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

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1 STATIC LOAD TESTING 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, electromechanical 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 distribution 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 acquisition system, using Catman Measurement software along with the strain gage outputs. The house system can accommodate 550 dual aquisition channels. Cygnus Spacecraft Load Testing Intelsat 27 Bus and Payload Module Load Testing Unique Proof Load Test Cability E-2C Radome in Static Test Fixture

2 STATIC LOAD TESTING 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: Description or Designation Quantity Available Nominal Full Capacity (lbs.) 220 kip 10-inch stroke kip 10-inch stroke K 10-inch stroke K 10-inch stroke K 10-inch stroke Cygnus in static loader P-122 in static loader Parker 50 kip 2.0-inch stroke Parker 30 kip 2.0-inch stroke Parker 12 kip 4.0-inch stroke Parker 7 kip 4.0-inch stroke MTS Systems actuator MTS Systems actuator MTS Systems actuator MTS Systems actuator Total Actuators Available 70 Orion Crew Escape Vehicle Adaptor Proof Load Test Frame Test Capabilities to 1 Million Pounds Orion Adapter Cone Testing Program Customer Spacecraft Test Type year Quantity IS-29 Payload Module BSS 702 MP Static Load Test Cage IS-29 Radiator Panels BSS 702 MP Proofload IS-29 Bus Core BSS 702 MP Static Load Test Cage P-122 Flight #1 Integrated Structure BSS P-122 Static Load Test Cage IS-27 Bus Core BSS 702 MP Static Load Test Cage IS-27 Bus and Payload Modules BSS 702 MP Static Load Test Cage Cygnus Spacecraft ORB 1 - ORB 8 Orbital Antares Static Load Test Cage MCP Solar Drums BSS MCP Proofload 2007 ~4-5 Adpater Cone Orbital Orion LAS Static Load Test Cage Nose Cose Orbital Orion LAS Nose Cone Fixture Cannard Orbital Orion LAS Cannard Test Fixture Interstage Orbital Orion LAS Interstage Test Fixture Trac A NG (E-2) N/A Proofload (Trac A Fixture) AHE L3 (E-2) N/A Proofload (Trac A Fixture) 2007/ Ybeams BSS HS 376 Proofload (Weld Table) A2100 LMMS VinoSAT/MUOS Paper Load 2007/ Pallets Harris WGS Prooftest HRM Boom NASA Hubble HRM Fixture Yokes Hughes ICO Yoke Fixture

3 NON-DESTRUCT TESTING Applied Aerospace Structures Corporation is a leader in the fabrication of advanced bonded assemblies. AASC has extensive heritage in the Nondestructive Testing of lightweight metallic 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 NADCAP Certification Complete through transmission ultrasonic systems can be designed with total immersion, squirter, or non-contact air-coupled 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 Horizontal TTU Equipment Air and water scan capable 4 x 4 Horizontal Scanning Unit 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 Vertical TTU Equipment

4 NON-DESTRUCT TESTING Through Hole Heat Pipe Heat Pipe Saddle Lower Density Core Section of a Large Heat Pipe Panel TTU Air Scan Penetrant Test A-Scan Capabilities, handheld scanning equipment C-Scan Plot AASC can retrofit existing Ultrasonic C-Scan systems, design flexible multitask scanners, or design and build specific purpose equipment for specialized applications like the Space Shuttle Remote Manipulator arm segments shown above.

5 MATERIAL TESTING 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 Instron Test Lab Insert Torque test Moment Testing 4 piont Beam Flexure Chemical Testing Solution and metal analysis via acid/base titrations and metal analysis via atomic absorbtion spectroscopy. Flatwise Tensile Insert Pullout Test Fixture

6 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 temperature conditions. The chamber heats up and cools down to supplier requirement. THERMAL CYCLE TESTING 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. New Thermal Cycle Chamber (12 x 15 x 10 ) Temperatures Range: -300 F to +400 F Medium Thermal Cycle Chamber (6 8 x 5 8 x 3 8 ) Temperatures Range: -300 F to +320 F Small Thermal Cycle Chamber (19 x 12 x 16 ) Temperatures Range: -250 F to +400 F

7 THERMAL DISTORTION TESTING 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 companies 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 Thermal Chamber, Turntable Accessories and Photogrammetry Equipment. AASC s New Thermal Cycle Chamber (12 x 15 x 10 ) Reflector Mounted on Turntable AASC s Photogrammetry Equipment SubReflector Setup in Thermal Distortion Chamber

8 SINUSOIDAL/VIBRATION TESTING Sinusoidal, random and acoustic vibration testing are 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. Vibration Test Set Up GMI Reflector Vibration Test Deep Impact DAWN MRO

9 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 Modal Tap Test - MRO 3m Reflector AASC Optical Bench FEM - Second Mode 188 Hz MRO Final Assembly Optical Bench Final Assembly First Vertical Bending Natural Frequency

10 ACOUSTIC TESTING 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. 1.5m Reflector shown Vibration Plate 1000lbs Mass Vibration Isolators Acoustic Test Set Up Acoustic Test Stand Deep Impact, MRO, DirecTV Deep Impact Deep Impact HGA DAWN