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THE VANGUARD

SATELLITE LAUNCHING VEHICLE--

AN ENGINEERING SUMMARY ;_

_'Engineering Report No. 11022_

April 1960

No, Nonr-1817 (00) 3

Prepared by: Technically Edited
and Approved by:

THE IMA WWTm N
FOREWORD
This engineering summary for the Vanguard satellite launching vehicle has
been prepared by the Martin Company for the National Aeronautics and Space
Administration, in fulfillment of Item AB of Martin Specification No. 1082, under
United States Navy Contract No. Nonr- 1817 (00).

The Martin Company acknowledges the valuable information and guidance
furnished by Mr. J. M. Bridger, of the National Aeronautics and Space Adminis-
tration, who instigated the report effort.

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CONTENTS
iii
FOREWORD ..........................................

iv
CONTENTS ...........................................

vii
SUMMARY ...........................................

I° INTRODUCTION ......................................

II. BACKGROUND

A. State of the Art in 1955 ............................... 3
4
B. Vanguard Program Philosophy ..........................

III. VEHICLE DESIGN AND DEVELOPMENT

7
A. Mission Requirements ................................
7
B. Trajectory Simulation .................................
8
C. Staging and Flight Path Considerations ...................
9
D. Performance Optimization .............................
10
E. Aerodynamics .......................................
F. Structure ........................................... 18
25
G. Weight Control ......................................
25
H. Final Vehicle Configuration'. ...........................

IV. SYSTEMS DESIGN AND DEVELOPMENT

A. Guidance and Control ................................ 29
40
B. First-Stage Propulsion ................................
51
C. Second-Stage Propulsion ...............................
62
D. Third-Stage Propulsion ................................
66
E. Separation ..........................................
F. Ordnance .......................................... 70
G. Electrical ........................................... 72
H. Mechanical ......................................... 77
8O
I. Hydraulic ..........................................
84
J. Range Safety ........................................
K. Instrumentation ...................................... 85
86
L. Systems and Payload Integration ........................

V. RELIABILITY

89
A. Requirement ........................................
B. Environmental Criteria ................................ 89
C. Component and System Qualification ..................... 89
D. Component and System Acceptance Testing ................ 95
E. Vehicle Acceptance Testing ............................ 95
96
F. Reliability Follow-up .................................
G. Observations on Reliability ............................. 98

iv
VI. FIELD OPERATIONS

A. Launch Complex .................................... 99
B. Field Testing ....................................... 104
C. Range Safety Considerations ........................... 106
D. Flight Loading and Performance Predictions ............... 106
E. Launch Operations ................................... 109

VII. VEHICLE FLIGHT ANALYSIS

A. Flight Summary ..................................... 112
B. Vehicle Trajectories .................................. 118
C. Aerodynamics ....................................... 118
D. Structure ........................................... 120

VIII. SYSTEMS FLIGHT ANALYSIS

A. Guidance and Control ................................ 123
B. First-Stage Propulsion ................................ 132
C. Second-Stage Propulsion ............................... 139
D. Third-Stage Propulsion ................................ 150
E. Separation .......................................... 151
F. Ordnance .......................................... 156
G. Electrical ........................................... 156
H. Mechanical ......................................... 159
I. Hydraulic .......................................... 159
J. Range Safety ........................................ 161
K. Instrumentation ...................................... 163

IX. SIGNIFICANT FLIGHT ANALYSIS TECHNIQUES

A. Philosophies ........................................ 165
B. Techniques .................. . ....................... 165

X0 PROGRAM ACCOMPLISHMENTS

A. Satellite Orbits ...................................... 169
B. Mission Capabilities of the Final Vehicle .................. 169
C. Advances in the State of the Art ........................ 170

XI. REFERENCES ........................................ 177

XII. BIBLIOGRAPHY ...................................... 179

APPENDIX: PROBABILITY METHOD OF PERFORMANCE
PREDICTION ....................................... A-1
SUMMARY
Project Vanguard was conceived in 1955 for the purpose of establishing a
scientific satellite in orbit about the earth during the International Geophysical Year
(July 1957 to December 1958). It was planned and implemented as a low priority,
economical effort that would not interfere with military missile development. This
report has been prepared by The Martin Company to summarize the engineering
of the rocket vehicle that launchedthe Vanguard satellites.

The Vanguard vehicle was a three-stage finless rocket with a liftoff weight
of approximately 22,800 pounds; 88% of this weight was propellant. The first
two stages were liquid-propellant rockets, guided by a "strapped-down" gyro
reference system, and controlled by engine gimbaling and reaction jets. The third
stage was a solid-propellant rocket motor, unguided but spin-stabilized. A jettison-
able nose cone protected the payload. Launchings were made from the Atlantic
Missile Range, Cape Canaveral, Florida.

Unique design concepts and advanced analytical techniques were developed
during the Vanguard program. Significant examples are the use of structural feed-
back to reduce structural loads, trajectory matching for flight analysis, and a
remarkably accurate statistical approach to performance prediction.

The established goal was at least one satellite orbit in six attempts. Actually,
the number of attempts was increased to eleven by the use of five vehicles initially
programmed for flight development testing. Three satellites were placed in orbit,
containing four of the six scientific experiments orginally planned for Project Van-
guard. The success of the satellite launching vehicle is further manifested by the
continuing use of Vanguard hardware, design concepts and analytical techniques in
other advanced rocket programs.

vii
I. INTRODUCTION
The concept of launching small earth satellites for scientific purposes during
the International Geophysical Year (IGY) was recommended for the consideration
of the participating nations in October 1954 by the planning committee of the
International Council of Scientific Unions. The U.S. National Committee for the
IGY investigated the feasibility and scientific value of such a project and in March
1955 reported favorably to their parent organization, the National Academy of
Sciences, and to the National Science Foundation. On 29 July 1955, the White
House announced that the United States would construct and launch a small instru-
mented earth satellite as a part of its contribution to the IGY.

The Department of Defense (DOD), directed by the President to implement
the program, had already under consideration several proposals from the military
services for the development of satellite launching vehicles. The recommendations
of the DOD Advisory Group on Special Capabilities (Stewart Committee) and the
DOD Policy Council resulted in a decision on 9 September 1955 to proceed with
the Navy's proposal. This plan contemplated a three-stage launching vehicle, based
on the Viking and Aerobee-Hi rockets, which would not interfere with concurrent
military missile programs. The Navy proposal included specific scientific uses for
the payload, and an international ground tracking system (Minitrack) to trace the
orbit and obtain data from the satellite.

A tri-service program was accordingly set up under Navy management and
designated Project Vanguard. The Office of Naval Research retained contractual
authority but delegated technical responsibility to the Naval Research Laboratory
(NRL). The Stewart Committee retained an overall monitoring function for DOD.
On 23 September 1955, The Martin Company was awarded the prime contract for
design, construction, test and preparation for flight of the satellite launching
vehicles. A detailed discussion of the history and organization of the Vanguard
program is given in Ref. 1.

The above organizational structure remained in effect until May 1958, at
which time the DOD monitoring function was shifted to the Advanced Research
Projects Agency. On 1 October 1958, the overall responsibility for Project Van-
guard was transferred from DOD to the newly created civilian agency, the National
Aeronautics and Space Administration (NASA).

This engineering summary report presents a documentation of the design,
development, test and flight analysis of the Vanguard satellite launching vehicles.
Special emphasis is placed on basic design decisions, significant development tests,
major development problems and their solutions, performance prediction methods,
flight analysis techniques and program results.
II. BACKGROUND
A. STATE OF THE ART IN 1955 Separation--There was little experience with tan-
dem staging; some tandem staging had been clone on
When the earth satellite program became a reality
the Bumper-Wac V-2 in 1949, the much smaller
in 1955, the state of the art of rocketry (in the Western
(1500-pound) Aerobee and various small rockets
world, at least) was barely ready for it. The early
(using solid-propellant motors). Some preliminary de-
work of Goddard and the other pioneers had been
signs had been conceived for large tandem stage separa-
accorded little recognition until the startling appear-
tion of liquid-propellant rockets. The Atlas 1-1/2 stage
ance of the German V-2 late in World War II. Post-
concept had progressed to the detailed design phase,
war rocket development, based largely upon the German but the problem of ignition at altitude had been avoided
work, had been sporadically promoted and financed. by starting all engines before launch.
The Navy had enjoyed success with the Viking single-
stage research rocket and was considering advanced 2. GUIDANCE AND ATTITUDE CONTROL
versions of this vehicle. The Army had successfully
Control configurations--Carbon jet vanes and
developed the single-stage Corporal and Redstone
aerodynamic surfaces were used for powered flight
ballistic missiles and had initiated design of the Jupiter control on the V-2 and later on the Redstone rocket.
IRBM. The Air Force Atlas ICBM was approaching The Viking had pioneered the use of a gimbaled rocket
the hardware stage, although the first flight was still engine, but still retained fixed fins and control tabs,
about two years away. The Thor and Titan programs
although a finless configuration had been studied. The
were just getting under way, essentially concurrent with
gimbaled engine approach was considered superior
Vanguard.
from the performance and reliability standpoints, be-
cause carbon vanes added drag and often burned or
1. VEHICLE SYSTEMS
broke off, while electro-hydraulic gimbal actuation sys-
Specific vehicles that preceded Vanguard had more tems were rapidly reaching high levels in efficiency and
or less avoided the loads problem by accepting rela- reliability. The background for coasting flight control
tively high structural safety factors (> 1.5), with was primarily that of the Viking "tumble-jet" system.
correspondingly low ratios of propellant to loaded There was no other approach then available that was
weights. In fact, the Viking, with a value of 0.8, had remotely competitive in terms of weight and demon-
the highest mass ratio of any vehicle flown to date. strated performance.

Aerodynamlcs---Considerable hypersonic wind tun- Re]erence systems--The attitude reference for
nel data and theoretical analysis had been developed, Viking was provided by a conventional medium-pre-
and there was some flight experience on vehicles such cision, vertical-directional gyro combination with drift
as V-2, Viking, Aerobee, and ordnance shells. Tran- rates on the order of l/s degree per minute. Appre-
sonic flow was not well understood. Little was known ciably lower drift vertical-directional gyro units capable
about heat transfer, since flight data were meager and of performing in the rocket environment were not in
theories were unconfirmed. existence. Gimbaled inertial platforms with greater
A general study of wind shear and gust probabilities precision were in development, but weighed in excess
had been made by the Air Force (Ref. 2) to be used of 100 pounds, including electronics. However, low-
for the design of operational military missiles on a drift, single degree of freedom integrating rate gyros
99% probability basis. However, this criterion was were becoming available.
considered too severe for a scientific research vehicle.
Autopilots--The Viking autopilot used d-c lead
The Air Force Air Weather Service had accumulated
circuits, a-c gyro pickoffs, d-c transfer valve and follow-
and analyzed a body of data on upper atmosphere
up excitation and miniature vacuum tube circuits for
winds and gusts at Patrick Air Force Base for a two-
the proportional channels. The arrangement was more
year period. Some White Sands Proving Grounds data
or less standard for contemporary missile systems,
were also available. Theoretical extrapolations of upper
although many used rate gyros for lead compensation.
atmosphere density, temperature and pressure to high
altitudes had been computed, but required almost con- For the periodic or "bang-bang" controls channels of
stant revision as later data became available. Wind- Viking during coasting flight (pitch, yaw and roll jets)
induced oscillations while the vehicle was on the launch the implementation was similar----except that threshold
stand had not been considered in previous designs. amplifiers, relays, and on-off valves were used instead
of transfer valves and follow-ups. There had been very quate for the attainment of such reliability and consisted
little use of reaction jets as "bang-bang" controls prior of six test vehicles (TV) and three backup vehicles
to the Viking program. (TV-BU). The first two test vehicles were basically
At the inception of the Vanguard program, two new Viking rockets. These were used because they were
approaches to autopilots were being considered by the available and well suited for initial checkouts of the
missile industry--magnetic amplifiers and transistor launching and tracking facilities and personnel and
circuits--to replace tubes. Magnetic amplifiers prom- for early flight testing of some Vanguard components.
ised longer life and greater reliability. Transistors Subsequent test vehicles introduced the actual Van-
promised smaller weight and volume as well as re- guard configuration in increasing stages of completeness
liability, but the state of development of basic transistor (see Claapter VII, Section A). Each backup vehicle
circuits was behind both vacuum tubes and magnetic was an identical replacement for one of the Vanguard
amplifiers. test vehicles, to be used as such only in the event of a
major deficiency in the primary test.
3. PROPULSION Plans for an instrumented nose cone for TV-3 were
changed in the summer of 1957 in favor of a small
Liquid rocket propulsion--Probably the largest
satellite payload that was also to be used in TV-4.
rocket in flight status in 1955 was the Army Redstone,
The change was made because a successful orbit would
with a takeoff thrust of about 75,000 pounds. The
smaller Navy Viking had a takeoff thrust of about permit ground checks of the world-wide tracking
20,000 pounds. Both rockets utilized liquid oxygen system (Minitrack). This was felt to be potentially
and alcohol as propellants, and delivered sea level more valuable than additional third-stage data in view
of the success with the TV-1 instrumented nose cone
specific impulse in the 190- to 220-second range, during
burning periods up to 1 l0 seconds. Engines were under flight. A small (four-pound) payload was chosen over
development, using hydrocarbon fuels, which would a full size (21.5-pound) satellite to increase the per-
increase specific impulse to the 240- to 250-second formance margin. A consequence of this change was
level. that the firing of the first three-stage Vanguard test
vehicle became a formal satellite launching attempt.
Solid rocket propulsion--In general, operational
solid rockets in 1955 were restricted to relatively short Production philosophy--While Vanguard could
hardly be termed a "production" program from a quan-
burning times and comparatively low specific impulse
(of the order of 210 seconds). Mass ratios as high as tity standpoint, the schedule did not permit the
"experimental," one-vehicle-at-a-time pace of the
0.85 were exceptional. Since their operation had been
earlier Viking program. Production engineering, and
generally as boosters within the sensible atmosphere,
even fabrication of vehicles, had to proceed concur-
where aerodynamic attitude control was feasible, little
or no development had occurred in thrust vector con- rently with design, development, and qualification.
trol. Similarly, there was little knowledge of the opera- Component and system selection---Another sig-
tional environment at very high altitudes. nificant effect of the schedule and budget was to dictate
the utilization, wherever feasible, of previously devel-
B. VANGUARD PROGRAM PHILOSOPHY oped components and systems for the launching vehicle.
Obviously, mission requirements, weight, environ-
The Vanguard program was planned from the outset mental criteria, materials compatibility, and reliability
as a comparatively low priority, economical effort, were the primary considerations, but this "off-the-shelf"
which would not be allowed to interfere with concur-
concept profoundly influenced early Vanguard design
rent military ballistic missile development. The sched-
decisions. In retrospect, it must now be conceded that
ule was predetermined by the fixed dates of the IGY
the "shelf" provided relatively little of the ultimate
(July 1957 through December 1958) which required
hardware.
completion of the entire program in about three years.
The combination of these factors introduced basic de- Per]ormance and weight control The critical
sign and test philosophies which set the pattern for the nature of orbital velocity and injection angle require-
project. ments (see Fig. 1), combined with the state of the
art of rocketry at the time, necessitated a con-
Vehicle program--In order to achieve the estab-
servative approach to the design of the launching ve-
lished goal of orbiting a satellite during the IGY, it
hicle from a performance standpoint. Design calcu-
was decided that six launching vehicles of the final con-
lations were based upon "minimum" or "maximum"
figuration (SLV) should be provided--a significant
measure of the initial reliability concept. The flight extremes of performance, which assumed all known
tolerances accumulated in the most unfavorable direc-
test program originally planned for development of the
SLV configuration was the minimum considered ade- tion. In fact, since it could never be guaranteed that
all possible tolerances had been considered, some ad- Test philosophy--The minimal nature of the flight
ditional performance margin was generally provided. test program dictated considerable emphasis upon
The extreme conservatism of this approach became ground testing, although extensive reliability testing of
more apparent as flight experience accumulated, and components and systems in quantity was incompatible
the vehicle ultimately demonstrated capability consid- with both schedule and budget. But this very fact--
erably in excess of the original mission requirements the absence of formal reliability data--placed addi-
(see Chapter X, Section B). This philosophy, com- tional reliance on development, qualification and ac-
bined with the launch weight limitations imposed by ceptance tests for components and systems, and on
first-stage thrust available, required that critical atten- plant and field functional checkout procedures for the
tion be given to vehicle weight control (see Chapter assembled rocket. The subject of reliability is treated
III, Section G). at length in Chapter V.

