Document No. QTR-72-1039RevisionRelease Date r '

NASA CR-

QUALIFICATION TEST REPORT

BUMP PROTECTION HAT

(SUBASSEMBLY OF

TO20/M509 HEAD PROTECTIVE ASSEMBLY)

CONTRACT NAS 9-11905

TYPE II DOCUMENT

DRL T-706, LINE ITEM 61

(NASA-CE-140347) QUALIFICATION TEST N75-12618EEPORT BUMP PROTECTION HAT (SUBASSEMBLYOF T020/M509 BEAD PROTECTIVE ASSEMBLY)(General Electric Co.) 39 p HC $3.75 Unclas

CSCL 06- G3/54 04254

PREPARED BY: I, C>D. B. Willis - " .Product Engineer

APPROVED BY: _ _/_ _

G. E. WoodProject Manager

. ..- / ': C ,

GENERAL ELECTRICAPOLLO AND GROUND SYSTEMS

HOUSTON PROGRAMSHouston, Texas

https://ntrs.nasa.gov/search.jsp?R=19750004546 2020-03-17T03:07:12+00:00Z

ABSTRACT

The BPH (Bump Protection Hat), P/N 793-102, S/N 1001, was subjected to impacttesting in accordance with QTP-72-1037, Qualification Test Procedure, andGE-TPS-C-010. The BPH underwent three impacts at 35 foot-pounds of energy.The impacts generated stress cracks, but no penetration. All impacts resultedin deflections of less than one-half inch.

The BPH successfully passed the testing and is considered to be qualified forSkylab and the Rescue Vehicle.

Document No. QTR-72-1039Revision

Release Date 0 5 7

TABLE OF CONTENTS

Paragraph Title Page

1.0 INTRODUCTION . .............. .... . . . . . .

2.0 TEST APPARATUS . ................. . . . . .

3.0 PROCEDURE ............. .... .... 1

4.0 RESULTS . . . . ... . . . . . . . . . . . . . . . . . . . 1

5.0 CONCLUSIONS ............... ... ....... 2

APPENDIX A

APPENDIX B

APPENDIX C

Document No. QTR-72-1039RevisionRelease Date rPage 1 of 2

1.0 INTRODUCTION

In accordance with QTP-72-1026, Qualification Test Plan for SkylabT020/M509 Head Protective -Assembly, the only test required to qualifythe assembly is to perform impact testing on the BPH (Bump ProtectionHat). This report documents the performance of the required impacttest.

Testing was performed in accordance with QTP-72-1037, Impact TestQualification Test Procedure for the BPH (see Appendix A). Testingwas performed on GE-TPS-C-010 (Appendix B). One deviation was madeto the-test procedure. Figure 3 of the test procedure called for impactsto be performed on one side, the front, and the back of the helmet.The actual impacts were performed on one side, the front, and the topof the helmet. The top was impacted instead of the back for tworeasons: (1) It was felt that a top impact would be more realisticthan a back impact. (2) The test facility would have to be modifiedto perform a back impact.

Testing was performed on the side and top of the helmet on October 30,1972. The pendulum then had to be modified in order to perform thefront impact. Front impact was performed November 16, 1972.

2.0 TEST APPARATUS

The test equipment is shown in Figures 1 and 2 of the test procedure(Appendix A). Photographs number 1, 4, and 8 of Appendix C show thetest setup for the three impacts performed. The stop watch used duringtesting was not calibrated, as indicated on the Test Summary Sheet(Attachment A of QTP-72-1037).

3.0 PROCEDURE

Test procedures were according to QTP-72-1037 (Appendix A) and GE-TPS-C-010(Appendix B).

4.0 RESULTS

All three impacts caused stress cracks on the outside of the BPH. Theside impact also caused stress cracks on the inside of the BPH. Therewere no stress cracks on the inside of the BPH for the top and frontimpacts. Analysis of the side impact cracks showed that the outsidestress cracks were not the sane as the inside cracks, hence, there wasno penetration of the helmet. All cracks were acceptable according tothe pass-fail criteria of QTP-72-1026.

Document No. QTR-72-1039RevisionRelease Date tpr 1 1q77Page 2 of 2

4.0 RESULTS (Continued)

Analysis of the high-speed film for shell deflection showed thefollowing results for the three impacts:

a. Side Impact - Less than 3/8" deflection, though the exact amountcould not be determined.

b. Top Impact - Approximately 3/8" deflection.

c. Front Impact - Less than " deflection, though the exact amountcould not be determined because the impact was a glancing blow.

