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three heavy space vehicles are being

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developed by the national aeronautics

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and space administration

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this film report number 16 will cover

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progress on the saturn 1 and 1b during

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a significant highlight of this report

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period was the checkout of pad b

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facilities launch complex 37 at cape

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canaveral using the sad5 booster the s4

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dynamics facility stage and ground

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support equipment

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wet tests at canaveral are designed to

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check out complex 37 equipment involved

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in propellant loading operations actual

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propellants are used in the tests

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simulated manual loading methods are

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checked first then the entire loading

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sequence is performed automatically

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some difficulties were encountered

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during first phase testing requiring

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additional components

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tests were resumed and successfully

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completed late in june

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following wet tests inspection revealed

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two welts on the hydrogen side of the

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common bulkhead of the s4 dynamics

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facility stage however the bulkhead

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showed no signs of leakage during the

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liquid hydrogen loading tests and the

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stage is acceptable for stratification

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also at the atlantic missile range work

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on saturn launch sites is progressing

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satisfactorily

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construction of launch complex 34's

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liquid hydrogen facility is on schedule

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with completion expected late next

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the design work on pad a complex 37 to

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the saturn one instrument unit

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electrical support equipment for pad b

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complex 37 arrived at the cape in late

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meanwhile at marshall the booster for

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the fifth saturn one flight vehicle sa5

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entered post static checkout

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discrepancies were discovered

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particularly in the propulsion system

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rework was necessary

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following completion of rework

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electrical systems checkout started in

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mid-may

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the booster will be shipped for arrival

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at the cape about two weeks before s45

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located at marshall's quality division

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is a saturn instrument unit motion

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simulator used for attitude calibration

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of the stabilizer and control system of

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the sa-5 instrument unit

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positioning capabilities are in three

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axes with displacement accuracy of one

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percent of displacement angle

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positioning the unit for attitude

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calibrations and simulated flight

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position leaves all components in their

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respective flight configurations

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eliminating loading effects from long

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cables and extraneous noise pickup

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the control system has automation

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capabilities that can be computer

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controlled permitting complete automated

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calibration and checkout of control

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the booster for the sixth flight vehicle

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sa-6 underwent two successful static

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test firings at marshall's test division

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the first for 35 seconds and the second

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for a period of 142 seconds

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post test inspection revealed minor

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discrepancies such as small fuel leaks

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and a torn gox diffuser screen

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the sa-6 booster second in the block 2

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series is now undergoing post static

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assembly of the booster for the seventh

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saturn flight test vehicle sa-7 was

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completed this quarter and the stage is

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structural fabrication of the spider

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beam for the ninth saturn flight vehicle

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sa-9 is complete assembly operations on

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the tail section and clustering of tanks

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the fairchild stratos corporation of

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hagerstown maryland is now underway in

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the fabrication of various components

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related to the micro meteoroid

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measurement device which will fly aboard

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sa-9 and sa-8

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manufacturing of the wing panels for the

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testing wing panel capacitors is

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accomplished by using a vacuum belt jar

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electronic components are subjected to

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rigid testing prior to acceptance

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micro modules are inspected through the

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chrysler corporation production

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contractor for saturn one and one b

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boosters at marshall's michoud

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operations in new orleans complete

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clustering of all propellant containers

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for the booster for the eighth flight

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vehicle sa-8 during this quarter

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delivery has been made of all h1 engines

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also fabrication of the barrel assembly

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and thrust and fin outriggers for the

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10th flight vehicle essay 10 is complete

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fabrication of the spider beam and

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thrust structure is underway

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at marshall's mishu operations

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construction work this quarter included

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the building of electronic fabrication

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and checkout facility

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and the installation of air conditioning

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systems in various offices and

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all construction work is being done

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under the direction of michoud's support

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services contractor the mason rust

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dynamic testing of the s4 stage

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instrument unit with both the jupiter

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nose cone and the boilerplate apollo

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spacecraft began at marshall's test

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division early this quarter and was

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the sad5 booster at the cape for complex

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37 facilities checkout was removed from

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pad b in late june and will be returned

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to marshall during the next quarter for

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a new clean facility was placed in

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operation this quarter in marshall's

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manufacturing engineering division the

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clean area is subjected to a higher

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internal air pressure in order to

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minimize the possibility of contaminants

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entering the room from external sources

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saturn vehicle parts to be clean are

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disassembled and passed through a drying

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then washed in an electronic cleaning

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vat filtering equipment removes

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contaminants down to the 10 micron or

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a final check of the part is made by

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using a microscope

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after completion of the cleaning process

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all parts are hermetically sealed then

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sent to the user

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the rl10 engine hydraulic actuator

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simulator for the s4 stage was tested

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this quarter at marshall for test

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purposes an engine is not used but is

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simulated by the masses pendulum

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two hydraulic actuators mounted 90

