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this was yesterday this is happening

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today saturn s 1c has moved from drawing

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board design to pilot fabrication nasa's

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marshall center is responsible for

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development of the s 1c booster stage of

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the saturn v vehicle the boeing company

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is the contractor for the booster

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development of manufacturing techniques

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consistent with reliability requirements

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state-of-the-art advancements and

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feasible production capabilities is a

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basically the s 1c booster is a tandem

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tank configuration with the oxidizer

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tank on top and enter tank structure

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next then the fuel tank assembly above

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and attached to the thrust structure

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which supports the fens based structures

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and the v f1 engines the first static

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test of the booster is scheduled for

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october 1964 pilot fabrication of the

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huge tank bulkheads is now underway six

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basic jigs are stations have been

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developed to perform this operation

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openings required for fittings are first

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cut and fittings installed then the apex

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and base parts of each core section are

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trimmed next the apex and base sections

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are welded together to form a gore

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segment the core is then trimmed and

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routed are grooved

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on each side for well two other sections

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next all four sections are welded

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together trimmed and the bulkhead

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assembly completed next operation is

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closure of the bulkhead utilizing this

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tooling the manufacturing engineering

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division at Marshall is presently

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performing pilot fabrication advantage

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of this manufacturing process can be

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depicted by following a bulkhead

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fabrication sequence through the six

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stations previous bulkhead fabrication

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techniques on smaller tank components

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utilized a moveable jig which traveled

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under a stationary weld head

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this approach was impractical for

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elliptical bulkheads of large diameters

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here we see an apex segment of Evora

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section being positioned on the station

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one fixture both tooling and bulkhead

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segments are fabricated by Boeing at

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Wichita the first operation is

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installation of various propellant line

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fittings as required here we see a

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cutout for a fixture these fittings

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short conical sleeves are used for

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structural support of propellant suction

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tunnels the bulkhead components are

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handled by overhead cranes which

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traverse the area over all jig stations

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the fixtures were designed by Marshall

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Center and fabricated to MSFC

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specifications by Boeing this fixture

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consists of a gantry under dolly the

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gantry suspends a rotating carriage over

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the weld area this carriage is being

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positioned in preparation for trimming

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and routing the cutout and preparation

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for welding operations the carriage

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supports both cutting and welded which

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may be attached without removal of the

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carriage the bulkhead section is

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anchored to the fixture by a hydraulic

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pull down system in accordance with the

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original manufacturing plan initial

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operations will be accomplished at

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Marshall with pilot operations followed

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by fabrication of ground test stages and

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the first flight vehicle this effort

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will include partial fabrication and

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assembly of the s-1 CT the first static

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firing stage s1 CD a dynamic test stage

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and one light beer all machine and

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fabrication techniques and procedures

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developed and proved feasible and

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reliable at Marshall will be utilized at

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masu and production fabrication of the

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s-1 sea all jigs and equipment will be

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transferred to miss Yu for use by Boeing

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and the production phase of the program

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after Marshall phases out of the s-1 C

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fusion welding of the structural

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components that comprise the propellant

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containers is accomplished automatically

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by both mechanical and electronic

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controls

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well thickness are fitting locations

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vary from two tenths to eight tenths of

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an edge depending upon the size of the

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fitting after welding is completed on

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each section the segment is removed and

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subjected to x-ray inspection then

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transported to the cleaning facility the

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part is aged formed where the well

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distortion is corrected the apex core

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segment is then cleaned and according of

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erudite 14 to our Aladin 1200 is applied

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next the apex segment and the base

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segment of a gore section are prepared

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for welding this operation is

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accomplished on the station to fixture

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which actually comprises two jigs one

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for the apex segment as shown here and

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one for the base segment in this view

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the depressions on the jig can be noted

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clearly vacuum affected at each of these

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points holds the material in place but

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does not bind the material to the jig as

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tightly as hold down clamps and allows

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the weld area to move thus the termsof

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tooling is applied this section the

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bottom of the apex segment is being

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trimmed the edges apex and base segments

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are cut into a concave or a convex shape

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to allow a tongue-and-groove type joint

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the concave section is approximately six

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hundredths of an inch deep this fixture