5
III. VEHICLE DESIGN AND DEVELOPMENT
A. MISSION REQUIREMENTS was the three-dimensional, six-degree-of-freedom, dig-
ital (IBM 704) trajectory program, designed to give the
The Vanguard contract was awarded on the basis of
details of the complete system at any time, as well as
a joint NRL-Martin preliminary study which indicated
the overall picture of the flight history. This program
that a three-stage vehicle of the order of 20,000 pounds
numerically integrated differential equations of motion
gross weight would be capable of imparting orbital
for the vehicle, which included atmospheric variations
velocity to a payload of 21.5 pounds. This payload
and second-order effects, such as earth oblateness and
weight was written into the original design specification
forces generated by the action of the gimbaled engines.
(Ref. 3). An improved third stage permitted a payload
Information was also provided for use in evaluating
increase to 55 pounds for the last vehicle.
An orbit lifetime of at least two weeks was considered range safety and radar tracking. Those items in the
program, but not directly concerned with the vehicle
necessary to provide sufficient data for the scientific
performance, included radar look angles, down-range
experiments. Although the uncertain composition of the
distance, cross-range distance, altitude, etc., as func-
atmosphere at extreme altitudes precluded an accurate
tions of vehicle performance and time.
determination, it was estimated that an initial orbit
The Vanguard 3-D trajectory program was probably
perigee of not less than 200 statute miles would ensure
the most important single tool of the project in defining
adequate lifetime, and this figure was specified. To
and solving the design and flight problems, especially
provide a workable margin for angular and velocity
in the areas of trajectory optimization, trajectory
errors at the point of injection into orbit, a "nominal"
matching, range safety determinations, and preflight
injection altitude of 300 statute miles was established.
performance predictions. The trajectory program also
Originally, the orbit apogee was considered to be
provided Keplerian satellite information and was at
limited by the requirements of the scientific experiments
times required to follow the satellite for one or two
to not more than 800 statute miles. However, the
orbits after injection.
stringent flight path demands imposed by the apogee
A two-dimensional digital trajectory program with a
limitation (illustrated in Fig. 1) caused reconsideration
of this requirement, which was relaxed to 1400 statute spherical earth, and a two-dimensional analog trajectory
program were available, and were of great value in the
miles and was subsequently eliminated altogether.
early days of the project. The digital 2-D program
The specification required capability for a maximum
survived the completion of the Vanguard 3-D program
of 45 degrees inclination of the orbit to the equator, al-
as an experimental tool to provide an economical, faster,
though the required easterly launch from Cape Cana-
but less detailed, look at a given trajectory. In this
veral would result in inclinations of the order of 30
manner, the gross effects of a wide range of parameters
degrees. A tolerance of two and one-half degrees was could be examined before more critical studies were
established for deviation of the initial orbit from the
made.
prescribed inclination angle.
In addition to these full-trajectory programs, others
The external configuration of the Government-
were devised to provide more detailed knowledge of the
furnished 21.5-pound satellite payload was chosen as
system at critical points of the trajectory. The launch-
a sphere for numerous reasons, the primary ones being
stand clearance program was a digital study to deter-
optimum light reflection for optical tracking and elimi-
mine vehicle position during the few seconds following
nation of the attitude variable from calculations of at-
ignition. First-stage separation was examined in an
mospheric density based on decay of the orbit. The
analog study with and without hardware. Third-stage
sphere diameter was desired to be as large as possible
separation was analyzed by a digital solution. The two-
to facilitate optical tracking. It was originally contem-
body spin problem for the heavy (_ 190-pounds) nose
plated as 30 inches, but early design studies established
cone of TV-1 was never rigorously solved. However,
20 inches as the maximum consistent with the vehicle
analytical work by the NORC group at the Naval Prov-
configuration and performance.
ing Grounds, Dahlgren, Virginia and The Martin Com-
pany was sufficiently complete to satisfy range safety
B. TRAJECTORY SIMULATIONS
requirements. A digital program was derived for
Many special calculation programs were derived for investigation of the two-body spin history and flight path
simulating the vehicle's trajectory on both analog and deviations for the heavy (_-50-pounds) payload of
digital computers. The most comprehensive of these TV-4BU.
r E
NOTE:
____ _,
INJECTION ALTITUDE 300 STAT MI.
FLIGHT PATH ANGLE WITH REFERENCE TO LOCAL HORIZONTAL. ] I k....1
,,
i
u.I

LIMIT
÷1 FOR
200-MILE
PERIGEE
O
z LIMIT LIMIT
< f FOR FOR
Ip- / f8OO-MILE 1400-MILE
< rAPOGEE APOGEE

i
0 ,I F-J
w-

i

24,800 25,000 25,200 25,400 25,600 25,800 26,000 26,200 26,400 26,600 26,800
ORBIT INJECTION VELOCITY (FPS}

I I t I I I I I i
99 100 101 102 103 104 105 106 107

PERCENT OF CIRCULAR ORBIT VELOCITY AT 300 STAT MI

Fig. I Orbit Injection Tolerancesfor Vanguard Mission

C. STAGING AND FLIGHT PATH this system offered simplicity in the later stages, it did
so by using an inefficient trajectory and by placing a
CONSIDERATIONS
high premium on first-stage guidance precision. A
The number of stages and the trajectory to be used three-stage vehicle with two guided stages and an un-
were perhaps the most basic decisions affecting perform- guided but spin-stabilized third stage, fired at second-
ance and guidance in the design of a statellite launching stage apogee, represented the most efficient vehicle com-
rocket vehicle to fulfill given orbit requirements. The bination consistent with rocket technology at that time.
actual selections influenced and were influenced by the Such a combination was reasonably compatible with
character and size of the individual stages, their type of the "off-the-shelf" concept--rocket engines existed
guidance, complexity, and types of propulsion system which, with some modification, would be suitable for at
and propellants (liquid or solid) to be used. least the first two stages. This configuration was selected
for the Vanguard vehicle prior to formal initiation of
Staging combinations--Single- or two-stage ve-
the program.
hicles offered much in simplicity and reliability but
would have made great demands upon propulsive effi- Trajectory--The Vanguard trajectory had to
ciency and guidance accuracy. The possible three-stage achieve the required injection conditions at 300 statute
combinations fell into three categories which depended miles while fulfilling various requirements. The initial
upon the extent of guidance chosen. A vehicle having vertical flight was limited to ten seconds by range safety
guidance in all three stages would alleviate stringent considerations, and the azimuth had to be such that
accuracy requirements, but the weight of the guidance impact could never occur on a land mass and command
in the final stage would require an excessively control capability could be maintained throughout
large vehicle. On the other hand, vehicles having un- flight.
guided second and third stages would require that the Aerodynamic forces in flight had to be minimized to
first-stage coasting apogee be, for all practical purposes, avoid excessive structural weight and consequent loss
the maximum orbit perigee obtainable, regardless of the in performance. For this reason, a near zero-lift trajec-
velocity contribution of the upper stages. Although tory was chosen during the portion of powered flight
whenatmospheric forceswereappreciable.Sincea mately 1.34 (Viking). Considerations of satisfactory
perfectzero-lifttrajectorywasnot practicalbecause of control of the vehicle during the initial phase of flight
probablewinddisturbances andgrossguidance system led to the selection of a lower design limit for T/W
complications, a simplifiedascenttrajectorywasused, of 1.20. Since minimum takeoff thrust was already
employing severalconstant ratesforchanging thepitch established at 27,000 pounds, this corresponded to a
gyroattitudereference. Thiscausedthevehicleto ap- design launch weight of 22,500 pounds.
proximatea zero-lifttrajectorythrougha still atmos- Selection procedure--The weights of propellant
phere.Themagnitudes andinsertiontimesof thepitch outages as functions of usable propellants and burning
ratesweredetermined by approximating, witha series times, the weights of propellants and tankages per unit
of carefullychosenstraightlines,theattitudehistoryof change in tankage length, and current configuration in-
thecomputed trajectorythatbestsatisfied theflightre- formation were used to determine the burning times for
quirements. the first two stages as functions of their weight. In con-
Thethird-stage trajectorywaslimitedby theconstant
sideration of design trends, burning times in terms of
attitudeof the spin-stabilized third stage.Third-stage
stage weight were also determined based on configura-
ignitiontime and attitudewereprogrammed toward
tions with the first-stage dry weight 200 pounds lighter,
achieving a horizontal flightpathatthird-stageburnout.
and the second-stage dry weight 100 pounds heavier,
Theresultant flightpathwastherefore dependent onthe
than the current configuration. With the burning times
flight-realizedperformanceof the propulsionand
as a function of stage weight, it was then possible to
guidance systems.
determine the performance of vehicles with specific
TheVanguard flightplanthatresultedfromthede-
stage weights.
signstudiesis shownin Table1. Thisbasicplanwas
A number of configurations, with various third-stage
usedthroughout theprogram.
weights and various ratios of second- plus third-stage
weight to gross weight, were arbitrarily chosen. Tra-
Table I
jectories were computed for each configuration to de-
Vanguard Flight Plan termine the velocity at the 300-mile second-stage
(1) Vertical flight for l0 seconds to attain forward velocity apogee. The appropriate third-stage velocity increment
and ground clearance before introducing any significant was added at apogee to obtain the injection velocity.
lateral motion.
Various assumptions were made regarding the third-
(2) Thereafter, gradual inclination of the flight path toward
stage mass ratio variation with total impulse, which
the horizontal, approximating a zero-lift trajectory at least
until aerodynamic forces were no longer significant. showed that optimum third-stage weight was critically
(3) Second-stage powered flight immediately following first- dependent on the assumptions chosen. The expected
stage burnout and separation. mass ratio variation, as a function of the total impulse,
(4) Nose cone jettison shortly after second-stage ignition, when was therefore carefully estimated on the basis of data
aerodynamic effects on the exposed payload would no
longer be critical. available from prospective vendors of the solid rocket.
(5) Following second-stage burnout, coasting flight along a
Design weight values--The results of these calcula-
ballistic trajectory, with vehicle attitude controlled to
tions were graphically analyzed to determine the stage
attain proper third-stage launching angle.
(6) At or near apogee of the coast trajectory, spinup of third weight distribution that resulted in maximum injection
stage, separation of second stage and ignition of third to velocity. On the basis of this optimization, design
provide the final velocity increment in a direction such gross weight values of 17,830, 4286 and 484 pounds,
that the resultant velocity at burnout would be parallel to
respectively, were chosen for the three stages. The
the local horizontal.
(7) After burnout, third stage may or may not be separated actual stage weights of the first of the Vanguard satel-
from the satellite. lite launching vehicles to be flown (SLV-l) were
17,892, 4419 and 453 pounds, respectively.
D. PERFORMANCE OPTIMIZATION
2. TRAJECTORY OPTIMIZATION
1. WEIGHT DISTRIBUTION AMONG STAGES
The optimum trajectory pitch program varies ac-
An optimization study was made to determine, for cording to a vehicle's propulsive efficiency and ability
a given overall weight, the weight of each stage which to control the payload injection angle. The estimated
woukt yield the greatest velocity at the time of injection characteristics of the Vanguard vehicle indicated that
of the satellite into orbit at an altitude of 300 miles. a wide range of pitch programs and combinations of
Calculatiohs confirmed that maximum second-stage injection velocity and flight path angle could attain an
apogee velocity was to be expected for the lowest initial orbit perigee of at least 200 statute miles. The
practical takeoff thrust-to-weight ratio (T/W). At the number of variables affecting the velocity capability
time, the lowest known design T/W at which a large appeared to be greater than the number affecting the
rocket had been successfully launched was approxi- attitude control capability. It was therefore decided
to givemoreemphasis to uncertainties
in the propul- errors. Thus, the tolerances in the coasting time com-
sionsystemperformance. Theobjectof thetrajectory puter (see Chapter IV, Section A) contributed less to
optimization,then, wasto selectthe trajectorythat injection angle uncertainty, and errors due to imperfect
maximizedthe injectionvelocitymarginover that relationships between firing times and indicated veloci-
velocityneededfor a 200-statute mile perigeewith ties were reduced. However, this reduction in trim
subminimum performance vehicles
havinga fixedmax- rate had the effect of increasing the spread of firing
imuminjectionangleerror. times, so longer periods of reliability were required for
the control jet gas reserves and rocket components
Powered flight pitch program--A "performance
operating during the coasting phase. A balance of these
map" of injection altitude as a function of injection
coasting phase design considerations yielded a trim-
velocity needed to orbit with a perigee of 200 statute
ming pitch rate and coasting time computer constants,
miles, for various injection flight path angles, is shown
which in combination furnished minimum satellite in-
in Fig. 2. Because of external disturbances and toler-
jection angles and nearly optimum third-stage firing
ances on the vehicle parameters, it was inevitable that
times over the entire expected range of vehicle per-
there would be some finite injection angle. A maximum
formance variations.
expected angle of 2.1 degrees, determined by simply
adding all known tolerances, was used in the trajectory Later optimization studies--Later in the program,
optimization study. a study was conducted to determine the optimum Van-
Also in Fig. 2 are curves called performance lines guard trajectory for maximum satellite lifetime. Satel-
that show the relationship between injection altitude lite lifetime curves, based on injection parameters, were
and injection velocity of vehicles of constant propulsion supplied by NRL for use in this analysis. The first
performance with varying zero-lift pitch programs. The phase of this study was determining the optimum pow-
lowest performing vehicle that can achieve an _)rbit ered flight pitch program. This was initiated by deter-
with a 200-mile perigee with an injection angle of 2.1 mining the zero-lift trajectory that maximized the orbit
degrees is the one whose performance line is tangent lifetime of the minimum vehicle selected. The existing
to the orbit requirement line for 2.1 degrees. This Vanguard SLV pitch rates could be made to match
subminimum performance vehicle has orbit capability this optimum zero-lift trajectory by changing insertion
only with the particular pitch program represented by times only. The results of this optimization did not
this point of tangency. The pitch program may be used differ drastically from those of previous optimizations;
to generate a "pitch-line" which is a line for a given hence the SLV pitch programs were not altered.
pitch program and varying vehicle performance (Fig.
3. EQUIVALENCES
2). This line is curved below minimum performance
vehicles because the performance in this range was By computing numerous zero-lift trajectories, with
downgraded by increasing propellant outage. constant second-stage apogee but variable weights, it
The actual pitch program used during first and sec- was possible to determine changes in injection velocity
ond-stage powered flight for the Vanguard design was as functions of stage burnout weight. The usefulness

