phil mottams-02 phase ii safety review1 vacuum case mechanical design alpha magnetic spectrometer...
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Phil MottAMS-02 Phase II Safety Review3 Vacuum Case Overview (cont.) The Vacuum Case attaches to the USS-02 at 10 locations: 8 Interface Plate locations (4 Upper & 4 Lower) 2 Diagonal Struts (Upper) The superconducting cryogenic magnet is being designed and fabricated by ETH/Space Cryomagnetics Ltd. (SCL) in Culham, England. The magnet is supported inside the VC by 16 straps attached to the Upper & Lower Support Rings. (The straps will be covered in a later presentation.) There are 25 Feedthru Ports, not including the strap ports, that are used for Cryocoolers, Cryocooler Access Ports, Fill Ports, Vent Ports, Burst Discs, Current Leads, and cable/tube routing into and out of the Vacuum Case. Feedthru Ports that are not used will be sealed with a blank cover plate. All O-Ring joints are sealed with a double O-Ring configuration. A test port is located between each O-Ring for individual leak checksTRANSCRIPT
Phil Mott AMS-02 Phase II Safety Review 1
Alpha Magnetic Spectrometer (AMS) - 02
Phase II Flight Safety Review
Vacuum Case Mechanical DesignVacuum Case Mechanical Design
Phil MottMay 21-25, 2007
Phil Mott AMS-02 Phase II Safety Review 2
Vacuum Case Overview The Vacuum Case (VC) is a structural member of the USS-02 and
supports the superconducting cryogenic magnet. This is regardless of the pressure state.
Two identical Vacuum Cases are being built: Structural Test Article (STA) Flight
The VC weighs 1,576 lbs and is approximately 9 feet in diameter by 5 feet high.
Vacuum Case Major Components: Upper Conical Flange Lower Conical Flange Upper Support Ring Lower Support Ring Inner Cylinder Outer Cylinder
Phil Mott AMS-02 Phase II Safety Review 3
Vacuum Case Overview (cont.) The Vacuum Case attaches to the USS-02 at 10 locations:
8 Interface Plate locations (4 Upper & 4 Lower) 2 Diagonal Struts (Upper)
The superconducting cryogenic magnet is being designed and fabricated by ETH/Space Cryomagnetics Ltd. (SCL) in Culham, England.
The magnet is supported inside the VC by 16 straps attached to the Upper & Lower Support Rings. (The straps will be covered in a later presentation.)
There are 25 Feedthru Ports, not including the strap ports, that are used for Cryocoolers, Cryocooler Access Ports, Fill Ports, Vent Ports, Burst Discs, Current Leads, and cable/tube routing into and out of the Vacuum Case.
Feedthru Ports that are not used will be sealed with a blank cover plate.
All O-Ring joints are sealed with a double O-Ring configuration. A test port is located between each O-Ring for individual leak
checks
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Vacuum Case (Shipping Configuration) Flight Shown – STA (Flight Backup) Identical
CLEVIS PLATE2X
OUTER CYLINDER
UPPER SUPPORT RING
UPPER INTERFACE PLATE4X
LOWER INTERFACE PLATE4X
LOWER SUPPORT RING
STRAP PORT 16X
ELECTRICAL/PLUMBING/CRYOCOOLER PORT25X
CONICAL FLANGE2X
INNER CYLINDER – not installed in this configuration
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SUPERFLUID HELIUM TANK
MAGNET RACETRACK
COIL(DIPOLE COIL ROTATED 90o)
VACUUM SPACE1 x 10-6 TORR
SUPER INSULATION & VAPOR
COOLED SHIELDS
SUPER INSULATION & VAPOR
COOLED SHIELDS
Vacuum Case Cross Section
UPPER CONICAL FLANGE
UPPER SUPPORT RING
UPPER INTERFACE PLATE
OUTER CYLINDER
INNER CYLINDER
OUTER JOINT
INNER JOINT
LOWER SUPPORT RING
LOWER INTERFACE PLATE
LOWER CONICAL FLANGE
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Flight Vacuum Case with Magnet
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Vacuum Case Assembly with Misc Attachments
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STA Vacuum Case
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STA Vacuum Case with CMR installed
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Qualification Spin Form Al 2219-T62 Spin Forming Original plate was Al 2219-T0
2.25” thick Plate is spin formed, solution heat
treated, and aged to final condition.
Spin Form procedures were reviewed and approved by NASA/ES.
Material tensile test samples were taken from throughout the blank.
Both L and LT directions were tested. 10 locations for each direction.
All test samples exceeded MIL-HDBK-5 values for Al 2219-T62 plate.
Conical Flange Qualification
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Spin Form Blank Tests (for all production blanks) Electrical Conductivity
• Test per AMS 2658• 8 places on both flanges
Hardness• Test per AMS 2658• 8 places on both flanges
Tensile• Test per ASTM B557• L & LT directions• 4 places on both flanges
Conical Flange Spin Form Blanks
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Total spin form blanks: 7 All 7 spin form blanks
were processed identical to the qualification spin formed blank.
Final machined parts are dye penetrant inspected.
