AMS 02 Thermal Control System Design AMS Thermal

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, Drj. Sun AMS TIM January, 2007 - Houston 1

AMS 02 –Thermal Control System Design AMS TCS - main components AMS TIM January, 2007 - Houston 2

AMS 02 –Thermal Control System Design TCS Mass budget Target mass for the TCS = 274 Kg AMS TIM January, 2007 - Houston 3

AMS 02 –Thermal Control System Design Gemini structure (radiator backbone) AMS TIM January, 2007 - Houston 4

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, 2007 - Houston 5

AMS 02 –Thermal Control System Design Radiator cross section AMS TIM January, 2007 - Houston 6

AMS 02 –Thermal Control System Design CAB LHP is to be fixed outside the WAKE radiator AMS TIM January, 2007 - Houston 7

AMS 02 –Thermal Control System Design Integration jig AMS TIM January, 2007 - Houston 8

AMS 02 –Thermal Control System Design Tracker radiators • They provide the sink to the TTCS AMS TIM January, 2007 - Houston 9

AMS 02 –Thermal Control System Design Tracker radiator assembly AMS TIM January, 2007 - Houston 10

AMS 02 –Thermal Control System Design Zenith radiators • They provide the sink to the Cryocoolers LHP AMS TIM January, 2007 - Houston 11

AMS 02 –Thermal Control System Design 4 zenith radiator quadrants AMS TIM January, 2007 - Houston 12

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, 2007 - Houston 13

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, 2007 - Houston 14

AMS 02 –Thermal Control System Design First vibration mode, Wake radiator 23 Hz AMS TIM January, 2007 - Houston 16

AMS 02 –Thermal Control System Design Max tension force on inserts Main radiator AMS TIM January, 2007 - Houston 17

AMS 02 –Thermal Control System Design AMS TIM January, 2007 - Houston 18

AMS 02 –Thermal Control System Design TENSION TEST 1792 N AMS TIM January, 2007 - Houston 19

AMS 02 –Thermal Control System Design Max shear force on inserts Main radiator AMS TIM January, 2007 - Houston 20

AMS 02 –Thermal Control System Design AMS TIM January, 2007 - Houston 21

AMS 02 –Thermal Control System Design SHEAR TEST 5375 N AMS TIM January, 2007 - Houston 22

AMS 02 –Thermal Control System Design Max tension force on inserts Tracker radiator AMS TIM January, 2007 - Houston 23

AMS 02 –Thermal Control System Design Max shear force on inserts Tracker radiator AMS TIM January, 2007 - Houston 24

AMS 02 –Thermal Control System Design 60 samples sent to NASA for testing AMS TIM January, 2007 - Houston 25

AMS 02 –Thermal Control System Design AMS TIM January, 2007 - Houston 26

AMS 02 –Thermal Control System Design Drum peel test Rupture Test Load [Nmm/mm] 34. 21 154. 61 36. 27 27. 33 AMS TIM January, 2007 - Houston 27

AMS 02 –Thermal Control System Design Flat wise test Rupture Test Load [Kg] 64. 61 68. 43 54. 01 156 65. 51 54. 21 AMS TIM January, 2007 - Houston 28

AMS 02 –Thermal Control System Design Lap shear AMS TIM January, 2007 - Houston 29

AMS 02 –Thermal Control System Design AMS TIM January, 2007 - Houston 30

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, 2007 - Houston 31

AMS 02 –Thermal Control System Design RADIATOR INSERT SPECIMEN TENSION TESTS (Summary Table) CGS Sample Identificatio n Number PLYFORM Sample Identification Number T 06023 ISO 1 Ultimate Test Load [N] 2 T 06023 ISO 2 1792. 78 3 T 06031 ISO 1 2217. 25 4 T 06031 ISO 2 2356. 70 1. 8 5 T 06031 ISO 3 2410. 88 1. 87 1 AMS TIM Analysis Limit Load [N] 1841. 55 Mo. S [SF 1. 4] Remarks 1. 19 600 January, 2007 - Houston 1. 13 1. 63 32

AMS 02 –Thermal Control System Design RADIATOR INSERT SPECIMEN SHEAR TESTS (Summary Table) AMS TIM CGS Sample Identificat ion 1 Number PLYFORM Sample Identification Number T 06028 ST 01 Ultimate Test Load [N] Analysis Limit Load [N] Mo. S [SF 1. 4] 4301. 94 3526 -0. 12 2 T 06028 ST 02 5375. 96 3526 -0. 088 3 T 06028 ST 03 5457. 32 3526 -0. 1 4 T 06028 ST 04 7967. 05 3526 0. 62 5 T 06028 ST 05 6887. 25 3526 0. 39 January, 2007 - Houston Remarks 33

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, 2007 - Houston 34

AMS 02 –Thermal Control System Design Test coupon AMS TIM January, 2007 - Houston 35

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, 2007 - Houston 36

AMS 02 –Thermal Control System Design AMS TIM January, 2007 - Houston 37

AMS 02 –Thermal Control System Design Inserts • Built by AIDC AMS TIM January, 2007 - Houston 38

AMS 02 –Thermal Control System Design Skins joint AMS TIM January, 2007 - Houston 39

AMS 02 –Thermal Control System Design Heat pipe • Filled with Ammonia, straight and bent • Profiles only, to be machined at AIDC AMS TIM January, 2007 - Houston 40

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, 2007 - Houston 41

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, 2007 - Houston 42

AMS 02 –Thermal Control System Design Distructive test (2) Reference values Test Type AMS TIM INSERT TENSILE Test Requirement ≥ 2350 [N] Specimens Quantity 15 (TBC) INSERT SHEAR ≥ 7500 [N] 15 (TBC) DRUM PEEL 5 FLAT-WISE ≥ 5. 5 [Nxmm/mm] ≥ 610 [N] LAP SHEAR ≥ 37 [N/mm 2] 5 January, 2007 - Houston 5 43

AMS 02 –Thermal Control System Design Non-distructive tests • Visual inspection • CMM measurement – Inserts position • Geometrical Tolerances AMS TIM January, 2007 - Houston 44

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, 2007 - Houston 45

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 delivery AMS TIM January, 2007 - Houston Jun 2008 46

AMS 02 –Thermal Control System Design FM schedule • MLI Mar 2008 • CAB LHP Apr 2008 AMS TIM January, 2007 - Houston 47