slightly modified to increase the overall probability of and numerical values of the stage weight equivalences
are discussed in Chapter III, Section G. Values of
an orbit. This pitch program was the one on the per-
change in injection velocity for varying values of
formance line midway between the minimum and sub-
second-stage specific impulse were also computed.
minimum performance lines, at the point where the
These values (_I,0z vs AVa), cross-plotted against the
performance line was tangent to a constant flight path
angle line. burnout weight variation (z_wz vs AVe), resulted in
a curve showing the variation of Isp 2 with _w_ which
Coasting flight pitch program--The rate times
was useful in establishing design criteria for the second-
for the pitch programs during powered flight, as de-
stage propulsion system. Similar computations for in-
termined by the performance map method, fix the flight
creased drag indicated that a 1% increase in drag
path through third-stage ignition. Flight path angle at
(Co-0.5, M_I) resulted in an injection velocity
third-stage ignition is therefore a function of ignition
decrement of 6 feet per second.
time only, once coasting flight has been established.
Studies indicated that a coasting pitch trim rate of
E. AERODYNAMICS
approximately --0.03 degrees per second was re-
required as the last continuous rate to correct for the Accurate data on air loads and aerodynamic charac-
changing local horizontal with third-stage firing times teristics of the external configuration were required to
at or near second-stage apogee. predict the trajectory, to design the structure and to
Reduction in the magnitude of the trim rate lessened verify the control system design criteria of the Vanguard
the sensitivity of injection angle errors to firing time vehicle.

10
_[_ MAXIMUM
360 \ '_ PERFORMANCE _.

Z_ NOMIN L
IL PERFORMANCE

2 280
.<

Z

240

MjN/MUM _. (OF NOMINAL VEHICLE)

t'I:KI-_K/wAr, I_I: _ "y 6 o

_. /--PERFORMANCE LINE -_= I
_'_(OF SUBMINIMUM VEHICLE}
200

'200 STAT MI

160
24,000 26,000 28,000 30,000 32,000

INJECTION VELOCITY (FPS)

Fig. 2 Performance Map for 200-Statute Mile Perigee Orbits

11
1. WIND TUNNEL TESTS in the supersonic regime. Later supersonic wind tunnel
tests were conducted in the tunnels at the Naval Air
Three basic velocity ranges--subsonic, transonic, and
supersonic--were investigated. The results of these Missile Test Center at Point Mugu, California, using a
tests (summarized in Fig. 3) were used to determine (or 1.75% scale modct of the final configuration to investi-
verify preliminary estimates of) aerodynamic coeffi- gate aerodynamic characteristics and pressure distribu-
tions at Mach numbers from 1.61 to 3.5 (Ref. 8). Roll
cients, pressure distributions, center of pressure loca-
tions and running loads for the vehicle. Aerodynamic jet shields produced slight increases in lift, drag and
parameters based on the wind tunnel tests were also pitching moment. The addition of a boundary layer trip
used to derive the aerodynamic transfer functions used behind the model nose produced no significant change
in the vehicle dynamic stability analysis. in lift or pitching moment but did increase the drag
somewhat. Conduit fairings could not be added to this
The first series low speed tests were made on a 12%
model because of the small scale.
model in the University of Maryland wind tunnel to
determine the subsonic aerodynamic characteristics of 2. AERODYNAMIC LOADS
the vehicle at angles of attack from zero (approximate
flight path) to 90 degrees (launch stand condition). The derivation of Vanguard air loads is described in
Several nose configurations were tested, along with detail in Ref. 9. Critical design conditions occurred
various orientations of first- and second-stage external when dynamic pressure reached a maximum value, when
conduit fairings. The tests (Ref. 4) were made at a transonic velocities were experienced, and when maxi-
mum wind shears were encountered. For the maximum
Reynolds number of 11.27 x 10 '_ (based on body
length) and an equivalent air speed of 150 miles per performance Vanguard trajectory, these events occurred
hour. The lift, drag and pitching moments were ap- practically simultaneously at a Mach number of about
preciably increased by the fairings, whereas the different 1.4 and at an altitude of 39,000 feet, after about 78
nose configurations tested had no appreciable overall seconds of flight.
effect. The preliminary running loads for structural design
A second series of low speed wind tunnel tests, using were based on the pressure distributions and force data
the same model and tunnel, were made to determine the determined from the Aberdeen supersonic wind tunnel
Reynolds number effect on the aerodynamic character- tests. The maximum dynamic pressure condition used
istics. A Reynolds number range from 4 x 10 '; to 16 x for design was established early in the design phase by
10 '_ was examined, which corresponded to a velocity estimating the maximum performance of the vehicle.
range between 50 and 200 miles per hour. The results At that time, the maximum dynamic pressure was ex-
(Ref. 5 ) showed a pronounced Reynolds number effect pected to be 590 psf and the maximum angle of attack
upon the aerodynamic characteristics of the complete for this flight condtion was expected to be 5.5 degrees.
vehicle at angles of attack above 30 degrees. Lift, drag This angle of attack was composed of a 4-degree
and pitching moment increased as the Reynolds number steady-state contribution, resulting from flying through
increased. These test data were also used to verify the a specified wind profile, and a 1.5-degree dynamic con-
aerodynamic data from the first series of low speed tribution, the result of a 20-fps true-velocity gust. New
tests. running loads (Fig. 4) were estimated as the configura-
A transonic test, in the WADC 10-foot tunnel at tion changed and better estimates of the performance
(Fig. 5) became available. The total loads used for the
Wright Field, used a 7% force model and a 4.5%
basic design criterion were found to be conservative as
pressure model in several configurations, one of which
later performance data became available.
included roll jet shields. In addition, tests were made
The factors which influenced the shears and bending
with a boundary layer trip to artificially induce transi-
moments imposed upon the vehicle included such items
tion of the boundary layer from laminar to turbulent
as mass distribution and internal tank pressures which
flow. The Mach number range was from 0.80 to 1.20
varied during the trajectory. Thus, to design the struc-
at a maximum Reynolds number of 3.75 x 10 '_for the
ture and controls system, it was deemed necessary to
7% model. These tests (Ref. 6) determined the aero-
investigate conditions other than the maximum aerody-
dynamic characteristics and pressure distributions at
namic load condition. The aerodynamic loads were
low angles of attack during transonic flight conditions.
determined for the launch and burnout conditions of the
Roll jet shields were found to increase lift and pitching
first stage, representing the extreme limits for the load
moment over the Mach range tested.
analysis, and for the condition at a flight time of 40
Preliminary supersonic wind tunnel tests were made
seconds, to represent a condition approximately halfway
on a 3.1% scale model at the Aberdeen Proving between launch and maximum dynamic pressure. In
Ground. The models used for these tests differed some- addition, a pre-launch study was included to determine
what from the final configuration. The test results (Ref. the wind criteria and structural requirements to prevent
7) were used as the basis for the preliminary air loads vehicle toppling while on the launch stand with the

12
LIFT-CURVE SLOPE
0.06

o.os

0.04

T
0.6

0.4

G
ANGLE OF ATTACK (DEG)

6
0.2

CENTER OF PRESSURE
60
O
Z
:E
O
,,v,
I.I.

