NASA Technical Reports Server (NTRS) 20080007518: External Tank (ET) Bipod Fitting Bolted Attachment Locking Insert Performance

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NASA/TM-2008-215099 (Corrected Copy)
NESC-RP-06-53/06-032-E
External Tank (ET) Bipod Fitting Bolted
Attachment Locking Insert Performance
Curtis E. Larsen
NASA Johnson Space Center, Houston, Texas
Tim R. Wilson
NASA Langley Research Center, Hampton,Virginia
Kenny B. Elliott
NASA Langley Research Center, Hampton, Virginia
Ivatury S. Raju
NASA Langley Research Center, Hampton, Virginia
John McManamen
NASA Johnson Space Center, Houston, Texas
January 2008
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NASA/TM-2008-215099 (Corrected Copy)
NESC-RP-06-53/06-032-E
External Tank (ET) Bipod Fitting Bolted
Attachment Locking Insert Performance
Curtis E. Larsen
NASA Johnson Space Center, Houston, Texas
Tim R. Wilson
NASA Langley Research Center, Hampton,Virginia
Kenny B. Elliott
NASA Langley Research Center, Hampton, Virginia
Ivatury S. Raju
NASA Langley Research Center, Hampton, Virginia
John McManamen
NASA Johnson Space Center, Houston, Texas
NASA Engineering and Safety Center
Langley Research Center
Hampton, Virginia 23681-2199
January 2008
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ERRATA
NASA/TM-2008-215099
External Tank (ET) Bipod Fitting Bolted Attachment Locking Insert
Performance
Curtis E. Larsen
NASA Johnson Space Center, Houston, Texas
Tim R. Wilson
NASA Langley Research Center, Hampton,Virginia
Kenny B. Elliott
NASA Langley Research Center, Hampton, Virginia
Ivatury S. Raju
NASA Langley Research Center, Hampton, Virginia
John McManamen
NASA Johnson Space Center, Houston, Texas
January 2008
Issue Date: 8/8/2008
Corrected copy issued to include replacing Mr. Elliot with Dr. Elliot (3 places on
page 10), and correcting references to Figure 4.1-1 to Figure 4.2-1 (page 11).
NASA Engineering and Safety Center
Langley Research Center
Hampton, Virginia 23681-2199
January 2008
NASA Engineering and Safety Center
Document #: Version:
Technical Position Paper RP-06-53 1.0
Title: Page #:
External Tank (ET) Bipod Fitting Bolted Attachment 1 of 18
Locking Insert Performance
External Tank Bipod Fitting Bolted Attachment
Locking Insert Performance
June 22, 2006
NESC Request No. 06-032-E
NASA Engineering and Safety Center
Document #: Version:
Technical Position Paper RP-06-53 1.0
Title: Page #:
External Tank (ET) Bipod Fitting Bolted Attachment 2 of 18
Locking Insert Performance
TABLE OF CONTENTS
Volume I: Technical Consultation Report
1.0 Signature Page...................................................................................................................3
2.0 Team Member List...........................................................................................................4
3.0 Executive Summary..........................................................................................................5
4.0 Findings, Recommendations, and Observations..........................................................11
4.1 Findings......................................................................................................................11
4.2 Recommendations.....................................................................................................11
4.3 Observations..............................................................................................................12
5.0 References........................................................................................................................13
Volume II: Appendices
Appendix A. ITA/I Request Form (NESC-PR-003-FM-01)........................................................14
Appendix B. Bipod Breakaway Torque........................................................................................17
List of Figures
Figure 3.0-1. Insert and Bolt Used in the Design..........................................................................5
Figure 3.0-2. Insert Locking Feature.............................................................................................6
Figure 3.0-3. Bipod Fitting Insert Locking Feature Test Results..................................................9
Figure 4.2-1. Example Component Test Specimens....................................................................12
List of Tables
Table 3.0-1. Measured Running Torque in the Attachment Bolts in ET-119 and 120 …………. 7
NESC Request No. 06-032-E
NASA Engineering and Safety Center
Document #: Version:
Technical Position Paper RP-06-53 1.0
Title: Page #:
External Tank (ET) Bipod Fitting Bolted Attachment 3 of 18
Locking Insert Performance
Volume I: Technical Position Paper
1.0 Signature Page
Technical Team Members
Team signatures on file – 01-16-08
Dr. Curtis Larsen, NESC Lead Dr. Kenny Elliott, LaRC
____________________________________ _________________________________
John McManamen, JSC Dr. Ivatury Raju, LaRC
____________________________________
Tim Wilson, LaRC
NESC Request No. 06-032-E
NASA Engineering and Safety Center
Document #: Version:
Technical Position Paper RP-06-53 1.0
Title: Page #:
External Tank (ET) Bipod Fitting Bolted Attachment 4 of 18
Locking Insert Performance
2.0 Team Member List
Dr. Curtis Larsen, NESC NESC Discipline Expert (NDE), Mechanical Analysis, Team Lead
Dr. Kenny Elliott, LaRC Structures
John McManamen, JSC NDE, Mechanical Systems
Dr. Ivatury Raju, LaRC NDE, Structures
Tim Wilson, LaRC NESC Deputy Director
NESC Request No. 06-032-E
NASA Engineering and Safety Center
Document #: Version:
Technical Position Paper RP-06-53 1.0
Title: Page #:
External Tank (ET) Bipod Fitting Bolted Attachment 5 of 18
Locking Insert Performance
3.0 Executive Summary
Following STS-107, the External Tank (ET) Project implemented corrective actions and
configuration changes at the ET bipod fitting. Among the corrective actions, the existing bolt
lock wire which provided resistance to potential bolt rotation was removed. The lock wire
removal was because of concerns with creating voids during foam application and potential for
lock wire to become debris. The bolts had been previously lubricated to facilitate assembly but,
because of elimination of the lock wire, the ET Project wanted to enable the locking feature of
the insert. Thus, the lubrication was removed from bolt threads and instead applied to the washer
under the bolt head. Lubrication is necessary to maximize joint pre-load while remaining within
the bolt torque specification. The locking feature is implemented by thread crimping in at four
places in the insert. As the bolt is torqued into the insert the bolt threads its way past the crimped
parts of the insert. This provides the locking of the bolt, as torque is required to loosen the joint
after clamping. Refer to Figures 3.0-1 and 3.0-2.
Figure 3.0-1. Insert and Bolt Used in the Design
[ref. Wingate, ET Bipod Fitting Bolted Joint Attachment Design and Locking Insert
Performance presentation, June 13, 2006]
NESC Request No. 06-032-E