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Saturn five quarterly film reports

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number eight covers progress during the

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period September October and November at

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1964 throughout the Porter Boeing and

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00:00:27,950 --> 00:00:23,300
Marshall continued s1c stage development

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manufacturing and testing at Marshall

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00:00:32,840 --> 00:00:30,119
Boeing successfully completed full

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00:00:35,750 --> 00:00:32,850
pressure hydrostatic testing of the s1c

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00:00:37,430 --> 00:00:35,760
test fuel tank after resolving the test

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equipment problems encountered last

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quarter this was followed by successful

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00:00:45,380 --> 00:00:43,559
LOX tunnel testing early in the quarter

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Marshall personnel during a routine

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00:00:51,680 --> 00:00:48,390
inspection discovered weld micro cracks

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on s1 CT and s-1 CS assemblies

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previously manufactured after detailed

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investigations and studies Marshall

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00:01:03,080 --> 00:00:59,910
resolved the problem by micro shaving

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all weld beads necessary action is being

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taken to prevent recurrence of the

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00:01:10,940 --> 00:01:09,090
problem despite the welding problem s 1c

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00:01:13,820 --> 00:01:10,950
stage manufacturing and assembly

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00:01:17,380 --> 00:01:13,830
continued at a satisfactory pace mating

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of the s1 CT forward skirt LOX tank and

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entertained section was completed on

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November 2nd this major assembly was

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moved from the vertical Assembly

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Building to the horizontal assembly area

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where final s 1ct assembly will take

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place

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s1 CT thrust structure manufacture was

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completed with installation of heat

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shield panels and locks and few old duct

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00:01:46,670 --> 00:01:44,670
supports the structure was then moved

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into the vertical Assembly Building and

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joined to the s1 CT fuel tank the unit

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00:01:54,230 --> 00:01:51,840
will be transferred to the horizontal

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00:01:58,550 --> 00:01:54,240
assembly area for final mating to the

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00:02:00,950 --> 00:01:58,560
LOX tank assembly early next quarter s1

40
00:02:03,050 --> 00:02:00,960
CS cylindrical skin assembly and

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bulkhead fabrication continued this

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quarter the forward locks bulkhead for

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this ground test stage is now being

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built at Marshall the original bulkhead

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fabricated by Boeing was rejected

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Mishu because of unacceptable welding

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Boeing is attempting to improve its

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welding techniques to prevent this

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problem from recurring the first inner

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tank for the s1 CS test program built by

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Boeing Michou has been placed in

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Marshalls new load tests tower and

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preparations are underway for structural

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00:02:41,870 --> 00:02:37,770
testing bulkhead fabrication for the

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first two flight stages s1 C 1 and s 1 C

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00:02:48,920 --> 00:02:46,200
2 is progressing steadily construction

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00:02:51,800 --> 00:02:48,930
of Marshalls s 1 C static test stand is

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virtually complete with hold down arms

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00:02:57,710 --> 00:02:55,170
installed this quarter at Marshalls

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00:03:01,460 --> 00:02:57,720
Michou Operations Boeing continued work

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on the s-1 cg dynamic test stage thrust

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structure base heat shield support for

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the thrust structure and inter tank

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00:03:14,720 --> 00:03:10,709
assembly of the stage bulkheads also

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00:03:16,940 --> 00:03:14,730
continued other s1 C component worked by

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00:03:19,360 --> 00:03:16,950
Boeing included assembly of the forward

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skirt for the first flight stage and

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chemical cleaning of the Y rings for the

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second flight stage major facilities

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00:03:30,770 --> 00:03:27,840
construction at Michou included work

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00:03:33,710 --> 00:03:30,780
under stage test facility the high

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pressure test facility and the vertical

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Assembly Building with its hydrostatic

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test tower and final assembly tower at

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the s2 static test facility at Santa

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Susana North American Aviation's space &

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Information Systems Division directed

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major activity during September and

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October toward preparations for the

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initial firing of a single engine of the

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battleship test stage this activity

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included the installation of the center

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00:04:09,740 --> 00:04:07,580
j2 engine under battleship and

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00:04:11,270 --> 00:04:09,750
installation and check out of ground

85
00:04:13,580 --> 00:04:11,280
support equipment and systems

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00:04:17,420 --> 00:04:13,590
development device at the test stand and

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00:04:19,719 --> 00:04:17,430
in the control center systems check out

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00:04:22,219 --> 00:04:19,729
and cryogenics testing were completed

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00:04:23,930 --> 00:04:22,229
continuity checks were made and the

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00:04:26,779 --> 00:04:23,940
integrated checkout or a sequential