_ 40 6 i

-r"
4
Z
2
.....1

0
0 ANGLE OF ATTACK (DEG)
" 20
2 3 4 5
MACH NUMBER

Fig. 3 Vehicle Lift, Drag Coefficient and Center of Pressure vs Mach Number

13
o 30
I
REYNOLDS NUMBER
x
(BASED ON BODY LENGTHI
0.8 m 20

_f_A -'_,
..-WITH sPolLER
''w/ L_L..s
_/
LAUNCH
Z

o
/ \
Z

Z_ 0.4 '/

a
,,(
0 w,..ou I I
O
-' 16
O
z 'i i
m ]] /
z
z WI
Z

-r
MACH NUMBER

J
J
12 U
1 f

/ ---- 40 SEC

i
zO
/I!1 _I_
i&
PRESSURE 800

4 ../

/ \
DYNAMIC PRESSURE

0 xa " __'-"N_:N _, 400

__ If"'_ "
_4 , i
U

Z / \
o J
40 80 120 160

TIME [SEC)

Fig. 5 Time Histories of the Design Reynolds Number,
--8 MuchNumber
ind Dynamk
Pressure

,_ 100 dynamic heating were investigated. The results were
needed for the selection of skin materials and thick-
O 80

/
.< nesses, to determine whether heating would cause the
60 nose cone tip to melt, to determine the optimum time to
dispose of the nose cone, and to analyze the aerody-
40
o namic heating of external antennas, conduits, etc., and

/
RUNNING DRAG
20 the conduction, convection, and radiation heating of

0
II1 the internal equipments.
0 20 40 60 80 100 To do this without the benefit of experimental data,
some of the more complex relationships were reduced
VEHICLE LENGTH (%)
by calculating an upper-limit temperature which was
Fig. 4 Running Airloids not expected to be exceeded during actual flight. The
vehicle experienced three different flow regimes during
its flight through the atmosphere. The first regime,
continuum flow, during which the fluid can be con-
Re
gantry removed. The maximum allowable wind for sidered homogeneous, exists when _- > 100, where Re
this condition, with all propellants aboard, was 48 is Reynolds number, based on distance from the nose,
miles per hour (Ref. 9). and M_ is local Mach number. Slip flow, which is
influenced by the molecular structure of the air, exists
3. AERODYNAMIC HEATING Re
Because of the vehicle's rapid ascent velocities while when 100 > _ > 1. Free molecular flow, in which the

still within the earth's atmosphere, the effects of aero- mean free path of the air molecules is of a magnitude

14
COMPARTMENT

A NOSE TIP
NOSE CONE

THIRD-STAGE
/ Y- cTv-2
FL'5"T__z
i f "--
CONTROLS

.._ TANKAGE

X./
TRANSITION

LOX TANK

"-'THEORETICAL MAXIMUM
SKIN TEMPERATURE
INTERTANKAGE

FUEL TANK

TAILCAN

- "" _ SKIRT
200 400 600 800
(OF)

Fig. 6 Theoretical Maximum Skin Temperature due to Aerodynamic Heating

greater than the thickness of the boundary layer, exists in actual flight and still permitted the use of reasonable
Re materials and thicknesses. Calculations made by other
when MI < 1. methods for the heating of blunt bodies showed that the
The heat transfer equation was solved for the con- solid nose tip would not melt during ascent, that the
tinuum flow regime. Following this, changes were made outer skin of the satellite would not exceed 300°F if
to the equations to accommodate slip flow. These the nose cone were ejected 30 seconds after first-stage
changes were believed important, since it was in the burnout, and that the antennas, heat shields and con-
slip flow regime that peak temperatures occurred. Free duits were of sufficient strength to withstand the effects
molecular flow was experienced beyond this peak, of aerodynamic heating. Further investigation revealed
therefore it was not necessary to further modify the that no internal equipment would be damaged by heat
analysis for this third regime. transfer from the outer skin. The design maximum tem-
The method developed for the calculation of aerody- peratures are shown in Fig. 6.
namic heating was successful, in that it provided a sim-
4. SMOOTHNESS AND ALIGNMENT
plified method which was readily programmed on auto-
matic digital computation equipment. It evaluated an The Vanguard vehicle was manufactured in keeping
upper-limit temperature which could not be exceeded with smoothness and flushness requirements established

15
_-'f" 1/4 ° ALL DIMENSIONS IN INCHES
II DIAMETER LONGITUDINAL
I GAPS FASTENERS WAVINESS OBLATENESS AT JUNCTION STEPS

A 1/32 +0
--0.005
0.010
0.005
LONG.
LAT.
1/16 -+0.015 +0
--0.015

+0 1/16 --+0.03 +0
1/32 1/16
--0.005 --0.015

1/16 1/8 1/16 1/16 -+ 0.03 -+ 0.03

+0 1/16 ±0.015 -----0.015
1/32 0.01
--0.01
J

1/8 1/8 I18 -+0.03 ±0.04

0.21 (TAILCAN
BOLTS)

EXTERNAL +0
+0
INSTALLATIONS 1/32 0.01 --0.015
--0.005

Fig. 7 Summary of Smoothness and FlushnessRequirements

to prevent excessive aerodynamic heating, roll disturb- than the design profile. To solve this problem, a wind
ances and drag. Vehicle alignment tolerances were shear criterion was established which enabled calcula-
established in order to maintain the center of gravity tion of the condition at which design limits were
position within limits required for launch stand clear- reached and which, in turn, permitted interpretation of
ance and flight control. The basic specifications for meteorological data taken prior to flight.
these requirements and tolerances are shown in Fig. 7. Trajectories were calculated with various combina-
tions of initial wind velocities, constant wind shears and
5. IN-FLIGHT WIND SHEAR CRITERIA
initial altitudes of these shears (Ref. 10). The moments
Structural design of the Vanguard vehicles was based produced by these shears were found to increase ap-
on a profile of the average winds measured by the Air proximately linearly with altitude until some peak value
Force Air Weather Service above Cape Canaveral dur- was obtained. The altitude increments (_h), over
ing February (the month for which largest average al- which these shears would have to act to produce the
titude wind speeds had been measured) and superim- design limit aerodynamic moment of 20,600 foot-
posed gust loads equivalent to a 40-fps true-velocity pounds, were plotted as a function of initial altitude for
gust (later changed to 20 fps). Direct comparison of different initial wind conditions. With these plots, the
a measured prelaunch wind profile with the average effect of a compound wind profile could be quickly
profile used for design did not necessarily indicate that estimated. The compound profile was divided into a
the measured profile was either more or less severe series of shears, acting over an altitude increment

16
28,000

24,000
J/11
20,000 12

,,_ 16,O00

z

SHEAR
000 FT
< 12,000 _ 20

8,000

-- 30

__j 40
J
4,000

0 10,000 20.000 30.000 40,000 50,000
INITIAL ALTITUDE OF WIND SHEAR (_)

Fig. 8 Maximum Allowable Wind Shear Duration-- No Steady Winds

17
I,

(z_a). The altitude increment (Ah) over which each F. STRUCTURE
shear would have to act to reach the design limit was
1. STRUCTURAL CONFIGURATION
obtained from the appropriate curve. The vehicle could
The primary structure of the three-stage Vanguard
fly through any wind profile that had x2 [Aa
_ 1 <1 vehicle is shown in Fig. 9. The design criteria for this
over all consecutive altitude increments for which the structure are given in Table 2.
slope of the wind profile had the same sign. First st_tge--The first stage was basically a 45-inch
Additional investigation of environmental conditions diameter cylinder. The tail can, located at the base
indicated that the critical gusts to be expected were of the first stage, was a semimonocoque cylinder con-
about 20 fps instead of 40 fps. The specification was sisting of 0.040- and 0.080-inch thick magnesium skin
changed accordingly. In the winter of 1957, successful and an all-aluminum chassis of four equally spaced
flights were made under wind shear conditions that had full-length longerons, several frames, two bulkheads,
been previously considered marginal. This, coupled four end support fittings and four engine mount fittings.
with an enhanced knowledge of the dynamic loads as a Access was provided by six structural doors and one
result of the TV-3BU flight malfunction investigation, large oval nonstructural door.
and with revised estimates of the aerodynamic moments The kerosene tank, located forward of the tail can,
based on the SLV-I flight, warranted re-examination was an integral semimonocoque, all-aluminum (6061-
of the wind shear criteria. This re-examination indicated T6) cylinder. It consisted of 0.063-inch external skin,
that the vehicle was capable of withstanding about 30 two 0.040-inch thick domes (spherical segments),
percent higher continuous wind shears than those dome chords, intermediate frames for ease of manu-
previously defined. The wind shear criteria as modified facturing, and a 0.049-inch thick reinforced internal
to agree with these relaxed requirements are shown in conduit for the liquid oxygen feed line. A 6-inch
Fig. 8. diameter nonstructural cleaning and inspection door
was provided on the upper dome. The tank spacer,
6. WIND-INDUCED OSCILLATIONS
located between the two propellant tanks, was a mono-
During the second series low speed wind tunnel coque cylinder of 0.090-inch magnesium sheet. Ac-
tests, the model experienced low frequency vibrations cessibility was provided by two 14-inch diameter
at angles of attack near 90 degrees. Because of the structural doors. The liquid oxygen tank was similar
low design margin and high flexibility of the Vanguard, in construction to the fuel tank, but had 0.050-inch
there was concern that vehicle structural failure might external skin and a conical 0.050-inch forward dome
occur on the launch stand. Further investigation was to withstand second-stage engine exhaust loads.
therefore required to define the origin of the oscillations. The transition section, which included portions of
Wind tunnel tests on a dynamic model were conducted
both first and second stages, was a semimonocoque
at the Massachusetts Institute of Technology to measure
truncated cone of 0.080-inch magnesium skin and an
the alternating forces and to evaluate the effectiveness
all-aluminum chassis of six equally spaced longerons
of a method to suppress them. These tests (Ref. 11)
(full length but discontinuous at the separation plane),
confirmed that the origin of the forces was the periodic
12 splice-bolt fittings, several frames, and a l/a-inch
shedding of vortices, arising from a steady wind stream
thick blast shield to deflect the second-stage engine
passing the vehicle.
exhaust. This section was spliced in the center by six
The tests indicated that wind-induced oscillations
steel, tension-type, explosive bolts. The aft portion
could be expected to exist in the Reynolds number included two 14-inch nonstructural "blast" doors which
range of interest for the Vanguard, and that the magni-
also served as access ports.
tude of the alternating forces acting at resonance could
result in structural failure of the vehicle if a steady
Table 2
wind of the appropriate velocity (16 fps) occurred for
a sufficient time (several seconds). To suppress the Structural Design Criteria

phenomenon, a number of spoiler arrangements were Minimum factor of safety--yield .................... 1.10
tested in the tunnel at various angles to the wind. A Minimum factors of safety--ultimate ................. 1.25
Where personnel safety was involved
spiral arrangement was found to be most successful in
during handling ........................... 1.50
minimizing the lateral oscillations for all wind direc- Pressure vessels where personnel
tions. safety was involved ........................ 2.00
Twelve rubber spoilers were therefore mounted in a Margin of safety--minimum ........................ 0
spiral pattern on the second stage of each vehicle. Maximum permanent set at design loads .............. 0.2%
Maximum ground handling loads--vertical ............ -+2 g
Drag cones ("scuppers") were attached to aid in
fore and aft ........ -+2g
separating the spoilers after liftoff, in order to minimize lateral ............. -+ Ig
weight, drag and rolling moment penalties. Static firing tie-down equipment safety factor .......... 5.0

18
m_D

c5

u___.,.r, I

-Zi 1;

O
<

"1-
I

N D
< Z

O
O-
O
3
<
O
O v
Z
<
I--

D
Z"_ 4:) x
o

o
Z

_o

19
Second stage--The second stage was basically a 2. STATIC LOADS
32-inch diameter cylinder. The aft skirt, located be-
The initial approach, based on experience gained
tween the transition section and the second-stage pro- with the Viking rocket, considered those static loads
peliant tanks, was a monocoque cylinder of 0.080-inch
imposed by aerodynamics (including gusts), inertia,
temperature-resistant magnesium-thorium sheet, fast-
and corrective engine deflections (except at burnout
ened with Monel rivets. Access was provided by two where a static hard-over engine deflection was consid-
12-inch diameter structural doors.
ered). Concern later developed over the possibility of
The propellant tankage was a 410 corrosion-resistant
an inadvertent hard-over engine deflection at any time
steel integral structure, consisting of a 0.050-inch thick
during powered flight, a condition incompatible with
monocoque oxidizer tank with a "conuckle" shaped
the original vehicle strength and weight criteria. Fur-
aft dome and a 0.050-inch thick monocoque fuel tank ther controls studies, however, indicated that the maxi-
with a hemispherical forward dome, joined together
mum first-stage engine deflections could be reduced
by a 32-inch diameter, 0.090-inch thick helium sphere.
from ± 5 to -4-3 degrees. This new limit did not
The forward skirt, separating the propellant tankage
violate the existing structural design loads.
from the equipment compartment, was a monocoque
In the all-out effort to maintain a minimum-weight
cylinder of 0.071-inch temperature-resistant, mag-
structure, a philosophy was established to control
nesium-thorium sheet, fastened with Monel rivets.
ground handling equipment design so that no weight
Access was provided by three structural doors. The
penalties would be imposed on the vehicle. The vehicle
equipment compartment was a semimonocoque cylin-
was designed to be critical for flight loads only. This
der with 0.050-inch temperature-resistant magnesium-
philosophy contributed to and affected the design and
thorium skin, bound by aluminum bulkheads at each
use of ground support equipment such as vehicle snub-
end. Further reinforcement was derived from a full-
bers, spoilers, static firing tie-down structure and wind
length, full-width, aluminum honeycomb vertical shear
shields. The mode of transporting the vehicle was also
shelf. Accessibility was provided by two full quadrant, affected.
full-length, removable, structural skin panels.
The third-stage motor compartment consisted of a 3. DYNAMIC LOADS
semimonocoque cylinder of 0.040- and 0.050-inch
The Vanguard vehicle structure was highly elastic.
temperature-resistant magnesium-thorium skin, and an
The outstanding problem from the standpoint of
all-aluminum chassis of four equally spaced stringers,
dynamics, therefore, was to find a solution to the
two intermediate frames, and two nose cone hinge
intricate interdependence of the structure and the con-
fittings. The forward end frame was 17-7 PH steel. Ac-
trol system, since angular displacements caused by
cess to this compartment was provided by two rec-
tangular structural doors at the top and two at the structural elastic deformations (as well as rigid body
bottom. attitude changes) generated flight control system com-
A disposable nose cone protected the satellite against mands. The engine response to these 6ommands set
aerodynamic heating and pressures during flight through up further bending deformations which, under certain
the atmosphere. The nose cone was made in halves, conditions, could combine to break up the structure.
each hinged at the base, and included 0.065-inch as- (The problem is generally referred to as structural
bestos phenolic skin, a titanium tip attached to one feedback. )
cone half, aluminum longitudinal edge members with Development o/ analysis methods--Preliminary
shear pins, a bottom closing frame with shear pins dynamic analyses were required at the start of the
and intermediate frames. An explosive bolt latch and
vehicle design phase. The immediate need for these
a jettison assembly, consisting of an explosive tension
analyses demanded a simplified hand solution which
bolt and a compression spring, were incorporated near
ignored all second-order effects, nonlinearities and
the tip.
cross-coupling, as well as the effects of structural feed-
Third stage--The third stage could be either of back on the bending moment distribution. The results
two solid-propellant rocket motors. The Grand Cen- indicated that transverse oscillatory loads resulting from
tral Rocket Company motor consisted of a thin skin aerodynamic and control system disturbances could,
(0.030-inch) steel cylinder with a hemispherical for- when superimposed upon the static loads, be of suffi-
ward dome and an aft dome fairing into a steel exit cient magnitude to cause vehicle structural failure. The
nozzle. A. shaft was provided at the forward dome condition was remedied by minor reinforcement in the
center to act as the forward spin axis and to support marginal areas.
the satellite. The Allegany Ballistics Laboratory motor The limitations of the hand solution were overcome
was similarly shaped, but with both case and nozzle by the later development of an analog solution that
made of glass-reinforced plastic. permitted an extensive mathematical study of the gov-

