i s must be made t o determine p r e c i s e heat f l u x shear loads and o t h e r f o r c e s a c t i n g on a l l a x i a l l o c a t i o n s from s t a g n a t i o n p o i n t a f t A comprehensive computer program would be r e q u i r e d T h i s can be done w i t h present s t a t e o f the a r t M a t e r i a l s f o r each l o c a t i o n must be s e l e c t e d on the b a s i s of optimum w e i g h t s t r e n g t h i n s u l a t i o n and e r o s i o n a n t i c i p a t e d i n the environment The computer program would a l s o be e n l a r g e d t o p r e d i c t m a t e r i a l r e q u i r e m e n t s and t h i c k n e s s e s o f s h i e l d and s t r u c t u r e M a t e r i a l parameters which c o u l d be v a r i e d w i t h i n the s t r u c t u r e would I n c l u d e d e n s i t y r e i n f o r c e m e n t and m a t r i x s e l e c t i o n as w e l l as f i b e r o r i e n t a t i o n A c o m p l e t e l y heterogeneous composite would r e s u l t APPROACH 1 Develop t o o l i n g and l a y up techniques f o r p o s i t i o n i n g and i n t e g r a t i n g r e i n f o r c e ment and o t h e r c o n s t i t u e n t s i n such a f a s h i o n as t o predetermine l o c a t i o n and d i r e c t i o n i n f i n a l component 2 S p h e r i c a l and C and D shapes specimens a p p r o x i m a t e l y 9 i n c h i n diameter should be f a b r i c a t e d p r e f e r a b l y u s i n g the same technique 3 Develop methods o f molding or c u r i n g such as t o develop d e s i r e d g r a d i e n t thermo p h y s i c a l p r o p e r t i e s t h r o u g h c o n t r o l of r e i n f o r c e m e n t s e l e c t i o n or r e s i n / r e i n f o r c e ment r a t i o d e n s i t y and r e i n f o r c e m e n t o r i e n t a t i o n where a p p l i c a b l e 4 I n v e s t i g a t e problems a s s o c i a t e d w i t h j o i n i n g a b l a t i v e heat s h i e l d t o s u b s t r a t e 5 Using ground t e s t f a c i l i t i e s or e q u i v a l e n t e v a l u a t e t o t a l performance of a t y p i c a l component Continued on next page

CHART 125 INSPECTION TECHNIQUES SUPPLEMENTAL RECCWIENDATIONS INSPECTION REQUIREMENT I n process and end i t e m measurement and c o n t r o l o f p r o p e r t i e s / b e h a v i o r c h a r a c t e r i s t l c s f o r a b l a t i v e s t r u c t u r e s having graded p r o p e r t i e s OBJECTIVE To determine the f a i l u r e mechanisms d e f i n e s i g n i f i c a n t m a t e r i a l v a r i a b l e s and develop t e c h n i q u e s f o r i n s p e c t i o n o f l e a d i n g edge a b l a t i v e s t r u c t u r e s BACKGROUND I f one accepts the n o t i o n t h a t an e n g i n e e r i n g m a t e r i a l i s one f o r which raw i n g r e d i e n t s and f a b r i c a t i o n techniques are s p e c i f i e d and whose p r o p e r t i e s are known and adequate ( i n c l u d i n g r e p r o d u c i b i l i t y ) f o r some e n g i n e e r i n g a p p l i c a t i o n then m a t e r i a l s o f t h e type r e q u i r e d here are n o t p r e s e n t l y a v a i l a b l e Development t o y i e l d such m a t e r i a l s i s now under way ( j u s t b e g i n n i n g ) S t u d i e s o f p r o p e r t i e s and f a i l u r e mechanisms under s e r v i c e environments have not been conducted Some i n v e s t i g a t i o n o f i n s p e c t i o n methods i s c o n c u r r e n t l y i n pr o g r e s s N e i t h e r the m a t e r i a l nor the I n s p e c t i o n methods are expected t o be d e f i n e d a d equately by 1970 However some progress i n d e f i n i n g m a t e r i a l v a r i a b l e s which must be c o n t r o l l e d should be made by 1970 At t h a t time another e f f o r t t o d e f i n e the s p e c i f i c s o f the i n s p e c t i o n problem should be made and t o p i n p o i n t the d i r e c t i o n o f t e s t methods development I n the i n t e r i m some obvious e f f o r t s t o c o n t r o l raw i n g r e d i e n t s and processes^ as w e l l as gross f l a w d e t e c t i o n , s h o u l d be undertaken For r e i n f o r c e m e n t e v a l u a t i o n NDT techniques should be developed f o r checking u n i f o r m i t y o f s i z e and p r o p e r t i e s o f m e t a l l i c and non m e t a l l i c f i l a m e n t s Eddy c u r r e n t (CBA) and d i e l e c t r i c (CDD) probes are a p p l i c a b l e t o c o n d u c t i n g or non co n d u c t i n g m a t e r i a l s f o r dynamic scanning o f monofilaments A p p l i c a t i o n t o r o v i n g or y a r n w i l l be more d i f f i c u l t and t o woven f a b r i c s even more d i f f i c u l t however some a t t e n t i o n should be g i v e n t o e v a l u a t i o n o f f i l a m e n t d e g r a d a t i o n d u r i n g these o p e r a t i o n s For i m p r e g n a t i o n c o n t r o l c o n t r o l s need t o be developed f o r p r e p r e g i n g o f mono f i l a m e n t s yarns tapes and f a b r i c s t o assure more u n i f o r m w e t t i n g out minimum p o r o s i t y and c o n t r o l of B s t a g i n g Small samples a n a l y s i s i s regarded as inadequate Dynamic 1007 i n s p e c t i o n techniques are r e q u i r e d C o n t r o l o f f i l a m e n t s u r f a c e p r e p a r a t i o n and couple agent a p p l i c a t i o n i s e s p e c i a l l y I m p o r t a n t t o end it e m q u a l i t y For some o f these processes prepregged r e i n f o r c e m e n t may not be used Reinforcements may be woven d r y f o l l o w e d by im p r e g n a t i o n o f s u b s t a n t i a l t h i c k nesses W e t t i n g o u t o f r e i n f o r c e m e n t i s e s p e c i a l l y d i f f i c u l t Co e v a l u a t e or c o n t r o l under these c o n d i t i o n s E f f o r t t o st u d y the r e l a t i o n s h i p o f u l t r a s o n i c (DA) v e l o c i t y measurements and r e i n f o r c e m e n t w e t t i n g should be conducted For end i t e m e v a l u a t i o n techniques r e q u i r e d w i l l depend on the thermo mechanical demands made upon the heat s h i e l d m a t e r i a l A b l a t i v e behavior i s c o n t r o l l e d p r i m a r i l y by c h e m i s t r y u n l e s s h i g h ( g r e a t e r t h a n 100 p s i ) shear f o r c e s appear a t the a b l a t i n g s u r f a c e The c h e m i s t r y i s governed m o s t l y by choice o f i n g r e d i e n t s i n the composite and l i t t l e can be c o n t r i b u t e d by end i t e m i n s p e c t i o n Mechanical p r o p e r t i e s a l s o I m p o r t a n t i n the heat s h i e l d are h i g h l y s t r u c t u r e dependent Degree o f cure i s c o r r e l a t a b l e w i t h e l a s t i c p r o p e r t i e s and d i e l e c t r i c p r o p e r t i e s U l t r a s o n i c (DA) v e l o c i t y measurements and d i e l e c t r i c (CDD) measurement are a v a i l a b l e f o r s p e c i f i c c o r r e l a t i o n Some success has a l s o been achieved r e c e n t l y i n r e l a t i n g u l t r a s o n i c v e l o c i t y measurements i n r e l a t i v e l y homogeneous p a r a l l e l r e i n f o r c e d l a m i n a t e s w i t h the amount and l o c a t i o n o f p o r o s i t y T h i s i n t u r n r e l a t e s t o mechanical p r o p e r t y v a l u e s The more complex problems a s s o c i a t e d w i t h graded p r o p e r t y composites are not y e t understood however and must be preceded by f a i l u r e mechanism s t u d i e s b e f o r e s i g n i f i c a n t m a t e r i a l v a r i a b l e s can be d e f i n e d For a n i s o t r o p y and r e i n f o r c e m e n t o r i e n t a t i o n c o n v e n t i o n a l r a d i o g r a p h y (BA) has co n t i n u e d on next page

C H A R T 126 INSPECTION TECHNIQUES SUPPLEMENTAL RECOMMENDATIONS, co n t i n u e d BACKGROUND, co n t i n u e d been found o f some hel p Again the s p e c i f i c m a t e r i a l has n o t y e t been s p e c i f i e d and w i l l s t r o n g l y I n f l u e n c e s e l e c t i o n o f a p p l i c a b l e NDT tech n i q u e s For bond e v a l u a t i o n between a b l a t o r and back up s t r u c t u r e SOA u l t r a s o n i c t e c h nlques (DA) should be adequate but must be o p t i m i z e d f o r the s p e c i f i c m a t e r i a l High a t t e n u a t i o n i n some m a t e r i a l f o r m u l a t i o n s may i n v a l i d a t e c o n v e n t i o n a l u l t r a s o n i c bond t e s t t echniques For f l a w d e t e c t i o n the n a t u r e o f i n h e r e n t s i g n i f i c a n t f l a w s w i l l have t o be d e f i n e d f o r each m a t e r i a l f a b r i c a t i o n process A p p l i c a b l e t e s t t e c h n i q u e s cannot be p r e s e l e c t e d APPROACH An NDT development e f f o r t i s urged f o r t h i s most complex m a t e r i a l I t should r u n c o n c u r r e n t l y w i t h the m a t e r i a l s development e f f o r t and be augmented by f a i l u r e mechanism s t u d i e s needed t o d e f i n e the m a t e r i a l v a r i a b l e s w h i c h must be e v a l u a t e d These v a r i a b l e s w i l l v a r y from one m a t e r i a l and f a b r i c a t i o n process t o another G e n e r a l i z a t i o n w i l l be d i f f i c u l t and dangerous u n t i l f a i l u r e mechanisms are understood A l l samples o f graded p r o p e r t y composite f a b r i c a t e d by a g i v e n process should be screened f o r v a r i a b i l i t y by NOT Samples c o n t a i n i n g graded degrees o f s e v e r i t y f o r t h e d e t e c t e d v a r i a b l e s should be s u b j e c t e d t o e n v i r o n m e n t a l t e s t s designed t o r e v e a l s i g n i f i c a n t f a i l u r e modes r e l a t e d t o s e r v i c e environments The prime purpose o f these s t u d i e s w i l l be t o separate r e l e v a n t from i r r e l e v a n t v a r i a b l e s and t o i d e n t i f y v a r i a b l e s n o t d e t e c t e d by NDT and which are c o n t r i b u t o r y t o f a i l u r e Some b a s i s f o r s e l e c t i o n / o p t i m i z a t i o n o f m e a n i n g f u l NDI w i l l t h e n be a v a i l a b l e and a complete l i s t o f r e q u i r e d a t t r i b u t e s can be d e f i n e d While some b a s i s e x i s t s f o r e v a l u a t i o n o f p r o p e r t i e s i n t e n d e d t o be u n i f o r m t h r o u g h the t h i c k n e s s e f f o r t t o c o n t r o l d e l i b e r a t e p r o p e r t y g r a d i e n t s may have t o depend on i n process i n s p e c t i o n T h i s might be accomplished by step by step NDT I n s p e c t i o n a f t e r each s i g n i f i c a n t process o p e r a t i o n which might i n f l u e n c e f i n a l p r o p e r t i e s The I n s p e c t i o n development program i s summarized 1 NDT screen samples o f developmental m a t e r i a l f o r c h e m i s t r y / s t r u c t u r e v a r i a b i l i t y 2 Conduct e n v i r o n m e n t a l or d e s t r u c t i v e t e s t s t o determine q u a n t i t a t i v e s i g n i f i c a n c e o f d e t e c t e d and u n a n t i c i p a t e d v a r i a b l e s by f a i l u r e mechanism s t u d i e s 3 S e l e c t / o p t i m i z e NDT f o r use as end i t e m i n s p e c t i o n or process c o n t r o l t e s t f o r each s i g n i f i c a n t v a r i a b l e or a t t r i b u t e 4 C a l i b r a t e NDt f o r q u a n t i t a t i v e measurement c a p a b i l i t y and develop t e s t technique c o n t r o l s t o assure r e p r o d u c i b l e s e n s i t i v i t y r e s o l u t i o n and i n t e r p r e t a t l o n 5 Prepare w r i t t e n NDT procedures

127 PRIORITY RATING WORKSHEET CHART P R O f i R A M FACTORS PR06RAM OF S U C C E S S PBOBABILITV • LOW • M O D E R A T E J t HIGH C R I T I C A L P R O B L E M S TO B E S O L V E D n F E W / N O T TOO DIFFICULT JA S O M E / D I F F I C U L T Q M A N Y / V E R Y D I F F I C U L T P R O C E S S GROWTH P O T E N T I A L D L I T T L E O B U N D E F I N A B L E X R E M ^ N I Z A B L E P O T E N T I A L A P P L I C A T I O N S O T H E R T H A N A IR FORCE • NONE S O M E MANY 8 NECESSITY FOR AIR FORCE FUNOINO • LOW H fiH INIUSTHV/'OTHCA 6Mr CFFOftr 4. yi M DMATI - StMC EFniLT OTHCK 'SOUĈ ES 0 • ticcuisit/e AiH F Wfc FUMOMa UKELy 14. z 5 8 z 8 o 4 o 4 N E E D FACTORS S Y S T E M S P R O B A B I L I T Y HICIH P80BABI I T Y FAIR PROBABILITY LOW P R O B A B I L I T V COMPONENT CRITICALITY VERY HICH HIAH FAIR L e w FREaUENCV OF REQUIREMENT IN S Y S T E M MOM THAN 3 COMPeNENTS Z 3 C«MPIlNENrS SINGLE OOMPONENT DESIGN A L T E R N A T E S No ALTERNATE R i a E 8 E E N ONE ALTERNATE SEVEILAL ALTERMATEfi MATERIALS IMPLIOATION NEW MATEBIAL PeVEtOfMtNT !?«<» O (AATtttlAL IMPlWVEMtOlT RElS D NO PROBLEM F fteSEEN 0 3 2±_ RAW SCoOES FOR R E F C E E M O P COMFONCMT M TA6LES AT L N D or PAMEl BEPOtT WITH liAW T « T « L S ENTEREP IM •SlIMUAEV AT eiGUT SYSTEMS A 3b A A R P RANN scoaes U7 CALCULATE P R I O R I T Y . STEP I CIRCLE HISHEST A A R P RAW S C O R E n e S T E P 2 IN EACH Cn-HER S Y S T E M C I R C L E NEXT H I O U E S T SCORE IF WITHIN »t POINTS OF T O P S C O R E *> NUMBER O F SysTEIWS HIAH I- LOW 5 i i r ] [ i E n n n • • • • • • • • • • i n • • I • • • • • • • • • • • • • • • • • • • • ] [ S T E P 3 C I R C L E FREOOENCY DISTRIBUTION FACTOR Mtoiaen. 00 sysreMS H s»« BELOWi 3 RMMf NUMBER O F SYSTEMS LOW 0 I 2 RMsce 1 0 1 £ I 4 1 1 1 3 1 f 1 £ 1 *f 1 4 TOTAL PRIORITY

128 TITLE FABRICATION OF VARYING COMPOSITION ABUTIVE HEAT SHIELDS FOR LIFTING RE ENTRY VEHICLES CHART PRIORITY RELATED C ^ ^ H A R T S MANUFACTURING REQUIREMENT To produce herai s p h e r i c a l and h e m i - c y l l n d r l c a l heat s h i e l d s up t o 3 f o o t diameter and w e i g h i n g up t o 200 pounds f o r heat f l u x exposures o f 200 BTU/ft^ sec f o r 5 t o 60 minute d u r a t i o n w i t h peaks o f 1200 BTU/ft^ sec AARP REFERENCES E Chort . 263 B Chorf. 119c 120d P&FVPS Charts APPLICABLE PROCESS Code L A Y UP BY HAND BY T A P E WRAPPING OR BY F I L A M E N T WINDING AND CURE BY 8 03 18 OVEN VACUUM BAG OR C L A V E 8 03 21 _^ 22 STATE O F THE ART ASSESSMENT Heat s h i e l d s t o date have been p r e d o m i n a n t l y m o n o l i t h i c homogeneous s t r u c t u r e s M a t e r i a l s used i n c l u d e woven r e i n f o r c e m e n t s such as g l a s s s i l i c a or carbon w i t h p h e n o l i c r e s i n m a t r i x F a b r i c a t i o n techniques i n c l u d e hand lay-up tape wrap or o t h e r f i b e r p o s i t i o n i n g approached f o l l o w e d by a cure i n an auto or h y d r o c l a v e or merely vacuum bag mol d i n g i n an oven For l e s s severe environment c a s t epoxy novalac and e l a s t o m e r i c systems have been I n c o r p o r a t e d I n any event the thermal p r o t e c t i v e systems have been p r i m a r i l y o f m o n o l i t h i c c o n s t r u c t i o n an appendage b o l t e d or a d h e s i v e l y bonded t o a s u b s t r u c t u r e Advanced f l i g h t v e h i c l e s w i l l r e q u i r e an o p t i m i z a t i o n o f the heat s h i e l d s from a weight and d i m e n s i o n a l r e t e n t i o n s t a n d p o i n t and i n t e g r a t i o n w i t h the s t r u c t u r a l member Three separate phases i n the c r o s s s e c t i o n s can be i d e n t i f i e d the a b l a t i v e o u t e r l a y e r which r e s i s t s the t h e r m a l and shear loads w h i l e e x p e r i e n c i n g minimum or low d i m e n s i o n a l l o s s an i n t e r mediate low weight i n s u l a t i o n l a y e r and the s t r u c t u r a l member I t s e l f a composite m a t e r i a l which must be t h e r m a l l y p r o t e c t e d t o m a i n t a i n i t s maximum s t r u c t u r a l I n t e g r i t y Adhesive bond J o i n t s cannot be depended upon t o p r o v i d e the man r a t e d r e l i a b i l i t y r e q u i r e d w i t h o u t excessive w e i g h t p e n a l t i e s as s a f e t y f a c t o r The environment i s not c o n s i d e r e d severe or beyond the c a p a b i l i t y o f e x i s t i n g or e a s i l y s y n t h e s i z e d m a t e r i a l s systems I t remains however t h r o u g h i n t e r d i s c i p l i n a r y i n t e g r a t i o n o f m a t e r i a l s f a b r i c a t i o n and d e s i g n t e c h n o l o g i e s t o develop a r e l i a b l e minimum w e i g h t heat s h i e l d The r e s u l t i n g s t r u c t u r e i s e n v i s i o n e d as a nonhomogeneous composite I n w h i c h each l e v e l or s t r a t a i s s e l e c t e d t o p e r f o r m a s p e c i f i c t a s k and I s o p t i m i z e d i n w e i g h t and performance f o r t h e p a r t i c u l a r environment experienced i n the s p e c i f i c l o c a t i o n on the v e h i c l e The unique f e a t u r e which must be developed i s the i n t e g r a t i o n o f the v a r i o u s phases r e q u i r e d i n t o a m o n o l i t h i c s t r u c t u r a l l y sound composite CRITICAL PROBLEMS 1 C o n t r o l o f mechanical a b l a t i v e and the r m a l p r o p e r t i e s t o p r e s e l e c t e d l i m i t i n g v a l u e s changing t h r o u g h the c r o s s - s e c t i o n w i l l be r e q u i r e d 2 N o n - d e s t r u c t i v e t e s t i n g i s e s s e n t i a l 3 Mechanical j o i n i n g t o m e t a l l i c s u b s t r a t e ALTERNATE PROCESSES NONE Code

129 CHART P R O P O S E D D E V E L O P M E N T P R O G R A M OBJECTIVES To develop techniques f o r p r o d u c i n g h e m i s p h e r i c a l and heml c y l i n d r i c a l f i b e r r e i n f o r c e d heat s h i e l d s up t o 3 f o o t diameter and weighing up t o 200 l b s u s i n g f i b e r r e i n f o r c e d a b l a t i v e c o m p o s i t i o n s f o r a p p l i c a t i o n i n moderate heat f l u x (1200 BTU/ft2 sec peak) and shear environments An Imp o r t a n t aspect i s t o achieve v a r i a b l e t h i c k n e s s and v a r i a b l e c ompositions and d e n s i t y across w a l l and along chord l e n g t h BACKGROUND Heat s h i e l d s t o date have g e n e r a l l y been m o n o l i t h i c homogeneous s t r u c t u r e s or m u l t i p l e x s t r u c t u r e s o f d i s s i m i l a r m a t e r i a l s a d h e s i v e l y bonded or molded I n t e g r a l l y For h i g h performance and o p t i m i z e d w e i g h t v e h i c l e s t h e r e i s a need f o r heat s h i e l d s t h a t are t a i l o r e d i n t h i c k n e s s and o f g r a d i e n t p r o p e r t i e s t o best accommodate the a b l a t i v e environment APPROACH 1 Develop s p e c i a l t y f i b e r f o r m weaves and shapes t o i n t e g r a t e d i s s i m i l a r m a t e r i a l s and t o p e r m i t d e s i r e d c o n s t r u c t i o n 2 Develop l a y up process t o p o s i t i o n f i b e r s i n predetermined p a t t e r n or o r i e n t a t i o n t o achieve p r e d i c t e d s t r e n g t h and e r o s i o n r e s i s t a n c e 3 Develop c u r i n g methods t o m a i n t a i n or achieve d e s i r e d f i b e r o r i e n t a t i o n mechanical and p h y s i c a l p r o p e r t i e s along l e n g t h and through c r o s s s e c t i o n Because o f the graded c o n s t r u c t i o n and d i s s i m i l a r m a t e r i a l c o n t e n t c o n t r o l o f di m e n s i o n a l t o l e r a n c e s mold s h r i n k a g e and the r m a l expansion c h a r a c t e r i s t i c s w i l l be c r i t i c a l 4 F a b r i c a t e s p h e r i c a l and c o n i c a l specimens s i m u l a t i n g components u s i n g the developed p r o c e s s i n g techniques and m a t e r i a l s s e l e c t e d S u f f i c i e n t q u a n t i t y should be produced t o demonstrate u n i f o r m i t y and r e p r o d u c i b i l i t y 5 I n v e s t i g a t e problems o f J o i n i n g t o s u b s t r a t e 6 Eva l u a t e t o t a l performance i n ground t e s t f a c i l i t i e s 7 Review of the v a r i o u s processes p o s s i b l e should be made and the most p r a c t i c a l one or two s e l e c t e d f o r u t i l i z a t i o n on t h i s program 8 A method f o r non d e s t r u c t i v e e v a l u a t i o n o f the component i s needed NOTE The program o u t l i n e d above i s s i m i l a r t o t h a t o f CAMR 623 and might be combined t o s a t i s f y m a n u f a c t u r i n g requirements t o both c h a r t s The i n s p e c t i o n recommendations o f CAMR 623 a p p l y t o bot h programs

