C2 to C5 fit up review-R41 Review of MC Type C to C assembly clearances with C2 to C5 shell surface interface details 12/19/06 Rev 4

2 Sec - C C2 C

3 Sec – D looking outside

4 Sec - B C2 C

5 Sec - A

6 Sec – D looking inside

7 Clamp interference

8 No local interferences with CAD defined services

9 Clamp interference

min CAD clearance

offset of inner surface of poloidal break leaves 0.073” clearance

offset of inner surface of poloidal break leaves 0.073” clearance Based on final C2 measurements, MC C2 poloidal break extends inward 0.19” along the full surface. See slide 24.

13 Type C ” min clearance to Interfacing Type C

” min clearance to Interfacing Type C

15 MTM metrology data points shown as white points. Steve’s original metrology data points are red points Interfacing Type-C wings is shown in overlay with underside surface represented.

16 There are minimum points to inspect but Se wing-c clearance looks okay with a 0.222” clearance identified at one location. The underside surface of the wing is typical out by ”, leaving a minimum clearance of 0.197” Slide taken from review: C2 MTM metrology review-R1 Type C2 Interfacing Type C wing

17 Type C2 Interfacing Type C wing 0.221” min clearance

18 Mark up for 1/6” -1/8” grind area Slide taken from review: C2 MTM metrology review-R1 Additional grinding on Type C2 was done in region shown.

19 The surface offset of pints in the pink area is in the range of +.021” to +.039” except where noted. The surface offset of pints in the blue area is in the range of +.075” to.102”. Nominal surface cut is.12” Are we deep enough? Offset of pints in the orange area is in the range of.020” to.037”. The values shown is the machined surface of the large Wing C male side. It will interface with the surface shown in slide 6. C to C Side Outside Large Wing E Side Slide taken from review: MC C5 review-R1

20 The following slides are full wing and flange scans of C2 and C5 Mike Ducdo data: _c2_wing_scan.IGS. Points shown are centers of 1.5” Ø measurement probe.

21 The as-built surface is generally off by ” with a few front edge point out be ” _c2_wing_scan DATA

” MTM 0.061” Duco 0.19” MTM 0.20” Duco 1.18” to C ” MTM 0.070” Duco 0.03” to 0.04” 0.23” min C to C CAD space 0.03” to 0.05” General 0.35” C to C CAD space in this area _c2_wing_scan DATA

” min C to C CAD space. surface measured data is in the range of 0.0” to +0.01” _c2_wing_scan DATA

” OOT at the root (point indicated) +0.02” to -.08” surface variation over the remainder of the cut region ” Out of Tolerance in the enclosed area. MC C2 metrology data shown

25 MC C2 poloidal break extends inward 0.19” along the full surface. MC C2 metrology data shown

26 Based on final measurements of C2 and C5 a gap of exists at the poloidal break interface area. Local grinding on this wing is needed to increase the gap. The C5 small wing geometry is similar to C2 (see slide 30).

27 The as-built surface is generally off in the range of ” to ” _c5_wing_scan DATA

” Duco 0.87” to C2 0.20” Duco 1.18” to C ” Duco 0.42” to C2 0.02” to 0.06” 0.23” min C to C CAD space 0.05” General 0.35” C to C CAD space in this area _c5_wing_scan DATA

” min C to C CAD space. surface measured data is in the range of -0.05” _c5_wing_scan DATA

” OOT at the root (point indicated) +0.05” to -.02” surface variation over the remainder of the cut region ” Out of Tolerance in the enclosed area. MC C5 metrology data shown

31 MC C5 poloidal break extends inward 0.18” along the full surface. MC C5 metrology data shown I though C5 break inner surface was nearly flush… check this.

32 MC C5 metrology data MC C2 metrology data Surface measures -0.07” to -0.13” Surface measures -0.13” to -0.17” Surface -0.02” to +0.14” Surface -0.05” to +0.15”

33 Measured CAD distance with C2 and C5 located in their translated positions. Origin (inches) Orientation (degrees) X Y Z About X About Y About Z C1r C2r C3r C4r The movement of C2 and C5 was made using Art’s large motion case (r1) provided in (FW C1-4 Realignment Coordinate Transformations in ProE nomenclature) dated 10/6/06. C2 was positioned using C2r1 data and C5 positioned using C4r1 data. The translated position is based on the CS0 coordinate system.

” CAD gap C2 C5

” CAD gap Large wing underside local surface C2 C5

” CAD gap Large wing local front nose surface C2 C5

” min bladder inner surface CAD gap Inside surface of bladder pocket C2 C5

” CAD gap C2 C5

” CAD gap C2 C5

” CAD gap Large wing local front nose surface C2 C5

” CAD gap C2 C ” CAD gap 0.560” CAD gap 0.567” CAD gap (inside corners) Side-B Side-A

” CAD clearance to underside surface of poloidal break. Expected gap = = +.051” C2 C5 0.58” at root +.06” AB +.2” AB break lower surface 4.35”

43 C2 C5 4.2” 0.387” CAD clearance to underside surface of poloidal break. Expected gap = = +.127” 0.62” at root

44 Post grinding C5 Plane located 4.35” from flange face ” red ” blue ” blue ” red ” red -0.00” red

45 ●●● 1.8 monuments are located on each mating MC, so positioned that they can be seen by the Lica metrology system which has been optimally positioned. The monuments are to be located on stable surfaces where part deflection is minimal. 2.The first MC is positioned on the Stage 2 support stand and secured in place. 3.A reference coordinate system (to be designated ACS0) will be determined through metrology measurement of the first MC, referencing the 8 monuments.

46

47 C2 pt 1 C2 pt 2 C2 pt 3 C5 corner pts