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00:04:27,770 --> 00:04:26,789
countdown conducted culminating these

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months of intense

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of preparation on November night the s2

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00:04:36,560 --> 00:04:33,240
battleship first ignition was

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successfully accomplished in the

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00:04:42,140 --> 00:04:38,760
vertical Assembly Building of s and I DS

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00:04:45,200 --> 00:04:42,150
C or Beach facility manufacturing of s2

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s structural test stage continued during

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the report period the common bulkhead

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completed last quarter was mated to the

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liquid hydrogen tank cylinder and the

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assembly was installed in the

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hydrostatic test station where

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hydrostatic testing was successfully

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accomplished in late October the after

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locks bulkhead for s2 s failed during

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its in process component hydrostatic

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testing prior to being welded to the LOX

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tank the character of the failure was a

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fracture which propagated through the

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apex sections of eight of the 12 gore

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segments of the bulkhead an extensive

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investigation by Marshall and s NID

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revealed that the failure was caused

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primarily by manufacturing defects and

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inadequate detail inspection corrective

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action has been initiated and a

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replacement bulkhead for s2 s will be

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available in December Assembly of the

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first s2 stage transporter was completed

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at the American machine and foundry

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corporation at York Pennsylvania

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acceptance testing was completed

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satisfactorily and the vehicle shipped

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to s and IDs seal Beach facility where

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functional testing and mobility runs

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were performed the transporter will be

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Douglas Aircraft Company Sacramento

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tests aerial preparations for the first

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s4v battleship hot firing were underway

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during September fuel leak checks and

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pneumatic lines checks were performed

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technicians checked engine bleed gas

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igniters and the water and propellant

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distribution complex and engine diffuser

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water tests was also run j2 engine

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thrust chamber chill down tests were

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successfully conducted in early October

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on November 7th the first hot firing was

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cut

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prior to mainstage by a gas generator

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over-temperature command a second firing

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on November 24th was a successful one

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second duration test ten and fifty

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second firings are scheduled in December

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at SAC tous gamma complex the attitude

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control engines for the s4v auxiliary

148
00:07:08,330 --> 00:07:04,919
propulsion system were installed in

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September a series of single and

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multiple engine first phase development

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firings was successfully conducted

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during October

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also at Sacto DAC continued preparing

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beta test stands number three for

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installing the facilities check out

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stage four propellant loading tests in

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early March at Douglass's Huntington

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Beach facility assembly and check out of

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the s4v dynamic test stage has been

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completed and the stage is being

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prepared for shipment to the Marshall

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Center in early December the original

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all system stage which has been

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redecorated the facilities checkout

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stage underwent cleaning and

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installation this quarter the stage will

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be used for propellant loading tests at

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SEC tow and facilities checkout at

169
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Kennedy Space Center components from the

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original facilities checkout stage have

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been reallocated for use on an s4v

172
00:08:08,899 --> 00:08:06,389
sectional mock-up which will be shipped

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to Marshall for use on an overall Saturn

174
00:08:16,040 --> 00:08:13,020
5 simulator fabrication and assembly of

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00:08:19,999 --> 00:08:16,050
components for the first Saturn 5 s4b

176
00:08:23,329 --> 00:08:20,009
flight stage 501 got underway at Douglas

177
00:08:25,129 --> 00:08:23,339
Santa Monica this quarter at the air

178
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research test facility in Phoenix

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Arizona pressure testing to failure of

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s4b propellant loading flex hoses was

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00:08:46,610 --> 00:08:44,060
at the edward's rocket engine test site

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00:08:48,830 --> 00:08:46,620
in California Rocketdyne began flight

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00:08:51,770 --> 00:08:48,840
rating tests of the f1 engine on

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November 16th the tests are progressing

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00:08:58,280 --> 00:08:54,300
satisfactorily and will be completed by

186
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December 31st operational readiness of

187
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the two new f1 production engine test

188
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stands at Edwards was marked by

189
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ceremonies held on October 9th

190
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the event was climaxed by a full

191
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as part of the continuing effort to

