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X-33 Tank Failure During Autoclave FabricationDuring a repair cure cycle on tank #1 of the X-33 liquid hydrogen tanks, a skin to core disbond occurred. Both the inner skin and outer skin of the lobe #1 sandwich panel was noted to have been disbonded and cracked- An investigation was undertaken to determine the cause of this failure. The investigation consisted of reviewing all of the processing data and performing testing on the failed lobe #1, as well as the other lobes, which did not fail during the cure cycle. The tests consisted of residual stress measurements in one of the intact lobes and "plug-pulls" to assess skin to core strength on all of the remaining lobes. Results showed an extremely low bondline strength due to lack of proper filleting of the adhesive, in addition, tests showed a very rapid decrease in strength with increasing temperature, as well as a further decrease in strength with a larger number of cycles. Also, the honeycomb used was not vented so pressure could build up within the cells. All of these factors appeared to be contributors to the failure.
Document ID
20020034965
Acquisition Source
Marshall Space Flight Center
Document Type
Preprint (Draft being sent to journal)
Authors
Nettles, Alan T.
(NASA Marshall Space Flight Center Huntsville, AL United States)
Munafo, Paul
Date Acquired
August 20, 2013
Publication Date
January 1, 2001
Subject Category
Engineering (General)
Meeting Information
Meeting: US Air Force Manufacturing Problem Prevention Program
Location: El Segundo, CA
Country: United States
Start Date: June 5, 2001
End Date: June 6, 2001
Sponsors: Department of the Air Force, Aerospace Corp.
Distribution Limits
Public
Copyright
Work of the US Gov. Public Use Permitted.

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