Maximum allowable deflection was 2'. All three deflections were withinthe allowable amount.

One DR was generated at post-test on the stress cracks (Appendix B).No FIAR's were generated. The DR is closed.

5.0 CONCLUSIONS

All three impacts successfully passed the test from the standpoint ofboth cracks and deflection.

It was agreed by the Test Conductor, Technical Monitor, and NASA QualityControl that the stop watch not being calibrated was no problem.Stop watches are normally not calibrated for such .tests. . Human reflexerror is a much more significant factor in timing the period ofoscillation.

The top of the helmet being impacted instead of the back is consideredvalid. for the following reasons:

1. A top impact is mudh more likely than a back impact.

2. It was originally not required to impact the top. It was agreedby the test parties that a top impact is desirable.

3. The back area of the helmet is similar to the front area, which wasimpacted.

4. Side impact is the most severe since there is no liner in theimpacted area to absorb part of the energy.

The BPH successfully completed qualification testing .for Skylab andRescue Vehicle.

APPENDIX A

TEST PROCEDURETEST SUMMARY SHEET

TEST DATA SHEETS

Document NJ. QTP-72-1037RevisionRelease Date ' [T 19 "M

IMPACT TEST

QUALIFICATION TEST PROCEDURE

LF'OR SKYIAB

BUMP PROTECTION HAT

P/N 793-102

CONTRACT NAS 9-11905 -

Type I. Document

DRL T-706, Line Item 63

PREPARED BY: A. 4" d APPROVED: /D. B. Willis Tec icaYonitorProduct Engineer

APPROVED: /e ,&APPROVED: / 1 4-. rBnch Chi e f

E. WoodProject Manager

APPROVED: ///

Chief ew "ystems Division

APPROVED: "tJ ; --/Qua ty Enginee ing

GENERAL ELECTRICAPOLLO & GROUND SYSTEMS

HOUSTON PROGRAMSHouston, Texas

Page i of ii

DOCUMENT CHANGE/REVISION 'LOG Dote

Chg Change Pages CEI S/NNo Authority Affected Change Description

- ii

Document No. QTP-72-1037Revision

Date nrT 1 177Page ii of ia

'TABLE OF' CONrENTS

Paragraph Title Page

1.0 INTRODUCTION . . . . . . . ............... . 2

2.0 PURPOSE . ....... .. . . . . ....... . . . 2

3.0 APPLICATION .............. ......... 2

4.0 REQUIREMENTS AND TEST PREPARATIONS ....... . ..... . 2

4.1 TEST EQUIPMENT AND FACILITY REQIJIRHE=NTS ... . ...... 2

4.2 TEST EQUIPMENT VALIDATION . ... ............ . 3

4.3 SAFETY PRECAUTIONS AND SPECIAL HANDLING .. ........ 3

4.4 TEST SETU ..P ....... ...... ..... . . . . . . . . . 3

4.5 TEST SETUP VALIDATION . ................. . 3

5.0 TEST PROCEDURE ... ......... . . . . .... 3

'REPRODbc .

ORIGLIN Ai iS 004 Document No. QTP-72-1037Revision

Date __

Page 2 of

1.0 INTRODUCTION PRECEDING PAGE BLANK NOT FILMED

This document details the procedure for subjecting the BPH (BumpProtection Hat) to impact testing according to QTP-72-1026, Qualifi-cation Test Plan for Skylab T020/M509 Head Protective Assembly.

2.0 PURPOSE

The purpose of the test is to determine the shock absorbing character-istics of the BPH when impacted with a fixed hemispherically shapedanvil. The impact shall be at 12 ft./sec. with a mass of 0.48 slugs,according to QTP-72-1026, or an equivalent energy of 35 foot pounds.High speed photography shall be used to determine the shell deflectionduring impact.

3.0 APPLICATION

Any discrepancies, difficulties, replacement of components,.deviationsfrom procedures, etc., experienced during the test shall be documentedon the Test Summary Sheet (Attachment A). The Test Conductor and theMSC Inspector shall sign the Test Summary Sheet. Any DR's or FIAR'sgenerated shall be written in accordance with paragraph 5.6.2 ofQTP-72-1026. Deviations from procedure shall be indicated on the TestData Sheet (Attachment B).