20
erningequations
of motion. The equations considered environment at launch was also considered. Such mis-
included: alignments could produce enough gyro tilt to cause an
(1) Rigid body degrees of freedom (pitch, trans- initial error signal; this error signal would then result
lation and motor motion). in an initial motor deflection, causing a suddenly ap-
plied lateral force at the gimbal point at the instant the
(2) Flexural motion degrees of freedom (with all
rocket left the launch stand. The resultant loads were
linear and nonlinear coupling effects).
found to be insignificant.
(3) Complete aerodynamic forces (with external
gusts and wind shears). Propellant slosh--The problem of propellant slosh-
(4) Engine thrust forces. ing is basically concerned with the effects of the motion
(5) Servomechanical engine actuation system of liquids with free surfaces which arise from the
forces. motion of the containing structure. Sloshing can change
the characteristic system response to control commands
wherein the apparent viscous damping forces were
to the point where it results in completely misleading
added to the structure equations based on damping
control stability predictions. The frequency associated
values which are classical for this type of structure. All
with sloshing on the Vanguard, however, was found
further dynamic load determination used this newly
to lie in the rigid body frequency band. Because of the
developed analog solution.
high elasticity of the structure and the differences in
Analog results---The flexibility of the analog solu- frequency between structural motion and propellant
tion permitted examination of numerous items. For slosh, the representation for sloshing amounted to a
example, a study of the effect of variations in the control correction to the rigid body dynamics acted upon by
system lag-circuit parameters was used to reduce the the aerodynamic forces.
dynamic loads from this source to a minimum. In effect,
Extensional motion--Dynamic loads in the longi-
the feedback phenomenon was employed to advantage,
since it caused structural oscillations to damp out faster tudinal direction due to the oscillatory thrust vector
than would have been the case had system feedback not were found to be negligible because the structure con-
tained many joints and other characteristics which
been present. It is apparent, therefore, that the repre-
tended to damp high frequency oscillations.
sentation of the complete analytical closed loop solution
in the analog facilities not only verified the overall Summation--The structural design of the Van-
structural integrity of the design, but provided a tool guard was unique in that about two-thirds of the design
for optimizing control system parameters as well. bending moment envelope arose from the elastic dy-
The rigid body stability was purposely slightly de- namics of the vehicle. Most of the bending moment
creased, as a result of the analog analysis, to accele- arising from this source was generated by the inter-
rate the effective decay rate of the structural oscilla- action of the elastic structure and the vehicle's auto-
tions. This design practice has been referred to as load pilot system through the gimbaling motion of the
control.
rocket engines.
Engine noise--The effects of an oscillatory motor
4. LOAD SUPERPOSITION
motion at varying amplitude and frequency on the over-
all vehicle load distribution were studied. The source The various structural loads were superimposed (Fig.
of this possible motor motion lay within the control 10) in order to determine the total load on the struc-
system itself and consisted of both feedback and con- ture. That is, the maximum bending moments due to
trol system noise. The noise was passed on to the wind shear transients, motor hard-over and engine noise
servo, which translated it into small amplitude motor were assumed to occur simultaneously, and were as-
motion. Filtering out this noise would have been expen- sumed to be added to the flight static loads. The launch
sive and impractical from a weights and system reli- condition assumed the superposition of the misalign-
ability point of view. The maximum allowable motor ment, motor hard-over, engine noise and static loads.
motion due to noise, therefore, was based on the This conservative approach was adopted for the Van-
bending moment available after having subtracted guard because of insufficient data on local wind shear
all other contributions from the design moment enve- gradients and their distribution. The probability of a
lope. Actual measurements, as obtained from operating control system malfunction in which the motor moved
hardware, indicated that the motor motion was so small hard-over to its limits and returned in time to regain
that the resultant loads were still safely within the control was not studied. A more sophisticated approach
moment envelope. would have been to determine the probability of occur-
Launch misalignment--Because of the possible rence of the various loads at some given instant. This
occurrence of an accumulation of manufacturing toler- approach could have been used if sufficient statistical
ances and launch stand misalignments, a transient load data of the required type had been available.

21
800,000

700,000

600,000

500,000
I

F- 400,000
z
u.J

0

0 300,000
z

z
I.g
_a

200,000

I00,000

100 200 300 400 500 600 700 800
STATION (IN.)

Fig. I0 Design Limit Bending Moment at Maximum DynamicPressure

5. STRUCTURAL TEST PROGRAM chem-milled first-stage helium spheres (including sur-
face finish effects), and slings, webbing and webbing
Any structure designed to the small margins of safety
used for Vanguard requires extensive structural tests. stitching.

In addition, verification is required on new, unproven Element test program--The element test program
methods of analysis as well as newly developed struc- made invaluable contributions to the successful struc-
tural configurations. The test program used for Van- tural design of the Vanguard. This test phase per-
guard is described in detail in Ref. 12. mitted optimization and verification of structural con-
Coupon tests--Coupon tests were performed to figurations, repairability evaluation, verification of the
supply design information in critical stress areas. These methods of design and evaluation of various redundant
included tests on the longitudinal joint of the first-stage parameters. The program included:
propellant tankage, the structural door attachments, the (1) Preliminary configmations of the first-stage

22
Fig. 11 Structural Test Fixture

23
tail can, propulsion tanks, firewall bulkhead, modification; i.e., the installation of rubber mounts
tank spacer, engine mount and gimbal ring. under the chassis mounted in the controls can. Other
(2) Development program and final design of the marginal areas were strengthened and another random
first-stage helium spheres and hydrogen per- vibration test was performed on the controls can. The
oxide tank. effectiveness of the new modifications was demonstrated

(3) Preliminary configuration and final design of by the improved performance of the controls can.
the transition section. Vibration levels monitored on TV-5, with the modified
panel, were considerably lower than those measured on
(4) Preliminary configuration of the second-stage
the earlier vehicles. Hence, it was concluded that the
equipment bay and forward structure.
modified controls can would perform satisfactorily in
(5) Second-stage propane tank and installation.
the vehicle vibration environment, with a considerable
(6) Third-stage support structure (spin table and
margin of safety.
forward support arms).
(7) Nose cone heat and load tests. Ground wind restrictions--Because of the variety
(8) Explosive bolts (steel and aluminum). of parameters affecting the strength of the vehicle struc-
ture, field operations had to be governed by compre-
Production article testsmProduction article tests
hensive and specific instructions limiting these param-
were performed in the structural test facility (Fig. 11 ) eters. These instructions took the form of maximum
on:
allowable ground wind placards for varying conditions
(1) First-stage overall structure, and installations of overall vehicle configuration (stage combinations),
of the helium sphere and peroxide tank. propellant loading, vortex spoiler usage, snubber usage,
(2) Second-stage lower dome and engine and vehicle shielding configuration, structural door usage,
gimbal support. type of operation (static firing or launch) and usage
(3) Third-stage support structure installation. of the work platform inserts. Typical wind placards
There was also a third-stage motor stress program with the gantry retired were: 30 miles per hour with
by Grand Central and a second-stage propulsion tank- kerosene and UDHM loaded, 33 miles per hour after
age stress program by Aerojet. additidn of WIFNA and 48 miles per hour fully loaded.

Nose cone heat tests--A radiant heat test facility
6. SPECIAL PROBLEMS AND TECHNIQUES
was used to study the combined effects of thermal and
Nose cone--There were large local thermal deflec- applied load stresses during rapid nose cone transient
tions of the skin, poor positive locking of the hinge heating. Maximum temperatures varied from 500°F
assembly, and misalignment problems associated with at the base to 950017 near the tip of the nose cone. In
the early nose cone design. The local thermal deflection the final test, the two halves of the nose cone were suc-
problem was rectified by the addition of a forward- cessfully separated by igniting the explosive bolt shortly
located explosive latch. The remaining problems were after maximum heat input and temperatures were
corrected through utilization of a "shim, trim and jig reached. The nose cone heat tests may be considered as
locate" technique in final installation and assembly, in typical of the scope of Vanguard structural tests.
conjunction with a proof load test.
Stress corrosion--Initial qualification tests at Aero-
Structural door attachment--Repeated removal jet revealed, by virtue of helium sphere failures, that the
and installation of structural doors during shop and structural configuration was sensitive to stress corrosion
field handling created oversized holes in the doors and cracking (material deterioration under the combined
coamings, thus degrading the load carrying capability effects of high stresses and of exposure to white inhi-
of these structural members. To ensure structural
bited fuming nitric acid). This critical condition was
integrity, ground handling and field procedures were remedied, after extensive testing of specimens and
amended to include comprehensive instructions for test spheres, by reducing the tempering temperature
periodic inspection and repair of all structural door from 825 ° to 600°F. The resulting reduction in the
installations.
ultimate strength from 180,000 to 170,000 psi did not
Controls bay equipment panel--Vibration levels violate the design ultimate safety factor of 1.25. Stress
monitored on the vertical honeycomb controls bay corrosion is discussed in detail in Chapter IV, Section C.
equipment panel on TV-3BU and TV-4 indicated that
7. SPECIAL TECHNIQUES
the level was higher than had been predicted. As a
result, the equipment panel and controls can mounting Tank wall design--A method of analysis was de-
structure were modified and the controls can requali- veloped for designing monocoque tank walls subjected
fled, using test vibrations based on spectral density to compression stresses with or without internal sta-
curves obtained from vehicle measurements. Test re- bilizing pressure. The method is applicable to cylindri-
suits were satisfactory with the incorporation of a minor cal and truncated conic sections, and includes pro-

24
ceduresfor establishing
both allowableand actual structural weight through the use of a heating charge
stresses.
Themethodwasverifiedto a highdegreeof in the second-stage helium sphere which reduced the
accuracyby a comprehensive full-scaleelementtest maximum sphere pressure required. Aluminum, rather
program.A detailedpresentation
of thistechnique
may than steel, was used for the second-stage thrust chamber
befoundin Ref.12. at the price of manufacturing problems and, ultimately,
Structural deflection due to thermal radiation-- a marginal chamber lifetime, for another 60 pounds. In
Structural deflections were caused by differential solar other areas, substantial weight saving was accomplished
heating while the vehicle was on the launch stand. Such by the deliberate interrelation of independent systems.
Instances of this were:
deflections changed the vehicle center of gravity, intro-
ducing another variable in the vehicle launch environ- (1) The use of residual second-stage helium, trap-
ment. A simplified analytical method for evaluating ped under pressure at burnout, to power the
these deflections (Ref. 12) was developed and verified vehicle attitude control jets during coasting
by measurements made on TV-2 at Cape Canaveral. flight.
(2) The utilization of turbopump exhaust to
Second-stage helium sphere design--Compre-
power the first-stage roll jets.
hensive studies resulted in the submerged helium sphere
(3) The basic design technique (not original with
configuration for the second-stage propulsion system.
Submergence of the sphere reduced the differential Vanguard) of using integral propellant tank-
age as vehicle structure.
pressure across the sphere walls by the amount of the
propellant tank pressures (approximately 340 psi, or To achieve the necessary emphasis, a formal and
20% ), which resulted in a sizable weight reduction of active weight control program was conducted through-
about 55 pounds. out the design phase. Optimistic goals were established,
IBM tabulations were maintained, weekly status reports
were issued, and weight saving suggestions were solic-
G. WEIGHT CONTROL
ited, evaluated and followed up. The result was a
Vehicle design criteria, as set forth in the specifica- vehicle with an overall mass ratio (total propellants to
gross weight) of 0.88.
tion (Ref. 3), included the following:
Actual weight data for the Vanguard SLV's are sum-
"Weight considerations--Because of the penalty
marized in Table 3. A more detailed weight break-
that weight imposes on performance, every effort
down by system for the "average SLV" is presented in
shall be made to reduce the weight of the vehicle."
Table 4. As a matter of interest, these final weights are
The significance of the penalty is best appreciated by compared in both tables with those established at the
considering the "rules-of-thumb" for the estimated outset of the program in the Design Specification (Ref.
reduction in final satellite injection velocity caused by 3) and also with the intentionally optimistic goals
the addition of one pound to the burnout weight of a originally set for the weight control program.
given stage:

First Stage: 1 fps H. FINAL VEHICLE CONFIGURATION
Second Stage: 8 fps
The final configuration of the complete Vanguard
Third Stage: 80 fps
satellite launching vehicle is shown on the inboard pro-
These original criteria, or current variations thereof,
file drawing, Fig. 12. This drawing specifically repre-
were applied many times during the design phase of the
sents the configuration of the last vehicle, TV-4BU.
project for evaluating compromises involving weight. With the exception of the third-stage rocket motor and
Some of these compromises are worthy of note. a few minor details, however, Fig. 12 is representative
There were cases where additional system complexity of the configurations of the preceding six SLV's as well.
was accepted in return for a substantial weight saving. Detailed descriptions of the individual systems are
Aerojet studies indicated a saving of 71 pounds in presented in Chapter IV.

