;nte rnai Letter 01% Rockweii Internationa iCate :

TO :

SLbject

24 February 1993flame . Organization, internal Address)

N: ' MPR-93-0065%

J. Halchak H. ConawayD/596 D/539-167055-AC 17 055-AC71

394-7304

WEEKLY ACTIVITY REPORT AS OF 24 FEBRUARY 1993

SSME ACTIVITIES

NOZZLE

Fabrication of Un-Recrystallized Weld Samples : Attempts to make weld samples inAlloy 718 that are not recrystallized are continuing . The latest effort yielded a .250 inchthick plate with only the root recrystallized . A new sample is being prepared thatincorporates an intermediate stress relief after weld of the root.

An informal summary of attempts to date, and an outline of possible actions wascompiled . This effort is now facing proposed HCF testing in support of the NozzleSteerhom Investigation .

POWERHEAD

INERTIA WELDING MAIN INJECTORS

(M . B right/T. Hosking/N . Waldron

The following tasks are being pursued at this time :

• A review of Rocketdyne's LOX post inventory and available 5/8" diameter Alloy 188barstock is being made to determine the availability of desirable material for inertiawelding twelve new main injectors.

• Main Injector, Unit 4027, is nearing MR release and should be available soon forinertia welding of its 600 LOX posts . Process control qualification samples will bewelded immediately after the unit's release .

• Six weld samples from a new material lot (Lot #J-7785) were inertia welded for thefirst time resulting in one low upset weld of 0 .054 inch (required minimum is 0 .055") .The other five samples yielded weld upsets ranging form 0 .061" to 0 .067", indicatingthat we may have problems satisfying process control qualification requirements .Other available weld sample lots have yielded similar results . Despite these results,the inertia welding machine performed well .

• The Main Injector O .E. Team is-studying options for accommodating current LOX postlots with low-upsetting tendency (low ductility) . Options include: (1) Qualify and usehigher energy input welding parameters, (2) weld the posts with the standardparameters and risk low upset welds and MR costs (the probability is low, but real), or(3) procure new LOX posts (i .e ., barstock) with more desirable welding andmetallurgical characteristics . To determine the feasibility of the latter option, aninquiry will be made to exchange current barstock with less than desirable weldabilitycharacteristics for barstock with finer grain structure and less carbide precipitation(features known to enhance the plastic deformation that occurs with inertia welding) .

(G. Snyder)

(A) = Achievement(P) = Problem

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OTHER ACTIVITIES

ELV

DIVISION CPI TEAM FOR WELDING

The ELV Thrust Chamber and Welding Work Center will participate in a Division CPITeam to address welding issues . The kick- off meeting (called by Byron Wood) was held2/17/93 . The team will be facilitated by Fritz Kuck and will be represented across bothprograms and functions .

(W. Garrison )

ELV TURBINE WHEELS CPI TEAM STATU S

The ELV Turbine Wheels CPI Team is in the cause and effect stage of the 8 stepprocess . The focus is on surface discontinuities in the blade to hub weld on P/N 458726that appear after the first and second lathe operation . The discontinuities are surfaceinclusions/oxides that prevent interpass fusion and are detected by visual and/orpenetrant inspection . Initial SEM'analysis of the defect areas reflect a presence ofaluminum. Subsequent analysis of the blades reveal aluminum products on theunground surfaces . The possibility of the presence of aluminum originating from aninvestment casting mold reactive product is under investigation . (i .e. ; cobalt aluminatemold inoculate as a surface grain refining agent.)

(W. Garrison )

SPACE STATION

BETA GIMBAL 4-BAR LINKAG E

In-Place Tube Weld Samples : Six aluminum 2219 tube samples have been in-placetube welded using the latest set of parameters . Radiographic inspection revealed five ofsix would not meet the porosity requirements due to oversize groups of porosity clusters .Currently , an effort is underway by Stress to determine the allowable cluster size for thiscomponent . In addition , welded samples are being prepared and will be radiographicallyinspected to establish levels of porosity when welding is performed manually.

(J . Dill )

PUMP AND FLOW CONTROL ASSEMBL Y

Status of Hamilton Standard Welding Sroecifications : Hamilton Standard has respondedto the latest review of their welding specifications . Most items are no impact or simply achange in verbiage. There are several items, though, which will need furthe rinvestigation to determine the degree of impact . The major items include requestedanalysis to justify their porosity spacing requirements of 1 times the diameter of thelargest pore versus Rocketdyne's more stringent requirement of 2 times the diameter .There is also a problem meeting NASA's requirement to fully inspect, surface andsubsurface, all weld repairs, including Class Il welds . Hamilton Standard stated that twoweeks are available for resolving the welding specification issues before a programschedule delay would occur.

(J . Dill)

(A) = Achievement(P) = Problem

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PHOTOVOLTAIC RADIATO R

A review of Loral Vought Systems ( LVS) Space Station Welding specification , 208-17-24B, and Standard Weld Repair Specification , 208-17 -25, has been completed . Thewelding specification was found acceptable , but the repair specification has a number ofareas which still need to be addressed to fully meet NASA 's requirements .

(J . Dill )

ROCKETDYNE CPI TEAM FOR WELDIN G

The first meeting of the Rocketdyne CPI Team for Welding was held . Tworepresentatives from Welding Technology and Application a ttended the meeting . At thefirst meeting the mission statements were defined . The goal of this team is to establishhow to make the decision to weld , incorporate the process into the design and developthe process for use in production .

(M. B right/J . Dill )

GENERIC

Trip to Weld Wire Supplier: A t rip to Bob Ma rtin Company in El Monte , California,originally scheduled for February 18, 1993, will be made on Thursday, February 25,1993, to discuss issues related to a weld wire shipment we received from them withmislabeled tab code identification . Members from Rocketdyne 's Purchasing , ReceivingInspection , and ME &T will attend the meeting .

(G. Snyder)

No unit meeting was held this week .

H . R. Conaway, ManagerWelding Technology and ApplicationWelding Producibility and Manufactu ringMate ri als Engineering and Technology

(A) = Achievement(P) = P roblem

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