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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 under the

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project name Saturn the largest Saturn

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vehicle designated Saturn five consists

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of three stages the s 1 C using 5 f 1

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engines the s 2 with 5 J 2 engines and

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the S 4 be using a single j2 engine plus

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the vehicle instrument unit and the

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Apollo spacecraft which saturn v will

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carry this second quarterly film report

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will cover progress on the Saturn 5

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vehicle during February March and April

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1963 highlighting major effort

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concentrated in areas of final tooling

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preparation and initiation of

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fabrication an important step in

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development of saturn v s/s 1c stage

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represented here by a 120th scale

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cutaway model was work during this

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report period on fabrication of bulkhead

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components for the liquid oxygen and

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fuel tanks the initial bulkhead core

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segments were formed in early february

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by the military aircraft systems

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division of the boeing company at

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wichita kansas heavy rollers first

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pressed sheets of aluminum alloy to the

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approximate required contour gore

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segments are made in two sections base

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and apex later welded together the

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rolled sections are then placed in this

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large bulge form die or final precision

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shaping through use of liquid pressure

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in a rubber bladder water is forced into

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the bladder by a pump as the bladder

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expands it forms the aluminum against a

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plastic liner at a maximum of 1,500

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upon delivery to the Marshall Center

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Gore segments our first heat treated or

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aged in a large oven for 24 hours at 325

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degrees Fahrenheit to increase their

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strength and hardness before they

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undergo the fabrication and assembly

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processes which will result in a

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finished bulkhead Marshalls bulkhead

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fabrication and assembly tooling

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underwent continued buildup in

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qualification during the report period

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with work also underway on the first

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bulkhead which will be part of a

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structural test fuel tank this initial

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station in the bulkhead assembly line

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performs routing and welding for all

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ghor fittings the second tooling fixture

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trims the top edge of the base and the

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bottom edge of the apex of each core

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segment in order to make a joint to weld

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the two pieces together at the third

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station this Gore welding fixture is

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used to join the Gore's base and apex

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portions mounted over a pit the welding

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platform can be tilted 30 degrees since

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it is desirable to weld uphill at all

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times at the fourth station a Meridian

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edge Gore trim fixture is employed to

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perform the job of trimming the gore

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segments lengthwise at station number

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five Gore's are installed on the

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bulkhead welding and assembly fixture

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where four operations take place

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Meridian weld bulkhead base trim

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bulkhead to Y ring weld and Y ring to

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skin weld to gore segments have been

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successfully welded together in the

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qualification operation eight gore

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welding for the first bulkhead is

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scheduled next quarter installation of

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the final station number six was

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completed during the report period check

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out of the fixture which will weld in

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the s-1 sea stage partial tails

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section mock-up has been moved into

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Marshalls newly completed mock-up

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building from the adjoining shop where

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it was fabricated after further build-up

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the unit will be installed on his for

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support costs during the next report

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period and the full-scale f1 engine

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mock-up will be attached manual gimbal

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in tests of the f1 mock-up have been

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performed to evaluate design of flame

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curtains compression compensation and

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cable installation a 1/8 scale model s1

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C liquid oxygen tank is being used at

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Marshall to study LOX flow

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characteristics and to develop efficient

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anti vortex devices such as baffles

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screens and stand pipes for testing the

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tank is filled with water with dye added

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to enhance engineering photography a

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rotating paddle is used to simulate

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vortexing which might be caused by

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vehicle movements in flight thus

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preventing sufficient LOX supply to

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engines

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construction of Marshalls Saturn 5 test

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facilities such as this hydrostatic test

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and vertical Assembly Building basic

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construction of the reinforced concrete

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block house or control center some 250

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yards from the stand has been completed

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and interior work is progressing to

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accommodate the electronic test

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equipment which will later be installed

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the instrumentation tunnel running

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between the block house and test stand

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is complete and ready for installation

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of cables a 40 foot deep excavation for

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Marshalls f1 single-engine static test

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stand has been finished and preparations

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have begun for pouring the foundation a

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contract was awarded in February for

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construction of the 105 foot tall

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concrete superstructure the west side of

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Marshalls s1 stage static test stand is

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now being modified to test f-1 engines

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this will allow start of f1 tests in

