Phil MottAMS-02 GSR Phase II1 AMS-02 Vacuum Case Overview Ground Safety Review – Phase II September 8-10, 2008 Phil Mott

AMS-02 GSR Phase II2 Vacuum Case CLEVIS PLATE 2X OUTER CYLINDER UPPER SUPPORT RING UPPER INTERFACE PLATE 4X LOWER INTERFACE PLATE 4X LOWER SUPPORT RING STRAP PORT 16X ELECTRICAL/PLUMBING/ CRYOCOOLER PORT 25X CONICAL FLANGE 2X INNER CYLINDER

Phil MottAMS-02 GSR Phase II3 Vacuum Case with External Hardware VC Burst Disc with Zero Thrust Vent Warm He Tank with MMOD Shield SFHe Tank Burst Disc with Zero Thrust Vent

Phil MottAMS-02 GSR Phase II4 SUPERFLUID HELIUM TANK MAGNET RACETRACK COIL (DIPOLE COIL ROTATED 90 o ) VACUUM SPACE 1 x TORR SUPER INSULATION & VAPOR COOLED SHIELDS UPPER CONICAL FLANGE Vacuum Case Cross Section UPPER SUPPORT RING UPPER INTERFACE PLATE OUTER CYLINDER INNER CYLINDER OUTER JOINT INNER JOINT LOWER SUPPORT RING LOWER INTERFACE PLATE LOWER CONICAL FLANGE Skin thickness between each rib varies from.152” -.265”

Phil MottAMS-02 GSR Phase II5 Inner Joint  Welded Joint – U Groove Design, 3 Pass.  O-Ring joint not possible due to design constraints on both sides of the joint.  Joint is designed for 3 welds – Initial plus 2 contingencies.  Three complete closeout welds will take place prior to the closeout weld on the Flight Assembly:  First Article (initial & 1 re- weld)  STA at vendor’s facility for pressure and leak tests.  STA at SCL in Culham, England. UPPER or LOWER CONICAL FLANGE INNER CYLINDER MAGNET KEEP-IN ZONE 5/16 WELD PREP COMPLETED WELD

Phil MottAMS-02 GSR Phase II6 Outer Joint  Double O-Ring bolted joint.  Mechanical attachment:  Conical Flange, Upper: UNJF  Outer Cylinder, Upper: UNJF  Outer Cylinder, Lower: UNJF & UNJF  Conical Flange, Lower: UNJF  O-Ring material is Viton, 75 Durometer.  Test ports between each O- Ring for individual leak checks. TYPICAL O-RING CONFIGURATION FOR SUPPORT RING TO OUTER CYLINDER AND SUPPORT RING TO CONICAL FLANGE HEX PLUG TO SEAL TEST PORT with O-Ring O-RINGS OUTER CYLINDER CONICAL FLANGE SUPPORT RING O-RING TEST PORT VACUUM SPACE INTERFACE PLATE

Phil MottAMS-02 GSR Phase II7 Feedthru Ports & Cryocooler Ports  Mechanical Attachment  UNJF  Double O-Ring joint  Viton, 75 Durometer  Test Port between O-Rings O-RING TEST PORT (HEX PLUG NOT SHOWN FOR CLARITY) ORIENTATION & LOCATION WILL VARY DEPENDING ON THE ATTACHED COMPONENT OUTER CYLINDER O-RINGS SUPPORT RING (UPPER OR LOWER) MATING COMPONENT VACUUM CASE FEEDTHRU PORT

Phil MottAMS-02 GSR Phase II8 Strap Port  Closeout Cap Mechanical Attachment  UNJF  Double O-Ring joint  Viton, 75 Durometer  Test Port between O-Rings SUPPORT RING STRAP CLOSEOUT CAP STRAP ASSEMBLY O-RINGS (TEST PORT NOT SHOWN IN THIS VIEW)

Phil MottAMS-02 GSR Phase II9 Closeout Weld

Phil MottAMS-02 GSR Phase II10 Closeout Weld Inspection  Joint design does not allow for x-ray inspection of the weld  Weld is visually and dye penetrant inspected.  Weld is ultrasonically inspected using a phased array system. The STA weld at the vendor was inspected manually.  Both methods have been qualified to MSFC-SPEC-504C using flat plates and a First Article.

Phil MottAMS-02 GSR Phase II11 Vacuum Leak Test  Both the Flight and STA VC’s were vacuum tested at the vendor. Both met the vacuum requirement of 1 x 10-6 torr.  Each O-Ring was individually tested.  Helium leak rate for both VC’s met the spec of 1.0 x 10-7 std cc/sec

Phil MottAMS-02 GSR Phase II12 Proof Pressure Test  The STA VC has been successfully proof pressure tested with argon at the vendor and at SM.  Proof pressure: 1.8 atm absolute (26.5 psi). [1.0 x MDP]