AMS TIM January, Houston 1 AMS 02 –Thermal Control System Design AMS Thermal Control System (TCS): A Status Report Group Leaders: Drj Sun – AIDC, M. Molina – CGS, J. Burger – MIT, J.-R. Tsai – NSPO, L. Cheng – SDU Presented by M. Molina, T.Luan, DrjSun

AMS TIM January, Houston 2 AMS 02 –Thermal Control System Design AMS TCS - main components

AMS TIM January, Houston 3 AMS 02 –Thermal Control System Design TCS Mass budget Target mass for the TCS = 274 Kg

AMS TIM January, Houston 4 AMS 02 –Thermal Control System Design Gemini structure (radiator backbone)

AMS TIM January, Houston 5 AMS 02 –Thermal Control System Design Main radiators They provide the sink to most of the electronic units The wake one provides the sink to the CAB LHP

AMS TIM January, Houston 6 AMS 02 –Thermal Control System Design Radiator cross section

AMS TIM January, Houston 7 AMS 02 –Thermal Control System Design CAB LHP is to be fixed outside the WAKE radiator

AMS TIM January, Houston 8 AMS 02 –Thermal Control System Design Integration jig

AMS TIM January, Houston 9 AMS 02 –Thermal Control System Design Tracker radiators They provide the sink to the TTCS

AMS TIM January, Houston 10 AMS 02 –Thermal Control System Design Tracker radiator assembly

AMS TIM January, Houston 11 AMS 02 –Thermal Control System Design Zenith radiators They provide the sink to the Cryocoolers LHP

AMS TIM January, Houston 12 AMS 02 –Thermal Control System Design 4 zenith radiator quadrants

AMS TIM January, Houston 13 AMS 02 –Thermal Control System Design Activities since last TIM (Oct 2006) STA structural analysis Inserts specimen construction TWG activities –test review –Thermal analysis TCS STA Integration Work with AIDC –Integration Jig –Test coupon design

AMS TIM January, Houston 14 AMS 02 –Thermal Control System Design STA structural analysis STA will undergo –Static test with 5 load cases –Modal survey test JS provided CGS/SDU the load cases and a new model of the USS to be used

AMS TIM January, Houston 15 AMS 02 –Thermal Control System Design Green model: old Red model: new

AMS TIM January, Houston 16 AMS 02 –Thermal Control System Design First vibration mode, Wake radiator 23 Hz

AMS TIM January, Houston 17 AMS 02 –Thermal Control System Design Max tension force on inserts Main radiator

AMS TIM January, Houston 18 AMS 02 –Thermal Control System Design

AMS TIM January, Houston 19 AMS 02 –Thermal Control System Design TENSION TEST 1792 N

AMS TIM January, Houston 20 AMS 02 –Thermal Control System Design Max shear force on inserts Main radiator

AMS TIM January, Houston 21 AMS 02 –Thermal Control System Design

AMS TIM January, Houston 22 AMS 02 –Thermal Control System Design SHEAR TEST 5375 N

AMS TIM January, Houston 23 AMS 02 –Thermal Control System Design Max tension force on inserts Tracker radiator

AMS TIM January, Houston 24 AMS 02 –Thermal Control System Design Max shear force on inserts Tracker radiator

AMS TIM January, Houston 25 AMS 02 –Thermal Control System Design 60 samples sent to NASA for testing

AMS TIM January, Houston 26 AMS 02 –Thermal Control System Design

AMS TIM January, Houston 27 AMS 02 –Thermal Control System Design Drum peel test Rupture Test Load [Nmm/mm]

AMS TIM January, Houston 28 AMS 02 –Thermal Control System Design Flat wise test Rupture Test Load [Kg]

AMS TIM January, Houston 29 AMS 02 –Thermal Control System Design Lap shear

AMS TIM January, Houston 30 AMS 02 –Thermal Control System Design

AMS TIM January, Houston 31 AMS 02 –Thermal Control System Design Flight loads analysis When subjected to FM loads inserts will show –Positive margin to tension –Positive margin to shear ONLY with an improved configuration (heavier, i.e. with more glue) No problem for the STA, because loads are lower Need of a stronger glue = HOT BONDING