25
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27
ELECTRICAL

DISCONNECT
DOOR

S-VOLT |ATTERY

SHELF

ill ' f _*'=='_
//

ANTENNA

LINK NO 2

ACCESS

DOOI (2)

|EACON ANTENNA

HYO MOTOR _' /
CUTOFF TIMER

TELEMETERING /

TRANSMrrrER _/

COASTING

COMPUTER /

DECODER _/
EXTERN _ SEMI:STRUCTURAL
/--COOLING AiR AL _.ONDUIT_, DOOR (12 DIAMETERI /
/ OISCONNECT DOOR r- DOOR \ /

_ SHELy ROU. JET_i {4, -

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DOOR HE*T GENERATOR DOOR 12i F HYDRAULIC G H
o,,o / FuE_FILL \ / / ' i FHEAT SHIELD I //----'_"

,l_rs / _ CONDUIT ill \ \ \ J / / _ ] ..... .-_" J/" ........... 1 .......

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ALL 01MENSIONS IN INCHES UNLESS OTHERWISE NOTED
OVERALL LENGTH 70 FT, 10.5 IN.
Fig. 12. Inboard Profile

28
IV. SYSTEMS
DESIGN AND DEVELOPMENT
A. GUIDANCE AND CONTROL mechanical stops. An isolation amplifier was used at
the pick-off output to permit controlled loading to
The Vanguard guidance and control system was
compensate for gyro flex lead elastic restraint effects,
designed to stabilize the vehicle flight attitudes in a
which maintained uniform drift over wide input angles.
controlled fashion and to determine the proper time
An a-c to d-c converter circuit was used for the gyros
to fire the unguided third stage to obtain the optimum
instead of a precision three-phase 400-cycle power
third-stage injection angle. The mechanism of chang-
supply, in order to provide a d-c output proportional
ing flight path was supplied by changing the vehicle
to the frequency of the input and to compensate for
attitude references according to plan during first- and
variations in input voltage and operating temperature.
second-stage powered flight. A complete description of
This feature was necessary because the torquing cur-
the design and operation of the Vanguard guidance
rent required for a precise rate was proportional to the
and control system may be found in Refs. 13 and 14.
synchronous speed of the gyro spin motor but was
Quantitative parameters for the system are given in
independent of input voltage.
Table 5.
The gyroscope reference system performed two
1. AIRBORNE GUIDANCE functions in the Vanguard vehicle: as an integral
Airborne guidance (shown in Fig. 13) consisted of part of the control system, it sent error signals to the
the gyroscope reference system, the program timer, control elements to attitude-stabilize the vehicle; as
and the airborne third-stage firing system. An air- part of the guidance system, it directed the vehicle along
borne guidance system block diagram is shown in a predetermined trajectory by means of a highly
Fig. 14. This diagram shows the pitch axis guidance accurate pitch program. The basic sensing com-
system in detail. The yaw axis diagram was identical ponents of the Vanguard reference system were the
except that there was no yaw program such as that in three rigidly mounted (strapped-down), single-axis,
pitch. The roll axis diagram is not shown, but was hermetically sealed, integrating gyros. The output
quite similar to those in pitch and yaw. signals from the reference system (pitch, yaw and
roll) were fed to the control system in the form of a-c
Gyroscope re]erence system--A Minneapolis-
voltages proportional to angular displacement from the
Honeywell "strapped-down" gyroscope reference sys-
desired reference axes. Departure of the vehicle from
tem and a gimbaled inertial platform were the only
the reference produced a gyroscopic torque about the
available systems that could operate with an angular
output axis. This torque was opposed by the viscous
accuracy of one-half degree in ten minutes in the Van-
damping torque of the flotation fluid, resulting in a
guard environment. The Minneapolis-Honeywell sys-
proportional rate of motion and a gimbal angle of
tem was selected because it appeared to offer a weight
rotation that was proportional to the angle of vehicle
advantage of 70 pounds. The assembly consisted of
departure from reference. The deflection resulted in
three modified HIG-6 gyros, a three-channel isolation
a proportional voltage being generated by the gyro
amplifier, three gyro temperature control amplifiers, a
signal generator, which was transmitted to the auto-
frequency-corrected torquer current supply, a drift
pilot through isolation amplifiers.
trim regulator, and a regulated d-c power supply.
These ten major components were mounted along with The pitch reference axis was changed by introducing

all necessary circuitry in a container, 14 x 14 x 13 current controlled by precision resistors through the

inches in size; the package weighed about 30 pounds. torquer coil of the gyro. This produced a precession of
This system, shown in Fig. 13, provided accuracy the gyro spin axis. The precision resistors for the

better than required, yet was the simplest, lightest and pitch program were mounted in a separate plug-in
one of the most economical available. chassis located in the controls can. The pitch program
could be easily modified by changing the plug-in
The design included modification to the HIG-6
chassis.
gyro to reduce the spin motor angular momentum by
a factor of two, in order to permit response to larger The pitch and yaw gyros were capable of being
input angles (about ±12 degrees) before hitting the torqued at command control rates of 1 degree per

29
COASTING TIME COMPUTER

PROGRAM TIMER

\

CONTROLS GYRO

Fig. 13 Major Components,Airborne GuidanceSystem

3O
i--

,.-+
,,P.+
0

"a
G

.._

31
Table 5. Guidance and Control System Parameters

GYRO SYSTEM
Rotor angular mome_tum 0.500 × 10 + gm-cm2/sec
Torquer: rate sensitivity 0.00665 deg/sec/ma
Scale factor 58 dyne-cm/ma
Command rate ± 1.0 deg/sec
Gyro time constant 1.5 ms
Minimum gyro input axis freedom ± 10 deg
Maximum signal phase shift -+-5.0 deg
Transfer function 200 mv/deg
Positive error signal + X roll ccw
+ Y pitch up
+ Z yaw right
Isolation amplifier load impedance 3000 ohms
Gain 1
Initial gyro alignment _+0.1 deg pitch
± 0.125 roll and yaw
Overall angular accuracy ± 0.5 deg pitch
± 2.0 deg roll and yaw
Cooling air flow (gyro package) 40 cfm (40°F)
System cooling air flow 70 cfm (40°F)
Power
28-v dc 150 watts
115-v ac--400 cps 105 watts

PROGRAM TIMER
Output frequency 400 ± 0.04 cps
Output power 45 mw

Input power 27.5-v dc

COASTING TIME COMPUTER
Gyro: Unbalanced moment 10.30 gm-cm
Torque summing member inertia 56.7 gm-cm 2
Angular momentum 10,000 dyne-cm-sec
Signal generator constant 27.9 volt/rad
Damping constant 10,000 dyne-cm-sec
Motor: Torque constant 890 dyne-era/volt
Damping constant 52 dyne-cm/sec
Motor inertia 1.07 gm-cm 2
Load inertia 17,800 gm-cm _

Power Required :
(a) 27.5-v dc 100 watts
(b) ll5-v, 400 cps 15 watts

PITCH AND YAW CONTROL SYSTEMS First Stage Second Stage

Engine Servo Systems
Static gain (engine deflection/gyro deflection) 1.2 0.375
Servo system response 50 rad/sec 50 rad/sec
Servo moment arm 13.54 in. 6.0 in.
Follow-up potentiometer
Length 3.05 in. 1.36 in.
Resistance 5,000 ohms 5,000 ohms
Follow-up potentiometer calibration 0.201 volts/deg 0.672 volts/deg

Lead circuit transfer function 3 (1 + 0.444S) 3 (.1 + 0.444S)
40 (1 + 0.0333S) 40 (1 + 0.0333S)

Lag circuit transfer function 1
1 + 0.040S

Filter circuit resonant frequencies 12.1 cps, 18.0 cps

Propellant slosh frequency 2.1 cps 2.0 cps

POWER REQUIREMENTS
Pitch or Yaw Roll
Amplifier Ampli[ier

27.5-v dc 1.5 amp 0.8 amp
150-v dc 0.06 amp 0.08 amp
l15-v ac, 400 cps 0.03 amp 0.010 amp

32
Table 5. Guidanceand Control System Parameters (Cont.)
JET SYSTEMS
Tumble Jets (Pitch and Yaw)
Pull-on signal +__0.40 deg
Drop-out signal _+0.36 deg

Lead circuit transfer function 1 (1 + 0.5S)
30 (1 ÷ 0.0167S)

Thrust 7.2 lb
Moment arm 16 in.

Limit cycle 14 sec

Jet time per cycle 1.5%

Roll Control Systems
Pull-on signal _+3.0 deg
Drop-out signal +_ 2.7 deg

Lead circuit transfer function 1 (1 4- 0.2S)
40 (1 + 0.005S)

First Stage Second Stage
Powered Powered Coasting
Flight Flight Flight

Roll jets: Minimum thrust (vacuum) 115 lb 8.0 lb 7.0 Ib
Moment arm 25 in. 17 in. 17 in.
Limit cycle -- 3.9 sec 4.1 sec
Jet-on time per cycle -- 7% 7%

second in the event that some external disturbance accuracy was finally obtained by using hand-wound
forced the vehicle to deviate from the desired trajectory. resistors for final adjustment during the calibration of
The torquer current supply for this function was located each circuit in final assembly.
in the controls can. In addition to pitch program flexi- The transistorized switching circuit used to control
bility, the flight path azimuth could be changed from gyro temperature had a high failure rate. An analysis
the launch azimuth by means of a roll program. This disclosed that the major fault was due to the com-
feature was employed on SLV-6 when a roll program ponents used and to insufficient rating of the output
rate of about 3 degrees per second was implemented transistor. The amplifiers were redesigned and the new
between 5 and 22 seconds after liftoff. The flight path units were retrofitted in all gyroscope packages.
of this vehicle was changed after being launched at Program timer--The Vanguard program timer
100 degrees azimuth to an effective flight azimuth of was designed and built by Designers for Industry,
48 degrees. Incorporated. Most conventional methods to provide
A study was made to determine the magnitude of high accuracy timers in 1955 required the use of a
the errors introduced by gyro cross coupling due to large rotating drum. However, to save space and
gimbal deflections during flight. Results indicated that weight, the proposed Vanguard timer used a synchron-
compensation was unnecessary because all errors were ous motor to drive a punched film. The tape was later
small. There were major problem areas in vibration changed from film to stainless steel to prevent stretch-
isolation, the a-c to d-c converter circuit, and tempera- ing and a possible wear problem. A fast-rewind d-c
ture controls in the amplifiers. The original vibration motor was eliminated from the package to save space
isolation system produced drift rates beyond those and weight.
allowed in the specification. These drift rates stemmed The ten-channel program timer, with an accuracy
from a coning effect produced by small differences in better than +0.1 out of 720 seconds, used a 25.6-kc
shock mount resonant frequency and transmissibility. crystal oscillator as the primary frequency standard.
The problem was solved by using silicone rubber vibra- This was divided through a transistor network to 400
tion isolators (matched to eliminate coning) with very ±0.04 cps. A transistor output stage then supplied the
low transmissibility. required power to drive a synchronous motor which,
The precise pitch rates required imposed an ac- in turn, drove a tape through an appropriate gear train
curacy requirement of ±0.1% on the output and clutch mechanism. Before launch, the programmer
linearity of this converter circuit, independent of input was turned on to allow the oscillator and motor to
voltage and ambient temperature. Additional com- reach stable operating conditions. At liftoff, a first
pensating circuits were added after initial design to cor- motion switch at the base of the vehicle sent a signal
rect for voltage and temperature characteristics. The to the clutch which connected the motor to the gear