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November several months earlier than

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scheduled

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the position will be converted back to

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s1 testing after completion of marshals

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f1 tests tan a new series of experiments

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in rocket sounds was begun at Marshall

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this quarter using a new and larger horn

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replacing one which was moved to

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Marshalls Mississippi test operations

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the huge horn which simulates the noise

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of a Saturn static firing is being used

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to learn more about the transmission of

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this low-frequency sound and to

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determine the most advantageous

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conditions for conducting static firings

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experiments in partially suppressing the

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noise of Saturn firings are also being

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conducted at the centre by firing a

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small engine into a specially

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constructed water tank microphones set

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up on a semicircle of sixteen poles near

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the tank record sound levels during

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firing various deflector calm and baffle

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devices inside the water tank help to

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dissipate the energy which creates the

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noise the tape recorded sound is later

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analyzed by technicians to determine the

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effectiveness of suppression a new jet

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impingement test facility was placed in

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operation this quarter to study the

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feasibility of launching space vehicles

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directly over a large body of water

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small solid propellant motors are

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presently being used in tests later f1

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models will be fired singly and in

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clusters the stand is designed for up to

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50,000 pounds thrust its platform can be

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varied from 0 to 10 feet above water

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surface portholes in the tank allow for

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photographic instrumentation the tank is

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51 feet in diameter 24 feet deep and

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splash effects jet penetration depths

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and effects of underwater deflectors

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will be study at the Boeing Company

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plant in Seattle Washington dynamic

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calibration tests using a three 100

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scale Saturn 5 model were performed this

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quarter an electrical shaker device with

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rod attachment induced vibration under

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controlled frequencies and amplitudes

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the same model with weight suspended to

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introduce linear deflection was also

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used in static calibration tests to

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measure vehicle bending moments a 120th

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scale model equipped with two receiving

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antennas was used in command destruct

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antenna pattern measurements to

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determine vehicle aspect angles over

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which the destruct signal can be

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received at Marshall's miss shoe

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operations in New Orleans

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the first s1 C stage Y ring was

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completed by Boeing in mid-february

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using the recently installed 42 foot

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boring mill to machine the ring to

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precise measurements machining of the

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second y ring has now also been

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completed the initial ring was removed

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from the boring mill for shipment to the

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Marshall Center where it will become

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part of the structural test tank machine

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marks in the open V cut on the top of

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the ring were removed by hand grinding

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the V forms the junction of the bulkhead

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and the inter tank or inter stage the

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two-ton ring was carefully wrapped and

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sealed to provide protection during

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handling and shipping the ring was

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shipped by barge from Mishu on February

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22nd and arrived at the Marshall Center

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ten days later work on misuse s1c

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vertical assembly building continued

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this quarter with relocation and

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installation of underground pipe and

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electric cables accomplished the

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foundation for the hydrostatic testing

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and cleaning pad was also under

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construction this is the last station

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the booster before it is returned to the

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final stage preparation area in the main

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plant for outfitting the VAB will have

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three turntables with the pits housing

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the turntable gears recessed in the

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foundation when the building is

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completed it will consist of two

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sections one for booster assembly and

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the other for hydrostatic testing and

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cleaning at Rocketdyne f1 engine work

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this quarter included assembly of an

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experimental concentric tube injector

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prior to installing the faceplate the

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igniter tubes are placed in the body of

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the injector there are 21 of these

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elements one for each compartment in the

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baffle locks tubes are inserted through

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the back of the injector the concentric

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fuel tubes and the baffles are then

236
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installed on the face in operation

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oxidizer is swirled in the center tube

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to form a cone of spray the fuel in the

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annular element is impinged on this cone

240
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and mixing occurs since injector

241
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elements are eight different lengths

242
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eight flame fronts are propagated in the

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combustion zone it is believed that this

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multiple flame front and concentric

245
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injection will increase dynamic

246
00:12:40,379 --> 00:12:38,350
stability testing of model mark 10

247
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inducers was conducted in a water tunnel

248
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under various operating conditions

249
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instrumentation photography permitted

250
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observance of such phenomena as

251
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cavitation backflow and blade tip

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vortexing at North American space and

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Information Systems Division contractor

254
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for the S two-stage bulkhead tooling was