PRIORITY RATING WORKSHEET CHART PR06RAM PROBABILITY OF S U C C E S S D LOW Z • MOOERATe 5 HIGH 8 CRITICAL PROBLEMS TO B E SOLVeO • feVt/HOT TOO DIFFICULT Z 30ME/D IFF ICULT 3 D MANV/ VERY PIFFICULT 8 GROWTH P O T E N T I A L • LITTLE OR. UNDEFINABLE O KeeoaNiiABLE pereur iAL 4 OTHER TVAN AIR FORCE NONE O SOME Jf. M A N Y e FOR AIR fORCf. FUN0IN(3 PROCESS PC APPLICATIONS • NECESSITY • LOW HISH INtUSTEV/'fiTHeA <SMr C F F O C T 4 J S M OtBATS - SIWC EFRxT orMtS 'SWClSeS 8 • tlC£UJSll(E AlR fotLet FUWPwa UKfL-J l i NEED FACTORS S Y S T E M S P R O B A B I L I T Y man P S O B A B I I T Y FAia PROSAeiL ITY LOW P R O B A B I L I T Y COMPONENT CRITICALITY VERY HIi'H HIAH FAIR Low FREQUENCY OF REflUlBEMENT IM «YSrE»A MARE THAM 3 C0MPSXEUT9 SINGLE COMPONENT DESIGN A L T E R N A T E S Ho A L T E R N A T E R M E s E E N O N E ALTERNATE S E V E R A L ALTERUATEC MATERIALS IMPLICATION Hew MATEe.lA PCV LO^MCMT C f a o MATERIAL IMPMVEMENT R E S P NO PROBLEM r o R t s e e n 8 6_ RAW scoaes FOR EACII REFCCeMCCP CoMIVNEWT IN TABLCi AT tWD or PAKEL WITH 12AI0 TOTALS ENTEREP IM <3UM>tAtV ewuT SVST MS A A R P RA<M seooes r»rir?7ii ii ii i • • • • • • • • • • ] [ • • • • • • • • • • • 1 • • • • • CALCULATE PRIORITY STEP I S T E P 2 S T E P 3 CIRCLE HIGHEST A A R P RAW S C O R E IN eACH OTHER S Y S T E M C I R C L E NEXT H I G H E S T IF WITHIN * POINTS o r T O P S C O R E *» ± tow 3 / NUMBER OF ^ISTEMS HIAH C I R C L E FREQUENCY DISTRIBUTION FACTOR NUMiaen. m s y s r e M * rt s»< I 2 3 «R MOU NUMBER OF SYSTEMS L e w D I 2 RMol l t 1 0 1 a I 4 1 1 1 3 1 ^ 1 7. 1 «f 1 4 SCORE B E L O W t TOTAL PRIORITY

131 TITLE VACUUM RAMMING OF LARGE ACID BONDED CERAMIC PARTS CHART PRIORITY RELATED CAMR CHARTS HL MANUFACTURING REQUIREMENT Ceramic elements are r e q u i r e d f o r h i g h temperature components and p r o p u l s i o n d e v i c e s Components f o r use up t o 3500 F w i l l g e n e r a l l y be t h i c k w a l l e d s h o r t h o l l o w c y l i n d e r s or f l a t t o s l i g h t l y curved vane shapes These i n c l u d e bodies o f r e v o l u t i o n up t o 6 f o o t diameter X 15 f o o t l o n g and vanes up t o 8 inches i n l e n g t h w i t h t h i c k n e s s e s from 0 010 i n c h t o 1 0 i n c h Ceramic r o c k e t n o z z l e t h r o a t I n s e r t s c o u l d be r e q u i r e d f o r use up t o 7000 F Sizes are up t o 8 Inches diameter by 12 Inches long w i t h w a l l t h i c k n e s s e s up t o 1/2 i n c h AARP REFERENCES B rktfar** B Charts — PAFVPS Charti Non Me t n l U r . F n b r l r n r l n n Nn. ? ^ APPLICABLE PROCESS Code VACUUM RAMMING 8 02 08 STATE-OF THE ART ASSESSMENT Ranming mixes o f t h i s type have been processed i n t o l e a d i n g edges 12 inch diameter nose cones and as r e i n f o r c e d c o a t i n g s f o r r a m j e t components I n vacuum ramming the uncured mix and mold are bagged and s u b j e c t e d t o vacuum t o remove a i r and undesir e d v o l a t i l e s I t i s then c o n s o l i d a t e d i n t o the mold by e x t e r n a l ramming However p a r t s 6 f o o t diameter and 15 f o o t l o n g have not been f a b r i c a t e d and are n o t l i k e l y t o be as a r e s u l t o f normal s t a t e o f the a r t p r o g r e s s i o n Since these m a t e r i a l s are u s u a l l y r e i n f o r c e d c o a t i n g s they must be pressed or c o n s o l i d a t e d o n t o the s u b s t r a t e The s i z e s and shapes p r e c l u d e c a s t i n g and d i c t a t e a ramming process Large l i q u i d p r o p e l l e n t r o c k e t nozzles are being coated by flame and plasma s p r a y i n g but c o a t i n g s are not as t h i c k i n 1966 Normal s t a t e o f the a r t advancements should enable these processes t o app l y the d e s i r e d t h i c k n e s s e s by the mid 1970 s CRITICAL PROBLEMS 1 Development o f procedures f o r p r e p a r i n g l a r g e amount o f low temperature c u r i n g cement a t i o u s ceramic i n a c o n t r o l l e d and r e p r o d u c i b l e manner Most o f these m a t e r i a l s c o n t a i n v e r y c o r r o s i v e a c i d s 2 Development o f d i e s s t r i p p a b l e c o a t i n g s t o o l s and procedures f o r placement o f t h e m a t e r i a l 3 Development o f c u r i n g ovens p r o v i d i n g the d e s i r e d temperature c o n t r o l and v e n t i n g f o r the c o r r o s i v e fumes A Development o f bagging m a t e r i a l s ramming equipment and i n process I n s p e c t i o n procedures which can cope w i t h the m e t a l r e i n f o r c e m e n t ALTERNATE PROCESSES GUNNING PLASMA SPRAYING FLAME SPRAYING Code 8 02 lA 8 02 07 8 02 06

132 CHART N O PROPOSED DEVELOPMENT PROGRAM OBJECTIVE The development of b a t c h i n g and a p p l i c a t i o n procedures f o r p r o c e s s i n g o f a c i d bonded ceramic mixes t o produce m e t a l r e i n f o r c e d ceramic a r t i c l e s up t o 6 f t diameter and 15 f t long BACKGROUND Rocket motors r a m j e t s and t u r b o j e t s v i l l r e q u i r e 5000 F r e s i s t a n t m e t a l r e i n f o r c e d c y l i n d e r s up t o 6 f t diameter and 15 f t long and vanes 3 f t x 3 f t X 1/2 i n c h These a r t i c l e s are e s s e n t i a l l y t h i c k r e i n f o r c e d c o a t i n g s a t t a c h e d t o a meta l s u b s t r a t e Since t h e y r e q u i r e c o n s o l i d a t i o n onto and around the r e i n f o r c i n g and a t t a c h i n g screen a ramming procedure i s optimum The use o f a tough f l e x i b l e membrane over the evacuated mix d u r i n g ramming i m p a r t s a d d i t i o n a l p l a s t i c i t y t o i t and hold s i t I n pla c e u n t i l c o n s o l i d a t e d Since the bonding m a t e r i a l i s u s u a l l y a c i d i c most o f the problems r e l a t e t o m i n i m i z i n g a t t a c k by the a c i d and t o the l a r g e s i z e o f p a r t s and amounts o f ceramic t o be processed APPROACH 1 Develop procedures f o r s i z i n g powders and b l e n d i n g and m i x i n g o f powders w i t h a c i d i c l i q u i d b i n d e r s t o produce ramming mixes w i t h d e s i r e d f l u i d i t y p l a s t i c i t y and s h e l f l i f e and dev i s e r e l a t e d storage and t r a n s p o r t a t i o n c o n t a i n e r s 2 Develop d i e m a t e r i a l s p r o t e c t i v e s t r l p p a b l e c o a t i n g s t o o l s and procedures f o r placement o f the cementacious mixes 3 Develop techniques f o r vacuum ramming t o in c r e a s e the i n p l a c e d e n s i t y 4 Develop c u r i n g ovens p r o v i d i n g the d e s i r e d temperature c o n t r o l and v e n t i n g f o r the c o r r o s i v e fumes 5 Develop bagging m a t e r i a l s ramming equipment and i n process I n s p e c t i o n procedures f o r i n t e g r i t y o f the metal r e i n f o r c e m e n t 6 F a b r i c a t e t y p i c a l p a r t i d e n t i f y NDT techniques and a p p l y them t o dete r m i n e p a r t u n i f o r m i t y INSPECTION TECHNIQUES SUPPLEMENTAL RECOMMENDATIONS INSPECTION REQUIREMENT Process c o n t r o l and end Item e v a l u a t i o n o f t h i c k w a l l e d c y l i n d e r s and s l i g h t l y curved vane shapes f l a t panels OBJECTIVE BACKGROUND To develop process c o n t r o l and i n s p e c t i o n techniques t o measure (a) a n l s o t r o p y and o r i e n t a t i o n o f r e i n f o r c e m e n t ( b ) r e s i d u a l s t r e s s ( c ) d e n s I t y / p o r o s l t y u n i f o r m i t y (d) clumping I n composites (e) r a t i o o f phases ( f ) t h i c k n e s s ( g ) I d e n t i f i c a t i o n o f raw m a t e r i a l s ( h ) s t r e n g t h / h a r d n e s s (1) f l a w s i n ceramic and ( J ) f l a w s i n welded r e l n f o r c e m s n t attachment t o s u b s t r a t e f o r vacuum rammed and a c i d bonded ceramic p a r t s Acceptance l i m i t s and d e t a i l e d procedures should a l s o be w r i t t e n f o r SOA techniques t o e v a l u a t e contour s u r f a c e roughness and dimensions I t I s somewhat d i f f i c u l t t o d i s c u s s the i n s p e c t i o n s t a t e o f the a r t f o r t h i s problem because o f the v a r i e t y o f c o n f i g u r a t i o n s i n v o l v e d and the l a c k o f s p e c i f i c d e t a i l e d d e s c r i p t i o n o f m a t e r i a l s and t h e i r d e s i g n / s e r v i c e r e q u i r e d p r o p e r t i e s I t i s expected t h a t an adequate u n d e r s t a n d i n g o f the n a t u r e o f the i n s p e c t i o n problem w i l l be a v a i l a b l e by 1970 Continued on next page

133 INSPECTION TECHNIQUES SUPPLEMENTAL RECOMMENDATIONS c o n t i n u e d CHART NO I t i s c l e a r t h a t a c o n c u r r e n t e f f o r t should be made i n s p e c t i o n methods s p e c i a l i s t s w o r k i n g w i t h m a t e r i a l s / f a b r i c a t i o n s p e c i a l i s t s ^ t o p r o v i d e f o r t e s t t echniques not now d e f i n a b l e A n t i c i p a t e d problem areas are discussed below For a n i s o t r o p v and r e i n f o r c e m e n t o r i e n t a t i o n , the NOT approach w i l l depend on whether the r e i n f o r c e m e n t i s i n the f o r m o f honeycomb or w i r e loops a t t a c h e d t o s u b s t r u c t u r e or d i s p e r s e d f i b e r s e t c I n each case the q u a n t i t a t i v e d e f i n i t i o n o f r e q u i r e d l i m i t s on c r u s h i n g o r i e n t a t i o n and clumping must be e s t a b l i s h e d i n r e l a t i o n t o s e r v i c e performance C o n v e n t i o n a l r a d i o g r a p h y (BAA) should be employed t o g e t a handle on what v a r i a b l e s r e s u l t from p r o c e s s i n g Eddy c u r r e n t (CBA) or d i e l e c t r i c t echniques (CDD) u l t r a s o n i c s (DA) and I n f r a r e d (ECB) techniques may a l s o be r e q u i r e d t o d e t e c t and e v a l u a t e more s u b t l e d e g r a d a t i o n n o t seen by r a d i o g r a p h y and caused by the vacuum ramming and the c o r r o s i v e b i n d e r s For r e s i d u a l s t r e s s p r e s e n t techniques are e i t h e r d e s t r u c t i v e or l i m i t e d t o s u p e r f i c i a l e v a l u a t i o n These I n c l u d e s t r a i n s e n s i t i v e c o a t i n g s (AC) x-ray d i f f r a c t i o n (BCA) and eddy c u r r e n t techniques (CBA) l i m i t e d t o use on the m e t a l l i c c o n s t i t u e n t s However t h e r e i s r e s e a r c h emphasis t o develop NOT s t r e s s / s t r a i n measurements c a p a b i l i t y which may open o t h e r p o s s i b i l i t i e s by 1970 I f they do not succeed process c o n t r o l may have t o be developed s u f f i c i e n t l y t o p e r m i t c o n t r o l o f r e s i d u a l s t r e s s d u r i n g p r o c e s s i n g For d e n s i t y / p o r o s i t y u n i f o r m i t y , a f a i r l y s t r o n g SOA e x i s t s f o r use on si m p l e r m a t e r i a l s Techniques a v a i l a b l e i n c l u d e r a d i o g r a p h y (BA) r a d i o m e t r i c gauging (BBA) eddy c u r r e n t (CBA) and r e s i s t i v i t y (CCA) f o r e l e c t r i c a l l y c o n d u c t i n g m a t e r i a l s d i e l e c t r i c (CDD) f o r non-conductors u l t r a s o n i c (DA) v e l o c i t y measurements and i n f r a r e d (ECB) techniques I n each case th e p o r o s i t y i n f l u e n c e s q u a n t i t a t i v e l y the p r o p a g a t i o n o f p r o b i n g energy and i s capable o f y i e l d i n g c a l i b r a t e d techniques i f the s i g n i f i c a n c e o f p o r o s i t y t o s e r v i c e behavior can be e s t a b l i s h e d For clumping o f c o n s t i t u e n t s many techniques are a v a i l a b l e but must be s e l e c t e d as r e q u i r e d t o c o r r e l a t e w i t h s e r v i c e p r o p e r t i e s The a v a i l a b l e approaches I n c l u d e r a d i o g r a p h y (BA) r a d i o m e t r i c gauging (BBA) eddy c u r r e n t (CBA) r e s i s t i v i t y (CCA) d i e l e c t r i c (CDD) u l t r a s o n i c (DA) temperature s e n s i t i v e c o a t i n g s (EB) and i n f r a r e d (ECB) S e l e c t i o n can be accomplished when the s p e c i f i c composite i s d e f i n e d For r a t i o o f phases i n the ceramic c o a t i n g which may i n f l u e n c e p r o p e r t y u n i f o r m i t y a v a i l a b l e techniques i n c l u d e x ra y d i f f r a c t i o n and spectroscopy (BC) d i e l e c t r i c (CDD) eddy c u r r e n t (CBA) u l t r a s o n i c (DA) and I n f r a r e d (ECB) Since some o f the ceramics under c o n s i d e r a t i o n may be e l e c t r i c a l l y c o n d u c t i n g and o t h e r s i n s u l a t i n g b o t h e l e c t r i c and d i e l e c t r i c NDT are suggested For t h i c k n e s s measurement the problem i s always c o m p l i c a t e d f o r the case o f composites I t i s c o n c e i v a b l e t h a t a l l o w a b l e v a r i a t i o n i n d i s t r i b u t i o n o f c o n s t i t u e n t s may so p e r t u r b the p r o p a g a t i o n o f energy used f o r t h i c k n e s s measure ment t h a t t h i c k n e s s accuracy i s i n t o l e r a b l y poor W i t h t h i s s i t u a t i o n i n mind a v a i l a b l e NOT techniques i n c l u d e r a d i o m e t r i c gauging (BBA) eddy c u r r e n t (CBA) r e s i s t i v i t y (CCA) d i e l e c t r i c (CDD) and u l t r a s o n i c (DA) For i d e n t i f i c a t i o n o f raw m a t e r i a l s c o n v e n t i o n a l chemical a n a l y s i s and x r a y a n a l y s i s (CB) tech n i q u e s would appear adequate They r e q u i r e procedure d e f i n i t i o n and c a l i b r a t i o n f o r the s p e c i f i c case however For s t r e n g t h / h a r d n e s s d e t e r m i n a t i o n techniques responsive t o d e n s i t y / p o r o s i t y and c e r a m i c - r e i n f o r c e m e n t d i s t r i b u t i o n as c i t e d above should be a p p l i c a b l e w i t h a p p r o p r i a t e s e l e c t i o n and c o r r e l a t i o n development Continued on next page

134 INSPECTION TECHNIQUES SUPPLEMENTAL RECOMMENDATIONS, c o n t i n u e d CHART NO ^o^>3 BACKGROUND, c o n t i n u e d For d e t e c t i o n o f f l a w s i n the ceramic and f o r welds used t o a t t a c h r e i n f o r c e m e n t t o s u b s t r a t e a p p l i c a b l e t e c h n i q u e s i n c l u d e o p t i c a l (AA) p e n e t r a n t (AB) r a d i o g r a p h i c (BA) eddy c u r r e n t (CBA) r e s i s t i v i t y (CCA) e l e c t r i f i e d p a r t i c l e (CDB) u l t r a s o n i c (DA) s e n s i t i v e c o a t i n g s (EB) I n f r a r e d (EC) and macro-etch (FA) t e c h n i q u e s While t h i s l i s t i s lo n g i t i s n o t v e r y s e l e c t i v e and cannot be more s p e c i f i c u n t i l the m a t e r i a l and i t s r e q u i r e m e n t s are d e f i n e d APPROACH Since the m a t e r i a l s I n v o l v e d are not p r e s e n t l y SOA as f a r as q u a l i t y c o n t r o l i s concerned i t i s v i t a l t h a t the i n s p e c t i o n problem be co n s i d e r e d c o n c u r r e n t w i t h f a b r i c a t i o n process development t o take advantage o f common specimens and en v i r o n m e n t a l t e s t s and t o o p t i m i z e communications between t e c h n i c a l d i s c i p l i n e s A l l samples o f m a t e r i a l s generated under the process development program should be screened by a p p l i c a b l e NDT te c h n i q u e s t o d e t e c t v a r i a b i l i t y Samples con t a i n l n g graded degrees o f s e v e r i t y f o r the d e t e c t e d v a r i a b l e s should be su b m i t t e d t o e n v i r o n m e n t a l t e s t s t o e s t a b l i s h t o l e r a n c e l e v e l s and t o separate r e l e v a n t f r o m n o n r e l e v a n t v a r i a b l e s These q u a n t i t a t i v e l i m i t s then become the d e f i n i t i o n o f the s p e c i f i c NDT i n s p e c t i o n problem and p e r m i t o p t i m i z a t i o n and s p e c i f i c method/technique s e l e c t i o n t o be made The above program i s summarized 1 Produce specimens u s i n g r e f e r e n c e process and e x p e r i m e n t a l v a r i a n t s on t h i s process 2 Screen w i t h NDT t o d e t e c t i n h e r e n t ( f o r each process) p a r t - t o p a r t and w i t h l n - p a r t v a r i a b i l i t y 3 P e r f o r m e n v i r o n m e n t a l t e s t s t o e s t a b l i s h f a i l u r e s i g n i f i c a n c e o f d e t e c t e d and unsuspected v a r i a b l e s F a i l u r e a n a l y s i s should e s t a b l i s h q u a n t i t a t i v e l i m i t s on s i g n i f i c a n t v a r i a b l e s 4 O p t i m i z e NDT tech n i q u e s r e g a r d i n g s e n s i t i v i t y r e s o l u t i o n and c a l i b r a t i o n t e chniques t o y i e l d unambiguous procedures f o r q u a n t i t a t i v e I n s p e c t i o n 5 Prepare w r i t t e n t e s t procedures f o r p r o d u c t i o n i n s p e c t i o n use

135 PRIORITY RATING WORKSHEET CHART ^ NO PROqpAM FACTORS PR06RAM PROBABILITY OF S U C C E S S • LOW Z • M O D E R A T E 5 > ( H I G H 8 C R I T I C A L P R O B L E M S TO B E SOLVEO • F E N V / N O T TOO O I F F U I U L T 2 JSS S O M E / D I F F I C U L T S D MANY/ VERY DIFFICULT 8 PROCESS G R O W T H P O T E N T I A L X LITTLE OR UNOEFINADLE O a ReCO^NlUtBLE POTENTIAL 4. A P P L I C A T I O N S OTHER THAN AIR F O R C E • NONE O S O M E ^ • MANY 8 N E C E S S I T Y FOR AIR FORCE FUNOINa D LOW HifiH iM iuST i iv /cn i£« 6 w r CFFiTtr ^ • vimULpm - M e E F R K T «TMce 9oua<!es e X eXCUISIVE AIR FtACL FUMPNa UKCL<4 |4. pa N E E D FACTORS S Y S T E M S P R O B A B I L I T Y MiaH P R O B A B I L I T Y FAIR PROBABILITY LOW P R O B A B I L I T Y C O M P O N E N T CRITICALITY YERY H I tH H I A H FAIR Low FREflUCNCY OF REQUIREMENT IM S Y S T E M MORE THAN 3 COMPONENTS £ 3 COMPCNENTS S I N G L E COMPONENT oesicN A L T E R N A T E S No A L T E R N A T E R w E s e E N ONE ALTERNATE S E V E R A L ALTERUATEC M A T E R I A L S IMPLICAriON New MATER.inL PEVELO|>yCMT REia D MATERIAL IMPRCVEMENT R E S D NO PROOLEM FoReSEEkl %9 RAW S C O R E S Foe EACH REFCEENOP COMPONENT M TAftLES AT kWB or PANEt RtPOtT WITH 1>AM TOTALS ENTEREV IM ^UUUAEV AT glfiUT CALCULATE PRIORITY STEP I CIRCLE HIGHEST A A R P RAW S C O R E rte S T E P 2 IN EACH OTHER S Y S T E M C I R C L E NEXT H I G H E S T IF WITHIN ft POtNTS OP TOP S C O R E n N U M B E R OF SySTEMS HlAH ^ LOW 5 S T E P 3 C I R C L E FREQUENCY DISTRIBUTION FACTOR f NUMQeit. OP s y s r e M * rt ei4 I 2 3 RMsce S Y S T E I A S A 3a 3D AARP RA>M SCORES iirii^fzfeiriirifxgi • • • • • • • • • • • • • • • • • • • • ] • • • • • DC SCORE BELOWi NUMacR OF SYSTEMS LOW 0 I 2 n M a u 1 0 1 2 < l 4 ^ 1 1 1 3 1 *f 1 2. 1 f 1 4 TOTAL PRIORITY

136 TITLE FILAMENT WOUND CHEMICALLY RESISTANT TANK FOR STORABLE LIQUID OR SOLID PROFELLANTS CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Produce a h i g h s t r e n g t h h i g h e l o n g a t i o n aluminum a l l o y t a n k l i n e r and f i l a m e n t w i n d over I t w i t h h i g h s t r e n g t h g l a s s f i l a m e n t s p r e lmpregna t ed o r wet w i t h b i n d i n g r e s i n The chamber i s t o be 10 f e e t l o n g and 4 f e e t I n d i ame te r des igned t o o p e r a t e a t 5000 p s l I t may be used f o r s o l i d or l i q u i d p r o p e l l a n t s AARP REFERENCES E Charts. B Charts. 139 65b 69b 71b PSFVPS Charts. APPLICABLE PROCESS FILAMENT WINDING Code 8 03 21 STATE OF THE ART ASSESSMENT A n a l y t i c a l s t u d i e s and l i m i t e d t e s t i n g have shown t h a t p r e s t r e s s e d aluminum a l l o y and f i b e r g l a s s f i l a m e n t w i n d i n g are e l a s t i c a l l y c o m p a t i b l e These l i n e r s have been overwound w i t h g l a s s f i l a m e n t s i n the g i r t h d i r e c t i o n o n l y or c o m p l e t e l y over the ends On s m a l l t anks the l i n e r may be spun f r o m a s i n g l e p i ece bu t on a A f e e t d i ame te r t a n k the l i n e r w i l l u n d o u b t e d l y i n v o l v e w e l d i n g w h i c h v a r i e s f r o m the system used I n pas t t e s t s A n a l y s i s o f t h i s type o f s t r u c t u r e has n o t been accompl i shed and more e f f e c t I s needed i n d e t e r m i n i n g the c o m p a t a b i l i t y o f t h e f a b r i c a t e d l i n e r w i t h the f i l a m e n t wound s t r u c t u r e H i g h s t r e n g t h t o w e i g h t v a l u e (3 x 10^ i n ) has been demons t ra ted i n 6 i n c h d i ame te r t e s t u n i t s a t p r e s su re s o f 3000 AOOO p s l Such v a l u e s have n o t been ach ieved i n l a r g e r v e s s e l s p r o b a b l y due t o the change i n r a t i o o f f i l a m e n t w i n d i n g t e n s i o n t o r a d i u s o f c u r v a t u r e o f t h e w i n d i n g p a t h T e s t s o f p r e s su re c y l i n d e r s have shown t h a t e l e c t r o formed n i c k e l l i n e r s i n f i b e r g l a s s f i l a m e n t wound s t r u c t u es may be c y c l e d I n the p l a s t i c ange a l i m i t e d b u t u s e f u l number o f t i m e s Recent work on t e t r a f l u o r o e t h y l e n e polymer shows v e r y p r o m i s i n g r e s u l t s however d e t a i l s have no t been deve loped s u f f i c i e n t l y t o enab le the p r o d u c t i o n o f a t a n k l i n e r o f the necessary h i g h s t r u c t u r a l I n t e g r i t y CRITICAL PROBLEMS 1 A n a l y t i c a l and p rocess methods are r e q u i r e d t o I n s u r e e l a s t i c and /o r p l a s t i c c o m p a t a b i l i t y o f s t r u c t u r e and t a n k l i n e r ( h a v i n g r e q u i r e d c h e m i c a l r e s i s t a n c e ) 2 A r e l i a b l e method i s needed f o r bonding the l i n e r t o the wound s t r u c t u r e t o p r e v e n t b u c k l i n g a t n e g a t i v e s t r a i n s 3 Design e f f o r t i s needed on p o l a r f i t t i n g s and t h e means f o r a t t a c h i n g these t o the l i n e r p r o v i d i n g a good s e a l ALTERNATE PROCESSES NONE Code