33
Table 5a Program Timer Functions

Rate Time
Channel Function (deg./sec) (sec)
1 First pitch rate 0.07143 10-24
2 Second pitch rate 0.2750 24-45
3 Third pitch rate 0.4762 45-112
4 Fourth pitch rate 0.2139 112-400
5 Arm critical functions 127-720
Backup for second-stage shutdown arming { -- 240-250
and nose cone separation
Start third-stage spinup and separation 540-720
sequence
7 Nose cone separation -- 172-190
8 Telemetering -- Every 10
9 Fifth pitch rate 0.02 400-720
l0 Arm second-stage shutdown and backup for { -- 240-720
nose cone separation

train. This set the tape in motion and microswitches The velocity indicator utilized a HIG-type unbalanced
and relays picked off the appropriate functions. The gyro, which was sensitive to linear accelerations along
program timer performed the functions shown in Table the axis of the vehicle. Its output was an angular
5a on the flight of TV-4BU. shaft position proportional to velocity. The time
Some program timers were rejected early in the pro- indicator was a hysteresis synchronous motor and gear
gram because the units did" not meet the required ac- train, and provided an output shaft position propor-
curacy specifications. The trouble was due to failure tional to time. The two shaft positions were combined
of an oscillator to hold frequency. This oscillator was in a mechanical analog computer to solve a linear
replaced by a new design that performed satisfactorily. equation. The 400-cps precision power supply ensured
that the gyro wheel and motor rotated at constant
Airborne third-stage firing system--The air- speed.
borne third-stage firing system contained an accelero- The CTC received a start signal from a first motion
meter that integrated (from liftoff to second-stage switch at liftoff. The integrating accelerometer started
burnout) the longitudinal acceleration resulting from calculating vehicle velocity by continuously integrating
external forces other than gravity. Thus, the system its acceleration. This process continued throughout
had the function of determining overall first- and sec- both first- and second-stage powered flight, resulting in
ond-stage performance by computing a gravity-free "in- the rotation of a velocity arm in the coasting time com-
dicated" velocity increment imparted by the first two puter. At second-stage burnout, a signal was sent to
propulsion systems. This indicated velocity was fed the unit, stopping further movement of the velocity
into a mechanical coasting time computer (CTC) arm and starting the timing mechanism. The timing
which then set a coast time such that the injection mechanism rotated a timing arm until it came into
angle error would be minimized for minimum and contact with the stationary velocity arm after an
nominal performance vehicles. elapsed coasting period that was directly related to the
The original concept for the CTC was to produce a velocity at second-stage burnout. At this instant of
contact, a signal from the computer started the third-
second-stage engine shutdown signal when the vehicle
stage spinup and separation sequence.
attained a preset velocity. Then the device was to
Major development problems were encountered
send another signal to the vehicle, t seconds later, to
during vibration and temperature testing of the CTC.
start the third-stage spinup and separation sequence.
Several undesirable resonances were discovered in the
The CTC operational concept was later changed to
velocity arm and timing arm when the unit was sub-
have the unit integrate vehicle acceleration until sec-
jected to vibration. The two arms were redesigned and
ond-stage shutdown occurred due to either fuel or
stiffening plates were added to the assembly to over-
oxidizer exhaustion. All coasting time computers were
come this problem. A severe resonance was also
manufactured and tested for the latter method of opera-
noted in the pendulous gyro assembly at a frequency
tion, with provisions to easily change back to the first of 135 cps. This resonance was eliminated by sup-
method if desired.
porting the gyro assembly at the upper end with an
The coasting time computer, designed by Elec- additional bearing.
tronics Communications, Incorporated, consisted of The gyro table would not revolve freely when the
four major components: a velocity indicator; a time unit was subjected to the cold temperature test.
indicator; a computer; and a precision power supply. Analysis indicated that this condition was caused by

34
contraction
of the outer race of the bearing supporting primary control system, with an electronic autopilot
the gyro assembly. Thermal isolation between the gyro (Viking circuits with subminiature tubes) as a backup
block and the mounting table, in the form of phenolic system. The transistor approach, though appealing,
washers between the two surfaces, provided proper was not considered because of the rudimentary state
unit operation at 20°F. of its development at the time. The vehicle wiring was
The sensitivity of the velocity measurement from the designed so that either system could be used by simply
coasting time computer was increased to provide more installing in the vehicle either a may-amp controls can
accurate telemetering data for the ground-based third- or an electronics controls can. The mag-amp auto-
stage firing system. This was accomplished by loading pilot program was cancelled in July 1957, when it
the velocity potentiometer with a fixed resistor. became evident that production flight units would not
be available for flight testing in the early test vehicles.
2. GROUND-BASED THIRD-STAGE FIRING SYSTEM
The Martin-designed subminiature vacuum tube elec-
An independent ground-based firing system was pro- tronic autopilot was then used as the control system
vided for the Vanguard vehicle as an alternate means for Vanguard.
of initiating the third-stage firing sequence (Ref. 15). Additional design considerations included the utili-
An IBM-704 digital computer was used to predict zation of only one roll amplifier for control of both
second-stage apogee time based upon C-band radar the first- and second-stage roll jet systems. This ap-
tracking data obtained during the 30-second interval proach allowed one compensating network to stabilize
just after second-stage burnout. A coast time, T_, was both the first- and second-stage roll jet systems, but
then calculated, using a quadratic conversion function made the deadspot and hysteresis the same for both
based on preflight estimates of vehicle performance. stages. Pressurized containers were used for mounting
T_ was compared to the coast time indicated by the the control system components to avoid environmental
airborne computer, TA, which was obtained through a problems and for ease of maintenance and testing.
telemetry link. These two coast times and their A high natural frequency of the thrust chamber
absolute difference were used by the ground-based supporting structure was maintained to preclude a
operator in deciding which system should fire the third frequency resonance instability problem. A relatively
stage. The decision criteria (e.g., Ref. 15) used by low control system external gain (1.2 for the first
the ground-based system operator included a display stage) was used to avoid a structural feedback and
radar roughness number, which was indicative of radar engine noise problem.
data reliability. If a decision was made to use the The second-stage engine gimbaling system was
ground-based system, command control transmitters activated prior to launch. This allowed a final check to
were employed to activate circuits in the vehicle which be made while the rocket was on the ground and,
initiated the third-stage firing sequence after a 100- even more important, it avoided the use of an in-flight
second delay. A direct command with no delay was hydraulic pump motor starting system and associated
also provided. electrical starting transients.
The airborne system, because of its simplicity, was Pitch and yaw control, powered fl_ght--Pitch
allowed to fire all vehicles where a margin of per- and yaw attitude control during first- and second'stage
formance existed. The inherently more accurate powered flight was achieved by means of gimbaled
ground-based system was favored in most operational engines. The engines were positioned by servos which
plans for initiating spinup of minimum performance were commanded by the gyro reference system through
vehicles. electro-hydraulic null-type control devices. The pitch
and yaw autopilot amplifiers were identical. Displace-
3. CONTROL SYSTEM
ment of the vehicle from the desired gyro reference
The control system was required to maintain vehicle axis produced an output signal from the gyro. This
attitude control to close limits about all three axes. signal passed through a gain control and was then
Powered flight control was maintained by gimbaled amplified and demodulated, resulting in a d-c signal.
engine motions in the pitch and yaw planes and by The signal passed through a cathode follower and then
reaction jets about the roll axis. Reaction jets were took two paths. One path was through a structural
used exclusively during second-stage coasting flight. feedback filter, lead network and lag network on to
The third stage had no control system; attitude was the first-stage internal loop; the other was through a
maintained by spin stabilization. Control system hard- lead network on to the second-stage internal loop. The
ware consisted primarily of pitch, yaw and roll ampli- internal loop for each stage contained d-c amplifiers
fiers and their associated circuitry. (See Fig. 15.) that converted the d-c signal into a differential current
Design--The plan at the start of the program was which was applied to the hydraulic transfer valve (see
to develop a magnetic-amplifier autopilot as the Chapter IV, Section I). This valve allowed hydraulic

35
PITCH AMPLIFIER

RELAY CHASSIS

YAW AMPLIFIER

ROLL AMPLIFIER

Fig. 15 Airborne Controls Can

36
fluid to flow in the proper direction to move an rotated 45 degrees in either direction to provide roll
actuator piston which deflected the rocket engine. The control when the vehicle attitude error exceeded 3 de-
engine continued to move until the feedback voltage grees. Minimum design roll jet thrust was 50 pounds
from the follow-up potentiometer attached to the piston per jet at sea level and ll5 pounds per jet at altitude.
equaled the compensated gyro signal voltage at the Residual helium gas, vented through these same jets,
internal loop input. augmented roll control during first-stage separation.
Pitch and yaw control, coasting flight--Coasting Second-stage roll control was achieved by ejecting
flight control in pitch and yaw was accomplished by gas from four fixed reaction jets, two for a clockwise
means of on-off reaction jet control. The four and two for a counterclockwise correcting moment. A
pitch/yaw jets used the residual helium in the second- separate propane system was used during powered
stage oxidizer tank as an energy source. The pitch and flight to keep the control system isolated from the
yaw jet amplifiers were identical and were contained on propulsion system. Liquid propane was stored in an
the same chassis as their respective engine gimbaling aluminum tank and heated to 120°F and 240 psia by
units. The jet amplifiers were operating during an electric heater blanket. Opening of the roll jet
powered flight but did not actuate the jets since the solenoid valves by the control system allowed gaseous
slave relays, and hence the jet solenoids, were not propane to flow from the tank. The gas supply was
armed until second-stage burnout. replenished by further evaporation of liquid propane
The jet amplifiers were of the on-off type, having a within the tank. A regulator reduced the upstream
system dead-zone of 0.4 degree. As in the case of the pressure at the nozzles to 62 psia, corresponding to a
servoamplifiers, the gyro signals were amplified, thrust level of 8.5 pounds per jet. At second-stage
demodulated and modified by an R-C lead network. burnout, the roll system was switched from propane to
The resulting signals were then amplified by high-gain the residual helium remaining in the fuel tank by
d-c differential amplifiers containing output plate actuating a solenoid-operated three-way valve.
relays in their final stages. The amplifiers operated The one roll amplifier actuated the first-stage,
linearly up to the output stage containing the relay. second-stage powered flight, and second-stage coasting
The relay tube was biased considerably below cutoff flight roll systems. The operation of the roll jet
so that a zero-rate gyro signal of 0.4 degree would just amplifier was similar to that previously described for
energize the relay. Changing the bias point (pull-in the pitch/yaw jet amplifier. However, the roll amplifier
point) did not change amplifier gain, and therefore did required less gain than the pitch/yaw amplifier because
not affect hysteresis. The plate relay operated a slave the system deadspot in roll was "4-3 degrees. Again, a
relay located on the relay chassis in the controls can, high , lead network (, = 40) was used to provide
which, in turn, operated the jet solenoid. A slave relay the least amount of jet-on time (_ 0.1 second) and
was required because the plate relay could not handle the maximum jet-off time (_ 2.2 seconds) com-
the high current requirements of the jet solenoid. A mensurate with adequate system stability. The roll
condenser was added across the slave relay contacts to amplifier output plate relay also operated a slave relay.
prevent high arcing currents from welding relay con- One set of slave relay contacts actuated the first-stage
tacts. system, while the second set actuated the second-stage
Flow of helium through the jet nozzles provided system after an arming signal was received at second-
correcting thrust, regulated to the design value of 7.2 stage ignition.
pounds per jet by an orifice at each solenoid valve. Third.stage control--No controls equipment was
When the attitude error decreased to a specified value, employed in the solid-propellant third stage. Disturb-
the plate relay dropped out, de-energizing the slave ing moments would normally result from thrust vector
relay and jet solenoid. The rocket then rotated about and principal axis misalignments, and changes in mass,
the cg at a constant velocity until the gyro error signal
pitch and roll inertias, and cg position during burning.
activated the opposite jet. This on-off process con- These disturbing moments were overcome by spinning
tinued throughout coasting flight. A high ,_ lead net- the third stage about its longitudinal axis. Various spin
work (, = 30) was used to provide a short jet-on studies were conducted to establish requirements for
time (_ 0.1 second) and a long jet-off time (_ 7 sec- the third-stage design which would maintain the flight
onds) for the pitch/yaw jet systems, so that consump- path error within tolerable limits and achieve desired
tion of residual helium would be minimized.
orbit injection conditions.
Roll control--First-stage roll control was obtained A special problem arose with the TV-1 configura-
by utilizing the first-stage engine turbine exhaust to tion, where the third-stage rocket motor carried a
provide the correcting moment. The two exhaust 180-pound instrumented nose cone. The stability of
nozzles (Fig. 32) normally pointed aft, providing a this configuration during third-stage burning, with the
small additional forward thrust, but were differentially motor spin inertia being transmitted to the heavy non-