4.0 REQUIREMENTS AND TEST PREPARATIONS

4.1 TEST EQUIPMENT AND FACILITY REQUIREMENTS

The test will be conducted by the special projects laboratory of theCrew Systems Division's Material Development Section. The testapparatus shall be a pendulum and wooden .mannequin head assembly asshown in photograph 1.

The test article shall be one Bump Protection Hat, P/N 793-102,S/N 1001.

Support equipment shall include the following:

Item Part No. Specification

Communications Carrier 16536G-03 or -01 Class III

Camera -- 400 frames/sec.

Stop Watch -- Calibrated

Grid -- , squares or less

Document No. QTP-72-1037RevisionDate UI 9 1 .,Page 3 of.

4.2 TEST.EQUIPMENT VALIDATION

Prior to start of the test, a receiving inspection shall be performedon the BPH to assure no damage. The camera and stop watch shall beverified to be calibrated and functioning properly.

4.3 SAFETY PRECAUTIONS AND SPECIAL HARD)LINGC

There are no special safety precautions involved in this test. Cautionshould be exercised while handling the BPH, camera, and stop watch toprevent damage to the hardware.

4.4 TEST SETUP

The test equipment shall be set up as shown in Figures I and 2. TheCommunications Carrier shall be placed on the mannequin head and theBPH strapped over the Communications Carrier.

NOTE: Adjust the BPH suspension system to the mannequin head size.

4.5 TEST SETUP VALIDATION

The MSC Inspector shall verify proper test setup and stamp the TestData Sheet accordingly, prior to commencing test.

5.0 TEST PROCEDURE

5.1 Prepare pendulum and wooden head assembly per Figures 1 and 2.

5.2 Suspend the impact head with the BPH and Communications Carrier mountedas a pendulum, and determine the period of oscillation. Determineperiod by swinging the pendulum through an arc of < 60 and timing theperiod through 10 oscillations, using the stop watch to time.

5.3 Calculate the center of pe cussion of the impact assembly by thefollowing formula: L = gt /(2,r) 2 where L is the length from thepivot point to center of' percussion, g is acceleration due to gravity,and t is the period of oscillation of the pendulum. (See Figure 1.)

Document No. QTP-72-1037RevisionDate FT 1 197Page of 8

5.4 Weigh and record weight of the impact assembly with the BPH andCommunications Carrier mounted on the head.

Weight

5.5 Calculate 'the releas e angle required for a 35 foot-pound impact bythe following formulas:

a. E mgh where m is the mass of the impact assembly, g is theacceleration due to gravity, and h-is the vertical height when thecenter of percussion is raised.

b. -- = cos - (L-h) where ,L and h are defined in 5.3 and 5.5 respectively.

5.6 Orient the impact assembly such that region I of Figure 3 will be impacted.

5.7 Pull impact assembly back to the desired release angle as calculatedin step 5.5.

5.8 Begin countdown of 5-4-3-2-1 - Release. Turn camera on at count of; 2.

5.9 Impact helmet. Do not let helmet strike the anvil more than once.Stop camera.

5.10 Orient the impact assembly such that region 2 of Figure 3 will beimpacted.

5.11 Repeat steps 5.7 through 5.9.

5.12 Orient the imrnpact asserRmbly :;mch that reg:ion 3 of Figure 3 will beimpacted.

5.13 Repeat. steps 5.7 through 5.9.

5.14 Remove the BPH and inspect for damage. Pass-fail criteria for the BPHis defined in paragraph 6.3.2.2.3 of QTP-72-1026.

Document No. QTP-7P-J-O37RevisionDate CT 1 1J07Page 5 f

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&&

4 -4

PHOTO # 1 - PENDLI~M ASSY

PIVOT POINT

LPENDULUM HEAD

WOODEN HEAD

IMPACT ANVIL2" Dia. Surface -t

HO CD0

FIG. /

FIG. 1 / 1 //// / ~/

BPHAdd weights if necessary to bringimpact assembly to a total of 15 25 -lbs., including BPH and Comm. Carrier

weight.

GRID

CAMERA

IIMPACT ANVIL

0 ,C

FIG. 2

-2tiC) ~s

CI

Document No. QTP-72-1037RevisionDate 1Page 8 of 8

Region 1 may beon either side.