137 CHART PROPOSED DEVELOPMENT PROGRAM OBJECTIVE BACKGROUND APPROACH To deve lop t e c h n i q u e s f o r p r o d u c i n g m e t a l l i n e r and o r g a n i c l i n e r f i l a m e n t wound t anks f o r s t o r a b l e l i q u i d or s o l i d p r o p e l l e n t On s m a l l s i z e t e s t samples 6 Inches I n d i ame te r u s i n g aluminum l i n e r s p r e s s u r e s o f 3000 - AOOO p s i have been ach ieved w i t h s t r e n g t h t o w e i g h t v a l u e s o f 3 x 10* i n on 4 f e e t I n d i ame te r s e c t i o n s w e l d i n g wou ld p r o b a b l y be r e q u i r e d and t h e compat i b i l l t y o f t h i s l i n e r s t r u c t u r e t o the f i l a m e n t wound e x t e r i o r has no t been e s t a b l i s h e d even a n a l y t i c a l l y as y e t I n p r i n c i p l e b o t h aluminum a l l o y s and e l e c t r o - f o r m e d n i c k e l l i n e r s show promise P r e l i m i n a r y work on o r g a n i c m a t e r i a l f o r l i n e r s a l s o shou ld be r e v i e w e d f o r p o s s i b l e a p p l i c a t i o n s t o t h i s t a n k p r o b l e m P r o m i s i n g work w i t h t e t r a f l u o r o e t h y l e n e po lymers i n d i c a t e s t h a t i t shou ld be c o n s i d e r e d as a p o s s i b l e m a t e r i a l f o r the t a n k l i n e r I n t h i s a p p l i c a t i o n T h i s e f f o r t has n o t y e t been i n i t i a t e d even i n the s m a l l e r s i z e s bu t because o f the g e n e r a l r a p i d p r o g r e s s I n t e t r a f l u o r o e t h y l e n e po lymers t e c h n o l o g y c o u l d w a r r a n t a t t e n t i o n now 1 I n v e s t i g a t e and deve lop s t r e s s a n a l y s i s p rocedures w h i c h w i l l accommodate s ca l e e f f e c t s f o r b o t h m e t a l l i n e r and o r g a n i c l i n e r concep t s 2 I s o l a t e and d e f i n e f a b r i c a t i o n process f e a t u r e s w h i c h tend t o degrade the pe r fo rmance o f l a r g e f i l a m e n t wound s t r u c t u r e s M o d i f y p r o c e s s i n g t e chn iques and equipment t o a l l e v i a t e these 3 F a b r i c a t e and t e s t sub - sca l e models i n w h i c h the f o l l o w i n g aspec t s are emphasized M e t a l l i n e r Develop f o r m i n g and w e l d i n g process f o r a luminum a l l o y l i n e r s p e r m i t t i n g a 2 t o 3 p e r c e n t p l a s t i c s t r a i n w i t h o u t leakage Develop a bonding p rocess w h i c h w i l l p r e v e n t b u c k l i n g and s e p a r a t i o n o f the l i n e r f r o m the wound s t r u c t u r e as i t compresses e l a s t i c a l l y a f t e r p r o o f t e s t i n g Organ ic l i n e r Develop f a b r i c a t i o n processes f o r w i n d i n g t e t r a f l u o r o e t h y l e n e polymer tape on a mandre l o v e r w i n d i n g w i t h d r y g l a s s f i b e r s and heat c o n s o l i d a t i n g Dry g l a s s f i b e r s m igh t be i n t e r w o u n d w i t h the o u t e r l a y e r o f t e t r a f l u o r o e t h y l e n e tape A l i n e r o f t h i s type may be c h e m i c a l l y t r e a t e d on the o u t e r s u r f a c e and f i l a m e n t wound t o produce the r e q u i r e d v e s s e l For the sub s ca l e a r t i c l e a v o i d a l l openings e x c e p t e q u a l d i ame te r p o l a r open ings P r o v i d e a t h r u s t r e a c t i o n p o i n t a t the c e n t e r o f the pay load as w e l l as a t the s k i r t a t t achment r i n g

133 PRIORITY RATING WORKSHEET CHART P R Q g R A M P A C T O a S P R O G R A M P R O B A B I L I T V OF S U C C E S S a LOW z D M o o e R A T e 5 *P< man 8 C R I T I C A L P R O B L E M S TO B E S O L V E D • F E W / N O T TOO PIFFUrULT Z ^ S O M E / D I F F I C U L T 5 D M A N Y / V E R V D I F F I C U L T 8 P R O C E S S G R O W T H P O T E N T I A L K U T T t e OR. U N D E F I N A O L E O a EZCO&HIZHBLE P o r e M T I A L 4 A P P L I C A T I O N S O T H E R T H A N A I R F O R C E D NONE O )S S O M E 4 • M A N Y e N E C E S S I T Y F O R A I R F O R C E F U N D I N Q D low HifiH imuSTev/oTHCA (UrtT t F P o s r 4 t* DCIIATE - SPMC Bffot-T OTHtX. SOUteCS B a E K f U i S l f E AIR F'tUk fUHVue, U K E L f \1. NEED FACTORS S Y S T E M S P R O B A B I L I T Y HIQH F ^ B A B i i r y FAIR. P R O S A B I L I T V LOW P R O B A B I L I T V C O M P O N E N T C R I T I C A L I T Y Mens H K T H H I A H F A I R L e w F R E a U E N C y OF R E Q U I R E M E N T IN Q V « r E M MOR£ THAN 3 COMPO^leHTS i. 3 c e M p e U E N r s s i N d L E C O M P O N E N T D E S I G N A L T E R M A T E S No A L T E R N A T e R W E B E E N O N E A L T E R M A T E S E V E R A L A L T E R M A T E C M A T E R I A L S I M P L l f A r i O N New M A EtiflL ptytio^MtNT eea v M A T C C I A L I M P O O V E M C M T R £ S > D NO P R O B L E M F o n e s e e k i CALCULATE PRIORITY STEP 1 S T E P 2 S T E P 3 8 2£- RAW s c o o e s r o R EACH R E F c e e t i c i P CoMPONctrr IN T A B L K S AT t N D o r PAMEt I J t P O t T W I T H T8A11) T O T A L S E N T E R E D IN K C l f i M T A A R P R A V J S e o R C S A <tbO) • • I • • • • • ] • • • • ] • • • • • • • • i : • • • • • CIRCLE HIGHEST A A R P RAW S C O R E IN EACH OTHER S Y S T E M C I R C L E NEXT H I G H E S T IF WITHIN 4 POINTS OF T O P S C O R E H * L O W ^ N U M B E R OF S y S T E A t S HldH C I R C L E F R E Q U E N C Y D I S T R I B U T I O N F A C T O R MUMseti. o s v s r s M S rt a t * I 2. 3 OK MMIE SCORE BE.LOW( N U M S E R O F S Y S T E M S L O W 0 I 2 BMOtt 1 0 1 z. 1 4 1 1 <r?> 1 ** 1 z 1 «f 1 4 TOTAL PRIORITY

139 TITLE FILAMENT WINDING OF SOLID AND LIQUID PROPELIANT LARGE MOTOR CASES CHART PRIORITY JUL RELATED CAMR CHARTS IM MANUFACTURING REQUIREMENT A p p l y h i g h s t r e n g t h h i g h modulus g l a s s or bo ron f i b e r s Impregnated w i t h low t empe ra tu r e c u r e r e s i n t o removable mandre l t o produce h i g h I n t e g r i t y l a r g e r o c k e t motor cases The a d a p t i o n o f t h i s mianufac tu r Ing method t o s i z e s o f 20 f e e t t o 50 f e e t d i ame te r w i l l r e q u i r e new d e s i g n s o f mandre l s c a l l n g - u p o f w i n d i n g machines and development o f l a r g e r f i b e r d e l i v e r y systems f o r h i g h e r r a t e a p p l i c a t i o n s T h i c k n e s s w i l l v a r y f r o m 0 1 I n c h t o 2 Inches and l e n g t h s f r o m 60 t o 200 f e e t T h i s l a r g e d i a m e t e r f i b e r g l a s s motor case I s f o r a f i r s t s t age r e c o v e r a b l e boos t e r e a r t h l aunch sys tem e i t h e r as a segmented^ h i g h I n t e r n a l p r e s su re case f o r s o l i d p r o p e l l e n t or a lower I n t e r n a l p r e s s u r e case w i t h non permeable c o r r o s i o n r e s i s t a n t l i n e r f o r l i q u i d p r o p e l l e n t AARP REFERENCES c n . - ^ . 157 R C h n r f . 83c d pnpvp<i r h f i r t . APPLICABLE PROCESS Code FILAMENT WINDING 8 03 21 STATE OF THE ART ASSESSMENT Smal l f i l a m e n t wound r o c k e t motor cases have been f a b r i c a t e d up t o 54 Inches d i ame te r X IS f e e t l o n g I n q u a n t i t y Sizes up t o 13 f e e t have been f a b r i c a t e d F i l a m e n t wound s t r u c t u r e s have been f a b r i c a t e d I n l a r g e q u a n t i t i e s u t i l i z i n g 550 000 p s l f i b e r s t r e n g t h and 12 m i l l i o n p s l f i b e r modulus L i m i t e d s i z e and number o f s t r u c t u r e s have been f a b r i c a t e d u t i l i z i n g f i b e r modulus as h i g h as 60 m i l l i o n p s l L a b o r a t o r y work has produced f i b e r s t r e n g t h up t o 1 300 000 p s l s t r e n g t h Large c y l i n d r i c a l t anks have been s u c c e s s f u l l y wound on l i g h t w e i g h t a luminum a l l o y segmented mandre l s w i t h a i r t i g h t ( t a n k ) l i n e r s a p p l i e d C o n t r o l o f I n t e r n a l a i r p r e s su re d u r i n g w i n d i n g and cu re can m a i n t a i n e q u a l p r e s t r e s s t h r o u g h o u t the w a l l Accompl ishment o f h i g h g l a s s con ten t ; and equa l or a p p r o p r i a t e l y programmed t e n s i o n i n g o f l a y e r s must be ach ieved CRITICAL PROBLEMS 1 L i g h t w e i g h t low d e f l e c t i o n mandre l i s r e q u i r e d f o r h o r i z o n t a l l y mounted machines when w i n d i n g l a r g e d i ame te r s t r u c t u r e s A v e r t i c a l l y mounted mandre l w i l l have l e s s s t r i n g e n t d e f l e c t i o n r e q u i r e m e n t s bu t may c o m p l i c a t e w i n d i n g machine d e s i g n and c o n s t r u c t i o n 2 C u r r e n t methods f o r d e s i g n and f a b r i c a t i o n o f s k i r t t o p r e s s u r e v e s s e l a t t achment f o r h i g h load a p p l i c a t i o n a re inadequa te f o r l a r g e r motor cases An i m p o r t a n t asse t t o s k i r t and a t t achment d e s i g n wou ld be the p r o v i s i o n o f a load b e a r i n g area near the c e n t e r o f the pay load ALTERNATE PROCESSES NONE Code

CHART 140 PROPOSED DEVELOPMENT PROGRAM OBJECTIVE BACKGROUND APPROACH Develop c r i t e r i a and d e s i g n a w i n d i n g machine and mandre l c o m b i n a t i o n t o wind r o c k e t motors t o SO f e e t I n d i ame te r and 200 f e e t l o n g u s i n g h i g h s t r e n g t h h i g h modulus g l a s s or boron f i b e r s Develop s a t i s f a c t o r y s k i r t - t o v e s s e l J o i n t s f o r l a r g e motor cases w h i c h a r e amenable t o p r a c t i c a l f a b r i c a t i o n S o l i d motor case t h i c k n e s s e s up t o 2 inches and l i q u i d p r o p e l l a n t t a n k t h i c k n e s s e s r a n g i n g f r o m 0 1 i n c h t o 0 5 i n c h a re t o be c o n s i d e r e d The r e l a t i o n s h i p between mandre l shape and f i l a m e n t p a t h i s f u n d a m e n t a l and independent o f s i z e T h i s r e l a t i o n s h i p must be c o r r e c t so t h a t w i n d i n g p rocedures w i l l no t be i m p a i r e d and s t r u c t u r a l pe r fo rmance w i l l be opt imum W i n d i n g machines o p e r a t i n g on b o t h a v e r t i c a l a x i s and h o r i z o n t a l a x i s have been b u i l t t he c h o i c e w o u l d seem t o r e l a t e n o t o n l y t o mandre l c o n s i d e r a t i o n s b u t t o o t h e r machine d e s i g n c o n s i d e r a t i o n s S k i r t t o v e s s e l j o i n t s h a v i n g a c a p a b i l i t y o f 3 500 l b / i n have been demons t ra ted t o da te f o r l a r g e motor cases w h i l e up t o 10 000 l b / i n have been demons t ra ted on s m a l l motor cases Des ign a w i n d i n g machine capab le o f f a b r i c a t i n g motor cases up t o 50 f e e t i n d i a m e t e r and 200 f e e t l ong I n d e t e r m i n i n g the o r i e n t a t i o n o f the machine c o n s i d e r a t i o n shou ld be g i v e n t o h a n d l i n g r e q u i r e m e n t s b e f o r e d u r i n g and a f t e r l o a d i n g mandre l d e f l e c t i o n d u r i n g w i n d i n g and I n t e r n a l p r e s s u r i z a t i o n o f the system d u r i n g w i n d i n g and c u r i n g Background da t a on s m a l l e r s i z e d u n i t s a re a v a i l a b l e f o r t h i s development d e s i g n An a n a l y t i c a l s t udy a long w i t h development t e s t i n g shou ld be conduc ted on s k i r t t o v e s s e l j o i n t s o f the s i z e s r e q u i r e d t o o b t a i n s t r e n g t h c a p a b i l i t i e s i n the range o f 10 000 l b / i n I f p o s s i b l e c o n s i d e r the a p p l i c a t i o n o f p a r t o f the l o a d t h r o u g h a l o a d b e a r i n g area near the c e n t e r o f the pay load D e f l e c t i o n s a long a l l t h r e e axes f o r a v a r i e t y o f t y p i c a l l o a d i n g c o n d i t i o n s shou ld be s t u d i e d C o n s t r u c t a machine and f a b r i c a t e two t y p i c a l p a r t s t o s u b s t a n t i a t e the c a p a b i l i t y developed f o r b o t h t h i n w a l l and t h i c k w a l l s t r u c t u r e s E s t a b l i s h non d e s t r u c t i v e t e s t methods and show they c o r r e c t l y i n d i c a t e the i n t e g r i t y o f the s t r u c t u r e INSPECTION TECHNIQUES SUPPLEMENTAL RECOMMENDATIONS OBJECTIVES I n s p e c t i o n o f g l a s s f i b e r / r e s i n m i s s i l e motor chambers f o r p rocess c o n t r o l and end i t e m q u a l i t y BACKGROUND One o r more chambers 23 f e e t i n d i ame te r by 60 f e e t l o n g have been wound on a h o r i z o n t a l mandre l a t the A e r o j e t Genera l Azuza P l a n t Rovings The l a y o f the r o v i n g s and the occu r r ence o f r e l a x e d r o v i n g s has been s u c c e s s f u l l y e v a l u a t e d i n t h i c k n e s s up t o one i n c h by r a d i o g r a p h y (BAA) C h a m b e r / I n s u l a t i o n Bond The bonding o f the pre impregna ted g l a s s f i b e r s has no t been a p r o b l e m T h i s has been p roved on the A2 and A3 P o l a r i s Stage I I the A3 P o l a r i s Stage I and a l l Mlnuteman Stage I I I u n i t s w h i c h were i n s p e c t e d w i t h t h r o u g h t r a n s m i s s i o n u l t r a s o n i c s (DAB) P r o p e l l a n t / I n s u l a t i o n Bond The bonding o f p r o p e l l a n t t o i n s u l a t i o n i s c u r r e n t l y e v a l u a t e d w i t h a t a n g e n t i a l r a d i o g r a p h i c t e c h n i q u e (BAA) T h i s t e c h n i q u e works f o r b o t h the bonding i n the booted areas and the dome ends and f o r the c y l i n d r i c a l C o n t i n u e d on n e x t page

141 INSPECTION TECHNIQUES SUPFLEMENIAL RECOMMENDATIONS c o n t i n u e d CHART N O 6 J * ? s i d e w a l l r e g i o n s Microwave methods (CDD) a re b e i n g e x p l o r e d by A e r o j e t Gene ra l - Sacramento f o r the I n s p e c t i o n o f the p r o p e l l a n t / b o o t bond i n m o t o r s t h a t a re t o o l a r g e f o r r a d i o g r a p h i c I n s p e c t i o n APPROACH No t e c h n i q u e development i s recommended because the I n s p e c t i o n r e q u i r e m e n t s s h o u l d be s t a t e o f t h e a r t by 1970-1985 The normal c h a r a c t e r i z a t i o n and d e f i n i n g o f q u a l i t y l i m i t s w i l l be r e q u i r e d f o r each c o m b i n a t i o n o f m a t e r i a l s i z e and c o n f i g u r a t i o n

142 PRIORITY RATING WORKSHEET CHART P R O f i R A M PACTOtt f i P R O d R A M P R O B A B I L I T V O F S U C C E S S • LOW • MODERATE C R I T I C A L P R O B L E M S TO B E S O L V E D *B FES^/NOT TOO plFFUJUtT n S O M E / D I F F I C U L T a M A N Y / V E R V O l f P I C U t T P R O C E S S G R O W T H P O T E N T I A L n L I T T L E OR U N D E F I N A D L E )tf CeCO&HllltBLe P O T E M T I A L A P P L I C A T I O N S O T H E R T H A N AIR P O R C E • NONE • S O M E NECESSITY FOR AIR FORCE FUNiOINO n LOW HifiH iMjuSTev/erHfa 6 « r CFFccr 4 • MeOHATE - EFRKLT OTHce 'SoUCCeS fl )II ttCUIStue Alt. F A c t U K E L 4 12. z 5 8 z » 8 o 4 o 4 N E E D FACTORS p a S Y S T E M S P R O B A B I L I T Y HIQH P B O B A B I I T Y F A I R P R O B A B I L I T Y LOW P R O B A B I L I T V C O M P O N E N T C R I T I C A L I T Y V E R Y HlfH HI<iH F A I R L o w F R E < 3 U E N C Y OF R E Q U I R E M E N T IN S Y S T E M M O M THAN 3 C 0 M C » « ' e » l T 9 a 3 C * M P e H E N r S S / W a L E C e M P O N E N T D E S I G N A L T E R M A T E S No A L T E R N A T C R n E S E E M ONE A L T e B N A T E S E V E B . A L A L T E R N A T E * M A T e C I A L S I M P L CAriON New M A T E R l f l L { leveLOfMENT S C O O MATERIAL I M P d O V E M t N T R E S P NO P R O e L E M f R C S C C k l IZ 8 4 14 9 3 3 2 I 6 3 « 4 o CALCULATE PRIORITY e e 3V R A W s c o a e s F O R £ACM REFCSENrtP C O M F M C M T IN T A B L M A T bNC o r PAklEt fePotT WITH V A W E N T E O C P IN SUMUACV AT eiSMT A A R P R A V J s e o f t C S • • • • i n STEP I S T E P 2 CIRCLE HIGHCST A A R P RAW S C O R E r IN EACH CTTHER S Y S T E M C I R C L E NEXT HIGMEST SCORC IF WITHIN 4 POINTS O F T O P S C O R E H N U M S E R Of S V S T E M S HldtH LOW • • • • • • • • • • • • • • S T E P 3 C I R C L E FREQUENCY DISTRIBUTION FACTOR NuMsen. OP sysrCMs H &A I 2. 3 O S M « U B £ L O W i N U M Q E R O F S Y S T E M S L O W 0 I 2 B. Mote 1 0 I 4 1 1 1 3 1 H 1 z 1 *¥ 1 4 TOTAL PRIORITY E

143 TITLE FILAMENT WINDING OF SOLID PROPELLAOT MOTOR CASES 4 FT DIAMETER AND 10 FT LONG THAT CAN WITHSTAND INTERNAL PRESSURE OF 5000 P S I I N CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Wind h i g h s t r e n g t h g l a s s f i l a m e n t s p r e lmpregna t ed or wet w i t h epoxy r e s i n on a s u i t a b l e remova l mandre l or d i r e c t l y on p r o p e l l e n t Cure a t e l e v a t e d or room tempera tu re w h i l e s u s t a i n i n g p re t e n s i o n i n the w i n d i n g w h i c h has been p l a c e d i n a p r e c i s e p a t t e r n f o r h i g h pe r fo rmance The case i s t o be 10 f e e t l o n g 4 f e e t i n d iamete r w i t h a w a l l t h i c k n e s s o f 1 i n c h and capab le o f w i t h s t a n d i n g an i n t e r n a l p r e s su re o f 5000 p s l AARP REFERENCES E Charts L l i B Charts 65a 69a 71a P&FVPS C h a r t s . APPLICABLE PROCESS MONOLITHIC FILAMENT WINDING Code 8 03 21 STATE OF THE ART ASSESSMENT H i g h s t r e n g t h t o w e i g n t v a l u e s (3 x 10^ i n ) have been demons t ra ted i n 6 i n c h d iamete r t e s t u n i t s a t p re s su res o f 3000 4000 p s l Larger v e s s e l s have shown v a l u e s o f 2 x 10° i n s p e c i f i c s t r e n g t h o f the compos i te I n o r d e r t o o b t a i n these v a l u e s i t i s necessary t o o r i e n t the g l a s s f i l a m e n t s c a r e f u l l y d u r i n g the w i n d i n g process c o n s t a n t l y m a i n t a i n i n g a w i n d i n g t e n s i o n c o m p a t i b l e w i t h the r a d i u s o f c u r v a t u r e o f the w i n d i n g p a t h So f a r v e r y l i t t l e a t t e n t i o n has been g i v e n t o s c a l e e f f e c t i n the a n a l y t i c a l approaches so i t i s no t r e a d i l y p o s s i b l e t o p r e d i c t the a b i l i t y t o ach ieve the h i g h e r s t r e s s v a l u e s i n l a r g e s i z e components A l t h o u g h non p o l a r open ings have demons t ra ted m o d e r a t e l y a c c e p t a b l e pe r fo rmance t h e y shou ld be avo ided f o r bes t pe r fo rmance o f f i l a m e n t wound cases The a p p l i c a t i o n o f boron f i l a m e n t t o t h i s a p p l i c a t i o n has no t y e t been made i t IS be ing used e x p e r l e m e n t a l l y i n o t h e r compos i te s t r u c t u r e s a l t h o u g h CRITICAL PROBLEMS A h i g h q u a l i t y f i l a m e n t w i n d i n g machine i s r e q u i r e d w h i c h w i l l program the l o c a t i o n o f the f i b e r s p r e c i s e l y m a i n t a i n the c o r r e c t t e n s i o n and h o l d the d e n s i t y r a t i o o f f i l a m e n t t o b i n d e r a t the opt imum v a l u e The l o c a t i o n o f openings c o m p l i c a t e s t h i s p rob lem ALTERNATE PROCESSES NONE Code