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degrees to each other represent either

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the vehicle's pitch or yaw axis

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the hydraulic actuator system reacts to

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the angle commanded by the vehicle's

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guidance system allowing for attitude

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control in the pitch and yaw planes

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stabilization and reduction of vehicle

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bending

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test analysis will help determine if the

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flight control circuits and mechanical

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power converters are adequate to satisfy

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vehicle requirements for flight

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at platten whitney's florida research

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and development center at west palm

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beach s4 stage rl10 engines are

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thoroughly inspected prior to acceptance

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each engine is inspected visually then

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taken into a booth for a black light

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inspection

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using an ultraviolet lamp all pump

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inlets and valves are examined carefully

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for defects utmost precautions are

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always taken with all parts associated

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after its final acceptance test each

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rl10 engine is weighed with all

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equipment attached

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the vehicle manufacturer must know the

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engine center of gravity since this is a

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factor which can strongly affect the

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at marshall's test division construction

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work was completed this quarter on a

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prototype sound suppression stand which

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the 165 000 pound thrust engine is fired

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into the suppressor tank results of the

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firings will provide data related to the

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basic acoustical scaling laws the sound

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suppression facility will itself be a

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model for much larger power plant

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suppression systems

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acoustic measurements are made during

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tests to check the effectiveness of the

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at rocketdyne's canoga park facility

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stainless steel furnace brazed thrust

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chambers for h1 engines are being

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developed to provide longer test life

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the first unit has successfully

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completed 2300 seconds of main stage

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engine test and the overall braze

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another development at rocketdyne was

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the testing of three types of injectors

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the low differential pressure fuel locks

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injector

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and the low differential pressure fuel

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injector the modified wagon wheel

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injector exhibited high frequency

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on may 4th the s4 battleship test

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program was completed at douglas's

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sacramento test operations with a final

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locks depletion firing of 444 seconds a

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total of five thousand four hundred and

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forty seconds of engine firings was

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at the conclusion of the firing program

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gimbal tests were run on the battleship

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vehicle to provide needed dynamic data

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on the engine actuation system the

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battleship tank was then stripped of

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accessories five of the engines and the

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tank were shipped to marshall the tank

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will be used for slash tests and the

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engines will be used on the s4 dynamic

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on april 1st at sacdo the initial all

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systems vehicle propellant loading test

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was aborted when a fill nozzle leak

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caused damage to the test stand

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corrective action was taken and the

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second test began on april 9th about one

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minute after storage pressure increase

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observers noted tank canning in a

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vertical plane

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canning partially smoothed out after

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several seconds

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following necessary internal insulation

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repair tacking procedures were modified

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and tests resumed problems encountered

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during detaching indicated leaks in the

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common bulkhead

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the vehicle was removed from the stand

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in mid bay for bulkhead weld and

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insulation patching additional tanking

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operations on test stand one will begin

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early next quarter

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on april 16th the s45 flight vehicle was

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moved from douglas's santa monica plant

246
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to the docks at san pedro

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the stage was transported aboard a barge

248
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to begin its water journey to the

249
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sacramento test facility the stage

250
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arrived at its destination five days

251
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later and was checked out in the

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engineering and development building

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prior to being installed in test stand

254
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the s45 was installed in test stand 2b

255
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and pre-static checkout began in late

256
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june

257
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a full duration hot firing is scheduled

258
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at santa monica douglas successfully

259
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bulge formed an aluminum sheet yielding

260
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two segments for the s4b stage's

261
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bulkhead dome

262
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bulge die techniques may be used to

263
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augment segment production on the

264
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stretch press

265
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overall construction on the s4b

266
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facilities at huntington beach is

267
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continuing during this quarter the

268
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fabrication and assembly building was

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completed and tooling installation was

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chicago bridge and iron company

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subcontractor for douglas shipped

272
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sections of the battleship tank to sacto

273
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from its salt lake city facility

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fabrication of the tank started in april

275
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and is scheduled for completion in

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douglas aircraft company has shipped a

277
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full-scale mock-up of the forward dome

278
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and skirt section of the s4b stage to

279
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marshall this quarter

280
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the mock-up will be used in connection

281
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with design of the saturn 1b instrument

282
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a two-month contract was led to

283
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aerospace lines incorporated by marshall

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to study the feasibility of using a

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modified boeing c97 for air transport of

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the s4 stage one and a half million

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pound thrust rocket engines and other

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massive components

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this mode of transportation would

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greatly reduce time required to move the

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cargo from the west coast to points in

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the south and east

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the modified strata cruiser now known as

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the b377pg

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pregnant guppy has successfully

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transported an inert saturn stage from

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the guppy is now undergoing rigid

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testing to prove its takeoff in flight

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and landing capabilities during federal

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aviation agency qualification tests

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these flights are expected to cut

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transportation time from three weeks now

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required for barging cargo through the