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AMS-02 Vacuum Case Design: Safety Review Phase II

Detailed overview of AMS-02 Vacuum Case components, joints, insulation & hardware for ground safety review. Includes specifications, weld designs, leak tests, and proof pressure test results.

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AMS-02 Vacuum Case Design: Safety Review Phase II

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

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

  3. Vacuum Case with External Hardware Warm He Tank with MMOD Shield VC Burst Disc with Zero Thrust Vent SFHe Tank Burst Disc with Zero Thrust Vent AMS-02 GSR Phase II

  4. SUPER INSULATION & VAPOR COOLED SHIELDS MAGNET RACETRACK COIL (DIPOLE COIL ROTATED 90o) SUPERFLUID HELIUM TANK VACUUM SPACE 1 x 10-6 TORR SUPER INSULATION & VAPOR COOLED SHIELDS OUTER JOINT UPPER CONICAL FLANGE UPPER SUPPORT RING INNER JOINT UPPER INTERFACE PLATE Vacuum Case Cross Section OUTER CYLINDER Skin thickness between each rib varies from .152” - .265” INNER CYLINDER LOWER INTERFACE PLATE LOWER CONICAL FLANGE LOWER SUPPORT RING AMS-02 GSR Phase II

  5. Inner Joint UPPER or LOWER CONICAL FLANGE • 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. 5/16 WELD PREP MAGNET KEEP-IN ZONE INNER CYLINDER COMPLETED WELD AMS-02 GSR Phase II

  6. INTERFACE PLATE O-RING TEST PORT SUPPORT RING CONICAL FLANGE VACUUM SPACE Outer Joint • Double O-Ring bolted joint. • Mechanical attachment: • Conical Flange, Upper: 232 .250-28UNJF • Outer Cylinder, Upper: 192 .250-28UNJF • Outer Cylinder, Lower: 168 .250-28UNJF & 32 .3125-24UNJF • Conical Flange, Lower: 192 .250-28UNJF • O-Ring material is Viton, 75 Durometer. • Test ports between each O-Ring for individual leak checks. HEX PLUG TO SEAL TEST PORT with O-Ring OUTER CYLINDER O-RINGS TYPICAL O-RING CONFIGURATION FOR SUPPORT RING TO OUTER CYLINDER AND SUPPORT RING TO CONICAL FLANGE AMS-02 GSR Phase II

  7. Feedthru Ports & Cryocooler Ports • Mechanical Attachment • 8 .190-32UNJF • 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 SUPPORT RING (UPPER OR LOWER) VACUUM CASE FEEDTHRU PORT O-RINGS MATING COMPONENT OUTER CYLINDER AMS-02 GSR Phase II

  8. Strap Port STRAP ASSEMBLY • Closeout Cap Mechanical Attachment • 8 .190-32UNJF • Double O-Ring joint • Viton, 75 Durometer • Test Port between O-Rings STRAP CLOSEOUT CAP SUPPORT RING O-RINGS (TEST PORT NOT SHOWN IN THIS VIEW) AMS-02 GSR Phase II

  9. Closeout Weld AMS-02 GSR Phase II

  10. 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. AMS-02 GSR Phase II

  11. 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 AMS-02 GSR Phase II

  12. 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] AMS-02 GSR Phase II

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