14A CHART PROPOSED DEVELOPMENT PROGRAM OBJECTIVE BACKGROUND APPROACH The f a b r i c a t i o n o f A f e e t d i ame te r by 1 0 f e e t l o n g f i b e r g l a s s f i l a m e n t wound r o c k e t motor cases w h i c h w i l l ope ra t e a t SOOO p s l w i t h a s t r e n g t h t o - w e l g h t r a t i o o f 3 X 1 0 6 Inches S t r e n g t h - t o w e i g h t v a l u e s as h i g h as 3 x 1 0 ^ Inches have been demons t ra ted on 6 I n c h d i a m e t e r t e s t u n i t s as p r e s s u r e s o f 3000 - 4000 p s l Such v a l u e s have no t been ach ieved I n l a r g e r v e s s e l s p r o b a b l y due t o the change I n r a t i o o f f i l a m e n t w i n d i n g t e n s i o n t o r a d i u s o f c u r v a t u r e o f the w i n d i n g p a t h S t r e s s a n a l y s i s p rocedures ( n e t t i n g and m a t r i x m o d i f i e d n e t t i n g ) do n o t r e c o g n i z e t h e e x i s t e n c e o f a s ca l e e f f e c t 1 I n v e s t i g a t e and deve lop s t r e s s a n a l y s i s p rocedures w h i c h w i l l accomodate s c a l e e f f e c t s 2 I s o l a t e and d e f i n e f a b r i c a t i o n process f e a t u r e s w h i c h tend t o degrade the pe r fo rmance o f l a r g e f i l a m e n t wound s t r u c t u r e s 3 Implement p r o c e s s i n g t e c h n i q u e s and equipment w h i c h w i l l a v o i d the d e f i n e d d e g r a d i n g f e a t u r e s 4 Demonstrate pe r fo rmance t h r o u g h f a b r i c a t i o n and t e s t o f r e l a t e d specimens and f u l l s c a l e a r t i c l e s Systems u s i n g f i l a m e n t wound s o l i d p r o p e l l a n t chambers s h o u l d a A v o i d a l l openings excep t e q u a l d i ame te r p o l a r openings b Promlde a t h u r s t r e a c t i o n p o i n t a t the c e n t e r o f the p a y l o a d w e l l as a t the s k i r t a t t achmen t r i n g c Seek means o f t h r u s t v e c t o r c o n t r o l and t e r m i n a t i o n o t h e r t h a n m u l t i p l e n o z z l e s and non p o l a r open ings INSPECTION TECHNIQUES SUPPLEMENTAL RECOMMENDATIONS I n s p e c t i o n o f g l a s s f i b e r / r e s l n m i s s i l e motor chambers f o r process c o n t r o l and end i t e m q u a l i t y BACKGROUND Rovings The l a y o f the r o v l n g s and the o c c u r r e n c e o f r e l a x e d r o v l n g s has been s u c c e s s f u l l y e v a l u a t e d I n t h i c k n e s s up t o one I n c h by r a d i o g r a p h y (BAA) C h a m b e r / I n s u l a t i o n Bond The bonding o f the p re impregnated g l a s s f i b e r s has no t been a p r o b l e m T h i s has been p roved on the A2 and A3 P o l a r i s Stage I I the A3 P o l a r i s Stage I and a l l Mlnuteman Stage I I I u n i t s w h i c h were I n s p e c t e d w i t h t h r o u g h - t r a n s m i s s i o n u l t r a s o n i c s (DAB) F r o p e l l a n t / I n s u l a t l o n Bond The bond ing o f p r o p e l l a n t t o I n s u l a t i o n I s c u r r e n t l y e v a l u a t e d w i t h a t a n g e n t i a l r a d i o g r a p h i c t e c h n i q u e (BAA) T h i s t e c h n i q u e works f o r b o t h the bond ing I n the booted areas and dome ends and f o r t h e c y l i n d r i c a l s i d e w a l l r e g i o n s Microwave methods (CDD) are b e i n g e x p l o r e d by A e r o j e t Gene ra l Sacramento f o r the I n s p e c t i o n o f the p r o p e l l a n t / b o o t bond I n mo to r s t h a t a re t oo l a r g e f o r r a d i o g r a p h i c I n s p e c t i o n or f o r a p re l a u n c h I n s p e c t i o n APPROACH No t e c h n i q u e development I s recommended because the I n s p e c t i o n r e q u i r e m e n t s w i l l a l l be s t a t e o f the a r t by 1970 1985 The normal c h a r a c t e r i z a t i o n and d e f i n i n g o f q u a l i t y l i m i t s w i l l be r e q u i r e d f o r each c o m b i n a t i o n o f m a t e r i a l s i z e and c o n f i g u r a t i o n OBJECTIVE

1 4 5 PRIORITY RATING WORKSHEET CHART P a O f i R A M T A C T O R S P R 0 6 R A M P R O B A B I L I T V O F S U C C E S S • LOW 2 • MOOERATC 5 V C H i a H 8 C R I T I C A L P R O B L E M S TO B E S O L V E D >A F t W / N O T Too PIFFU7ULT Z D S O M e / O I F F l O / t T 5 • M A N Y / V E R Y D I f P I C U t T 8 P R O C E S S G R O W T H P O T E N T I A L • L I T T L E OR U N O E F I N A B L E O > l geC06HtUiBie m C M T I A L 4 A P P L I C A T I O N S O T H E R T H A N AIR F O R C E • NONE O • S O M E 4 Pr MAMY S NECESSITY F O R A I R F O R C E FUNDINa n LOW HisH i H i u S T K V / e r H f A < a « r CFFOCr 4 . a MeocAATs - s m e E F n « . r eruce. ^aiteea e J g tiC£Ul^\V£ A I R feOei. F U M D M A U K E L V 14. P a N E E D FACTORS SYSTEMS P R O B A B I L I T Y H i a H P R O B A e i I T Y FAIR. P B O S A B I L I T Y LOW P R O B A B I L I T Y C O M P O N E N T C R I T l C A L I T Y V E R Y H1<RH H I « H F A l A L e w F R e a u C N C Y OF BEauiREMENT IN S Y S T E M MeRC THAN 3 C e M P e N E M T S £ 3 C O M C e N E M T S O e g i O N A L T E R M A , T e S No A L T e S N A T E R M C G E E N ONE A L T E R N A T E S E V E B . A L A L T E R M A T e « 1 V I A T E B I A L 3 I M P L I C A T I O N NEW M A T E R I A L PeyELOfMENT e c « O MATERIAL I M P R O V E M E N T R E S P NO P t t e S L E M F o R E S e e N CALCULATE P R I O R I T Y . g A. 1^ RAW S C O R E S roft E A C H REFCREMfCP COMP^NEMT IN TABLES AT ENB OF PANEL 1JEP«t.T WITH PAIO T O T A L S E N T E O r O IN QilluilAtV A T ClSWT s v s « . s A A R P » ! A > W S C O W S • • • • • • I • ] • ] • • • • • • STEP I S T E P 2 S T E P 3 n 1 28 C I R C L E UiaHCST A A R P S C O R E IN eACM en-HER S Y S T E M C I R C L E NEXT H i a u e s T SCORE IF WITHIN * POINTS OP TOP S C O R E N U M S E R OF SVSTEA4S H iaH ^ LOW L- C I R C L E FREOUENCY DISTRIBUTION FACTOR M i v i a e n . OP s y s r e M S H I 7. Son HMt NUMSER O F S Y S T E M S L O W 0 I 2 B M O t t 1 0 1 z I '^ 1 1 1 H 1 z 1 «̂ 1 4 p = n x f = T O T A L - 3£_ PRIORITY I a ®

146 TITLE MANUFACTURE OF FIBERGLASS REINFORCED PLASTIC CABLE CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Produce h i g h s p e c i f i c s t r e n g t h f l e x i b l e a b r a s i o n r e s i s t a n t n y l o n or o t h e r o r g a n i c coa ted f i b e r g l a s s c a b l e i n s i z e s o f 1/16 I n c h t o 1 i n c h d i a m e t e r and up t o 100 f t l e n g t h s f o r space a p p l i c a t i o n i n env i ronmen t s o f 240 t o 225 F and ha rd vacuum AARP REFERENCES E C h n r f . B C h a n 167, 173 P&FVPS Chort, APPLICABLE PROCESS Code INJECTION MOLDING 8 03 01 STATE OF THE ART ASSESSMENT S a t i s f a c t o r y c a b l e has no t been produced t o da te funded programs a re underway t o deve lop a p p r o p r i a t e o r g methods f o r p r o d u c i n g g l a s s r e i n f o r c e d cab l e f o r e a r t h t l o n s I t i s expec ted t h a t g e n e r a l t e c h n o l o g y f o r p rod a v a i l a b l e by 1970 bu t s p e c i a l c o n s i d e r a t i o n must be g i v on o r g a n i c c o a t i n g s C o n s i d e r a t i o n must a l s o be g i v e n s t r e n g t h r e q u i r e m e n t s w h i c h may n e c e s s i t a t e i n d i v i d u a l a n t i s e l f a b r a s i o n purposes End f i t t i n g s w i l l r e q u i r e f u l l s t r e n g t h c a p a b i l i t y o f the c a b l e However p r i v a t e and A i r Force a n i c c o a t i n g s and f a b r i c a t i o n atmosphere and hydrospace a p p l i c a u c i n g g l a s s c a b l i n g w i l l be en t o space env i ronmen t e f f e c t s t o f l e x i b i l i t y and s p e c i f i c f i b e r c o a t i n g f o r l u b r i c i t y and s p e c i a l a t t e n t i o n t o deve lop the S t a t e o f the a r t g r o w t h i s c o n s i d e r e d adequate as the m a j o r d i f f i c u l t y l i e s i n the d e t a i l development a s s o c i a t e d w i t h the p r o d u c t i o n o f each s i z e CRITICAL PROBLEMS NONE ALTERNATE PROCESSES FIBER COATING Code 8 04 05

147 TITLE FORMING AND SIZING PLASTIC SANDWICH CORE CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT To f o r m p l a s t i c honeycomb co re i n t o c o n t o u r s m a i n t a i n i n g c e l l c o n f i g u r a t i o n s t r e n g t h and d i m e n s i o n a l t o l e r a n c e s on t h i c k n e s s i n s i z e s up t o SAO inches l o n g and up t o 12 inches t h i c k AARP REFERENCES c \ . n a r T s . . r - L - . , 95a 96 98c APPLICABLE PROCESS Code SHAPING CORE IN HEATED DIES 8 03 26 STATE OF THE ART ASSESSMENT P l a s t i c honeycomb core i s c u r r e n t l y shaped by d i e m o l d i n g cured core wh ich has been heated above i t s heat d i s t o r t i o n t empera tu re f o r s h o r t p e r i o d s The method i s no t p r a c t i c a l f o r v e r y l a r g e d i a m e t e r s or t h i c k n e s s e s I t i s conc luded f r o m c o n t a c t w i t h core m a n u f a c t u r e r s t h a t by 1970 however p r i v a t e r e s e a r c h w i l l have developed a f l e x i b l e co re c o n f i g u r a t i o n s i m i l a r t o t h a t a l r e a d y a v a i l a b l e I n m e t a l s w i t h e q u i v a l e n t p r o p e r t i e s t o r i g i d co r e S t a t e o f the a r t g r o w t h I s c o n s i d e r e d adequate CRITICAL PROBLEMS NONE ALTERNATE PROCESSES NONE Code

148- TITLE FABRICATION OF A LARGE HIGH TEMPERATURE ELECTROMAGNETIC WINDOW BY SILICA VAPOR DEPOSITION CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT P r o v i d e l a r g e h i g h t empera tu re e l e c t r o m a g n e t i c t r a n s m i s s i o n windows (and s u p p o r t i n g n o n - m e t a l l i c s t r u c t u r e s t o h o l d the window) w e i g h i n g 10 t o 40 l b s maximum d imens ions up t o 60 inches F l a t pane l s a re d e s i r e d w i t h c l o s e l y c o n t r o l l e d u n i f o r m m e c h a n i c a l and e l e c t r i c a l p r o p e r t i e s good e r o s i o n c h a r a c t e r i s t i c s and a s t r e n g t h o f a t l e a s t 2000 p s i a t 2000 F AARP REFERENCES E C h n r t . 72 B Chorts 30e P4FVPS Chart* APPLICABLE PROCESS Code SILICA VAPOR DEPOSITION 8 02 05 STATE OF THE ART ASSESSMENT T r a n s p a r e n t or s l i p c a s t and s i n t e r e d f u s e d s i l i c a or q u a r t z w i l l meet the above s t a t e d r e q u i r e m e n t s Of these m a t e r i a l s f u s e d s i l i c a i s the most l i k e l y c a n d i d a t e f r o m the s tand p o i n t o f m a n u f a c t u r i n g economy v e r s u s pe r fo rmance F a c i l i t i e s f o r f o r m i n g f u s e d s i l i c a p a r t s s e v e r a l inches (up t o 12) t h i c k and up t o 120 inches i n d i ame te r e x i s t C o r n i n g Glass Works I s p r e s e n t l y f o r m i n g such p a r t s v i a the r e d u c t i o n o f s i l i c o n t e t r a c h l o r i d e t o f o r m the o x i d e Th icknesses up t o s e v e r a l Inches have y i e l d e d good t o e x c e l l e n t m a t e r i a l homogenei ty S e l e c t i o n o f areas w i t h i n the formed s l a b o f g l a s s w i l l p r o v i d e s e c t i o n s o f the s i z e and q u a l i t y r e q u i r e d No m a n u f a c t u r i n g development i s recommended An a l t e r n a t e p r o c e s s f o r f o r m i n g f u s e d s i l i c a e l e c t r o m a g n e t i c windows where o p t i c a l t r a n s p a r e n c y i s n o t r e q u i r e d i s by the s l i p c a s t i n g and s i n t e r i n g p rocess T h i s method produces m a t e r i a l w h i c h i s no t q u i t e as s t r o n g as the t r a n s p a r e n t v a r i e t y b u t the p rob lems o f c u t t i n g g r i n d i n g (and p o l i s h i n g ) can be l a r g e l y c i r c u m v e n t e d as t h i s method w i l l produce p a r t s c l o s e t o the r e q u i r e d f i n a l d imens ions F a b r i c a t i o n o f l a r g e s i z e pane l s i s covered by CAMR 603 CRITICAL PROBLEMS NONE ALTERNATE PROCESSES NONE C o d e

149 TITLE FABRICATION OF A 600 F RESISTANT REIMFORCED PLASTIC RADOME UP TO SEVEN FEET I N DIAMETER CHART PRIORITY N O ^OS- RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Mold p l a s t i c radomes up t o seven f e e t I n d i ame te r o r radome m a t e r i a l homogenei ty and t h i c k n e s s t o l e r a n c e s o f the o r d e r o f ; f 0 s e c t i o n s 005 i n c h and m a i n t a i n AARP REFERENCES F r i . . . r » . 291 B C h a r l i 135a, b P A F V P S C h n r t . APPLICABLE PROCESS One o f the f o l l o w i n g (A) MATCHED METAL MOLDING (B) TAPE WRAPPING AND EXTERNAL GRINDING AFTER CURE (C) SEGMENT LAMINATING MACHINING TO DIMENSIONAL TOLERANCE AND SECONDARY BONDING OF SEGMENTS Code (A) 8 03 02 (B) 8 03 18 lr\ 8 03 17 STATE OF THE ART ASSESSMENT M a t e r i a l s capable o f w i t h s t a n d i n g the s p e c i f i e d t empera tu re e x i s t I n the f o r m o f the s i l i c o n e s and the new h e t e r o c y c l i c po lymers ( P I F B I e t c ) The p r o c e s s i n g methods f o r making l a r g e radomes a l s o e x i s t For example some companies are c u r r e n t l y tape w r a p p i n g and g r i n d i n g radomes o f s m a l l e r s i z e s Others are p r o p o s i n g the l a m i n a t i o n and mach in ing o f segments f o l l o w e d by subsequent secondary bonding A s t r e s s a n a l y s i s on a t y p i c a l f o u r f e e t I n d i ame te r t w e l v e f e e t l o n g o g l v a l radome showed t h i s t o be a f e a s i b l e approach Optimum process c o n t r o l s f o r maximum m a t e r i a l u n i f o r m i t y as w e l l as d i m e n s i o n a l t o l e r a n c e s on l a r g e components have no t been deve loped However c u r r e n t work on A i r Force deve lop ment programs as w e l l as the supe r son i c t r a n s p o r t shou ld b r i n g t h i s w i t h i n the s t a t e o f the a r t p r i o r t o 1970 S t a t e o f the a r t g r o w t h i s c o n s i d e r e d adequate CRITICAL PROBLEMS NONE ALTERNATE PROCESSES Code NONE

150 TITLE FABRICATION OF SMALL SHAPED QUARTZ OR FUSED SILICA BLANKS INTO / LARGE OPTICAL TELESCOPE MIRROR (50 t o 100 d i a m e t e r ) CHART PRIORITY REUTED CAMR CHARTS MANUFACTURING REQUIREMENT Develop methods f o r s h r i n k f i t t i n g o f m e t a l l i c s l eeves over q u a r t z o r f u s e d s i l i c a segments t o f o r m a l a r g e component thus p r e s t r e s s i n g i n compress ion G r i n d and p o l i s h preassembled segments t o meet o p t i c a l p r e c i s i o n o f 1/20 w a v e l e n g t h F i n i s h e d m i r r o r must w i t h s t a n d 8g l a u n c h loads i n e r t l a l l oads and 150 F t o 175 F tempera- t u r e v a r i a t i o n w i t h no undue d i s t o r t i o n AARP REFERENCES E Charts B C h a r t s . 177b PSFVPS C h a r t s . APPLICABLE PROCESS ASSEMBLY OF A SHRINK F I T MOSAIC Code STATE OF THE ART ASSESSMENT A l l o f the i n d i v i d u a l p rocess s t eps ( 1 ) Fused s i l i c a o r q u a r t z f o r m i n g by s i l i c a vapor d e p o s i t i o n or r e s i s t a n c e m e l t i n g ( 2 ) C u t t i n g and g r i n d i n g o f b l a n k s t o e x t r e m e l y c l o s e t o l e r a n c e shapes ( 3 ) S h r i n k f i t t i n g o f m e t a l s l eeves i n t o g l a s s b l a n k s and ( 4 ) o p t i c a l g r i n d i n g and p o l i s h i n g o f assembly are w i t h i n the s t a t e o f the a r t and have been accom p l l s h e d i n d i v i d u a l l y The p r o b l e m i s one o f d e s i g n w h e r e i n compensa t ion must be made t o a v o i d d i s t o r t i o n o f the s u r f a c e d u r i n g ext remes o f hea t and c o l d f o u n d I n space T h e r e f o r e no m a n u f a c t u r i n g development type program i s f o r e s e e n u n t i l a d e s i g n p rogram I s o l a t e s a p a r t i c u l a r manu f a c t u r i n g p r o b l e m I f any S t a t e o f the a r t i s c o n s i d e r e d adequate CRITICAL PROBLEMS NONE ALTERNATE PROCESSES FABRICATION OF MONOLITHIC QUARTZ OR FUSED SILICA MIRROR (OF MUCH GREATER THICKNESS AND WEIGHT) Code

- 1 5 1 TITLE FABRICATION OF GLASS OPTICAL TRANSPARENCIES CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Develop a window w h i c h has the c a p a b i l i t y o f w i t h s t a n d i n g s t a g n a t i o n p res su res up t o 250 p s i and t empera tu re s up t o 1800 F and w h i c h c o n t a i n s a n t l r ads capable o f r e s i s t i n g h i g h gamma and n e u t r o n r a d i a t i o n S izes i n v o l v e d are 1/2 i n c h by 3 i n c h maximum d iamete r ( T h i s may be augmented w i t h a window 1 f o o t by 2 f e e t by 1/2 i n c h w h i c h wou ld r e m a i n covered by a m e t a l l i c load b e a r i n g and t h e r m a l s h i e l d d u r i n g h i g h speed o p e r a t i o n ) AARP REFERENCES c ^ L . ^ ^ . 23 B C h a r t s • • APPLICABLE PROCESS Code EITHER (A) SILICA VAPOR DEPOSITION OR (B) RESISTANCE MELTING (A) 8 02 05 (B) 8 02 15 STATE OF THE ART ASSESSMENT C u r r e n t f u s e d s i l i c a g l a s s has the t empera tu re c a p a b i l i t y r e q u i r e d and i t i s l e a s t a f f e c t e d by r a d i a t i o n Glass o f the s i z e s i n v o l v e d can e a s i l y be produced w i t h c u r r e n t s t a t e o f the a r t t e chn iques (A) Vapor d e p o s i t i o n c u t t i n g g r i n d i n g p o l i s h i n g or (B) r e s i s t a n t m e l t i n g p r e s s i n g t o w i t h s t a n d the s t a t e d env i ronmen t s ( i n s m a l l s i z e s 1/2 i n c h by 3 i n c h d i a m e t e r ) or when p r o t e c t e d by a m e t a l l i c hea t s h i e l d d u r i n g the h i g h speed p o r t i o n s o f the m i s s i o n The p r o p e r t i e s o f f u s e d s i l i c a namely v e r y low t h e r m a l expans ion and h i g h t empe ra tu r e r e s i s t a n c e are such t h a t a one f o o t by two f e e t p l a t e o f t h i c k n e s s g r e a t e r t h a n one h a l f i n c h c o u l d e l i m i n a t e the m e t a l l i c heat and load b e a r i n g s h i e l d A g a i n t he r e i s no p rob lem i n m a n u f a c t u r i n g such a s i l i c a p l a t e i n t h i c k n e s s e s up t o s e v e r a l i nches Moun t ing o f the g l a z i n g sys tem i n a m e t a l l i c f r ame t o reduce s t r e s s e s a r i s i n g f r o m g l a s s and f r a m e t h e r m a l expans ion d i f f e r e n t i a l s may be a d e s i g n p r o b l e m r e q u i r i n g p r o t o t y p e a r t i c l e f a b r i c a t i o n bu t such problems can be a d e q u a t e l y s o l v e d d u r i n g systems development. I t i s b e l i e v e d t h a t no advanced s p e c i f i c m a n u f a c t u r i n g development e f f o r t i s r e q u i r e d C R I T I C A L P R O B L E M S NONE ALTERNATE PROCESSES NONE Code