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is used with the base segment of the

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gore section vacuum locations are

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evident here in the base segment is

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being positioned on the jig preparatory

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to final trimming of the base line

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trimming and routing operations are

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performed by tooling that travels on a

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fixed track which is a part of the

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fixture assuring the same cut or routing

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on each segment next the apex and base

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segments will be welded into a course

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section assembly this operation is

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accomplished on the apex two base weld

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fixture our station number three this

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fixture consists of three sections and

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overhead support holds the well

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head and track for the unit to travel

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over a two-part Dalek type fixture

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utilizing vacuum pulldown Positioning

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Systems holds the gore segments this

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approach extensively used at MSFC called

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soft tooling will be utilized at masu

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wherever practical the apex segment is

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being positioned for welding after

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positioning the fixture is locked

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next the base segment is positioned and

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locked the two parts of the Dalek

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platform are attached forming an

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integral unit this platform is tilted

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allowing the immediate weld area to

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remain in an uphill position this method

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precludes running our fooling of the

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weld material wells are made with single

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passes of the head the well track

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follows the contour of the head assembly

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but the proximity of the head to work

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surface does not depend on the accuracy

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of the track this is accomplished by an

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electronic sensing device which

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compensates for variations in curvature

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of the work surface and proximity of the

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weld head to the part rate of travel of

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the weld head angle of attack and other

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control aspects are programmed and

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monitored electronically this provides a

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system that effectively reduces human

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error and provides a high degree of

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reliability next the gore sections are

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positioned on the bulkhead Gore trim and

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route fixture this is station number 4

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here the section is trimmed to Meridian

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trim lines then routed on both sides one

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side of the section is routed concave

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and the other convex which allows a

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tongue-and-groove

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fitting between sections the gore

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sections used in this pilot fabrication

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are of 2219 aluminum the same material

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which will be used in all test and

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production boosters the entire portion

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of the gore is held down by vacuum there

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by holding the part in position until

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the operation is complete after trimming

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the gore is removed and placed on the

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bulkhead assembly jig station number

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five where the eight core sections are

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joined together

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to form the bulkhead this fixture

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consists of a 396 inch diameter

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turntable clamping device a 17 foot tall

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Center pedestal and a vacuum Chuck the

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size of two side-by-side Gore's joining

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the pedestal to the ring assembly of a

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bulkhead begins with two four sections

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being positioned to form the vacuum

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Chuck the sections fit together with a

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tongue and groove joint the weld head

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suspended from a curved arm makes a

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Meridian but weld along the joint of the

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two wars starting at the base and moving

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up and on an elliptical path the head

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makes a single pass to weld the two bars

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together and well thickness will vary

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between 2/10 and 8/10 of an edge after a

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pass the head will be swung out of the

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way and the welded seam x-rayed the

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world head travels on an overhead track

215
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and is controlled by a similar system

216
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used at station number three where the

217
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segments are welded together after one

218
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well joint is completed and x-ray

219
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accepted that turntable is rotated

220
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positioning the next core section joint

221
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and the well process repeated until all

222
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eight drawers have been welded together

223
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to form the bulkhead the base of the

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bulkhead will be trimmed and the entire

225
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section moved to station number six the

226
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center piece trim and well fixture this

227
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center piece fixture performs cutout

228
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final trim and weld operations to

229
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install the 54 inch disc of aluminum

230
00:10:46,100 --> 00:10:42,930
alloy in the bulkhead center the center

231
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disc closes the top of the bulkhead this

232
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jig consists of a Center pedestal and

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eight support arms the bulkhead is

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lowered over the pedestal onto the arms

235
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after this operation the bulkhead has

236
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returned to station 5 where the wiring

237
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is welded to the base section of the

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bulkhead tooling has felt the influence

239
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of a team effort in design fabrication

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and installation since Marshall Space

241
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Flight Center had several month lead on

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Boeing and tool development ma division

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tool designer

244
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laid ground rules and development then

245
00:11:27,710 --> 00:11:24,480
worked out the major design concepts in

246
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the area of bulkhead fabrication joint

247
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effort is not an abstract term in the

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relationship between MSFC and the boeing

249
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company it is an evident truth the s1c