GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 1

GLAST Large Area Telescope:GLAST Large Area Telescope:

Mechanical Systems Peer Review27 March 2003Section 4.7 Fabrication & Verification

Radiator, XLAT, Heatpipes

Brenda CostanzoLockheed MartinSystem Engineer

brenda.costanzo@lmco.com

Gamma-ray Large Gamma-ray Large Area Space Area Space TelescopeTelescope

GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 2

Radiator Fabrication (1 of 2)Radiator Fabrication (1 of 2)

ObtainFacesheetMaterial

Shear N/C Machine InspectClean, Etch

& Prime

Bond PipesTo OB

Facesheet

Inspect Thermal Bond

Visual

Fit CheckCore

MachineTransferDatums

Assemble Panel and

Bond

Verify CureProfile

ProcessSamplesTo Lab

CMM InspectGeometry

InspectHoles w/

Pins

Prep and Install Inserts

& Spools

InspectInserts &Spools

Bond IB DoublersRT Cure

Bond OBDoublersAC Cure

Verify CureProfile

InspectDoublers

Bond TopEdge Closure

Obtain Remaining Flight Materials

Inspect Verify Flight

Materials

Log Flight Materials

A

Inspection/Test

Manufacturing

Purchasing

GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 3

Radiator Fabrication (2 of 2)Radiator Fabrication (2 of 2)

Notes1) All panel moves require: inspection documentation of panel for damage; packaging for

transport; and flight approved move procedures. 2) No outside storage.3) Qualified flight transportation personnel and equipment.

Apply EdgeClosure Tape

InspectBushings

InstallReservoirBushings

StructuralTesting

ApplyThermalBlanket

Apply BlanketVelcro

Final CosmeticDamage

Map

ThermalTesting

InspectBushings

Fit CheckReservoirBushings

InspectReservoirSupports

BondReservoirSupports

MachineBushingsA

GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 4

M & P Plan, EEE PartsM & P Plan, EEE Parts

• M & P Plan submitted to SLAC (GLS00018-2, dated 1 Feb 2003)• EEE Parts

– Heaters: Minco Kapton Foil Heaters per GSFC S-311-P-079– Thermistors: YSI Thermistors per GSFC S-311-P-18– RTDs: Rosemount PRT per GSFC S-311– Solid State Thermostats: Micropac 52372”O”

• Submitted to SLAC for approval Nov 2002

GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 5

Overall Test PhilosophyOverall Test Philosophy

• Tests are broken into three categories

– In process

– Assembly

– Joint assembly

• Benchmark tests will be performed to assess any changes due to environmental testing

– IR Heat pipe signature

– Low level sine vibration

• Test plan is document GLS0002-03

• All testing will have procedures written prior to commencement

• Inspection occurs throughout the testing at points specified in the procedure

• Flash reports will be written within 3 working days of test completion

• Full reports will be written within 30 days of test completion or by pre-ship review, whichever is earlier

GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 6

Overall Test FlowOverall Test Flow

Heat Pipe In-Process

Tests

X-LAT Assy Acceptance

Tests

Integrated Radiator & X-

LAT Assy Thermal Test

Delivery In-Place to SLAC

Heat Pipe Acceptance

Tests

X-LAT In-Process

Tests

VCHPs Only

X-LAT CCHPs Only

Radiator Acceptance

Tests

Radiator In-Process

Tests

TCS Thermal Test

X-LAT Plate Qualification

Tests

Delivery to SLAC

GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 7

Heat Pipe In-Process and Acceptance Heat Pipe In-Process and Acceptance TestingTesting

• In process testing– Verification of material certifications– Inspection of physical dimensions– Verification that LM procedures are followed

• Acceptance testing

CCHP

VCHP

Integrate into Next Higher Assembly

Heat Transport Test

Non-Condensable Gas Test

Proof Pressure Test

HP Assy Proof Pressure Test

Heat Transport Test

Reservoir Proof Pressure Test

Gas Charge Test

GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 8

Radiator and X-LAT Panel In-Process Radiator and X-LAT Panel In-Process TestingTesting

• Radiator and X-LAT Panels– Verification of material certifications– Inspection of physical dimensions– Verification the LM procedures are followed