AMS TIM January, Houston 32 AMS 02 –Thermal Control System Design RADIATOR INSERT SPECIMEN TENSION TESTS (Summary Table) CGS Sample Identificatio n Number PLYFORM Sample Identification Number Ultimate Test Load [N] Analysis Limit Load [N] MoS [SF 1.4] Remarks 1T ISO T ISO T ISO T ISO T ISO

AMS TIM January, Houston 33 AMS 02 –Thermal Control System Design RADIATOR INSERT SPECIMEN SHEAR TESTS (Summary Table) CGS Sample Identificat ion Number PLYFORM Sample Identification Number Ultimate Test Load [N] Analysis Limit Load [N] MoS [SF 1.4] Remarks 1T ST T ST T ST T ST T ST

AMS TIM January, Houston 34 AMS 02 –Thermal Control System Design Conclusion on inserts testing A first set of samples has been tested in Italy –OK for the STA –OK for the FM with an improved (heavier) configuration SOLUTION = Hot bonding process Cold bonded samples have been sent to NASA for testing and SWG approval Hot bonded samples will be built and tested by AIDC

AMS TIM January, Houston 35 AMS 02 –Thermal Control System Design Test coupon

AMS TIM January, Houston 36 AMS 02 –Thermal Control System Design Aim of test coupon Establish and test CGS-AIDC data exchange Set-up Rohacell sandwich panel technology –Inserts precise positioning –Heat pipes bending and gluing –Skin joining

AMS TIM January, Houston 37 AMS 02 –Thermal Control System Design

AMS TIM January, Houston 38 AMS 02 –Thermal Control System Design Inserts Built by AIDC

AMS TIM January, Houston 39 AMS 02 –Thermal Control System Design Skins joint

AMS TIM January, Houston 40 AMS 02 –Thermal Control System Design Heat pipe Filled with Ammonia, straight and bent Profiles only, to be machined at AIDC

AMS TIM January, Houston 41 AMS 02 –Thermal Control System Design Test spec. for the test coupon Document „AMS-PR-CGS-002“ has been issued and delivered to AIDC –DISTRUCTIVE TESTS ON SPECIMENS –NON DISTRUCTIVE TESTS ON THE TWO TEST COUPONS Mechanical tests Thermal tests

AMS TIM January, Houston 42 AMS 02 –Thermal Control System Design Distructive test (1) The specimens shall be manufactured in according to the following requirements: –Same item materials, coming from the same production lot. –Same surface treatment (according to the Test Coupon Engineering Drawing). –Same item manufacturing procedures. –Same vacuum bag. –Same curing cycle.

AMS TIM January, Houston 43 AMS 02 –Thermal Control System Design Distructive test (2) Reference values Test TypeTest Requirement Specimens Quantity INSERT TENSILE≥ 2350 [N]15 (TBC) INSERT SHEAR≥ 7500 [N]15 (TBC) DRUM PEEL≥ 5.5 [Nxmm/mm] 5 FLAT-WISE≥ 610 [N]5 LAP SHEAR≥ 37 [N/mm2]5

AMS TIM January, Houston 44 AMS 02 –Thermal Control System Design Non-distructive tests Visual inspection CMM measurement –Inserts position Geometrical Tolerances

AMS TIM January, Houston 45 AMS 02 –Thermal Control System Design Thermal test at NSPO Scope –Determine suitable heat conductance between radiator skin and heat pipes Details are to be defined by NSPO Concept: IR Lamp one side, IR camera on the opposite

AMS TIM January, Houston 46 AMS 02 –Thermal Control System Design FM schedule Integration jig and crate links Jul 2007 All radiators, brackets and rods Jan 2008 (TBC with AIDC) Zenith radiator deliveryJun 2008

AMS TIM January, Houston 47 AMS 02 –Thermal Control System Design FM schedule MLI Mar 2008 CAB LHP Apr 2008

AMS TIM January, Houston 48 AMS 02 –Thermal Control System Design