-152 TITLE FABRICATION OF LARGE ELASTOMERIC 0 RINGS CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Fabricate 0 Ring 3 f t diameter and 0 1 Inch thickness for app l i c a t i o n I n hard (10 16 Torr) vacuum at 100 F and subject to solar and nuclear r a d i a t i o n w i t h maximum leakage of 1 lb/day of a i r for one year The 0 Ring Is used as a c i r c u l a r seal In a space vehicle docking port be subjected to 50 cycles at 0 2 g during docking maneuvers and may AARP REFERENCES E Chnrf. 318 B Charts 152 P&FVPS Charts APPLICABLE PROCESS Code MOLDING 8 03 02 STATE OF THE ART ASSESSMENT Materials are not available to withstand a l l factors of environment Fluoroelastomers are best suited to hard vacuum but no data to 10~16 nm/Hg However they are not r e s i l i e n t below 40 F and are marginal on r a d i a t i o n resistance Silicones ate r e s i l i e n t at required temperature but are deteriorated by vacuum and ra d i a t i o n Molding processes are available for producing "0 Rings of ex i s t i n g elastomerlc materials with required tolerances Therefore I f the environment can be modified materials and processes may be considered w i t h i n the state of the a r t One concept might be to provide a resistance heater for bhe 0 Ring or 0 Ring Groove to adjust the temperature above the b r i t t l e temperature of the elastomer A materials development program would otherwise be advisable No manufacturing technology program Is required CRITICAL PROBLEMS NONE ALTERNATE PROCESSES NONE Code

153- TITLE FABRICATION AND ATTACHMENT OF A HIGH EFFICIENCY ABLATIVE INSULATION ORGANIC CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Develop an organic ablative coating w i t h a heat of ablation of IS 000 BTU/lb s t r a i n c a p a b i l i t y up to 4 percent without cracking and a Develop a means of applying or attaching the i n s u l a t i o n to missile me t a l l i c or composite substrates The component which does the adhering to the substrate should be capable of approximately 100 p s i shear strength up to 1200 F and should cure at no more than 300 F AARP REFERENCES E C h a r t s . B C h a r t s . 141 6Aa PAFVPS Char ts . APPLICABLE PROCESS ADHESIVE BONDING (HEAT CURING) Cede 6 08 02 STATE OF THE ART ASSESSMENT Present day ablators are approaching the values desired p a r t i c u l a r l y at the high heat rates some form of elastomeric-silica combination may be developed which could provide the thermal protection desired The major problem then becomes one of providing a bond between t h i s material and the structures Since t h i s i n s u l a t i o n may be used on a motor case the curing temperature of the bond must remain below 300 F so as not to damage the i n t e g r i t y of t h i s component No bond material i s available today that can s a t i s f y a l l these requirements Adhesives such as c e r t a i n modified phenolics and polybenzimidazole ( I m i d i t e ) w i l l come very close to f u l f i l l i n g the temperature/strength objective but i n order to do so they must be cured at temperatures approaching the ultimate use temperature Adhesives which cure at 350 F or less are generally l i m i t e d to usage below 5000 F Current programs are underway to increase the strength c a p a b i l i t i e s of these materials at the higher temperatures and some success has been achieved at 800 F but for very short time periods This therefore i s b a s i c a l l y a material development program and no specific manufacturing problem can be defined at t h i s time CRITICAL PROBLEMS NONE ALTERNATE PROCESSES NONE Code

TITLE FABRICATION OF A HIGH TEMPERATURE CERAMIC ELECTROMAGNETIC WINDOW 154 HIGH THERMAL SHOCK RESISTANT CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Provide an electromagnetic transparency which w i l l withstand operational temperatures (up to 2500 F for 30 minutes duration) erosion and thermal shock of lOOF/second The window is a f l a t port w i t h a maximum diameter of 1 foot approximately 1 inch t h i c k f l u s h mounted i n a s t r u c t u r a l frame and may have an albative overlay i f required to protect a thermal shock sensitive transparency Such an overlay must not i n t e r f e r e w i t h incoming or outgoing signals before and during ablation and ablation products must not degrade the window AARP REFERENCES P r K„H. 280 B Chorts P&FVPS Chnrt« APPLICABLE PROCESS Code LAMINATION OF ORGANIC ABLATIVE PROTECTIVE COATING ONTO A REFRACTORY CERAMIC 8 03 20 STATE OF THE ART ASSESSMENT There are materials which w i l l t o l e r a t e the maximum temperature but not the Indicated thermal shock and materials which w i l l withstand the shock rate but not the protracted time at temperature Fused s i l i c a i s excellent for thermal shock resistance because of i t s low c o e f f i c i e n t of thermal expansion I t i s however temperature l i m i t e d to 2000 to 2200 F Other ceramics such as alumina are capable of withstanding temperatures i n excess of 2500 F but because of higher thermal expansion properties and b r l t t l e n e s s are extremely prone to breakage by thermal shock Therefore i f a way could be found to reduce large thermal gradients i n an alumina window i t could e a s i l y withstand the specified temperature Such a way can be provided by placing a melting or ablating organic i n s u l a t i n g cover over the ceramic window which would protect the window during the high heat input phase of the mission allowing the window to heat at a slower rate Present state of the a r t therefore would c a l l for a r e f r a c t o r y ceramic component (alumina etc ) which is protected by an organic a b l a t i v e coating The manufacturing techniques for ceramic components of t h i s size are w i t h i n present state of the a r t Thus the problem reduces i t s e l f to one of choosing the r i g h t type and thickness of organic coating for a p a r t i c u l a r a p p l i c a t i o n and thermal p r o f i l e T r n n s m l s s l b i l i t y during and a f t e r ablation i s largely related to the chemistry of the ablative material and can be checked during the material selection operation During t h i s operation material variables may be encountered which influence t r a n a m i s s i b l l i t y during or a f t e r ablation and which should be covered by Inspection of manufactured end items before ablation From t h i s assessment i t appears that the problem becomes p r i m a r i l y one of i d e n t i f y i n g an appropriate compatible organic ablative coating and applying i t uniformly to the ceramic substrate A special manufacturing development program Is not recommended CRITICAL PROBLEMS NONE ALTERNATE PROCESSES NONE

^ 155 TITLE CALENIKRING METALLIC FOIL TO PLASTIC SHEETS IN LARGE SIZES CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Bond t h i n m e t a l l i c f o i l (less than 0 001 t h i c k ) to p l a s t i c sheets 0 005 to 0 250 inches t h i c k by the use of pressure from heated r o l l s up to 10 feet wide and i n continuous lengths up to 100 feet AARP REFERENCES C r k n r t i 221 B Chort. 107f 109c APPLICABLE PROCESS Code FOIL UNROLLED FRCM A DRUM IS CAI£NDERED TO THE PLASTIC BY PASSING IT 8 03 10 THROUGH A SET OF HEATED ROLLS STATE OF THE ART ASSESSMENT Present state of the a r t provides the c a p a b i l i t y of calendering aluminum f o i l to p l a s t i c i n widths up to 84 Inches These fi l m s are processed on a backing material for handling The f o i l i s unrolled and passed between heated r o l l s i n contact w i t h the p l a s t i c A heat set adhesive fastens the f o i l t o the p l a s t i c and the backing material i s discarded To match the physical properties of the p l a s t i c a f o i l i n the wrought condition i s used Sprayed or deposited metal i s i n the cast condition and generally not compatible with the p l a s t i c except that on some loca l areas i t might be used to cover seams or make small repairs State of the a r t growth i s considered adequate to cover the 10 f t widths fa c t u r i n g technology program i s required No manu- Conslderation should be given to handling the large sizes required q u a l i t y control w i l l present problems Inspection and C R I T I C A L P R O B L E M S NONE ALTERNATE PROCESSES FOIL CAN BE APPLIED TO A SHEET OF PLASTIC BY THE USE OF A HEATED PLATEN Code 8 03 07

156 AARP REFERENCES E Chart . 220 B Charts 107f P4FVPS Charts APPLICABLE PROCESS Code STATE OF THE ART ASSESSMENT TITLE HANDLING OF LAR<ffi AREA FLEXIBLE SHEET MATERIALS MANUFACTURING REQUIREMENT CHART PRIORITY RELATED CAMR CHARTS Develop appropriate AGE f i x t u r e s and handling procedures f o r I n f l a t a b l e structures for spacecraft h u l l up to 20 feet I n diameter and 40 feet long The gamut of conditions discussed In t h i s problem create such a wide range of situations that a single answer Is Impossible However I t Is f e l t that good coordination In the design phase to provide hard points f o r handling and competent supervision of a l l personnel I n contact should s u f f i c e Experience gained on thermal blankets and Echo types hardware should be advantageous to the solut i o n of the p o t e n t i a l problem CRITICAL PROBLEMS NONE ALTERNATE PROCESSES NONE Code

157_ TITLE FABRICATION OF LARGE THICK PYROLYTIC GRAPHITE SHAPES CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Provide a p y r o l y t l c graphite r e r a d i a t i v e heat shield as a p i l o t enclosure for return from o r b i t or i n the event of malfunction as a re-entry capsule The enclosure would be l i k e a bathtub or saucer In shape and must withstand high temperature gradients without thermal shock f a i l u r e and must r e s i s t oxidation f a i l u r e at temperatures i n excess of 4000 F for periods of up to 30 minutes Minimum weight i s desired The part would have a local radius of up to 10 inches w i t h thickness up to 2 Inches AARP REFERENCES E Chortf B Char ts . 174a P&FVPS C h a r t s . APPLICABLE PROCESS GRAPHITE VAPOR DEPOSITION Code 8 05 14 STATE OF THE ART ASSESSMENT Current state of the a r t would allow the manufacture of p y r o l y t l c graphite i n the shape described above but not to the thickness specified The thickness to radius r a t i o c u r r e n t l y obtainable i s 0 05 which would y i e l d a part 0 5 inch t h i c k i f local radius were 10 Inches Analysis of the heat f l u x and duration and strength requirements Indicate that the 0 5 inch thickness should be adequate for p y r o l y t l c graphite Material has been made for use on programs meeting these parameters I t would appear that the greater thickness specified might be based on oxidation loss for hot pressed graphites The process for p y r o l y t l c graphite Is deposition of carbon from methane onto a heated substrate having the desired shape High temperature and reduced pressure promote formation of the grjiphite structures I f d e t a i l design analyses should v e r i f y that thickness to radius r a t i o s greater than now available are i n fact required two approaches are suggested One u t i l i z e a design concept of stacked concentric rings as has been previously adopted for other applications Or second undertake a program to overcome t h i s r e s t r i c t i o n This would involve use of such tools as the electron microprobe for analysis of delamlnated areas to determine whether contaminants or structure differences can be I d e n t i f i e d as responsible factors Much work has previously been done by Industry on delamlnations I n p y r o l y t l c graphite t h i c k bodies and I t Is not considered too l i k e l y that additional e f f o r t would be more f r u i t f u l I f process modification were Indicated however t h i s could involve heating system modification to control c r y s t a l o r i e n t a t i o n for structure differences or p u r i f i c a t i o n of the system and feed gas and/or addition of beneficlatlng materials (such as boron) to Improve composition c o n t r o l This action Is not presently recommended CRITICAL PROBICMS NONE ALTERNATE PROCESSES NONE Code

158 TITLE FABRICATION OF LAUNCH PAD CERAMIC FLAME DETECTOR CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT / n n ceramic cementaclous mix and placement procedures to produce parts up to 400 000 pounds maximum thickness of 3 inches with a c a p a b i l i t y of withstanding exhaust gases up to 7000 F containing metal p a r t i c l e s w i t h v e l o c i t i e s to 15 000 fps acoustic noise > 200 db and withstanding 10 launches AARP REFERENCES E Cha ts B Charts 160a PSFVPS Char ts . APPLICABLE PROCESS EITHER (A) CERAMIC GUNNING OR (B) RAMMING (A) (B) Code 8 02 14 8 02 08 STATE OF THE ART ASSESSMENT Materials of t h i s type are unavailable at the present time and would have to be developed f o r t h i s a p p l i c a t i o n However placement techniques for such materials are c u r r e n t l y available i n the form of the various techniques used for placement of concrete or f o r gunned and rammed r e f r a c t o r y l i n e r s for m e t a l l u r g i c a l cases In the l a t t e r processes,quite precise c o n t r o l of density and uniformity is obtained In spray application followed by ramming to increase density These materials are even applied to walls and c e i l i n g s of furnaces CRITICAL PROBLEMS NONE ALTERNATE PROCESSES NONE Code

159- TITLE FABRICATION OF SONAR ABSORBING FILLED HONEYCOMB CHART PRIORITY A A A . RELATED CAMR CHARTS 10^ MANUFACTURING REQUIREMENT To fabricate s i l i c o n e elastomer f i l l e d honeycomb (asbestos or fiberglass reinforced phenolic) i n shapes up to 3 f t x 3 f t which e x h i b i t high sonar absorption low s e n s i t i v i t y to a magnetometer resistance to sea water for up to 3 years and capable of withstanding pressures greater than 500 p s i Honeycomb panels are bonded to aluminum or titanium substructures These honeycomb sandwich sonar shields are required for underwater missile launch f a c i l i t i e s AARP REFERENCES B Charts 1̂ 2 , . - PAFVPS Charts APPLICABLE PROCESS Code 8 03 19 CASTING OF ELASTOMER IN HONEYCOMB ADHESIVE BONDING TO SUBSTRUCTURE 6 08 00 STATE-OF THE ART ASSESSMENT Materials are available to produce the necessary strength corrosion resistance and anti-detection c h a r a c t e r i s t i c s However the r e s u l t i n g designed composite w i l l contain a va r i e t y of s t r u c t u r a l energy absorbing and water r e s i s t a n t coatings I t w i l l therefore be necessary f o r the designer to Incorporate these materials i n t o the design i n such a manner as to provide the required performance and be capable of being e a s i l y manufactured More precise knowledge of conditions w i l l be required to evaluate f e a s i b i l i t y supplemented by more information on the e f f e c t of water on adheslves reinforced p l a s t i c s and other materials i n t h i s construction I t i s not believed that Joining constitutes the l i m i t i n g factor i n t h i s structure Because of the d i r e c t r e l a t i o n to water operations Inter service coordination on technical aspects i s recommended This i s p r e i m a r l l y a design development and no manufacturing development program i s recommended at t h i s time P l a s t i c materials w i l l p i c k up water w i t h time leading^to degradation Better under standing of the mechanisms of water d i f f u s i o n through polysers and i n t e r a c t i o n at interfaces such as polymer-metal and polymer glass i s required to make a meaningful attack on t h i s problem This background information may become available as a re s u l t of more basic research programs c u r r e n t l y i n progress or planned f o r the next few years The approach to combat water degradation must be based on circumvention of the established mechanism An inspection problem may be definable a f t e r Che approach is more f u l l y established CRITICAL PROBLEMS NONE ALTERNATE PROCESSES NONE Code

160- TITLE LOW FRICTION EXTRA THIN GAS SEALS FOR SPACE APPLICATIONS CHART PRIORITY R E U T E D CAiMR CHARTS ^Al MANUFACTURING REQUIREMENT , To produce a low f r i c t i o n seal which may be e l e c t r i c a l l y conductive for a telescoping antenna up to 800 f t long extended by gas pressure and retracted by an i n t e r n a l nylon cord Seal to be i n the range of 0 0015 to 0 002 inch t h i c k AARP REFERENCES E Chnri< B Chnr,. P4FVPS Chnrf< APPLICABLE PROCESS Code SPRAY COATING 7 05 04 STATE OF THE ART ASSESSMENT Dimensional l i m i t a t i o n s preclude the use of molded type seals Such thicknesses can be produced s a t i s f a c t o r i l y by spray coating Material selection presents a problem since low f r i c t i o n materials such as the fluorocarbons cannot be made s u f f i c i e n t l y conductive and elastomers f i l l e d w ith metal or graphite may not have s u f f i c i e n t l y low f r i c t i o n c o e f f i c i e n t As an alternate^ dry f i l m coatings would provide both l u b r i c i t y and conductivity They may not however provide a gas seal Since the antenna would be gas f i l l e d only during actuation^ l i m i t e d leakage could be tolerated I f a non m e t a l l i c seal is used a means for obtaining e l e c t r i c a l c o n ductivity such as wi t h s l i d i n g metal spring c l i p s could be employed Adequate spray coating technology i s c u r r e n t l y available precluding the need for a development program Other design concepts should also be considered CRITICAL PROBLEMS NONE ALTERNATE PROCESSES NONE Code

161 TITLE FABRICATION OF GRAPHITE LEADING EDGES AND NOSE CONES CHART PRIORITY RELATED CAMR CHARTS MANUFACTURING REQUIREMENT Produce graphite bodies w i t h t e n s i l e strength of at least 5000 p s i at 3000 F i n C and D shapes w i t h thickness up to 1 inch chord lengths up to 6 inches and span length to 12 Inches as w e l l as nose cones w i t h diameters up to 12 inches w i t h tolerances of +0 010 inch AARP REFERENCES c riorf. 74 R Chnri< 28a, b, 29a P4FVPS Charts APPLICABLE PROCESS Code HOT PRESSED GRAPHITES AND GRAPHITE COMPOSITES (JTA) 8 05 02 STATE OF THE ART ASSESSMENT The process u t i l i z e d i s one of progressive d e n s i f i c a t l o n and conversion of carbonaceous materials to the g r a p h i t i c c r y s t a l l i n e form i n a heated platen press The nature of Impreg nants temperature and pressure regimes are varied to create the desired properties In current practice the materials are formed int o blocks and required shapes are machined The sizes and shapes specified can be manufactured with the present state of the ar t CRITICAL PROBLEMS NONE ALTERNATE PROCESSES NONE Code

162 TITLE ~ BORON FILAMENT PRODUCTION OF QUANTITIES FOR PROTOTYPE COMPONENT FABRICATION CHART PRIORITY RELATED CAMR CHARTS: MANUFACTURING REQUIREMENT To make large qu a n t i t i e s of long close tolerance boron f i b e r s for filament winding Tolerance co n t r o l should be i n the range of + 0 00015 inches to preclude voids overlapping and consequent loss of strength AARP REFERENCES E Chnrt. 158 B Charts 83c d PftFVPS Charts APPLICABLE PROCESS Code VAPOR DEPOSITION ON TUNGSTEN" FILAMENT WITH BCl^ 1 05 01 STATE OF THE ART ASSESSMENT The only successful method at present is vapor deposition on tungsten filament from BCI3 H2 reduction at 1900 2400 F Other promising methods at present are the low temperature (1200 1300F) decomposition of B2H6 and the duo p l a t i n g procedure f i r s t from B2H6 then from BCI3 H2 S i l i c a or quartz substrates appear promising for a draw p l a t i n g (draw substrate and plate simultaneously) procedure which would increase the p o t e n t i a l speed of the process from the present approximately 10 ft/mln to 750-1000 ft/min The successful development of t h i s method appears to be 2 to 3 years away The development of f i n e r filament i s dependent upon fin d i n g l i g h t e r substrates than tungsten or elimi n a t i o n of the requirement for a substrate No manufacturing development program is necessary since the c a p a b i l i t y now exist s to facture Quantities of boron f i l f l t n e n i ! to t-hp r*»aiitr#>moTitD AntaVi i - Ioh^ri #-v,̂ A A D U However no manuraccuring aeveiopment program is necessary since the c a p a b i l i t y now exist manufacture quantities of boron filament to the requirements established by the AARP as process development continues through the supply of experimental quantities some should receive p a r t i c u l a r a t t e n t i o n A Vapor deposition aspects Work should continue on vapor deposition with emphasis on continuous filament tolerance control and substrate removal or s u b s t i t u t i o n of l i g h t e r substrate B A program should be developed to control surface contamination and eliminate etching C Melting and Drawing This method would eliminate the substrate and provide the p o t e n t i a l for long continuous filaments The po t e n t i a l of thi s method is l i m i t e d by the tendency of boron to unite with v i r t u a l l y a l l elements at the melting temperature D Raw material supply Emphasis must be continued on making a supply of high p u r i t y boron available Worj^^houW_cont£nu^t^^dev^ ALTERNATE PROCESSES VAPOR DEPOSITION ON TUNGSTEN FILAMENI FROM B2H6 DUO CHEMICAL PLATING FROM B2H6 (low temp) and BCI3-H2 (higher temp) DRAW PLATING ON CARBON COATED SILICA OR QUARTZ SUBSTRATE MELT BORON AND DRAW FILAMENT WITH OR WITHOUT A SUBSTRATE Code 1 05 01 1 05 01 1 05 03 1 05 03

PROPOSED DEVELOPMENT PROGRAM No s p e c i f i c process development e f f o r t i s recommended to make available adequate quan t i t i e s of boron filament for prototype hardware development i n view of current A i r Force a c t i v i t y However a c o r o l l a r y program on non destructive inspection development Is proposed INSPECTION TECHNIQUES SUPPLEMENTAL RECOMMENDATIONS INSPECTION REQUIREMENT OBJECTIVE BACKGROUND APPROACH In-process and end-item evaluation of production q u a n t i t i e s of boron filament for application to composite f a b r i c a t i o n To establish controls on f a b r i c a t i o n process and filament q u a l i t y evaluation with respect to (a) diameter (b) flaw i n filaments and (c) properties of filaments Although a minimum e f f o r t has been made to apply NDT as process control and boron filament inspection the e f f o r t has not been exhaustive (1) There Is some ex i s t i n g f e e l i n g that filament q u a l i t y v a r i a b i l i t y becomes s t a t i s t i c a l l y less important when wound Into a composite This f e e l i n g has not been tested In d e t a i l however and could lead to inspection problems when time to solve them has slipped away The s p e c i f i c q u a n t i t a t i v e filament v a r i a b i l i t y problem must be defined for each filament/composite f a b r i c a t i o n process For filament diameter measurement, a capacitance gauge (CDD) Is suggested because of the e l e c t r i c a l properties of boron I t is a poor e l e c t r i c a l conductor or a lossy d i e l e c t r i c Eddy current techniques (CBA) have not been found readily applicable but t h i s w i l l depend on filament properties as produced by various processes For flaws In filaments, microradiography (BA) of composite specimens has been found useful provided the number of filament layers Is severely l i m i t e d (2 or 3 layers) Penetrants (ABB) have revealed filament s p l i t t i n g In small composite specimens For filament properties dynamic modulus techniques based on Induced vibrations (DA) have shown th e o r e t i c a l and p r a c t i c a l c a p a b i l i t y Equipment Is available for dynamic modulus determinations on t h e - f l y for long filament lengths Although not studied I t is expected that other filament mechanical properties can be correlated with e l e c t r i c a l properties as gauges dynamically with d i e l e c t r i c (CCD) or eddy current (CBA) probes An NDT study should be i n i t i a t e d to operate concurrently with e x i s t i n g or new filament f a b r i c a t i o n process development The Important filament q u a l i t i e s should be defined i n terms of r e s u l t i n g composite q u a l i t y Composite f a i l u r e mechanisms c l e a r l y traceable t o filament q u a l i t y should be separated from those associated with prepreglng and composite f a b r i c a t i o n These then become the target for NDT technique development for the filaments themselves Techniques should be selected/ optimized and calibrated for q u a n t i t a t i v e measurement of s i g n i f i c a n t a t t r i b u t e s The development program i s summarized 1 Apply NDT to detect v a r i a b i l i t y i n boron filaments (thickness flaws properties) Continued on next page

164- INSFECTION TECHNIQUES SUPPLEMENTAL RECOMMENDATIONS continued CHART. _ . NO _fe3Z_ 2 Conduct f a i l u r e mechanism studies of composites fabricated from the NOT characterized filaments 3 Define s i g n i f i c a n t filament a t t r i b u t e s separate from non- relevant filament variables 4 Select/optimize NDT for the s i g n i f i c a n t variables and establish q u a n t i t a t i v e c a l i b r a t i o n s NDT should be developed as filament f a b r i c a t i o n process controls when possible 5 Write detailed NDT procedures REFERENCE (1) Stinebrlng R D and Zurbrick J R Property Determination and Process Control of Boron Filament Composites Using Non-destructive Test Methods Proceedings of 10th National Symposium of Aerospace Material and Process Engineers San Diego C a l i f o r n i a November 10 1966