SIDE VIEW

Region 3 is the sameas region 2, exceptthat it shall be onthe back side.

FRONT VIEW

Figure 3

Document No. QTP-72-1037

Attachment A

TEST SUMMARY SHEET

FOR

IMPACT TEST OF BUMP PROTECTION HAT

I. Test Hardware P/N 79 3- / Z

Test Hardware S/N / /

Date Test Performed /0/: :/7 L

2. Indicate Test Procedure deviations below:

qt i

3. Indicate DR's generated during test below:

4. Indicate FIAR's generated during test below:

5. Additional test data information:

o n q-oo

6. With the exceptions noted above, the test was successfully performedaccording to the procedures of QTP-72-1037, Impact Test QualificationTest Procedure for Skylab Bump Protection Hat.

st Conductor MSC Quali Inspector

Cdiin a tifac od. Ha

5.6 PH oriented for re 793on 1.

5.9 BPTs impacted for region 1.

5.10 BPH oriented for region

PARA5.11 BPH impacted for region 2l

42RcinInpc TECH INS p NASA

5.12 BPH oriented for region er3.formed n

Co5.13 PH dit ion satisfactoryn 3.

5.1 BPH inspected for P/N dam

5 generated at Post-Tesg hre. eo any DR's

Record any F lARis generated at Post-Pest hes

501M ASD4ij rn

EST DATA SHEET Attachment BTL SMD 7813 UOUNCLAI aI 1

Qual Test Procedure Bump Protection Hat 416PARV no no

793-102OCUMIW tlu ui l Irn ALWQQTTP-72-1037 1001 Pa1 of 1 Pages

PROCEDURE TECH IJNSP NASA

4.2 Receiving Inspection performed on BPH.Condition satisfactory.

BPH P/N 7?-- /BPH S/N fr,

4.2 Support equipment calibrated and functioningproperly.

4.5 Test setup verified proper.

5.2 Period of oscillation determined. Period isl2 "seconds.

5.3 Center of percussion determined. L isS _, 95 _ ft.

5.4 Weight of impact assembly is /5y,~2 lbs.,including BPH, Communication Carrier.

5.5 Release Angle = - degrees.

5.6 BPH oriented for region 1.

5.9 BPH impacted for region l.

5.10 BPH oriented for region 2.

5.11 BPH impacted for region 2.

5.12 BPH oriented for region 3.(R ~e4 2 of

5.13 BPH impacted region 3. 3 '

5.14 BPH inspected for damage. Record any DR'sgenerated at Post-Test here.

Record any FIAR's generated at Post-Test here.

eFsm ASOID 21

APPENDIX B

TPS' SDR'S

1,. A ConfigurationT Change 2. TPS No. -

B Non-Configuration T PREPARATION SHEET 3. S/C ca. o

4. Mod. Sheet Nu er-- NAS - MANNED SPACECRAFT CENTER

5. Page..L__ of6 S/C No /Model No. .7 Date 8. Time 9. Need Date

10. Drawings, Documents, Ocp's, & Part Numbers) 11. Confract Number

__ T --7 - _L 37 2' 3- - -__12. Serial Number

__ '4 6-- O Se TPS13. System 14. Ref. E. O. Number

15. TPS Short Title 16. Wt. Req.

17. Reason for Work: T f -J4 " " i ,- -- " -h, t -

18. DESCRIPTION (Print or Type) 21. Insp.Tech. 22. T

2c/IASA--6C-1 s/bA /o, v _o __

Ar i-'i- -..---- '..

i1~-1 L i3 , e, _ / ,-

c \4, j aj+ " •- a - K±C4LLSf ,. , ,_19. Prepared By 20. Final Acceptnc

~ REFER TO PROCEDURES FOR REQUIRED SIGNATURES REFER TO PROCEDURES FOR REQUIRED SIGNATURESContracDart e________ Date

MSC FORM 725 (JUL 65)NASA OC-m I.,: Hlv COPT I

TEST PREPARATION SHEET TPS No. 6 Tr-S/C Cat. No.

CONTINUATION SHEETNASA - MANNED SPACECRAFT CENTER

Page of

Insp.DESCRIPTION (Print or Type) Tech.Cont. NASA

_ _i w i a e i f

S_ VI P-

o__ C•ya ! •. I

- / d/ V '1 C7 - _,

s _ . ,Zz esiu'; .