192
00:09:40,240 --> 00:09:37,520
improve f1 engine reliability Rocketdyne

193
00:09:43,270 --> 00:09:40,250
has designed and tested a new tight fit

194
00:09:45,490 --> 00:09:43,280
locks impeller spline coupling test

195
00:09:48,340 --> 00:09:45,500
results indicate the new design with

196
00:09:52,660 --> 00:09:48,350
reduction of turbo pump rpm will

197
00:09:55,120 --> 00:09:52,670
eliminate LOX pump explosions testing of

198
00:09:57,790 --> 00:09:55,130
the mark 10 turbo pump with shot peened

199
00:10:00,070 --> 00:09:57,800
locks impellers indicated a tenfold

200
00:10:03,250 --> 00:10:00,080
increase in the number of cycles to

201
00:10:04,990 --> 00:10:03,260
failure as a result all existing turbo

202
00:10:08,830 --> 00:10:05,000
pumps have been retrofitted with the

203
00:10:10,740 --> 00:10:08,840
shot peened impeller production of f1

204
00:10:13,360 --> 00:10:10,750
engines at rocky dines canoga park

205
00:10:14,650 --> 00:10:13,370
manufacturing area progressed steadily

206
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during the quarter

207
00:10:19,720 --> 00:10:17,060
this facility is capable of handling the

208
00:10:23,680 --> 00:10:19,730
final assembly and check out of six f-1

209
00:10:25,990 --> 00:10:23,690
engines simultaneously progress is

210
00:10:28,390 --> 00:10:26,000
continuing toward an early 1965

211
00:10:35,260 --> 00:10:28,400
completion of rocky Dynes manufacturing

212
00:10:38,140 --> 00:10:35,270
building number four Santa Susana the

213
00:10:40,000 --> 00:10:38,150
two position tests turned Bravo one has

214
00:10:42,820 --> 00:10:40,010
been converted to an f1 engine

215
00:10:44,890 --> 00:10:42,830
components test facility providing for

216
00:10:47,410 --> 00:10:44,900
longer duration tests than were formerly

217
00:10:50,140 --> 00:10:47,420
possible one position would be used for

218
00:10:58,390 --> 00:10:50,150
gas generator testing and the other for

219
00:11:00,700 --> 00:10:58,400
heat exchanger tests at the Marshall

220
00:11:03,340 --> 00:11:00,710
Center propulsion system testing of the

221
00:11:05,740 --> 00:11:03,350
second f1 production engine began last

222
00:11:08,110 --> 00:11:05,750
quarter continued during this report

223
00:11:10,930 --> 00:11:08,120
period the first production engine is

224
00:11:14,050 --> 00:11:10,940
undergoing minor rework in preparation

225
00:11:17,380 --> 00:11:14,060
for installation in Marshalls new f1

226
00:11:19,450 --> 00:11:17,390
engine static test and in January the

227
00:11:28,780 --> 00:11:19,460
first firing in the new stand is

228
00:11:32,410 --> 00:11:28,790
scheduled for early 1965 during a static

229
00:11:34,600 --> 00:11:32,420
firing of engine j2 mm on September 19th

230
00:11:38,280 --> 00:11:34,610
at Santa Susana a gas generator

231
00:11:41,079 --> 00:11:38,290
explosion occurred as a result

232
00:11:41,920 --> 00:11:41,089
Rocketdyne built this mock-up of the j2

233
00:11:44,139 --> 00:11:41,930
new matte

234
00:11:47,019 --> 00:11:44,149
control system including the gas

235
00:11:50,829 --> 00:11:47,029
generator to evaluate possible solutions

236
00:11:53,290 --> 00:11:50,839
to the problem analysis of test data on

237
00:11:55,450 --> 00:11:53,300
one proposed solution connecting the gas

238
00:11:57,820 --> 00:11:55,460
generator valve cast to the control

239
00:11:59,889 --> 00:11:57,830
pressure point indicated this would be

240
00:12:03,310 --> 00:11:59,899
successful in preventing one possible

241
00:12:04,930 --> 00:12:03,320
cause of the explosion other research

242
00:12:06,850 --> 00:12:04,940
and development activity and the j2

243
00:12:09,670 --> 00:12:06,860
engine by rocky day in this quarter

244
00:12:11,410 --> 00:12:09,680
included flame resistance testing of the

245
00:12:14,680 --> 00:12:11,420
connector for the flexible armored

246
00:12:16,780 --> 00:12:14,690
harness now used for all j2 electrical

247
00:12:19,660 --> 00:12:16,790
control and instrumentation harness

248
00:12:22,360 --> 00:12:19,670
wiring in this test the system did not

249
00:12:34,540 --> 00:12:22,370
short out for 6 and 1/2 minutes under a

250
00:12:39,650 --> 00:12:37,790
J two-engine preliminary flight rating

251
00:12:42,860 --> 00:12:39,660
tests were successfully completed

252
00:12:45,980 --> 00:12:42,870
November 25th by Rocketdyne at its santa

253
00:12:48,559 --> 00:12:45,990
susana test site the j2 flight rating

254
00:12:52,639 --> 00:12:48,569
test is scheduled to be conducted early

255
00:12:55,850 --> 00:12:52,649
in 1965 following a final test vertical

256
00:12:59,119 --> 00:12:55,860
test stand 3a at Santa Susana was closed

257
00:13:01,429 --> 00:12:59,129
for extensive renovation close coupling

258
00:13:03,829 --> 00:13:01,439
of propellant tanks and improved vacuum

259
00:13:05,960 --> 00:13:03,839
jacketing under hydrogen lines are

260
00:13:08,090 --> 00:13:05,970
expected to provide a better engine

261
00:13:11,049 --> 00:13:08,100
start condition and more effective

262
00:13:13,999 --> 00:13:11,059
altitude simulation for a flight rating

263
00:13:16,100 --> 00:13:14,009
at the Marshall Center construction of

264
00:13:18,889 --> 00:13:16,110
the j2 engine test facility is

265
00:13:27,259 --> 00:13:18,899
approximately 95% finished with

266
00:13:29,809 --> 00:13:27,269
completion due in January the first

267
00:13:32,150 --> 00:13:29,819
redesigned Saturn 5 instrument unit

268
00:13:34,519 --> 00:13:32,160
structure was delivered to Marshall by

269
00:13:36,920 --> 00:13:34,529
General Dynamics Fort Worth Texas this

270
00:13:40,639 --> 00:13:36,930
quarter the structure will be used for

271
00:13:43,240 --> 00:13:40,649
the dynamic test unit vibration testing

272
00:13:46,639 --> 00:13:43,250
for evaluation of IU cold plates

273
00:13:49,220 --> 00:13:46,649
manufactured by four vendors fqo North

274
00:13:51,499 --> 00:13:49,230
American solar aircraft and air angka

275
00:13:53,629 --> 00:13:51,509
was in progress at Marshall during the

276
00:13:55,939 --> 00:13:53,639
quarter vendor selection will be made

277
00:13:59,689 --> 00:13:55,949
following completion of evaluation

278
00:14:01,639 --> 00:13:59,699
testing as negotiations continued with

279
00:14:04,999 --> 00:14:01,649
International Business Machines for the

280
00:14:07,129 --> 00:14:05,009
IU mission contract IBM personnel are

281
00:14:11,059 --> 00:14:07,139
already at work in their new Huntsville

282
00:14:13,549 --> 00:14:11,069
engineering laboratories one of the most

