AASC. STATIC LOAD TESTING Proof Load Data Aquisition. Applied Aerospace Structures Corp.

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Proof Load Data Aquisition

AASC has a state-of-the-art static load test capability at our Stockton facility. The new MTS Corporation system includes hydraulic pumps, electro-mechanical controls, actuators, load cells, and system level controls.

The hydraulic system consists of a Hydraulic Pressure unit (HPU) that feeds the Hydraulics Service Manifold (HSM), which in turn feeds the

distri-bution manifolds. From there the fluid feeds through individual load abort modules to the actuators. The system is currently configured to run up to forty (40) actuators. Each actuator has a two-bridge load cell on its output end and a displacement transducer on the piston rear.

The system is governed by the Aero ST Control System which controls the test completely closed loop either by displacement or by force. A test configuration is programmed into the system and a test simulation is performed to validate the program before any hardware is touched. We use the system in force-control mode using one bridge of each load cell for feedback; the load cell’s second bridge is wired into the HBM data acquisi

-tion system, using Catman Measurement software along with the strain gage outputs. The house system can accommodate 550 dual aquisi-tion

channels.

STATIC LOAD TESTING

Unique Proof Load Test Cability

Cygnus Spacecraft Load Testing Intelsat 27 Bus and Payload Module Load Testing

E-2C Radome in Static Test Fixture

Specializing in Lightweight Composite and Metal Bonded Structures for the Aerospace Industry

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STATIC LOAD TESTING

Orion Crew Escape Vehicle

Adaptor Proof Load Test Frame

Test Capabilities to 1 Million Pounds

Proof Load Data Aquisition

• Equipment allows for the recording of strain displacement load temperature. • Ability to record large quantities of data (up to 550 channels of strain along with

multiple displacement load and strain data)

• Inside Dimensions ~15’ x 15’ x 18’ High

AASC load actuators:

IS-29 Payload Module BSS 702 MP Static Load Test Cage 2014 1

IS-29 Radiator Panels BSS 702 MP Proofload 2013 1

IS-29 Bus Core BSS 702 MP Static Load Test Cage 2013 1 P-122 Flight #1 Integrated Structure BSS P-122 Static Load Test Cage 2013 1 IS-27 Bus Core BSS 702 MP Static Load Test Cage 2012 1 IS-27 Bus and Payload Modules BSS 702 MP Static Load Test Cage 2011 1 Cygnus Spacecraft ORB 1 - ORB 8 Orbital Antares Static Load Test Cage 2010 - 2013 1

MCP Solar Drums BSS MCP Proofload 2007 ~4-5

Adpater Cone Orbital Orion LAS Static Load Test Cage 2008 2 Nose Cose Orbital Orion LAS Nose Cone Fixture 2008 2 Cannard Orbital Orion LAS Cannard Test Fixture 2008 2 Interstage Orbital Orion LAS Interstage Test Fixture 2008 2 Trac A NG (E-2) N/A Proofload (Trac A Fixture) 2002-2008 39 AHE L3 (E-2) N/A Proofload (Trac A Fixture) 2007/2008 2

Ybeams BSS HS 376 Proofload (Weld Table) 2002 1

A2100 LMMS VinoSAT/MUOS Paper Load 2007/2008 40

Pallets Harris WGS Prooftest 2005-2008 12

HRM Boom NASA Hubble HRM Fixture 2002-2008 4

Yokes Hughes ICO Yoke Fixture 1998-1999 12

220 kip 10-inch stroke 6 220000

100 kip 10-inch stroke 2 100000

55K 10-inch stroke 4 55000

Parker 50 kip 2.0-inch stroke 1 49400

242.03 MTS Systems actuator 6 3300 242.02 MTS Systems actuator 6 2200

242.01 MTS Systems actuator 12 1100

242.00 MTS Systems actuator 6 660

Total Actuators Available 70

Program Customer Spacecraft Test Type year Quantity Description or Designation Quantity Available Nominal Full Capacity (lbs.)

Orion Adapter Cone Testing

P-122 in static loader

Cygnus in static loader

AASC

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Applied Aerospace Structures Corporation is a

leader in the fabrication of advanced bonded

assemblies. AASC has extensive heritage in the

Nondestructive Testing of lightweight metal

-lic and composite bonding, and has Nadcap

Accreditation in both UT and PT methods, to

provide the highest quality testing possible.

• Two Thru-Transmission Ultrasonic (TTU) Test Machines 8’ x 16’ and 4’ x 4’ • TTU is Air, Water, and C-Scan Capable • A-Scan Capable

• Digital X-ray

• Ultrasonic and Fluorescent Penetrant Testing

Complete through transmission ultrasonic systems can be de

-signed with total immersion, squirter, or non-contact air-cou -pled instrumentation for water sensitive material applications.

Our systems utilize ‘Winspect’, the state of the art software for instrumentation and computer-based data acquisition and

analysis systems.

