1. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy1 GLAST Large Area Telescope: Mechanical Systems Peer Review 27 March 2003 Section 4.7 Fabrication & Verification Radiator, XLAT, Heatpipes Brenda Costanzo Lockheed Martin System Engineer brenda.costanzo@lmco.com Gamma-ray Large Area Space Telescope

2. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy2 Radiator Fabrication (1 of 2) Obtain Facesheet Material Shear N/C Machine Inspect Clean, Etch & Prime Bond Pipes To OB Facesheet Inspect Thermal Bond Visual Fit Check Core Machine Transfer Datums Assemble Panel and Bond Verify Cure Profile Process Samples To Lab CMM Inspect Geometry Inspect Holes w/ Pins Prep and Install Inserts & Spools Inspect Inserts & Spools Bond IB Doublers RT Cure Bond OB Doublers AC Cure Verify Cure Profile Inspect Doublers Bond Top Edge Closure Obtain Remaining Flight Materials Inspect Verify Flight Materials Log Flight Materials A Inspection/Test Manufacturing Purchasing

3. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy3 Radiator Fabrication (2 of 2) Notes 1)All panel moves require: inspection documentation of panel for damage; packaging for transport; and flight approved move procedures. 2)No outside storage. 3)Qualified flight transportation personnel and equipment. Apply Edge Closure Tape Inspect Bushings Install Reservoir Bushings Structural Testing Apply Thermal Blanket Apply Blanket Velcro Final Cosmetic Damage Map Thermal Testing Inspect Bushings Fit Check Reservoir Bushings Inspect Reservoir Supports Bond Reservoir Supports Machine Bushings A

4. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy4 M & P Plan, EEE Parts M & P Plan submitted to SLAC (GLS00018-2, dated 1 Feb 2003) EEE Parts –Heaters: Minco Kapton Foil Heaters per GSFC S-311-P-079 –Thermistors: YSI Thermistors per GSFC S-311-P-18 –RTDs: Rosemount PRT per GSFC S-311 –Solid State Thermostats: Micropac 52372”O” Submitted to SLAC for approval Nov 2002

5. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy5 Overall Test Philosophy Tests are broken into three categories –In process –Assembly –Joint assembly Benchmark tests will be performed to assess any changes due to environmental testing –IR Heat pipe signature –Low level sine vibration Test plan is document GLS0002-03 All testing will have procedures written prior to commencement Inspection occurs throughout the testing at points specified in the procedure Flash reports will be written within 3 working days of test completion Full reports will be written within 30 days of test completion or by pre-ship review, whichever is earlier

6. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy6 Overall Test Flow Heat Pipe In-Process Tests X-LAT Assy Acceptance Tests Integrated Radiator & X- LAT Assy Thermal Test Delivery In- Place to SLAC Heat Pipe Acceptance Tests X-LAT In-Process Tests VCHPs Only X-LAT CCHPs Only Radiator Acceptance Tests Radiator In-Process Tests TCS Thermal Test X-LAT Plate Qualification Tests Delivery to SLAC

7. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy7 Heat Pipe In-Process and Acceptance Testing In process testing –Verification of material certifications –Inspection of physical dimensions –Verification that LM procedures are followed Acceptance testing CCHP VCHP Integrate into Next Higher Assembly Heat Transport Test Non-Condensable Gas Test Proof Pressure Test HP Assy Proof Pressure Test Heat Transport Test Reservoir Proof Pressure Test Gas Charge Test

8. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy8 Radiator and X-LAT Panel In-Process Testing Radiator and X-LAT Panels –Verification of material certifications –Inspection of physical dimensions –Verification the LM procedures are followed Radiator Panels X-LAT Panels –Visual inspection of pipe/panel bonds Flatwise Tensile Test Visual Inspection of Pipe/Panel Bonds Lap Shear Test Bulk Load Test Insert Pull Test Radiator Assembly Acceptance Testing

9. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy9 Radiator Mechanical Acceptance Tests Test configuration –Each radiator panel assembly tested separately Test flow Vibration Testing Pre- Vibration IR Signature Low Level Sine Survey Sine Vibration Limit Load Test Acoustic Vibration Post- Vibration IR Signature Low Level Sine Survey Mass Properties X-LAT/Radiator Assy Thermal Testing Radiated Emissions Conducted Emissions Radiated Susceptibility Conducted Susceptibility EMI Testing

10. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy10 X-LAT Plate Qualification Testing Test configuration –One protoqual X-LAT plate assembly Test flow Mass Properties Deliver to SLAC Vibration Testing Low Level Sine Survey Sine Vibration (TBR) Static Load Test Acoustic Vibration (TBR) Low Level Sine Survey Random Vibration (TBR) Thermal Cycle 2 Hot Thermal Balance Cold Thermal Balance Thermal Cycle 4 Cold Thermal Cycle Hot Thermal Balance Thermal Cycle 1Thermal Cycle 3 Thermal Testing

11. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy11 X-LAT Assy Mechanical Acceptance Tests Test configuration –X-LAT Assy (two X-LAT panels and one mid-plate) Test flow Pre-Vibration IR Signature Low Level Sine Survey Vibration Testing Sine Vibration (TBR) Static Load Test Acoustic Vibration (TBR) Post-Vibration IR Signature Low Level Sine Survey Mass Properties X-LAT/Radiator Assy Thermal Testing Random Vibration (TBR)

12. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy12 X-LAT/Radiator Assy Thermal Testing Combining the X-LAT and Radiator Assy thermal testing –Cost savings (1 test versus 2 tests) –Minimizes STE –Tests X-LAT pipe to Radiator pipe thermal joint Hardware configuration –X-LAT Assy –Radiator Assy –Heater plate to introduce heat into the system –Lab electronics to control VCHPs Hardware orientation –+X side up –Level within 0.10”

13. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy13 Test Orientation +Z +Y Gravity is Into the Page Cold Wall MLI Blanket Flight Radiators (2) +X +Y Gravity is Down Flight X-LAT Assy Cold Wall Flight Radiators (2) MLI Blanket NO SCALE Flight X-LAT Assy Heater Plate

14. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy14 X-LAT/Radiator Assy Thermal Test Flow Pre-Cycling Functional Test Pump Down Chamber Thermal Cycle 1 Bakeout / Hot Survival Hot Temperature Turn-On Cold Survival Cold Temperature Turn-On Thermal Cycle 3 Cold Balance Point Thermal Cycle 2 Hot Balance Point Thermal Cycle 4 Hot Balance Point Cold Portion of Thermal Cycle Post-Cycling Functional Test Delivery In- Place to SLAC TCS Thermal Testing IR Signature

15. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy15 TCS Thermal Testing Hardware Configuration –Radiator Assy –X-LAT Assy –Downspout heat pipes (TBR) –LAT mass simulator Test Objective –Verify VCHP reservoir heater operational algorithm Test Flow Bakeout / Hot Survival Hot Temperature Turn-On Pre-Cycling Functional Test Pump Down Chamber Cold Balance Point Hot Balance Point Post-Cycling Functional Test Cold Survival Cold Temperature Turn-On Hot Balance Point Cold Temperature Turn-Off Repressurize Chamber

16. GLAST LAT ProjectDOE/NASA Mechanical Systems Peer Review, March 27, 2003 Section 4.7 - Mechanical Systems Radiator and X-LAT Assy16 Further Work Determine appropriate structural testing for Radiator and X-LAT Assemblies Determine X-LAT Assy and Radiator Assy configuration for thermal testing (together or separate) –Design STE (Special Test Equipment) and GSE (Ground Support Equipment) Determine if TCS thermal test objective can be achieved during XLAT / Radiator Assy thermal test –Determine what additional hardware will be available –If performing separate TCS test, design LAT mass simulator Write test procedures