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significant activities in which IBM is

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participating is preparation for the

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flight systems test program a thermal

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vacuum test of the entire IU under

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simulated space flight conditions to be

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performed in an environmental chamber at

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Douglas aircrafts Huntington Beach

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facility to reduce costly duplication of

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testing facilities special test

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equipment which will be required both at

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Huntsville and Huntington Beach is being

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installed in trailers which can be air

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transported between these locations IB

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personnel this quarter also performed

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functional testing of the IU radar

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altimeter using an MSF C furnished test

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set another test involved a circuit

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analysis of the I use remote digital sub

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multiplexer breadboard circuit modules

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which duplicate production hardware in

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component utilization and location are

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tested in a temperature chamber to

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detect possible circuit malfunctions

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resulting from components tolerance

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accumulations also in progress this

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quarter were desired evaluation Studies

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on a newly designed channel unit for the

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IU telemetry system all these operations

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are providing valuable experience as IBM

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phases into complete responsibility for

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a mission qualified Saturn 5 instrument

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unit the construction phase of the

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Saturn 5 dynamic test stand at Marshall

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is complete except for installation of

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small items such as bracket tray and

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grating components of the second s1c

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transporter delivered by frou Hoff of

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Los Angeles in early November have been

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assembled at Marshall at the Saturn 5

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ground support equipment test facility

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construction is virtually complete

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except for installation of cryogenic

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lines all technical systems equipment

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has been delivered and installation is

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about 50% finished with completion due

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in January overall construction of the

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Saturn 5 barge dock and loading facility

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on the Tennessee River is practically

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complete at Marshalls Mississippi test

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facility construction proceeded under

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test complex comprising the s 1 C dual

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position static test stand and the 2 s 2

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static test stands the laboratory and

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engineering complex which contains the

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office and administration building the

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data handling center and the telephone

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and terminal building and the support

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services complex including such

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facilities as

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emergency services building MTF

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warehouse site maintenance building and

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central heating plant in summary

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September October and November 1964 were

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months of highly significant

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achievements in the Saturn 5 program

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Assembly of s1c stages progressed

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steadily major milestones were reached

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in the upper stage programs with both

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the first s - battleship Hut firing and

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the first s4b battleship Hut firing

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significant progress was also achieved

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on the engine programs the instrument