EXPLANATION OF CAMR REFERENCES TO SYSTEMS, COMPONENTS, AND AARP RATING FACTORS CAMR CHMtr NUHBtR I &0I 6i>t 6es 609 RBF B-173: Componenc 02.09.0 SPACECRAFT CENTRIFUGE CONNECTING LIMKAGB f o r C-3b envtrormental c o n t r o l e x t e r n a l centiLfuge-suppoxc syotem. RBF B-167- Componenc 09.09.0 LAUNCH FACXLITY CABLE TIB-DOVN f o r C-le lunar base. R£F B-95a, 96, 98c: Coraponenta 02.04 0 FRESSURE VESSEL, 02.08 0 MAJOR FITTING (BULKHEAD) and 08.01.0/08.04.0 HEAT SHIELD/EROSION-CORROSION SHIELD f o r B - l b ( l ) and B-lb(2} space launch Byatena - e a r t h o r b i t launch and lunar launch — — — — I ElEF B-41e Component 01 01.1 ABROIffNAKIC LIFT & P ^ J I CONTROL STRUCTURE-RIGID SKIN f o r A-3b hypersonic boost g l i d e s t r a t e g i c or t a c t i c a l v e h i c l e 1 REF B-30c' Component 01.01 1 AERODYNAMIC LIFT & ^0*^ COITTROL STRUCTURE-RIGID SKIN f o r A-3a hypersonic c r u i s e high a l t i t u d e or low a l t i t u d e v e h i c l e s . REF ,B-133a,b Component 07.02.0 BLECTROHAGNETIC TRANSPARENCIES (RADOMBS, RADAR WINDOWS) f o r B-3b drag entry v e h i c l e s . REF B-177b: Component 07 04 0 OPTICAL MIRROR £. I REFLECTOR f o r C-Sa c o l l e c t o r m i r r o r / o p t i c a l telescope REF B-12 component 07 02.0 ELECTROMAGNETIC TRANSPARENCIES (RAMMES,- RADAR WINDOWS) f o r A-2 — I (RA CO 9 I supersonic n i r c r a f REF B-152 Component 09 02 0 SEAL'for B-4b space lending vehicles REF B-64a Component 08 02 0 THERMAL INSULATION for A-4b(4) s t r a t e g i c re-entry m i s s i l e systems 1 REF B-124 Component 07 02 0 ELECTROMAGNETIC TRANSPARENCIES (RADOMES, RADAR WINDOWS) f o r B-3a l i f t r e - entry v e h i c l e s . cn REF 8-166 Component 03 01 0 LUNAR SHELTER, MANNED for C-le lunar base REF B-179 Component 05 05.0 DOCKING ATTACHMENT fo r C-6a work device docking gear REF B-174C Component 08 07 0 RE-EKFRY ENCLOSURE (INDIVIDUAL) f o r C-3c l i f e support and environ- mental c o n t r o l abort/mission enclosure k SYSTEM PROBABILirr OOMPOKEKT OUTICkUTY FREBUCNCV OF S t tVlT rN s m e w i DESIQN MATCRIUS iMrucATum A A R P RAW SCORES IX- e-t 3 - « - ( q - & 3 6 - 4 - 0 1 1 6 e 1̂ 26 H- 6 1 < o 0 '7 It 9 Z 3 o i> 26 /t & z 3 0 0 2 3 . ̂ 'A , /t 9 z 3 0 0 2i / Z z e> 0 zi 6 / 2 z 9 o 0 3/ /z 6 / 6 0 e 9 / 0 £ z 9 0 0 t? , f /2. f 6 6 n & / £ & ,33a., e & / / 6 0 z r f 9 6 0 z ^ i / z 9 1 3 i> 29 ,<??.'. 8 9 / e

EXPLANATION OF CAMR REFERENCES TO SYSTEMS, COMPONENTS, AND AARP RATING FACTORS I CAMR OMMCr NUHHR £ / 2 &I3 EBP B-108b, 136bi Componanc 02.02.0 srAaciATT VmxBKL STEWTUHE t o r B - 2 . ( l ) , B-2.0). D-2.(3) near space opaTatlooi apacecraft-aarth a a t e l l l t a , apaca a t a t l o n , and lunar v a h l c l a . and B*2e apacaerafc a h u c t l e , and B-3b drag e n t r y v e h i c l e . aHF B-112a,b, 13Jb: CODficnenc 07.02.0 SLECTKOMkOSTIC TBANSPAKENCISS (BADOIQS, BAUR WINII0II5) f o r B-2a(l>, B-2a(2), B-2a(3), B-2c, and B-3b v e h i c l e s as above. BE7 B-14Sa.b, K9a, ISOa.b: Components 01.02.1 A2R0DrNU4IC LIFT & COKTROL STRUCIUBZ-FLBIIBIE (FLEX-WmC), 01.02.3 (FLBX IBCBLBRATOR) , and 01.02.<> v(?LEX ROTOR) f o r B-4a e a r t h landing syatens. BE? B-108b, 136b; Conponent 02.02.0 SPACECRAFT IKTERNAl, STRUCTURE f o r B - 2 a ( l ) . B-2a(2), B-2a(3) near space operations epacecraft-earth s a t e l l i t e , space a t a t l o n , and lunar v e h i c l e , and B-2c apacecraft a h u t t l e , and B-3b drag e n t r y v e h i c l e . REF B-112a,b, 135b: Component 07.02.0 ELECTRO- KAGNETIC TRANSPARENCIES (RADOHES, RADAR WDmOWS) f o r B - 2 a ( l ) , B-2a<2), B-2a(3), B-2c, and B-3b v e h i c l e s as above. REF B-107f, 109c: Components 02.01.0 SPACECRAFT HULL snd 02.03.0 SPACECRAFT EXIEIIHAL STRUCTURE f o r B-2a near spsce operetlons spacecraft-earth s a t e l l i t e , space s t a t i o n , and lunar v e h l c l s , and B-2c apacecraft s h u t t l e . REF B-2, 20b: Component 08.03.0 RADIATION SHIELD f o r A-lb subsonic long endurance a i r c r a f t , nuclear powered, and A-2a and A-2b supersonic h i g h a l t i t u d e long range a i r c r a f t , chemical or nuclear powered. 1 REF B-107f: Component 02.01.0 SFACECBAFT HULL fo r B-2a near space operatlona spacecraft - e a r t h s a t e l l i t e , space a t a t l o n , lunar v e h i c l e , and B-2c spacecraft a h u t t l e . i 1̂ SYSTEM PBOBABlun COMPONENT OlITICAUir FREgUCNCV OF lavit IN SYSTEM DESIGN ALTERNA-'a MATERUUS IMnJCAnoi AARP RAW SCORES I t - 8 - * S - I - l 6 - 4 - 0 T»TAL ff 6 z c [> J o et.pt.e^ f,it)(lt^ /* * & 0 3e ¥ & i f 0 2 2 et.ot.o sze 6 6 1^ ' 1 • ' .\ } / a 3 ¥ <> 2 7 6 0 J e 7 C 0 So e i « 0 » 2 8 6 2 c 0 2K .e>7^et.o _^-3lf /Z C z 0 3o Phot^l. ,S:'k . /z /« a 0 5 V (> A / 2 9 2. / i rt 2 <? y 0 5 9 IX 6 2 H 0 3 o /* i % 1 0 3o * 0 az e 6 2 ft-^to. Mill. 8 3 2 6 « 0 J 3 ,cre2x> fi^fr). n. «. 0 5 o o7.oi.t,^ ,et«,(t) It. 6 Z. 6 y <) 3o ¥ t 2 6 8 & •2. c 6 - s * / a 6 z- O 3o 12 2- c 0 t> 32 e / a 1̂ 0 0 28 /a. 2 0 0 2 6 £ 2- c o 1̂ 2 2 2 i> & 0 ; 27 P9r0%0 ,/*-?5(«. /a. 4. 6, 0,8.c3o , A-ih 9 3- 6 & 0 27 n i» 3 9 o [> ?<' .<!>'.•?(•<> 8 / 2 3 9 0 i> 3S.

NUHISCK REF B-174.: Component 08.07.0 RE-EOTKY ENCLOSURE I I (INDIVIOUAl.) f o r C-3c l i f e support and environmental EXPLANATION OF CAMR REFERENCES TO SYSTEMS. COMPONENTS, AND AARP RATING FACTORS 6ie c o n t r o l abOTt/mlSBLon enclosure. R E F B-95a, 96, 98c: Componencs 02.0A.0 P R E S S U R E V E S S E L , 02.08.0 M A J O R F I T T I N G ( B U L K H E A D ) and 08.01.0/08.04.0 H E A T S H I E L O / E R O S I O N - C O R R O S I O N S H I E L D f o r B - l b ( L ) and B-lb<2) space launch syste earth o r b i t launch, and lunar launch. 62X REF B-160a: Component 03.07.0 EXHAUST DEFLECTION STRUCTURE f o r C-la earth base launch pad. REF B-162: Conponent 08.09.0 HONEYCOMB SANCWICH SONAR SHIELD f o r C-lc earth base water launch f a c i U t y . REF B-30d, 41d: Component 01.01.1 AERODYNAMIC LIFT AND CONTROL STRICTURE-RIGID SKIN f o r A-3a hypersonic c r u i s e high a l t i t u d e or l o v a l t i t u d e v e h i c l e s and A-3b hypersonic boost g l i d e s t r a t e g i c oc t a c t i c a l v e h i c l e s . REP B-28e: Component 01.03.0 NOSE f o r A-3a hypersonic c r u i s e v e h i c l e s . REF B-120c: Component 01.0^.0 LEADING EXE f o r B-3a l i f t r e - e n t r y v e h i c l e s . REF B-121b,c: Component 08-01.0 HEAT SHIELD fo r 3-3a l i f t re-entry v e h i c l e s . REF B-164: Component 07.01 0 ANTENNA for C-ld space s t a t i o n . R E F B-39a- Component 01.03.0 N O S E f o r A-3b hypotsonic boost g l i d e s t r a t e g i c or t a c t i c a l v e h i c l e s . R E F B - ^ O B : Component 01.04.0 L E A D I N G E D G E f o r A-3b v e h i c l e as above. REF B-n9c: Component 01.03.0 NOSE for B-3a l i f t r e - e n t r y v e h i c l e s . REF B-120d: Component 01.04.0 LEADING EDGE f o r B-3a l i f t r e - e n t r y v e h i c l e s . REF Propulsion Requirement Non-raetalllc F a b r i c a t i o n No. 2: Component 10.07.0 TURBOJET AFTERBURNER / ^ S * FLAPS for A-2a supersonic high s l t i t u d c long range — 1 a i r c r a f t . A-2c supersonic t a c t i c a l V/STOL f i g h t e r . and B-la earth launch recoverable booster. - Components 13.02.0 RAMJET DIFFUSER SKINS and 13.03.0 COMBUSTION CHAMBER f o r A-3a hypersonic c r u i s e high a l t i t u d e or low a l t i t u d e v e h i c l e and B-la e a r t h launch recoverable booster. PROBAeain COMPONENT aMTlCAUTT FRCauCNCV OF BJVIT N SYSTEM OESIGN ALTERNA-a Mru CATION AARP RAW S C O R E S T'vTAL V .oe,ci%», ,C:3e. , 1*- 8 - tt-"l - 6 - 3 9 1 3 9 1, 3 o i> 3.6, 9 1 3 o tz & z. 3 0 0 2 3 6 z . 3 9 2 3 0 d> 26 9 Z. 3 0 . 0 fS e a C> 3t V 1 £ . O A * / , / 6 / 2 t 3 (, 0 31 pi Ml. A-U. /% 1 3 (> zc 9 2- 3 0 26 9 % 3 e /z Z 3 0 31 fitoifi, .C:/.4. n 9 / 3 29 V f z £ 6 pt.pf.o . 9 O 37 8 9 2 6 <) 3/ pi,e<fo ,0-3*., 9 2. t 6 0 3/ /t i / 3 ,/0.O7A , /z / 3 V 6 2. 3 y 0 zs e 9 Z 3 8 9 Z S 9- ze,

EXPLANATION OF CAMR REFERENCES. TO SYSTEMS. COMPONENTS, AND AARP RATING FACTORS NUHBCR I 62S I t28 630 637 6Z9 Condnued from preceding pege BKF Propulelon aequlrenent Ron-oote l l lc Febr ice t lon Ko. 2: Coapooent 14.02.0 LIQUID BOCXST MOTOR NOZOE for B-l« earth launch recoverable booacer. Conponenta 16.03.0 SOLID BOCKEI MOTOS HOZZU and 16.07.0 THRUST VECTOR COOTHOL GUITB VAHBS for A ^ b s t r a t e g i c n l a s l l e a and B- la earth launch recoverable booacer. RBP B-28a,b. 29a: Components 01.03.0 HOSB and Ol.O'i.O LEADING E K E for A-3a hypersonic c ru ise high a l t i tude or low a l t i tude v e h U l e s . REP B-6ib, 69b, 71b: Component 02.05.0 HOTOR CASE, SOLID PROPELLAms for A - 4 a ( l ) t a c t i c a l ground launched a n t l - o l s s l l e , A - 4 b ( l ) , A-ftb(2), A-4b(3) acrateglc m l s s l l e s - o o b l l e ICBH, s torsble ICBH, space launched ICBH. REI" B-107b,c: Cooponent 02.01.0 SPACECRAFT HULL for B - 2 a ( l ) . B-2a<2). B-2a(3) near space operations earth s a t e l l i t e , space s t a t i o n , and lunar v e h i c l e , a B-2c spacecraf t ahut t le . REF B-83c,d: Confionent 02.05.0 MOTOR CASE, SOLID FROFEUJlHrS for B - l a ( l ) and B-l .<2) earth launch system recoverable booster Including single-stage- to-orblt booster. REF B-65a, 69a, 71a: Couvonent 02.05.0 MOTOR CASE SOLID FROTELLANTS for A-4a( l> t a c t i c a l m i s s i l e ground launched a n t l - m l s s l l e , A-4a(2) t a c t i c a l mlaal le space launched e n t l - o l s a l l e , A - 4 b ( l ) , A-4b(2) , and A-4b(3) s t ra teg ic m i s s i l e s - mobile ICBH, s torsble ICBH, and space launched ICBH. REF B-83c.d; Component 02.05.0 MOTOR CASE, SOLID I PROTELUHTS for B - l a ( l ) end B- la (2 ) earth launch 1 1 system recoverable booster Including s l n g l e - s t a g e - to-orbl t booster. 13.03.0 ftt,t>.S..o. k SYSTEM PRODABILir OOMPONEHl r CRITICAUiy FREaueNCY OF lajviT IN SYSTEM DESIGN ALTERNA.-£ AARP RAW SCORES It- 8 - It Ct-1-fe-i 3--2-I e 9 2 3 ¥ i> zc 9 Z 3 0 Z.6 8 9 2 •3 9- 0 2< n 9 2. 3 0 3C , B f 2. 3 i> zc fl e a. S 0 27 8 6 z 3 9- t> 23 e 9 z 3 o 0 2Z /4 •2- 3 o 0 2S^ Afar 9 t £ V 0 X A-W') 9 1 i> 2M A m 9 / 0 32 B 9 1 & 0 26 /Z. /z t 6 0 ? / >z /2 1 f. o 0 ? / tt. 1 <f 0 23 S-Ze 8 /<• / 6 e> 0 27 e 9 t & o 0 2<^ ¥ f / & e t> 20 AM MoT /itee 9 / 6. e 0 X H 9 / & o 1̂ Zo /2 9 t o i> 2B ttm rata 9 / 0 i> K 9 9 t 6 0 <> 3<< 8 9 1 3 V 9 / 3

•169- PANEL ON INSPECTION AND EVALUATION TECHNIQUES Members; L i a i s o n - Dr. Robert B. O l i v e r , Chairman Mr. Thomas L . Campbell Mr. C a r l t o n H astings Mr. David E. D r i s c o l l Mr. D. W. B a l l a r d Mr. F o r r e s t S. Wi l l i a m s

-171- 2 3 INSPECTION AND EVALUATION TECHNiqJES A Summary of Problems and Recommendations G e n e r a l l y speaking, i n s p e c t i o n and t e s t i n g d i s c i p l i n e s a r e d i a g n o s t i c techniques based on experience and employing the measure- ment of any p h y s i c a l or p h y s i c a l - c h e m i c a l phenomenon that can be c o r r e l a t e d to the d e s i r e d f u n c t i o n a l or performance c h a r a c t e r i s t i c of the end product The property or a t t r i b u t e being measured may not i n i t s e l f be c r i t i c a l but i s one which can be c o r r e l a t e d , through f u n c t i o n a l or d e s t r u c t i v e t e s t s , w i t h the s p e c i f i e d c r i t i c a l product c h a r a c t e r i s t i c The methods are p r i m a r i l y i n d i r e c t and u s u a l l y must be t a i l o r e d to a s p e c i f i c problem c o n s i d e r i n g s i z e , m a t e r i a l , shape or c o n f i g u r a t i o n , and o r i e n t a t i o n w i t h r e f e r e n c e to a c c e s s i b l e s u r f a c e s I t i s seldom the c a s e t h a t one method i s adequate f o r a complete i n s p e c t i o n or e v a l u a t i o n While one method may be optimum f o r i n s p e c t i o n of a s p e c i f i c c h a r a c t e r i s t i c , supplemental methods may be r e q u i r e d f o r other parameters I n n e a r l y a l l c a s e s , a c o r r e l a t i o n study of n o n - d e s t r u c t i v e and d e s t r u c - t i v e t e s t r e s u l t s w i l l be needed A c t u a l l y , n o n - d e s t r u c t i v e t e s t methods have v a l u e f a r g r e a t e r than f o r a simple a c c e p t / r e j e c t f u n c t i o n Many of these methods have the c a p a b i l i t y to a s s e s s p h y s i c a l p r o p e r t i e s of the m a t e r i a l s and to r e v e a l the adequacy and constancy of p r o c e s s e s I n a l l c a s e s , regard- l e s s of the l e v e l of e f f o r t , development of i n s p e c t i o n and e v a l u a t i o n techniques should run c o n c u r r e n t l y w i t h the development of m a t e r i a l s and p r o c e s s e s they a r e intended to c o n t r o l T h i s development must c o n s i d e r m o d e s - o f - f a i l u r e , a t t r i b u t e s to be e v a l u a t e d , c o r r e l a t i o n and c a l i b r a t i o n of a s s o c i a t e d equipment and the f a b r i c a t i o n of r e f e r e n c e standards L a s t of a l l , a d e t a i l e d procedure must be generated and followed to ensure uniform a p p l i c a t i o n of the t e s t s S i n c e the a p p l i c a t i o n techniques are dependent on m a t e r i a l s of c o n s t r u c t i o n or combination of m a t e r i a l s and shape or c o n f i g u r a t i o n , the s p e c i f i c technique s e l e c t e d must be optimized f o r each a p p l i c a t i o n I n the appendix of t h i s volume I s a l i s t of i n s p e c t i o n and t e s t methods which were used by the I n s p e c t i o n Panel i n I t s review of p r o c e s s - o r i e n t e d c h a r t s w r i t t e n by other CAMR panels The l i s t a l s o i d e n t i f i e s the measurable a t t r i b u t e s to which the i n s p e c t i o n method i s d i r e c t e d Three problem l e v e l s were found a f t e r a review of the c h a r t s submitted by other panels The f i r s t I n v o l v e d a l a r g e number of i n s p e c t i o n and e v a l u a t i o n problems co n s i d e r e d to be s t a t e of the a r t by 1970, and r e q u i r i n g only a minimal c a l i b r a t i o n or f i x t u r i n g e f f o r t Hence, s o l u t i o n s to these problems g e n e r a l l y were not i n c l u d e d w i t h the p r o c e s s - o r i e n t e d c h a r t s T h i s l a c k of comment by the I n s p e c t i o n Panel does not imply t h a t e x t e n s i v e NOT e f f o r t I s not r e q u i r e d By d e f i n i t i o n , such e f f o r t does not i n v o l v e development of new i n s p e c t i o n c a p a b i l i t i e s but r a t h e r a p p l i c a t i o n of known technology Secondly, numerous i n s p e c - t i o n and t e s t i n g problems were found t h a t d i d r e q u i r e development e f f o r t and were d i r e c t l y a s s o c i a t e d w i t h the manufacturing problems I n these i n s t a n c e s , the I n s p e c t i o n Panel added a supplement to the c h a r t .