M ,k -OM V5 (JLcILs-ieu S651 CPA . 4 .,C

___ 1 4-, 16U-_-r V_;I__O_- e o VV

QC FQRM1225A (JUL 6 5)

TEST PREPARATION SHEET s o.TP

S/C Cat. No.CONTINUATION SHEET

NASA - MANNED SPACECRAFT CENTER Page of 3

DESCRIPTION (Print or Type) Tech. In p.___ _Cont. NASA

__ ;- A+ v: c- - V ' -rv /_ ov __

13.. "/ .

MSC FOaM 25A (JUL 65) • COPY I

1. A ConfigurationChange 2. TPS No. o- d O

P B Non-Configuration TEST PREPARATION SHEET 3 s Cat. No.

4. Mod. Sheet Number NASA- MANNED SPACECRAFT CENTER

S _7_ - 15. Page of6. S/C No/Model No. 7. Date .8. Time 9. Need Date

10. Drawings. Documents. Ocp's, & Part Number(s) 11. Contract Number

.4A+7- he 412. Serial Number

13. System 14. Ref. E. 0. Number

15. TPS Short Title 16. Wt. Req.

17. Reason for Work:

18. DESCRIPTION (Print or Type) 21. Insp.Tech. . CONT 2 A

~f f _ P__ / /_1k-

____+ w-tA 4 "4:' 4__T'J; _ ___.__,

• , r. e . _ _

19, Prepared Y 20. Final Acceptance Date

REFER TO PROCEDURES FOR REQUIRED SIGNATURES REFER TO PROCEDURES FOR REQUIRED SIGNATURESContractor Date NA" I----Date

FOM 22 JUl 65 NASA-MS--. Com.. ". '• ,"'es Coov 1

1. CategoryDISCREPANCY REPORT/MATERIAL REVIEW RECORD

NASA - MANNED SPACECRAFT CENTER PAGE / OF_/2. Arti Na 3. Drawing Number 4. Serial/Lot Number 5. RECORDNUMBER

f, ; rZiA /T" 7- o_7 /o o/ ,DR6. ontractor's Name 7. Contractor's Drawing Number 8. Contractor's Serial Number -6e4L 1l:ci-R T c DR/MRR g 0o

9. Supplier's Name 10. Supplier's Drawing Number i1. Supplier's Serial No. 12. Next Higher Assy. / 0-b

13. REF. Document No. 4. ce aft 1516 . 17. Cuse rigin 18. S e 19. Disposition

DISCREPANCY

F eA/c6 /, o - Ps - (2 J/ _21&JLFJ7-cr04,F r . - Z 'c7-. 4~/ L, _ -. sT-ss -- g _-, s ,4" A466

20. In I Sign 21. Stamp Number 22. Organization and Location/ lnitator 23. Dt

DISPOSITION24. MR Action Requiredl 25. Replacement Part Number 26. Retest Required 27. Retest Accept Date 28. FIAR Number

Y<ES O No ] Yes No

29. MRB Decision INSTRUC STAMPINSTRUCTIONS QC S AMP

O USE.AS IS" CONT. NASA

O REPAIR

0 REWORK l %.'O SCRAP

l30. DATE-./

0 /.DAE7 ,- FINAL ACCEPTANCE

MRB APPROVAL SIGNATURES

31 (Cneer a or) DATE 32 fngi _ee I SA) DATE

33 ty Co tro oC ) DATE/ 34. y C P) DA

P m Offic p. (Office Code) ATE DATE

ISC FORM 2176 (Re Apr 68) NASA-MSC--Coml., Houston, Texas

APPENDIX C

PHOTOGRAPHS

Document No. QTR-72-1039RevisionRelease DateT rTt Tij

PHOTOGRAPH DESCRIPTIONS BY NUMBER

1. Test Setup for Side Impact

2. Side Impact Viewed from outside helmet

3. Side impact viewed from inside helmet

4. Test setup for top impact

5. Top of helmet viewed prior to impact

6. Top of helmet after impact (magnified 3 times)

7. Top inside of helmet after impact

8. Test setup for front impact

9. Front of helmet viewed prior to impact

10. Front of' helmet after impact

11. Front inside of helmet after impact

NOTE: All high-speed film taken to determine deflection is in file atGeneral Electric.

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