AASC NDT Personnel

• One Level III UT/PT, ASNT Level III,

NAS 410 Employee

• Two Level II UT/PT, NAS 410 Employees

NON-DESTRUCT TESTING

4’ x 4’ Horizontal Scanning Unit

Vertical TTU Equipment

Specialty Fixtures: TTU Inspection of Large Strut Tube

Specialty fixtures can be fabricated for: • Large strut tubes

• Complex shaped structures

Vertical TTU Equipment

• Air and water scan capable

Horizontal TTU Equipment

• Air and water scan capable NADCAP Certification

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NON-DESTRUCT TESTING

Penetrant Test

C-Scan Plot

Section of a Large

Heat Pipe Panel TTU Air Scan

Through Hole

Heat Pipe Heat Pipe Saddle

Lower Density Core

AASC can retrofit existing Ultrasonic C-Scan systems, design flexible multi-task scanners, or design and build specific purpose equipment for special

-ized applications like the Space Shuttle Remote Manipulator arm segments

shown above. A-Scan Capabilities, handheld scanning equipment

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Physical Materials Testing

• Fiber volume • Void content

• Resin content testing via acid digestion and furnace burn off of the resin matrix • Thermal property analysis via DSC or DMA techniques

• Glass transition temperature testing via DSC or DMA techniques.

Mechanical Analysis

• Performed by Instron Testing Machines, with a load capacity of up to 56,200 lbs. • Wide variety of Wyoming test fixtures utilized for ASTM testing.

• Wide variety of testing techniques per ASTM and ISO test specifications listed below: - Tensile testing (strength and modulus)

- Compression Testing (strength and modulus)

- Interlaminar Shear - In-Plane Shear

- Laminate Interlaminar Flatwise Strength - Flexure (strength and modulus)

Mechanical Analysis of Adhesives

1. Peel testing

Honeycomb peels, or metal-to-metal bonded sandwich structures

2. Lap Shear Testing

Tests the shear strength of adhesives and verifies the integrity of chemically

cleaned and primed metal surfaces.

3. Wedge Durability Testing

Tests the durability of adhesive bonded structures. Routinely performed when

parts undergo Phosphoric Acid Anodization

Chemical Testing

Solution and metal analysis via acid/base titrations and metal analysis via atomic absorbtion spectroscopy.

MATERIAL TESTING

Insert Torque test

Flatwise Tensile Insert Pullout Test Fixture

4 piont Beam Flexure Moment Testing Instron Test Lab

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Program Listing

Thermal Cycle Testing serves as a way to check

the levels of expansion and contraction on parts

that will ultimately be subjected to varying tem -perature conditions. The chamber heats up and

cools down to supplier requirement.

AASC has four Thermal Cycle Chambers onsite

(two small, one medium, and one large). The two

small thermal chambers can be placed on AASC

mechanical test frame and allows for testing of mechanical properties at temperatures ranging from -250° F to +400°F.

THERMAL CYCLE TESTING

Medium Thermal Cycle Chamber (6‘8”x 5’8” x 3’8”) Temperatures Range: -300˚F to +320˚F

New Thermal Cycle Chamber (12’ x 15’ x 10’) Temperatures Range: -300˚F to +400˚F

Small Thermal Cycle Chamber (19” x 12” x 16”) Temperatures Range: -250˚F to +400˚F

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Deployment mechanisms require a high degree of positional accuracy and repeatability; the final deployment

position and the subsequent thermal distortion of the mechanism are greatly affected by the temperature

changes occurring before and after deployment. AASC maintains a close relationship with outsource compa

-nies to fulfill this form of testing.

AASC has its own in house capability to perform Thermal Distortion Testing using our new 12’ X 15’ X 10’ Ther

-mal Chamber, Turntable Accessories and Photogrammetry Equipment.

THERMAL DISTORTION TESTING

AASC’s New Thermal Cycle Chamber (12’ x 15’ x 10’)

SubReflector Setup in Thermal Distortion Chamber AASC’s Photogrammetry Equipment

Reflector Mounted on Turntable

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Sinusoidal, random and acoustic vibration testing are commonly used to validate the integrity of a manufactured part under condi

-tions simulating those expected in use. The parameters for the test typically come from customer requirements but AASC can also derive and recommend test profiles. Combined with thermal or thermal vacuum cycling, vibration testing followed by NDE can fully test and validate the design, analysis and integrity of an assembly.

SINUSOIDAL/VIBRATION TESTING

MRO

DAWN Deep Impact

GMI Reflector Vibration Test

Vibration Test Set Up

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Modal signature, or tap test, is used to evaluate a fabricated structure’s modal signature or stiffness. Data is recorded from a series of accelerometers specifically placed on the structure when

the structure is excited with a measured impulse. The data is then

compared to the component finite element model (FEM) and if necessary the FEM is adjusted to match the component signature.

MODAL/TAP TESTING

Optical Bench Final Assembly First Vertical Bending Natural Frequency

AASC Optical Bench FEM - Second Mode 188 Hz Modal Tap Test - MRO 3m Reflector

MRO Final Assembly

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Acoustic vibration testing is commonly used to

validate the integrity of a manufactured part

under conditions simulating those expected in

use. The parameters for the test typically come

from customer requirements but AASC can also

derive and recommend test profiles. Combined

with thermal or thermal vacuum cycling, vibration

testing followed by NDE can fully test and validate

the design, analysis and integrity of an assembly.

ACOUSTIC TESTING

Deep Impact

Deep Impact HGA

Deep Impact, MRO, DirecTV

Acoustic Test Set Up

1.5m Reflector shown Vibration Plate 1000lbs Mass Vibration Isolators Acoustic Test Stand DAWN Specializing in Lightweight Composite and Metal Bonded Structures for the Aerospace Industry