255
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being installed this quarter in the new

256
00:13:07,050 --> 00:13:04,750
seal Beach California facility including

257
00:13:10,829 --> 00:13:07,060
the bulkhead Gore segment welding tool

258
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dollar weld tool the autoclave which

259
00:13:16,769 --> 00:13:12,430
will provide heat and pressure for

260
00:13:18,060 --> 00:13:16,779
bonding insulation to bulkheads and the

261
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acid bath tank

262
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for the etching Rome the s2

263
00:13:26,820 --> 00:13:24,580
electromechanical mock-up scheduled for

264
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first use in July is being fabricated

265
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and assembled at s and IDs County plan

266
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the mock-up will be used in three areas

267
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manufacturing to check placement of

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lines components and engines for

269
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interference and accessibility testing

270
00:13:44,780 --> 00:13:42,130
to check out compatibility of flight

271
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systems as units and with each other and

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GSE development to check out automatic

273
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GSE and make check out computer tapes to

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be used with flight stages fabrication

275
00:14:04,980 --> 00:14:02,800
of the s2 battleship test stage depicted

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here in model form is proceeding on

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schedule initial use is set for the

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first quarter of 1964 marking the first

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time for j2 engines to be fired in

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cluster fabrication of the s2 structural

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stage for use in checking entire vehicle

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structures is also underway at s and IDs

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el Toro facility activated this quarter

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high energy forming tests have been

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successfully performed on waffle

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sections of the s2 s common bulkhead the

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part to be formed is embedded in a

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castable epoxy urethane an explosive

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charge of primer cord is used to provide

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the shockwave for forming at SATA suzana

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roughed site preparation of the coca

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area of rocket dean's propulsion field

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laboratory has been completed the s2

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battleship will be installed in test

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stand number one test stand number four

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00:15:07,590 --> 00:15:05,110
is being prepared for installation of

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the all system stage the first flight

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wait s to test vehicle at Rocketdyne

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contractor for the j2 engine common to

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s2 and s4 b stages a relatively new

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metal forming technique electrolytic

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erosion is being used in manufacture of

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j2 injectors the forming die made of

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compressed graphite acts as an electrode

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and a non conductive

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removes the eroded material built up

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with facilities for the j2 engine

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program at Propulsion Laboratory at

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Santa Susana continued during the report

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period with work on the liquid hydrogen

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storage area run tanks and horizontal

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and vertical static test stands at

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Douglas Aircraft Company santa monica

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fabrication of production tooling

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fixtures for Saturn fives third stage

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s4b

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00:16:08,370 --> 00:16:06,310
was well underway this quarter the first

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vehicle manufactured will be used for

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hydrostatic testing a full scale

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engineering mock-up is under

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construction or use in verifying flight

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type system compatibility with ground

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support equipment both tank domes have

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been completed and installed in handling

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jigs the forward interstate structure

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was attached to the forward dome and the

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aft skirt to the apt dome work is

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proceeding on design and layout of

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automatic check out ground support

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equipment and its housing facilities for

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complete sets of ground support

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equipment will be fabricated the testing

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program in progress for s4b includes

334
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research development qualification

335
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production and reliability verification

336
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testing construction of the s4 be static

337
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firing test facility complex beta at

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Sacramento is progressing satisfactorily

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a contract for the battleship tank for

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00:17:12,990 --> 00:17:08,980
test stand number one was awarded this

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quarter at Huntington Beach construction

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of the Douglas Space Science Center is

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also underway this facility will include

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an assembly and hydrostatic test our

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mock-up and fabrication building space

346
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simulator and s4b

347
00:17:32,880 --> 00:17:30,280
systems integration area structural

348
00:17:34,950 --> 00:17:32,890
design layout of the Saturn 5 instrument

349
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unit which will be located between the

350
00:17:40,880 --> 00:17:38,020
s4b stage and the Apollo spacecraft is

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in process at the Marshall Center

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guidance and control tracking and

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telemetry equipment will be

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around the periphery of the unit which

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is three feet high and 21 feet eight

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inches in diameter circulation of a

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coolant through panels will provide

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temperature control the unused volume in

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00:18:03,320 --> 00:18:00,659
the center will allow the legs of the

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Apollo's lunar excursion module to