• Radiator Panels

• X-LAT Panels– Visual inspection of pipe/panel bonds

Flatwise Tensile Test

Visual Inspection of Pipe/Panel Bonds

Lap Shear Test

Bulk Load Test

Insert Pull Test

Radiator Assembly Acceptance

Testing

GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 9

Radiator Mechanical Acceptance TestsRadiator Mechanical Acceptance Tests

• Test configuration– Each radiator panel assembly tested separately

• Test flowVibration Testing

Pre-Vibration IR

Signature

Low Level Sine

Survey

Sine Vibration

Limit Load Test

Acoustic Vibration

Post-Vibration IR

Signature

Low Level Sine

Survey

Mass Properties

X-LAT/Radiator Assy Thermal Testing

Radiated Emissions

Conducted Emissions

Radiated Susceptibility

Conducted Susceptibility

EMI Testing

GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 10

X-LAT Plate Qualification TestingX-LAT Plate Qualification Testing

• Test configuration– One protoqual X-LAT plate assembly

• Test flow

Mass Properties

Deliver to SLAC

Vibration Testing

Low Level Sine Survey

Sine Vibration (TBR)

Static Load Test

Acoustic Vibration (TBR)

Low Level Sine Survey

Random Vibration (TBR)

Thermal Cycle 2

Hot Thermal Balance

Cold Thermal Balance

Thermal Cycle 4

Cold Thermal

Cycle

Hot Thermal Balance

Thermal Cycle 1 Thermal Cycle 3

Thermal Testing

GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 11

X-LAT Assy Mechanical Acceptance TestsX-LAT Assy Mechanical Acceptance Tests

• Test configuration– X-LAT Assy (two X-LAT panels and one mid-plate)

• Test flow

Pre-Vibration IR Signature

Low Level Sine Survey

Vibration Testing

Sine Vibration (TBR)

Static Load Test

Acoustic Vibration (TBR)

Post-Vibration IR Signature

Low Level Sine Survey

Mass Properties

X-LAT/Radiator Assy Thermal Testing

Random Vibration (TBR)

GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 12

X-LAT/Radiator Assy Thermal TestingX-LAT/Radiator Assy Thermal Testing

• Combining the X-LAT and Radiator Assy thermal testing– Cost savings (1 test versus 2 tests)– Minimizes STE– Tests X-LAT pipe to Radiator pipe thermal joint

• Hardware configuration– X-LAT Assy– Radiator Assy– Heater plate to introduce heat into the system– Lab electronics to control VCHPs

• Hardware orientation– +X side up– Level within 0.10”

GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 13

Test OrientationTest Orientation

+Z

+Y

Gravity isInto the

Page

Cold Wall

MLI Blanket

Flight Radiators

(2)

+X

+Y

Gravity isDown

Flight X-LAT Assy

Cold Wall

Flight Radiators (2)

MLI Blanket

NO SCALE

Flight X-LATAssy

Heater Plate

GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 14

X-LAT/Radiator Assy Thermal Test FlowX-LAT/Radiator Assy Thermal Test Flow

Pre-Cycling Functional Test

Pump Down Chamber

Thermal Cycle 1

Bakeout / Hot Survival

Hot Temperature Turn-On

Cold Survival

Cold Temperature Turn-On

Thermal Cycle 3

Cold Balance Point

Thermal Cycle 2

Hot Balance Point

Thermal Cycle 4

Hot Balance Point

Cold Portion of Thermal Cycle

Post-Cycling Functional Test

Delivery In-Place to SLAC

TCS Thermal Testing

IR Signature

GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 15

TCS Thermal TestingTCS Thermal Testing

• Hardware Configuration– Radiator Assy– X-LAT Assy– Downspout heat pipes (TBR)– LAT mass simulator

• Test Objective– Verify VCHP reservoir heater operational algorithm

• Test Flow

Bakeout / Hot Survival

Hot Temperature Turn-On

Pre-Cycling Functional Test

Pump Down Chamber

Cold Balance Point

Hot Balance Point

Post-Cycling Functional Test

Cold Survival

Cold Temperature Turn-On

Hot Balance Point

Cold Temperature Turn-Off

Repressurize Chamber

GLAST LAT Project DOE/NASA Mechanical Systems Peer Review, March 27, 2003

Section 4.7 - Mechanical Systems Radiator and X-LAT Assy 16

Further WorkFurther Work

• Determine appropriate structural testing for Radiator and X-LAT Assemblies

• Determine X-LAT Assy and Radiator Assy configuration for thermal testing (together or separate)– Design STE (Special Test Equipment) and GSE (Ground

Support Equipment)• Determine if TCS thermal test objective can be achieved during

XLAT / Radiator Assy thermal test– Determine what additional hardware will be available– If performing separate TCS test, design LAT mass

simulator• Write test procedures