Conical Flange
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Al 7050-T7451 Rolled Ring Forging.
Forging Size:OD = 109.62 ID = 104.75H = 53.25
Forging requirements and inspection data were reviewed and approved by NASA/ES.
Additional tensile samples were taken from both ends of the forging for verification.
Ring stiffened structure.
Outer Cylinder
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Al 2219-T851 Rolled Ring Forging.
Forging requirements and inspection data were reviewed and approved by NASA/ES.
Monocoque structure. Initial machining has been
completed. Inner Cylinders are left long and completed at assembly.
Final machining includes machining to the proper length, with weld shrinkage allowance, and machining the weld groove.
Inner Cylinder
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Al 7050-T7451 Rolled Ring Forging. Forging Size: OD = 110.00
ID = 97.50
H = 6.500
Forging requirements and inspection data were reviewed and approved by NASA/ES.
Additional tensile samples were taken for forging verification.
One Forging has been cut up and used for material tests.
The Support Rings are the primary structure for the VC
All 16 straps attach to the Support Rings.
All Feedthru Ports are located in the Support Rings.
Upper & Lower Support Rings
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Interface Plates / Clevis Plates Interface Plates
Al 7050-T7451 Plate Clevis Plates
CRES A286
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Strap Port Closeout Cap Mechanical
Attachment 8 .190-32UNJF
Double O-Ring joint Viton, 75 Durometer
Test Port between O-Rings
SUPPORT RING
STRAP CLOSEOUT CAP
STRAP ASSEMBLY
O-RINGS (TEST PORT NOT SHOWN IN THIS VIEW)
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Strap Port
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Feedthru Ports & Cryocooler Ports Mechanical Attachment
8 .190-32UNJF Double O-Ring joint
Viton, 75 Durometer
Test Port between O-Rings
O-RING TEST PORT (HEX PLUG NOT SHOWN FOR CLARITY)
ORIENTATION & LOCATION WILL VARY DEPENDING ON THE ATTACHED COMPONENT
OUTER CYLINDER
O-RINGS
SUPPORT RING (UPPER OR LOWER)
MATING COMPONENT
VACUUM CASE FEEDTHRU PORT
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Feedthru Ports & Cryocooler Ports
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Outer Joint Double O-Ring bolted joint. Mechanical attachment:
Conical Flange, Upper: 232 .250-28UNJF Outer Cylinder, Upper: 192 .250-28UNJF Outer Cylinder, Lower: 168 .250-28UNJF & 32 .3125-
24UNJF Conical Flange, Lower: 192 .250-28UNJF
Fasteners are wet installed with Super Korpon at final assembly in England.
O-Ring material is Viton, 75 Durometer. Test ports between each O-Ring for individual leak
checks.
Phil Mott AMS-02 Phase II Safety Review 22
Outer Joint
CONICAL FLANGE
SUPPORT RING
OUTER CYLINDER
O-RING TEST PORT
TYPICAL O-RING CONFIGURATION FOR SUPPORT RING TO OUTER CYLINDER AND SUPPORT RING TO CONICAL FLANGE
VACUUM S
PACE
HEX PLUG TO SEAL TEST PORT
O-RING
O-RINGS
INTERFACE PLATE
Phil Mott AMS-02 Phase II Safety Review 23
Inner Joint
Welded Joint – U Groove Design, 3 Pass. O-Ring joint not possible due to design constraints on
both sides of the joint. Joint is designed for 3 welds – Initial plus 2
contingencies. Weld crown will be shaved flush to accommodate
ultrasonic inspection. Three complete closeout welds will take place prior to
the closeout weld on the Flight Assembly: First Article (initial & 1 re-weld) STA at vendor’s facility for pressure and leak tests. STA at SCL in Culham, England.
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Inner Joint
UPPER or LOWER CONICAL FLANGE
INNER CYLINDER
MAGNET KEEP-IN ZONE
5/16 WELD PREP
COMPLETED WELD
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First Article Weld at VC Vendor
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STA VC Weld at Vendor
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STA VC Weld at SCL
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Closeout Weld Inspection Joint design does not allow for x-ray
inspection of the weld Weld is visually and dye penetrant
inspected.
Weld is ultrasonically inspected using a phased array system. The STA weld at the vendor was inspected manually.
Both methods have been qualified to MSFC-SPEC-504C using flat plates and the First Article.
The STA weld at the vendor required 3 minor repairs.
No repairs were required for the final STA weld in England.
Phil Mott AMS-02 Phase II Safety Review 29
Vacuum Leak Tests Both the Flight and STA VC’s were
vacuum tested at the vendor. Both met the requirement of 10-6 torr.
Each O-Ring was individually tested.
Helium leak rate for both VC’s met the spec.
STA VC was leak checked again at SCL after the Cold Mass Replica was installed.
Phil Mott AMS-02 Phase II Safety Review 30
Proof Pressure Tests The STA VC has been successfully
proof pressure tested with argon at the vendor and at SCL after welding.
Proof pressure: 1.8 atm absolute (26.5 psi). [1.0 x MDP]
Flight VC to be proof pressure tested after the magnet is installed and the closeout weld completed.