•172- reconmendlng Chat a s p e c i f i c i n s p e c t i o n or t e s t development be c l o s e l y c o o rdinated w i t h the o u t l i n e d manufacturing p r o c e s s development The t h i r d category of problems was connected w i t h , or i n f e r r e d by, s e v e r a l s i m i l a r manufacturing problems and i n these c a s e s s p e c i f i c "700" s e r i e s I n s p e c t i o n and E v a l u a t i o n Techniques C h a r t s were generated Where r e f e r e n c e s are made to " s t a t e of the a r t , " t h i s should be understood as knowledge, p r a c t i c e , or othe r information p u b l i s h e d p r e v i o u s l y i n any open l i t e r a t u r e , DOD r e p o r t s , or AEC r e p o r t s I t must be understood t h a t the p h y s i c a l bases f o r NDT are most o f t e n adapted f o r p r a c t i c a l problem s o l u t i o n from such f i e l d s as p h y s i c s , chemistry, e l e c t r o n i c s , m a t e r i a l s e n g i n e e r i n g , s t a t i s t i c s , and ot h e r s These bases may not c a r r y the l a b e l of NDT l i t e r a t u r e , hence, i n g e n u i t y and energy of unusual magnitude i s n e c e s s a r y to ma i n t a i n f a m i l i a r i t y or to seek out the s t a t e of the a r t regarding a given problem Outlook The f i e l d of i n s p e c t i o n and e v a l u a t i o n techniques (and s p e c i f i c a l l y n o n - d e s t r u c t i v e t e s t i n g ) i s about a q u a r t e r - c e n t u r y o l d During t h i s development p e r i o d t h e r e has been an e v e r - i n c r e a s i n g growth and we can c o n f i d e n t l y p r e d i c t continued a c c e l e r a t e d expansion Experience has shown t h a t most of t h i s growth has r e s u l t e d from a problem- o r i e n t e d approach, w i t h l i t t l e i n v e s t i g a t i o n which was not aimed s p e c i f i c a l l y a t s o l v i n g a s e r i o u s problem T h i s Panel f e e l s t h a t funding must be made a v a i l a b l e to sponsor s c i e n t i f i c approaches to uncover new and b e t t e r methods I n a s s e s s i n g the s t a t e of the a r t we f i n d t h a t , except f o r a few hundred p r a c t i t i o n e r s i n the f i e l d , people do not rec o g n i z e the advances that have been made or the d i f f i c u l t problems t h a t have been solv e d Most of these problems have been s o l v e d w i t h commercially a v a i l a b l e equipment by ingenious design of t o o l i n g Some have r e q u i r e d c o n s i d e r a b l e imagination i n f i n d i n g measurable a t t r i b u t e s from which can be i n f e r r e d c h a r a c t e r i s t i c s not d i r e c t l y measurable Most of the problems def i n e d by AARP and the other panels of CAMR can probably be sol v e d w i t h s t a t e of the a r t equipment and techniques The balance of the problems d e s c r i b e d i n the "700" s e r i e s c h a r t s w i l l r e q u i r e major developmental e f f o r t , and i n some c a s e s they w i l l r e q u i r e a d d i t i o n a l b a s i c knowledge A l l the problems uncovered by the I n s p e c t i o n Panel can be t r a c e d to AARP systems requirements These problems a r e b r i e f l y p resented as f o l l o w s Strength of Bonds NDT methods have been c o r r e l a t e d to the s t r e n g t h of the bond l a y e r ( c o h e s i v e s t r e n g t h ) , but no way to n o n - d e s t r u c t i v e l y e v a l u a t e the adhesive s t r e n g t h i s known T h i s problem can only be s o l v e d a f t e r b a s i c r e s e a r c h on adherence r e v e a l s a s i g n i f i c a n t , measurable a t t r i b u t e

•173- Coating - Adherence and I n t e g r i t y No s o l u t i o n to measure adherence i s f o r e s e e a b l e Many p o s s i b l e approaches e x i s t f o r the e v a l u a t i o n of i n t e g r i t y , but each system w i l l r e q u i r e a s e p a r a t e approach Composites I n s p e c t i o n of g l a s s / r e s i n composites i s w e l l advanced, numerous and d i f f i c u l t i n s p e c t i o n problems Long L i n e a r Measurement The l a r g e o b j e c t s w i t h c l o s e t o l e r a n c e s point to the need f o r b e t t e r measuring methods t h a t are Independent of temperature C l e a n l i n e s s B e t t e r d e f i n e d and b e t t e r c o r r e l a t e d methods are needed The major problem w i l l be to d i f f e r e n t i a t e between i n e r t and v i a b l e s o i l s I n s p e c t i o n i n Space I f c o n s t r u c t i o n of man-ratable s t r u c t u r e s i n space becomes a r e a l i t y , r a d i c a l l y new i n s t r u m e n t a t i o n w i t h lower power requirements w i l l be needed Data P r o c e s s i n g Development i s n e c e s s a r y to improve methods of NDT data c o l l e c t i o n and s i g n a l a n a l y s i s techniques to improve and expedite data p r o c e s s i n g The program should i n c l u d e the development of genera- t i o n and d e t e c t i o n techniques which lend themselves to data storage and c o r r e l a t i o n methods The s u i t a b l e c o r r e l a t i o n technique v a s t l y i n c r e a s e s the s e n s i t i v i t y of a l l the known n o n - d e s t r u c t i v e techniques, p e r m i t t i n g the immediate comparison of t e s t s i g n a l s w i t h those from a known good component or from an i d e a l New Techniques P o l a r i z e d microwave beams and coherent l a s e r beams have been used i n a v e r y l i m i t e d way They appear to have great p o t e n t i a l and should be i n t e n s i v e l y explored f o r i n s p e c t i o n of s u r f a c e p r o p e r t i e s and of non-conductive m a t e r i a l s

-174 AARP REFERENCES E Chnrf. B Charts P4FVPS Charts APPLICABLE PROCESS Code LASER AND MICROWAVE INTERFEROMETERS STATE OF THE ART ASSESSMENT TITLE MEASURE CONTOUR AND RADIUS OF FORMED OBJECTS FROM 50 inches to 600 inches WITH A TOLERANCE OF BETTER THAN 0 1 percent CHART N O PRIORITY REl|TED CAMR CHARTS MANUFACTURING REQUIREMENT C y l i n d r i c a l conical spherical e l l i p s o i d a l and t o r o i d a l vessels and tankage up to 500 inch radius are required Close tolerances are required for f i t - u p for j o i n i n g of segments or f o r bonding of covers t o cores NOTE Recommendations of t h i s CAMR chart are incorporated by reference i n the following charts 106 20A 208 209 213 217 220 A28 431 433 447 618 and 619 222 303 304 402 403 Standard t o o l i n g and measuring instruments are adequate up to about 125 to 150 inch radius when temperature corrected Beyond t h i s size the measuring devices become heavy and the accuracy i s noticeably affected by ambient temperatures Electromagnetic methods such as o p t i c a l interferometers time ranging radar doppler radar and microwave i n t e r ferometers have been used f o r precise measurement of change of distance at ranges up to 106 miles These r e l a t i v e measurements are independent of ambient temperatures CRITICAL PROBLEMS 1 Attach accuracies f o r absolute measurement comparable to accuracies c u r r e n t l y attained for r e l a t i v e measurement 2 Development of to o l i n g to mount the Instrumentation for the evaluation of contour of cover and core 3 Primary c a l i b r a t i o n reference procedure and standard ALTERNATE PROCESSES STANDARD TOOLING AND MEASURING INSTRUMENTS Code

175 CHART NO 101 PROPOSED DEVELOPMENT PROGRAM OBJECTIVE Develop Instrumentation and t o o l i n g to u t i l i z e the precision measurement c a p a b i l i t i e s of laser and microwave beams f o r the evaluation of contour and determination of radius for objects having r a d i i up to 600 Inches BACKGROUND The portion of the electromagnetic spectrum that has been used has measurement wave lengths from 40 micro Inches to 2 Inches Current Instrumentation can rea d i l y measure differences In dimensions of 1/lOOth to 1/lOOOth of a wave length In the above range Laser Interferometers are being used to c a l i b r a t e numerically controlled machine tools and a d i f f e r e n t i a l microwave Instrument has been used for high speed continuous gauging of s t r i p Also a microwave u n i t has been used for the dimensional Inspection of domes for Saturn tankage APPROACH 1 Evaluate r e l a t i v e merits and areas of applications for microwave and laser measuring techniques 2 Investigate sophisticated time and frequency based radar techniques for absolute measurement over Che range of 10 feet to 100 feet 3 Develop tooling for mounting the selected Instrumentation to measure contour perhaps referencing to a master template I* Following Instrument and t o o l i n g concept selection construct a prototype system for t r i a l and proofing

176 PRIORITY RATING WORKSHEET CHART P R O f i R A M P A C T o a a . P R 0 6 R A M P R O B A B I L I T Y O F S U C C E S S • LOW Z • M O D E R A T e 5 >C HIGH 8 C R I T I C A L P R O B L E M S TO B E S O L V E D • F E ^ / N O T TOO DIFFUMILT Z X a o M E / ' O I F F I W L T S a M A N Y / V E R V P I F F I C U t r S P R O C e S S G R O W T H P O T E N T I A L • L I T T L E OR U N D E F I N A B L E O a ftece&HVLi^M p o r e M T i A L 4 A P P L I C A T I O N S OTHER. T H A N AIR F O R C E • NONE O • S O M E Jt iC MAMV d NECESSITY FOR AIR FORCE FUNDIMa n LOW HlfiH |«ltUST<lV/'DTH£« SeWT C F F s C r * B M D(lt/tTB - E F n c r OTHCe 'SMASeS 0 • e i u : u i s i y e AiR fttiCk. F U M C M A UKCL<I vi. NEED FACTORS S Y S T E M S P R O B A B I L I T Y HIQH P S O B A B I I T Y 12 F A I R P a O B A S I L I T Y 8 LOW P R O B A B I L I T Y 4 C O M P O N E N T C R I T l C A L I T Y t / E R Y H I C H I I H I « H 9 F A l A 6 L o w 3 F R E O U E N C Y OF R E Q U I R E M E N T IN « V « T E M M«B£ THAN 3 C O M P e t ' E M T S 3 Z 3 C O M P t U E M T S 2 S I N f l L E C e M P O N E N T 1 D E S I G N A L T E R M A T E S No A L T E R N A T G F M E B E E N ^ ONE A L T E R N A T e 6 S E v r e - A L A L T e B M A r e o 3 M A T E l Z l A L S I M P L I C A T I O N NEW MATEIL IAL P e y E l O f M E N T R C A O 6 IHIATCRIAL I M P O O V E M C M T R E S P 4 NO P R O B L E M F o K E S C e i a O 6 6 0 ? 3 RAW s c o o e s roQ. EACH REFCSeMOP COMFONCMT M T A B L M AT E N S or PANEL I Z E P e t T UJITH Wwo T O T A L S E N T E R f p IN ÛMUAEV AT t2l6«T A A R P R A > M S e o t t C S • • • • • To A AlVMBes. Of vrnee. /fisntsr /tf»/v/PUAL • • • • • • • • • • [ • • • C Z ] • • • • • • • • • • ] • • • • ] • • • • : • • • • • • • • • • • • • I • • • c CALCULATE PRIORITY- STEP I CIRCLE HIGHEST AARP SCORE IN eACH OTHER SVSTEM C I R C L E NEXT HIGHEST SCORE 42. S T E P 2 STEP 3 IF WITHIN 4 POINTS N U M 6 E R OF ^ V S T E I W S Hlf in OP T O P S C O R E n > g LOW >»- C I R C L E fReOUENCY DISTRIBUTION FACTOR MuMQen. ov s v s r e i ^ * Kia»« B E . L O W C NUMecR O F S Y S T E M S L o w 0 I 2 AMOCt 1 0 1 z » 4 1 1 1 3 1 f 1 z 1 *!• TOTAL PRIORITY

177 CHART PRIORITY | IPX ' RELATED TITLE INSPECTION AND EVALUATION TECHNIQUES FOR AIMESIVE BOND STRENGTH CAMR CHARTS MANUFACTURING REQUIREMENT Non destructive measurement or p r e d i c t i o n of bond strength for adhesive Joints NOTE Recommendations of t h i s CAMR chart are Incorporated by reference In the following charts 403 405 407 408 409 410 411 423 620 AARP REFERENCES E Chortt B Char ts . P4FVPS Chor ts . APPLICABLE PROCESS one or more of the following DIELECTRIC (Including microwave) TECHNIQUES ODD ULTRASONIC/SONIC DAC RADIOGRAPHIC BAA INFRA RED (thermal e x c i t a t i o n ) ECB X-OR BETA-RAY BACKSCATTER BBB OPTICAL REFLECTOMETRV AAC EliCTRODE POTENTIAL FCA PENhTRANT ABB NEUTRON ACTIVATION BCB ELECTROMAGNETIC CBA Code STATE OF-THE ART ASSESSMENT NDT c a p a b i l i t y now exists for detection of unbonded areas In c e r t a i n assembly j o i n t s but cannot q u a n t i t a t i v e l y evaluate the strength of adhesive bonding for the general case of a finished Joint By 1970 I f the factors which con t r o l bond strength are I d e n t i f i e d and rated as to r e l a t i v e significance some" of these may be amenable to NDT c o n t r o l In spite of the attractiveness of the idea d i r e c t non destructive measurement of the strength of finished bonded Joints Is regarded as an Impractical goal No non destructive material energy interactions are presently recognized which would permit the attainment of t h i s ideal An alternate NOT process-control approach Is outlined below Present bonded Joint design endeavors to place the ultimate f a i l u r e mode w i t h i n the adhesive (although some p r a c t i c a l Joints may be designed to place f a i l u r e i n a substrate) Correct execution of the bonding process allows the design requirements to be met I f t h i s correct execution can be attained the working strength of the Joint i s a function of the cohesive strength of the adhesive and the l o c a l residual stress w i t h i n the j o i n t Cohesive strength i s a t t r i b u t a b l e to the molecular structure of the adhesive (as Influenced by macro defects) and l o c a l stresses are a function of both p r a c t i c a l j o i n t design and excellence i n execution At present c r i t i c a l Joints must be greatly overdeslgned to assure u n f a i l i n g performance from one assembly to the next Yet even with t h i s precaution and current means of c o n t r o l of Joint preparation no adhesively bonded part can be p o s i t i v e l y guaranteed to perform as required There are too many process variables not possible of evaluation i n the completed Joint to expect that t h i s can be accomplished non d e s t r u c t i v e l y Two major problem areas i n achieving correct execution of an adhesive bonding operation are 1 Residual stresses i n the adhesive play an Important part among many other variables i n the ultimate strength of an adhesive bonded Joint I n the present Continued on next page ALTERNATE PROCESSES NONE Code

178 I CHART NO STATE OF THE ART ASSESSMENT continued state of the a r t residual stress must be control l e d by the design of the Joint configura t i o n the selection of adhesive the proper set le v e l etc The non-destructive measure- ments of residual stress i n an adhesive Joint i s beyond present c a p a b i l i t i e s and not expected by 1970 2 The strength of adhesion between adherents and adhesive cannot presently be measured non-destructively at the end item stage NDT controls may be developed however to assure proper processing (raw materials surface preparation cure cycle etc ) and thus assure proper end item adhesion when coupled w i t h end-item NOT directed at adhesive variables such as voids cracks e l a s t i c properties etc Development work on improved destructive tests including t e n s i l e tests f o r honeycomb core material i s required as a basis f o r c a l i b r a t i o n of NOT process con t r o l tests CRITICAL PROBLEMS 1 Define and rate r e l a t i v e significance of a l l parameters which influence j o i n t strength 2 Develop/select NOT fo r measurement of the most s i g n i f i c a n t parameters during the bonding process Surface preparation/cleanliness measurements most c r i t i c a l 3 Develop improved basic destructive t e s t s for measuring Jo i n t strength Honeycomb j o i n t s are p a r t i c u l a r l y d i f f i c u l t at present PROPOSED DEVELOPMENT PROGRAM OBJECTIVE BACKGROUND APPROACH 1 To l i s t and determine the r e l a t i v e importance of each factor (materials or process) a f f e c t i n g bond strength i n p r a c t i c a l bond configurations 2 To develop and evaluate NOT methods and techniques f o r q u a n t i t a t i v e l y measuring and c o n t r o l l i n g as many of these factors as possible w i t h primary e f f o r t directed at those of greatest significance Adhesive j o i n t s should be examined t o establish NOT controls which assure adequate strength rather than to develop NOT for measuring strength A t t e n t i o n should be given to each facet of adhesive j o i n i n g processes including a substrate and adhesive raw materials e j o i n t assembly b surface preparation f j o i n t curing c adhesive formulation g finished bond q u a l i t y d adhesive app l i c a t i o n processes This approach should be applied not only to the face sheet to core bonds but also to the node bonds of honeycomb i e a l l Joints i n an assembly Final v e r i f i c a t i o n of the u t i l i t y of developed or selected NOT contr o l tests should be accomplished by c o r r e l a t i o n with destructive tests to provide q u a n t i t a t i v e significance related to design strength properties 1 Develop or select destructive strength t e s t methods f o r use i n parametric studies of process variables 2 Fabricate c a r e f u l l y c o n t r o l l e d specimens involving only one process variable at a time r e l a t i v e to core node Joints and face sheet t o core Joints Q u a n t i t a t i v e l y characterize each variable 3 Determine the q u a n t i t a t i v e Influence of each variable on j o i n t strength by destructive test 4 Develop or optimize NOT techniques f o r measuring the most s i g n i f i c a n t variables and c a l i b r a t e against destructive t e s t data 5 Develop and/or specify NOT equipment applicable to production Joint configurations 6 Write NOT bond process c o n t r o l procedures and t r a i n q u a l i t y assurance personnel i n t h e i r use

179 PRIORITY RATING WORKSHEET CHART P R Q g R A M FACTORS P R 0 6 R A M P R O B A B I L I T Y O F S U C C E S S D LOW Z f t M O D E R A T e 5 • H I G H 8 C R I T I C A L P R O B L E M S TO B E S O L V E D D F C \ V / N O T TOO DIFFU7ULT Z • S O M E / D I F F I C U L T 3 V M A N Y / V E R Y D I F F I C U L T S P R O C E S S G R O W T H P O T E N T I A L D L I T T L E O R U N O e F I N A O L E O eecoamii^BLe POT-EMTIAL 4 A P P L I C A T I O N S O T H E R T M A N AIR F O R C E • NONE O • S O M E 4 X MANY e N E C E S S I T Y F O R A I R F O R C E F U N D I N O n LOW Hifix i«nust t tV /erH£« <awr C F F < « T it a IHeOESATB - S W C E F « l t r OTHOt ^OUCOES S ^ tiC£ms\¥e AIR F » A £ t F U M V M a UKCL<4 fL P a NEED FACTORS S Y S T E M S P R O B A B I L I T Y H i a H P e o B A B I T Y F A I R P R O B A B I L I T Y LOW P R O B A B I L I T Y C O M P O N E N T C R I T I C A L I T Y V E R Y H I C H H I A H F A I R L o w F R E f l U E N C y OF R E Q U I R E M E N T IN S Y S T E M MORE THAN 3 C O M P a N E N T S Z 3 C e M P D N E N r S S / N f l L E C e M P O H i E N T O e S I S N A L T E R N A T E S Ho A L T E R N A T e R M E S E E N ONE A L T E R N A T E S E V E B . A L A L T E R M A T e « M A T E R I A L S I M P L I C A T I O N N t w M A T e n i f l L pev£u>f« iCNT e e a o MATtClAL I M C M V E M C N T R C A D NO P B O S L E M F o R t s c e H CALCULATE PRIORITY. S T E P S T t P 8 e 37 RAW s c o o e s FOR EACH COMF0NCNT M T A B L E S AT t N D OF PANEL B t P o t T WITH IJAtO ToTBLS ENTEOCP IN AT AARP RAVJ seooes Te A NumRat Of erneH fftettfsr iNPiviouAi. - 38 Ci^M/i tfo3 • • • • • • • • • • • D C • • • • • • • • • • C I R C L E H I G H E S T A A R P R A W S C O R E n< IN EACH CTTHER S V e T E M C I R C L E N E X T H i a H K S T IP W I T H I N N U M 5 E R OF i^ P O I N T S o r T O P S C O R C n > 3 L O W > g S T E P 3 C l R C u e NUM&ER. O F S Y S T E M S L O W F R E O U e w C Y D I S T R I B U T t O N NUMSen. e s v s r c M S I 2. F A C T O R ri s H SORMMLC 0 I 2 R M O U t 0 1 z. \ 4 1 1 1 3 1 *f 1 z 1 f T O T A t B E L O W i PRIORITY

180 TITLE DEVELOPMENT OF TEST METHOD AND CROSS-COMPARISON OF TECHNIQUES CAPABLE OF QUANTITATIVELY MEASURING THE CLEANLINESS LEVELS OF SURFACES OF ALL SHAPES OF COMPONENTS VESSELS AND STRUCTURES CHART N O 703 REUITH) PRIORITY CH. MANUFACTURING REQUIREMENT High levels of surface cleanliness w i l l be required for adhesive bonding p l a t i n g vapor deposition and similar processes Testing of spacecraft for viable organisms w i l l also require s t e r i l e assembly conditions NOTE Recommendations of t h i s CAMR chart are Incorporated by reference In the following charts 417 503 504 505 507 508 511 512 515 523 524 AARP REFERENCES E Charts B Charts P i F V P S C h a r t s . APPLICABLE PROCESS One or more of the following INDIUM ADHESION TEST GONIOMETER (surface tension) SOLVENT PURITY TESTER (cleanliness tester) LIGHT SCATTERING PHOTOMETRY CLEANOMETER (C^^ evaporation rate) REPLICA TRANSFER METHOD Code STATE OF THE ART ASSESSMENT Most of the test methods cu r r e n t l y being used to assess surface cleanliness are q u a l i t a t i v e i n nature and very l i m i t e d or sp e c i f i c i n t h e i r applications Included In t h i s group are such methods as v i s u a l inspection with natural or u l t r a v i o l e t l i g h t (with or without enhancement by o p t i c a l magnification) water break test and the water fog tests Other methods c u r r e n t l y i n use are q u i t e i n d i r e c t and non s p e c i f i c i n i n d i c a t i n g the exact loc a t i o n of contamination for example flushing surfaces with solvents and c o l l e c t i n g p a r t i c u l a t e contamination on f i l t e r s for microscopic examination P a r a l l e l w i t h the development of more e f f e c t i v e clean rooms i s the need f o r more sophisticated cleanliness tests capable of i d e n t i f y i n g locations and amounts of contamination i n s i t u While some progress i n the SOA can be projected as indicated below a coordinated study of newer methods with subsequent cross-evaluations of t h e i r effectiveness Is d e f i n i t e l y needed Indium Adhesion Test i s a method of q u a n t i t a t i v e l y measuring the adhesive force between a t i p of v i r g i n indium metal and the actual surface of the part being examined This adhesive force i s compared with the adhesive force of the indium t i p on a sheet of fre s h l y cleaved mica Any contamination present on the part (1 e a f i n g e r p r i n t ) reduces the adhesive force required to p u l l the indium t i p from the surface ASTM i s now studying t h i s new test method as a standard test for materials used for electronic componentry Solvent P u r i t y Test provides a ppm reading of non v o l a t i l e residues (NVR) contained i n various solvents (water alcohol Freon etc ) Samples of the solvent are nebulized and passed through a drying tube to a l i g h t scattering photometer Droplets containing contamination such as hydrocarbons solder f l u x and skin o i l have a higher vapor pressure than clean solvent and carry over to the photometer for counting An i n d i r e c t Index of cleanliness of surfaces can be obtained by sampling the solvent used to clean the surface This test method Is also being considered by ASTM i n Committee F 1 Cleanometer provides an in d i c a t i o n of surface cleanliness by measuring the evaporation rate of monolayers of Carbon 14 ( i n s o l u t i o n w i t h solvent) deposited on the surface of the part Continued on next page ALTERNATE PROCESSES NONE Code

181 STATE OF-THE-ART ASSESSMENT continued CHART NO 703 being inspected This evaporation rate is d i r e c t l y correlated w i t h surface contamination levels and a Geiger Mueller r a d i a t i o n counter i s used to measure the Carbon 14 evaporation rate Goniometer test provides a qu a n t i t a t i v e measurement of surface tension of droplets deposited on the surface of Interest The instrument reads the contact angle of the droplet w i t h the surface and t h i s variable can be d i r e c t l y related to surface cleanliness levels Light scattering Photometry using a vacuum probe c o l l e c t o r for the surface contaminants provides a qu a n t i t a t i v e method to both size and count pa r t i c u l a t e s dislodged from the surface This same technique i s now widely used to v e r i f y clean room cleanliness as required by Federal Standard 209A Replica Transfer Technique This a n a l y t i c a l t e s t Involves the c o l l e c t i o n of trace amounts of contamination from surfaces such as contact points of relays by t r a n s f e r r i n g the contaminant to a t h i n p l a s t i c sheet Electron mlcroprobes and/or in f r a r e d spectrophotometry i s then used to i d e n t i f y the composition of the contamination The above SOA assessments do not cover a l l the l a t e s t methods f o r estimating cleanliness but do r e f l e c t the wide number of approaches being specified and used on aerospace hardware i n 1967 A cross-comparison test of these new methods i s complicated by the lack of a generally agreed on d e f i n i t i o n of cleanliness and the lack of an absolute standard for c a l i b r a t i o n purposes CRITICAL PROBLEMS 1 Screening the available q u a n t i t a t i v e methods for t h e i r a p p l i c a b i l i t y to the wide v a r i e t y of aerospace materials surface fini s h e s and contours 2 Developing and defining a workable standardization method for the q u a n t i t a t i v e index of cleanliness 3 Design and development of t o o l i n g to enable the te s t method to be used for i n s i t u measurements of cleanliness levels PROPOSED DEVELOPMENT PROGRAM OBJECTIVE BACKGROUND A P P R O A C H To evaluate a l l advanced test methods for assessing surface cleanliness i n a qua n t i t a t i v e comparison study Attempt to define l i m i t a t i o n s and c a p a b i l i t i e s of each method and a common basis f o r c o r r e l a t i n g indexes of cleanliness derived from such measurements The cleanliness t e s t evaluation program should be a closely coordinated e f f o r t involving comparison testing of the same test objects by a l l advanced methods Of necessity t h i s e f f o r t could best be accomplished at one laboratory l o c a t i o n since contamination levels are t r a n s i t o r y i n nature Erroneous test r e s u l t s could be anticipated i f long periods of time occurred between measurements 1 Select one of more of the process cleanliness problems represented i n the referenced charts and prepare surface samples containing graded degrees of contam I n a t i o n of various types ( p a r t i c u l a t e s surface f i l m s gaseous layers) Submit these to q u a n t i t a t i v e tests by the available advanced test methods Some of the test samples should contain viable organisms such as non pathogenic bacteria and dry spores 2 Round-robin tests would be performed for r e p e a t a b i l i t y and for cross c o r r e l a t i o n between methods areas of application 3 Each test method would be evaluated f o r r e l a t i v e merits and t h e i r advantages and l i m i t a t i o n s 4 The evaluation should have as one of i t s objectives the determination of c a l i b r a t i o n technique(s) and a common d e f i n i t i o n of cleanliness of surfaces a common

182 PRIORITY RATING WORKSHEET CHART P R O f i R A M PACTOttS. P R O G R A M P R O B A B I L I T Y O F S U C C E S S • LOW 2 • MODE R A T S a > ( HIQH 8 C R I T I C A L P R O B L E M S TO B E S O L V E D P F E W / N O T TOO DIFFICULT Z • S O M E / D I F F I C U L T a X M A N Y / V E R Y D I F F I C U L T 8 P R O C E S S Q R O W T H P O T E N T I A L a L I T T L E OB. U N D E F I N A I ^ L E O X R e e 0 6 N l t A B L E P e r E N T I A L 4 A P P L I C A T I O N S OTHER. T H A N AIR P O R C E • NONE O 3i S O M E 4 n MANY e N E C E S S I T Y F O R A I R fOIKX. F U N D J N O n lew HisM musiti/enicti Oarr CFFocr 4 yi vtmim - SOME EFoiLr erHcs «Meoe9 e • e x f u i s i y f AiR f'tiCi. F U M V M& U K C L V I X NEED FACTORS S Y S T E M S P R O B A B I L I T Y HIGH P R O B A e i i r v F A I R P R O B A B I L I T Y LOW P R O B A B I L I T Y C O M P O N E N T C R I T l C A L I T Y V E R V H I C H H I A H F A I R L O W F R E O U E N C Y OF R E Q U I R E M E N T IN S Y S T E M MORE THAN 3 C O M P a N E M T S 2 3 C O M P e N E N T S S I N G L E C e i M P O N E N T O e S l S N A L T E R M A T E S No A L r E R N A T E ( B a e s E E N ONE A L T E R N A T E S E V E H A L A L T E R N A T E S M A T E R I A L S I M P L I C A T I O N NEW MATEIZ.IAL PEyEUtPMCMT R E a 0 MATERIAL I M P I U V E M E I l I T R E S D NO P R O B L E M f o R E S E e N CALCULATE PRIORITY. 8 9 S2. RAW s c o p e s FOR E A C H RCFCfteMOP COMPDNENT IN T A B L E S A T E N D Of P A N E L UJITH P A W T O T A L S E N T E R C P IN <3UMUAeV m AARP RA>M SCORES • • • • • • • • • • CAtAH ptOGHms AV MiCATtp Bv Kefeeettees OoMPoHtttT KAtu SceAe • • • • • • • • • • • • • • • • • • • • • • • • • • • ! • • • ! • • • • • • • • • • • • • S T E P I C I R C L E H I G H E S T A A R P R A W S C O R E n s S T E P Z IN E A C H O T H E R S V S T E M C I R C L E N E X T U i a M E S T I F W I T H I N 4 P O I N T S O P T O P S C O R E n N U M S E R OF S y s T E i i t s H l A H L O W ^ ^ 2^ S T E P 3 C I R C L E P R E O O E N C Y D I S T R I B U T I O N F A C T O R NUMaen. OP s y s r c M t H u a H I 2. 3 at Moee S C O R E BELOWi N U M S E R O F S Y S T E M S t o w 0 I 2 A M a u 1 0 1 a \ 4 1 1 1 3 1 £ 1 *¥ TOTAL PRIORITY

183 TITLE IHSPECTION AND EVALUATION OF DIFFUSION BOND STRENGTH AND FLAWS CHART PRIORITY N O I RELATED CAMR CHARTS See l/i>Te B£LeW MANUFACTURING REQUIREMENT Evaluation of d i f f u s i o n bond strength and q u a l i t y of bond NOTE Recommendations of t h i s CAMR chart are incorporated by reference i n the following charts 407 409 410 411 431 434 436 437 438 AARP REFERENCES B Charts . P A F \ / P < ; r h n r t . APPLICABLE PROCESS One or more of the following (1) ULTRASONIC/SONIC DAA DAC (2) INFRA RED (thermal e x c i t a t i o n ) ECB (3) DIELECTRIC TECHNIQUES CDD (4) X-RAY BACKSCATTER BBB (5) ELECTRIC CURRENT INJECTION Code STATE OF THE ART ASSESSMENT Present NET techniques can sometimes determine the presence of unbonds i n d i f f u s i o n bonded materials but they cannot evaluate bond strength I t i s not expected that SOA techniques w i l l be adequate by 1970 to q u a n t i t a t i v e l y define bond strength i n d i f f u s i o n bonded components At present there exists no known nondestructive material-energy i n t e r a c t i o n which would enable one to estimate j o i n t strength Diffusion bond q u a l i t y i s related to the presence of an actual metal l u r g i c a l bond as opposed to mere intimate faying surface contact There e x i s t c u r r e n t l y three methods of achieving a d i f f u s i o n bond the f i r s t i s a s e l f bond the second an intermediate f o i l (a pure metal which i s the base of the a l l o y being joined and t h i r d an intermediate f o i l ) which i s d i f f e r e n t than the a l l o y being bonded Most of the d i f f u s i o n bonds to t h i s date have been concerned with bonds of the second and t h i r d types Requirements of the intermediate f o i l type include adequate strength at temperature s u b s t i t u t i o n a l d l f f u s i o n a l s t a b i l i t y and no sink action for I n t e r s t l t i a l s Bond strength is not only related to actual metallurgical bonding but the type of metal l u r g i c a l bond 1 e formation of e m b r i t t l i n g compounds such as carbides void formation from an Imbalance i n s u b s t i t u t i o n a l d i f f u s i o n rates etc I t would appear impractical to set as a goal techniques which would a r b i t r a r i l y set q u a n t i t a t i v e values on d i f f u s i o n bonds The most p r a c t i c a l technique i s one i n which defects can be defined q u a n t i t a t i v e l y as we l l as q u a l i t a t i v e l y and these defects related to bond l i f e There are c r i t i c a l aspects to the d i f f u s i o n bonding process which must be closely con t r o l l o d to achieve optimum bond q u a l i t y These are 1 Distinguishing between an actual meta l l u r g i c a l bond and mere Intimate faying surface contact Simple configurations can be inspected by present techniques however readout i s d i f f i c u l t and complicated configurations cannot be evaluated and w i l l not be SOA i n 1970 2 The actual bond strength of the components comprising the bond cannot be defined q u a n t i t a t i v e l y by NDT techniques at the end-item lev e l In-process NDI techniques w i l l have to be developed to Insure proper selection of elements f o r the bonding process proper surface preparation adequate pressure and temperature cycles and proper component configuration End Item Inspection techniques w i l l have to be optimized In order to re a d i l y i d e n t i f y material and processing flaws Continued on next page ALTERNATE PROCESSES NONE Code

184 STATE-OF THE ART ASSESSMENT continued CHART 3 An important part of the development of i n process NOT techniques w i l l be the development of destructive methods of tes t i n g Standards must be set when developing i n process inspection techniques consequently destructive tests r e s u l t s are the most p r a c t i c a l way to reali z e q u a n t i t a t i v e goals New and Improved methods of tes t i n g become essential for evaluating large and complicated d i f f u s i o n bonded configurations CRITICAL PROBLEMS 1 Evaluate and establish order of importance of material variables which e f f e c t d i f f u s i o n bond strength and component l i f e 2 I n process NOT technique must be developed i n order to evaluate the q u a l i t y of the d i f f u s i o n bond The c r i t i c a l factors are unbond detection and the detection of surface contaminants such as oxides etc 3 Develop and coordinate destructive tests for q u a n t i t a t i v e l y defining bond strengths Improve destructive methods of t e s t i n g d i f f u s i o n bonds of complicated structures PROPOSED DEVELOPMENT PROGRAM OBJECTIVE To evaluate the many material variables which a f f e c t d i f f u s i o n bond strength i n order to separate the relevant from the i r r e l e v a n t data To develop i n process NOT techniques which w i l l enable the production of bonds with set q u a n t i t a t i v e strength standards and q u a l i t y BACKGROUND Quantitative d e f i n i t i o n of bond strength can only be achieved by s t r i c t in process co n t r o l of the s i g n i f i c a n t variables which Influence bond f a i l u r e Most important are selection of metals/ceramics which w i l l be compatible with one another i n the bonded configuration proper application of pressure and temperature to avoid embrittlement and void formation adequate specimen configurations (avoid high stress configurations) high bond q u a l i t y i n the finished product Destructive tests must be upgraded and developed so as to assist i n evaluating bond strength by i n process NOT techniques These specimens w i l l serve as standards for future work associated w i t h establishing stress f a i l u r e levels i n s p e c i f i c environments for d i f f u s i o n bonded materials APPROACH 1 Manufacture controlled specimens where degrees of the various processing variables are established one variable taken at a time 2 Develop destructive tests to establish relevant variables which are most important i n determining bond strength and q u a l i t y 3 Determine the e f f e c t of each material and processing variable on bond strength/ q u a l i t y by destructive test methods 4 Define q u a n t i t a t i v e l i m i t s for each variable and set standards which must be met through i n process NOT techniques 5 Develop and optimize in-process NOT techniques to establish q u a n t i t a t i v e l i m i t s on d i f f u s i o n bonded materials 6 Optimize NOT techniques and equipment as to s e n s i t i v i t y r e s o l u t i o n cost etc 7 Prepare formal w r i t t e n procedure to be followed by NOT personnel

185 PRIORITY RATING WORKSHEET C H A R T PR<?qpAt^ FACT9RS P R 0 6 R A M P B O B A B I L I T V O F S U C C E S S • LOW Z > l MODERATe 5 • H i e H e C R I T I C A L PROBtEMS TO B E S O L V E D • F E W / N O T TOO PIFFltfOLT Z • 3 0 M e / 0 1 F F ( C U I . T ff > 1 M A N Y / V E R Y D I F P I C U t T S P R O C e S S G R O W T H P O T E N T I A L • L I T T L E OR U N D E F I N A Q L E O X iZeiMfiNIUtBLE P o r e M T I A L 4- A P P L I C A T I O N S O T H E R T X A N AIR F O R C E Q NONE O n S O M E 4 t r MANY 0 NECESSITY FOR AIR FORCe FUNOIMO a L w HisH mtusiay / ' i i r rHta <io«r c F F M r * • IXraeSATt - SOME EFCMLT « r H « 'SMCCeS e ) C wmsij/e A I R F»tt£k F U M P M A U K E L W i i . Pa N E E D F A C T O R S S Y S T E M S P R O B A B I L I T Y HIQH P O O B A B I T Y F A I R P R O B A B I L C T V LOW P R O B A B I L I T Y C O M P O N E N T C R I T I C A L I T Y V E R Y H I t H H I A H F A I R . L e w F R E Q U E N C Y OF R E Q U I R E M E N T IN S Y S T E M MOBe THAN 3 c o M P e n e u T s 2. 3 c e M F e U E M r s S I N G L E C O M P O N E N T O e S l S N A L T E R N A T E S NO A L T E B N A T E R w E S E E N ONE A U T E I l N A T e S E V E R A L A L T E R M A T C C M A T E R I A L S I M P L I C A T I O N New M A T E R I A L PEVELOPMEMT R t U V MATERIAL I M P f W V E M E W T R E a P NO P R O O L E M F o R C S E E i a C A L C U L A T E P R I O R I T Y . STSP S T E P S T E P 3 e s -37 R A W S C O R E S F O R E A C H R E F C E E l M e COM WM C U T M T A B l U AT t N B O F P A U E t I J t P O t T WITH l lAK) T O T A L S E N T E R C P IM ^UMMACV w eisMT A A R P »2A^ SCOMS ] • • • • ] • • • • THi9 fiaeiSR/>» Afifiues To CAMA pitceeMAs AS L _ i n i • • I • • • • • • • • I CIRCLE HIGHEST A A R P RAW S C O R E n< IN EACH cn'HER S V S T 6 M C I R C L E NEXT H i a U C S T IF WITHIN N U M B E R OF 4 POJNTS O F TOP S C O R E >3 LOW C I R C L E FREQUENCY DISTRIBUTION FACTOR SCORE B&LOWi N U M a e R O F S Y S T E M S L O W 0 I 2 B Meu 1 0 t a 1 4 1 1 1 3 1 f 1 z 1 f TOTAL PRIORITY

-1S6 TITLE INSPECTION AND EVALUATION OP DIFFUSION COATINGS ON REFRACTORY AND SUFERALLOY SUBSTRATES CHART PRIORITY CH L ITS. , MANUFACTURING REQUIREMENT Failure mechanlBO studies and development of nondestructive measurement or p r e d i c t i o n techniques for r e l i a b i l i t y c o n t r o l of coating/substrate material variables NOT are required for a p p l i c a t i o n at three phases (a) process control (b) end-Item hardware Inspection (c) In service l i f e p r e d i c t i o n Substrate materials are columblum molybdenum tantalum and tungsten base alloys or n i c k e l and cobalt base superalloys and dispersion strengthened n i c k e l Substrate thicknesses vary from 0 001 0 003 Inch f o i l to 2 0 Inch thickness with surface areas up to 100 f t ^ some parts having b l i n d holes as small as 0 030 inch diameter x 6 Inches long which must be coated and Inspected Honeycomb core and other complex sandwich constructions are include^ as w e l l as contoured sheets tubes and forged shapes Coatings are t h l n ^ ^ 0 002 Inch) s l l i c i d e s or aluminides deposited by f l u i d i z e d bed vapor deposition pack cementation vapor deposition s l i p pack vapor deposition and melting s l u r r y techniques NOTE Recommendations of t h i s CAMR chart are incorporated by reference i n the following charts 501 515 521 528 532 53A AARP REFERENCES F rknr t i B Chart . PSFVPS Chart . APPLICABLE PROCESS Cede STATE OF THE ART ASSESSMENT A F M L TR66 2 2 1 (Reference I ) discusses recently acquired understanding of the inspection problem and progress toward i t s s o l u t i o n The problem has been solved f o r c e r t a i n s p e c i f i c coating/substrate combinations i n f l a t or gently contoured surfaces A c a p a b i l i t y for p r e d i c t i n g f a i l u r e based on substrate and coated end Item inspection has been developed for the W 3 coating on TZM a l l o y and for Or T i Si coating on Cb 752 a l l o y applied by pack cementation vapor deposition The R S 1 2 A s l u r r y coating on B - 6 6 a l l o y and R S 1 2 E s l u r r y coating on tantalum a l l o y are c u r r e n t l y under study L i f e p r e d i c t i o n c a p a b i l i t y based on periodic i n service NOT has also been developed Each coating/substrate system should be studied I n d i v i d u a l l y since I t can be expected to have unique f a i l u r e mechanisms and l i f e l i m i t i n g material variables Failure mechanisms have been found very sensitive to the l i f e (destructive environmental) test technique For example previous reports of a majority of edge f a i l u r e s (70X Incidence) a t t r i b u t e d to specimen edge contour were shown to be caused by chemical I n t e r a c t i o n between the coating and s l o t t e d Vycor specimen holders i n the furnace test Redesign of specimen holders p r a c t i c a l l y eliminated edge f a i l u r e s for the Cb 752/Cr T i SI and TAMAf 3 systems Static furnace environmental tests In p r i o r common use are not regarded as an adequate simulation of the pressure gas v e l o c i t y thermal cycling rates and other environmental factors encountered i n service Good service simulation can Introduce new f a i l u r e modes (as compared w i t h poor simulation) which require d i f f e r e n t types of NDT i f f a i l u r e / l i f e p r e d i c t i o n c a p a b i l i t y is to be developed For the coatings/substrates studied i n Reference 1 backscatter radiography (BBS) and l i q u i d penetrants (ABB) detected chromium poor spots i n the Or T i Si coating which led to Continued on next page ALTERNATE PROCESSES N O N E Code

CHART -187 STATE-OF THE ART ASSESSMENT continued pinhole burn through f a i l u r e s I n i t i a l coating thickness and changes In thickness with environmental exposure time were monitored by eddy current (CBA) techniques t o provide a l i f e p r e d i c t i o n c a p a b i l i t y both before and at inte r v a l s of exposure (Cb 752/Cr T i Si and TZM/W 3 systems) Chemical v a r i a b i l i t y of the chromium-poor spots was also detected w i t h a thermoelectric technique (EAA) Since thickness changes are accompanied by compositional changes for the RS12A s l u r r y (dip application) coating the thermoelectric technique detected t h i n coating at edges of dip coated specimens This edge thinning correlated with edge f a i l u r e for the RS12A specimens TZM delaminatlon was detected at specimen edges by penetrant (ABB) techniques Although many of the coating/substrate systems have not been subjected to the type of study described above they are regarded as equally susceptible to soluti o n by the same general approach Adaptation of proven NDT techniques to inspection of small cooling passages or complex geometries w i l l require ingenuity i n equipment design and technique development Since brazed or other type j o i n t s may show d i f f e r e n t f a i l u r e mechanisms than the substrate metal i t s e l f special a t t e n t i o n should be given to t h i s recognized coating f a i l u r e problem Unique NOT may be required for coated Joint evaluation Reference 1 USAF Contract AF33(615) 2855 and 3877 Development of Nondestructive Methods for Evaluating D i f f u s i o n Formed Coatings on Metall i c Substrates AFML TR 66 221 November 1966 CRITICAL PROBLEMS Ingenious development of probes and test techniques (procedures) applicable to small b l i n d holes and to complex shapes such as honeycomb core a f t e r coating For greatest economy and success process development NDT development should be concurrent with coating PROPOSED DEVELOPMENT PROGRAM OBJECTIVE 1 To perform f a i l u r e mechanism studies aimed at i d e n t i f y i n g each f a i l u r e c o n t r o l l i n g material variable i n base metal d i f f u s i o n zone and coating 2 Develop/select NDT methods and techniques for q u a n t i t a t i v e l y measuring and c o n t r o l l i n g these material variables 3 Consider a p p l i c a b i l i t y (Including equipment design) for coating process con t r o l end Item Inspection and i n service l i f e p r e d i c t i o n and monitoring APPROACH A systematic i t e r a t i v e approach concurrent w i t h coating process development should be taken to define f a i l u r e t r i g g e r i n g material variables and NDT capable of evaluating them Each coating/substrate should be studied independently to seek unique variables under w e l l simulated service environmental tests A l l applicable NDT should be used to screen uncoated specimens (simple geometry) for substrate v a r i a b i l i t y These specimens should again be screened by NDT af t e r coating to isolate and detect coating and d i f f u s i o n zone variables Coated samples containing examples of each variable are then submitted to environmental exposure p e r i o d i c a l l y Continued on next page

188 PROPOSED DEVELOPhENT PROGRAM continued CHART NO 7 ^ 3 checking t h e i r progress towards f a i l u r e by use of NDT methods which are e f f e c t i v e In detecting v a r i a b i l i t y Those NDT proven s i g n i f i c a n t by t h e i r r e l a t i o n s h i p with observed f a i l u r e and f a i l u r e c o n t r o l l i n g variables can be optimized for s e n s i t i v i t y and re s o l u t i o n and q u a n t i t a t i v e l y calibrated against destructive analysis of variables to provide a pred i c t i o n c a p a b i l i t y The above approach suggests coating process Improvements aimed at Improving system r e l i a b i l i t y NOT should be applied to monitor c r i t i c a l process steps when possible A d d i t i o n a l l y c o r r e l a t i o n of periodic NOT wit h coating performance during environmental test to f a i l u r e should lead to i n service NOT c a p a b i l i t y for l i f e remaining evaluation Following the development of NOT methods for simple geometry specimens v e r l f i c a t l o n on prototype hardware i n t y p i c a l shapes should be accomplished Equipment and technique innovations required to cope wi t h shape size and thickness l i m l t a tions can be developed Expected problem areas Include small bl i n d coated holes coated honeycomb c e l l s and compound curved shapes such as vanes blades for gas turbine engines etc Cal i b r a t i o n of spec i f i c NOT equipment for each hardware coating system problem must be followed by preparation of spec i f i c w r i t t e n procedures for implementation and t r a i n i n g of using personnel PROGRAM SUMMARY 1 Screen simple coupons (2 x 2 ) of uncoated substrate for variables (delamina t l o n thickness v a r i a t i o n foreign Inclusions conductivity/chemistry segregation etc ) using a l l applicable NOT 2 Coat specimens and rescreen for coating and d i f f u s i o n zone variables using a l l applicable NOT 3 Submit coupons to good simulation environmental exposure screen c y c l i c a l l y using NOT found useful i n steps 1 and 2 4 I d e n t i f y and define nature of f a i l u r e producing variables ( f a i l u r e analysis) 5 Select NOT proven meaningful i n steps 1 through 4 6 Correlate environmental destructive and NOT data to seek q u a n t i t a t i v e c a l i b r a t i o n for meaningful NOT 7 Perform applications analysis to determine which NOT are most useful for a I n process c o n t r o l of coatings b End item inspection c In-service l i f e p r e d i c t i o n 8 Devise novel equipment for complex geometrical shapes and v e r i f y on prototype hardware 9 Prepare detailed procedures for each useful NOT equipment and technique and t r a i n personnel i n t h e i r use

189 PRIORITY RATING WORKSHEET CHART P B O f i R A M FACTORS P R 0 6 R A M P C O B A B I L I T Y O F S U C C E S S D uow • M O D E R A T E C R I T I C A L P R O B L E M S TO B E S O L V E D a F K \ ^ / N O T T O O DierXCULT • S O M E / D I F F I C U L T K M A N Y / V E R V P I F P I C U L T P R O C E S S G R O W T H P O T E N T I A L a LITTLE OK UNDEFINABLE X R e ^ N l l A B L E p o f E M T I A L A P P L I C A T I O N S O T H E R T H A N AIR P O R C E • NONE X S O M E • MANV N E C E S S I T Y F O R A I R F O R C t F U N D I N Q • l a w HlfiH IMIUSTIIV/'CTNCA GMT CFFVCT <̂ • MooKATE - s m e E F m t r emce. ^eiiea€9 e U t ^ U l s i V E AiK F « l t £ t FUMV Ma U K C L f It. 2. s 8 z S S O 4- 4 3 Pa NEED FACTORS S Y S T E M S P R O B A B I L I T Y H i a H P e o B A B I I T Y 12 F A I R P R O B A B i L i r r S LOW P R O B A B I L I T Y 4 C O M P O N E N T C R I T l C A L l T Y V E R Y H I C H H H I A H 9 F A l A & L o w 3 F R E Q U E N C Y OF R E a u i R E M E N T I M S Y S T E M Mene T H A N 3 C O M P S M E U T S 3 a 3 c o M P o M E u r s 2 S I N G L E C O M P O N E N T I O e S I S N A L T E R N A T E S No A L T E R N A T e ( t e E e E E N 4 ONE A L T E B N A T E 6 S E V E I L A L A L T E R N A T E * 3 M A T E R I A L S I M P L I C A T I O N NEW M A T E I ^ I f l L P e v E L O f M E N T S C O O £ MATERIAL I M P H O V E M C W T R E S D 4 NO P R O S L E M F o f t E S e e M O 0 RAW s c o « e s F O R EACM R E F c e e M n » Co»APONl»fT M T A B L E S AT E N D o r PANEL T2EP«tT WITH l iAW TOTALS ENTEREP M ^UMMACV AT tZlSMT A A R P RANM scows • • • • • THIS m^/lAM APfittes To ^ L _ J L J ] [ • • • • • • • • • • CALCULATE PRIORITY STEP I S T E P 2 3 f CIRCLE HISHCST A A R P RAW S C O R E IN EACH OTHER S Y S T E M C I R C L E NEXT H I G H E S T SCORE IF WITHIN N U M B E R OF POIMTS S V S T E I W S HIAH o r T O P S C O R E >3 u w STEP 3 C i R C t e FREQUENCY DISTRIBUHON FACTOR MUMsen. Of s y s r C M * rtiait I 2. 3 SB BE.LOWt N U M B E R O F S Y S T E M S L O W 2 BMOtt 1 0 1 2. 1 1 1 1 3 1 £ 1 *f TOTAL PRIORITY

APPENDIX A SYSTEMS CODE