37
rotatingnosecone,wasopento seriousdoubt.Also, trol telemetering circuit, the fifth pitch program relay
the re-entryvelocitywassufficiently low to presenta and the program timer test relay.
rangesafetyproblemin caseof azimuthdeviation. 4. DEVELOPMENT TESTING AND PROBLEMS
This two-bodyspin problemwas neverrigorously
solved, but studies
indicatedthatthestabilitydeteriora- Engine and control jet mockups were used for
tion wasnot of a seriousmagnitude andthat range dynamic testing and problem investigations of control
safetywouldnotbejeopardized. system components.
Initial Vanguardconfiguration studieswherebased Engine mockup development tests--The engine
onthearbitraryrequirement thattheflightpathshould mockups were used to dynamically test system opera-
not deviatemorethan0.25degreeduringthird-stage tion and performance, using prototype hardware. The
poweredflight. Equationsof motionusedfor these first-stage pitch/yaw engine mockup consisted mainly
earlystudieswerefor a rigid,spinningsymmetric body of a thrust chamber mounted in its supporting struc-
with the disturbingmoments fixedwith respectto the ture. This entire assembly was inverted from its normal
bodyaxes.Theassumption of rigiditybetweenmotor position and bolted to the floor. A first-stage hydraulic
andpayloadwasconsidered adequate onthebasisof a servo was used with the mockup. The pitch amplifier,
payloadconsiderably lighter than the initial motor power supplies and test equipment were located on a
weight.The resultingminimumspinraterequirement bench near the mockup. Hydraulic pressure was sup-
was150rpm. However,sincetheTV-4BUflightused plied to the actuator by an external Greer hydraulic
a differentmotorandcarrieda heavierpayload,it was unit. Some of the more important tests performed on
felt necessary to investigatethe expectedflight path the first-stage mockup (Ref. 14) were: servo
deviationsconsideringthe two-bodyspin problem. loop frequency responses; servo loop transient re-
Arbitrarypitchandroll moments to simulatetheeffect sponses; complete system frequency responses; com-
of thespinningsatellitewereincludedin thenewstudy. plete system transient responses; complete system
The maximumpossiblethird-stageflightpath devia- linearity tests; complete system drift tests; and closed-
tion duringpoweredflightwasfoundto be 0.43de- loop analog computer tests.
greefor the TV-4BU configuration.This deviation Servo loop frequency responses showed that the
wasconsidered acceptable. response was substantially independent of 10%
Auxiliary devices--Auxiliary electronic devices variations in hydraulic pressure or B+ voltage. Tests
required by the control system and contained in the also verified that the gain and stability of the loop were
controls can included a B + voltage supply, slave relay adequate. Transient response tests verified that loop
chassis and auxiliary chassis. The B+ power supply damping, overshoot and stability were adequate. Com-
produced 150 volts dc, used as a plate supply voltage plete system frequency responses verified that the actual
for the electronic autopilot. The final design of this first-stage hardware had the same characteristics as
unit (flown on the last two vehicles) was a transformer- those predicted for the lead network, structural feedback
rectified, Zener-diode regulated voltage supply. The filter and lag network. Tests also showed that response
unit received three-phase l l5 volts ac at 400 cps characteristics were substantially independent of 10%
from the inverter as the primary input voltage. This variations in hydraulic pressure, B+ voltage or a-c
voltage was then converted to dc by a full-wave recti- voltage. Complete system transient responses, linearity
fier. The d-c output voltage was next filtered by a 7r tests and drift checks all produced results well within
type L-C filter and regulated by a 50-watt, 150-volt the predicted and specification limits.
Zener diode. This system replaced a dynamotor and Analog computers were used extensively with the
electronic noise filter combination that was used on first-stage mockup to simulate vehicle dynamics and
previous vehicles. structure dynamics. Tests performed with the analog
The slave relay chassis contained the six pitch, yaw computers were chiefly transient response and noise
and roll slave relays, the pitch/yaw power relay and tests. Results indicated satisfactory closed-loop system
the helium dump relay. The pitch/yaw power relay operation.
armed the pitch/yaw jets at second-stage burnout, The second-stage pitch/yaw engine mockup con-
actuated the three-way pilot valve, and sent a signal to sisted of a mass, simulating engine inertia, mounted on
the coasting time computer to start the timing mechan- top of a tank duplicating the second-stage oxidizer
ism. The helium dump relay, when activated, energized tank. The tank was pressurized to 100 psig to simulate
the pitch, yaw and roll jets and the three-way pilot actual flight conditions so that the effect of structural
valve to dump helium from the second stage. resonances would be taken into account. The test
The auxiliary chassis contained the engine remote setup was the same as that described for the first
centering motor-driven potentiometers, the command stage. Tests performed on this mockup were similar
control relays and voltage supply, the command con- to the first-stage mockup tests. Test results demon-

38
strated that systemperformancewas more than The mockup rotated in a vertical plane on bearings to
adequate (Ref.14). lessen friction effects. Included on the mockup were
Theenginemockups weremaintained
in an operat- a helium supply, jet solenoids, two fixed jets and a
ing condition throughout the program. This proved HIG gyro, with the controls and instrumentation
worthwhile, since troubleshooting could conveniently equipment in the blockhouse. Preliminary tests re-
be done during factory, field and flight tests without vealed that system damping and overshoot was not
causing the schedule delays that would have accom- adequate when tests were made at large initial mockup
panied troubleshooting on the vehicle. The mockups displacements. An investigation indicated that vacuum
were also used to check any changes made to the sys- tube saturation was the problem. Proper jet amplifier
tem. operation was attained by decreasing the a-c amplifier
Jet mockup development tests--Three jet mock- gain to prevent saturation, while increasing the d-c
ups were used to dynamically check operation of the amplifier gain to maintain the specified 90% hysteresis.
systems using prototype hardware. Tests were made on Also, the Filtor slave relay did not have a high enough
the first-stage roll system, second-stage roll system contact current rating to prevent pitting and eventual
and second-stage pitch/yaw coasting system. The first- welding of contacts. The Filtor relay was replaced
stage roll mockup was supported from an A-frame by with a Hart relay. Discovery of these two problems
a chain and was free to rotate in the horizontal plane. early in the program certainly justified the mockup
Included on the mockup were helium pressurization tests. This early awareness of problems avoided
tanks, a hydrogen peroxide tank, a catalyst chamber, schedule delays and possibly flight difficulties.
a plenum chamber, two rotatable roll jets and a HIG System tests made on the redesigned pitch/yaw jet
gyro. The roll amplifier, power supply, slave relays, system were similar to those performed on the roll
control panel, gyro panel and recording oscillograph systems. For pitch/yaw tests, a 254 foot-pound dis-
were located in a blockhouse near the mockup. Sys- turbance for 0.5 second was imposed on the mockup
tem performance was checked as simulated flight to simulate the engine shutdown disturbance. Adequate
disturbing moments were imposed and as parameters system stability and performance were demonstrated
such as deadspot, 28-volt de, B+ voltage, initial in the 35 tests performed on the pitch/yaw coasting
mockup direction and displacement were varied. Sys- flight system (Ref. 14).
tem stability and performance were adequately demon- Development problems--The major autopilot
strated in the more than 20 tests made on the problem on Vanguard was "structural feedback" (see
first-stage roll jet system (Ref. 14). Chapter III, Section F). The solution to this problem
The second-stage roll jet mockup was also sup- was to stabilize the structural loops so that the control
ported from an A-frame by chains. Propulsion con- system would perform its normal task in the presence
trols, a propane tank, a helium tank, roll jet solenoids, of body-bending vibrations. The problem on Van-
four fixed roll jets and a HIG gyro were located on guard was particularly difficult because the autopilot
the mockup. Propane or helium could be fed to the natural frequency was quite close to the first-mode
roll jets by simply actuating a three-way valve from bending frequency, and the erigine gimbaling control
the blockhouse. Control and instrumentation devices system response was appreciable at the second bend-
were located in the blockhouse. Tests similar to those ing mode frequency. This problem was further
performed on the first-stage roll system were performed aggravated by the extremely low inherent structural
on the second-stage system. Constant disturbing damping.
moments were also imposed on the mockup to check Stability analyses showed that the autopilot was
system stability for simulated thrust misalignment and unstable near both first- and second-mode bending
engine shutdown disturbances. A test was made on the frequencies. Stability was achieved by attentuating
propane system to check flow rates, total jet-on time the control system response near the second-mode
and the total amount of fuel that would be used during frequency with a double-notch rejection filter, and by
powered flight. Results showed that a more than phase-shifting the control system response near the
adequate amount of fuel was available for powered first-mode frequency with a simple lag network. This
flight roll control. Proper solenoid valve and slave solution produced loop stability and enabled the con-
relay opening and closing times were also checked and trol system to effectively damp out vibrations induced
agreed closely with those used previously in a phase by gusts, wind shears, etc.
plane analysis. System stability and performance were Two minor development problems encountered
verified by the 35 test runs made on the second-stage during the program were engine noise due to gyro
roll jet system (Ref. 14). heater cycling and slave relay contact failures. In the
The second-stage pitch/yaw coasting flight mockup early vehicles, an engine drift or movement was
utilized an 18-foot beam to simulate vehicle inertia. observed whenever the gyroscope heaters cycled. The

39
magnitudes
of these shifts ranged from 0.1 to 0.3 standard for its day. The X-400 was proposed, and
degree in the pitch and yaw axes. This problem was had some firing history, using gasoline as the fuel,
eliminated by shortening the 28-volt d-c leads, by which provided a significant increase in specific
shielding the 400-cps leads, and by placing the dyna- impulse. Early in the X-405 design phase, a decision
motor input on the second-stage battery and the gyro- was made to use kerosene instead of gasoline, primarily
scope heaters on the first-stage battery. Heater cycling because of its higher and more predictable density,
effects were negligible during second-stage powered which would allow a weight saving in smaller tankage
flight, when both the dynamotor and heaters were on and permit more accurate prediction of fuel loadings
the second-stage battery. Here all wire runs were short, to minimize outage.
the second-stage control system gain was low and, by Engine package concept--Viking experience in-
this time, less heater cycling occurred because the dicated the necessity for an "engine package" con-
gyros had warmed up. cept, whereby the vendor-supplied engine was a fully
Several pitch/yaw relays failed during controls integrated, tested and calibrated unit whichwould mate
ground tests when the contacts on the slave relays properly with Martin-built tankage and pressurization
became welded together. Steps taken to eliminate this systems. To assure proper integration, specifications
problem were the addition of capacitors across the were established for engine pump inlet pressures and
slave relay contacts to prevent arcing and welding, and temperatures (Table 6). The engine manufacturer
revision of all plant and field test procedures to keep was required to maintain these conditions while
the vehicle pitch/yaw solenoids disconnected for all demonstrating engine performance and compliance
tests except polarity checks. with other specification requirements. The Martin
tankage and pressurization systems were designed to
B. FIRST.STAGE PROPULSION comply with the same pump inlet conditions. This
1. BASIC DESIGN DECISIONS concept also simplified the interchange of engine pack-
ages from one vehicle to another.
The Vanguard first stage was originally envisioned
as a "modified Viking," and indeed the concepts and
Table 6. X-405 Rocket Engine Propellant Inlet Specifications
experience (if not the actual hardware) of the success-
Oxidizer Fuel Peroxide
ful earlier program were conspicuous in its design.
Temperature, °F - 294.7+2 60+30 60±30
Whenever possible, proven Viking concepts were used
Operating pressure,
for Vanguard, with refinements introduced to obtain psia 49+5 24.9+5 650 (670 max)
maximum weight economy and full integration of the Maximum lockup
pressure, psia 61 39.9 690
engine with the propellant supply systems.
Engine selection--The original satellite vehicle Tankage and pressurization systems--The princi-
design studies by the NRL and The Martin Company pal design philosophy for the Martin portion of the
had established first-stage propulsion requirements that first stage was similarity to proven Viking systems,
were considered beyond the reach of the existing except where refinements were introduced for weight
Viking powerplant. However, advanced design studies saving or reliability reasons, or to meet the more
for another application of Viking had considered the stringent Vanguard requirements.
use of the General Electric Hermes A-3B engine, Serious consideration was given to using an auto-
which appeared capable of development to meet the matic propellant utilization system to minimize outage,
Vanguard requirements. There was actually no other but it was finally concluded that careful design of the
existing rocket engine in this performance range, so pressurization system, accurate engine calibrations and
that the "off-the-shelf" concept dictated selection of precise propellant loading would provide mixture ratio
the improved Hermes engine, designated X-400, to accuracy such that nominal outage would not exceed
be developed for the Vanguard first stage. 2%. On this basis, the complexity and weight of the
A purchase order was issued to the General Electric propellant utilization system could not be justified.
Company on 1 October 1955 to develop, test and Vanguard flight results (Chapter VIII, Section B)
deliver calibrated engine packages in accordance with testified to the soundness of this decision.
a Martin Development Specification (Ref. 16). The
2. SYSTEM DESCRIPTION
new engine was designated X-405. The first produc-
tion uni.t was scheduled for delivery within one year, The general arrangement of the first stage is shown
which was not considered unrealistic, since only a in Fig. 12 and a schematic diagram of the propulsion
modest development program was anticipated to verify system is given in Fig. 16.
the necessary modifications. Propellant tankage--The main propellant tank
Propellants--The original Hermes engine had diameters were 45 inches, the same as Viking. This
burned liquid oxygen and alcohol, as was fairly permitted the use of some existing Viking tooling, with

40
slightmodificationas to length,for tank fabrication. turer's Model Specification (Ref. 17). It used liquid
Averagetank volumesand capacitiesare shownin oxygen and kerosene as propellants, at a nominal mix-
Fig. 16. Theliquidoxygentankwaslocatedforward ture ratio (O/F) of 2.2, and was capable of operation
of the kerosene tank in orderto keepthevehiclecen- for a minimum of 150 seconds at a nominal sea level
ter of gravityforward,to takeadvantage of thegreater thrust rating of 27,835 pounds. Other pertinent de-
liquidhead,to economize on pressurization gasandto sign parameters are listed in Table 7.
maintaina higherliquid oxygendensityby stabilizing
the bulktemperature throughincreased oxygenboiloff Table 7. First-Stage Rocket Engine Design Parameters
dueto thelowergaspressure. TheLOX tanktopwas Minimum Nominal Maximum
conicalin orderto betterwithstand highexternalpres- Burning time--sec 150
suresfromthe second-stage engineduringthe separa- Thrust at sea level--lb 27,000 27,835 28,670
Specific impulse at sea level
tion sequence. The LOX tanktop wascappedwith a (overall average between
plasticlaminantandinsulatingblanketfor thermal 90% rated thrust points)--sec 248 254
protectionduringsecond-stage ignitionandseparation, Oxidizer flow rate--lb/sec 73.6
Fuel flow rate--lb/sec 33.5
andalsoto reducethe coolingeffectof the LOX on Optimum mixture ratio (O/F,
the secondstage.A quick-disconnect fill fittingwas by weight) 2.2
provided in thesideofthefueltank. Hydrogen peroxide flow rate--
lb/sec 2.2 2.4
Thehydrogen peroxidetankwasmounted abovethe Chamber pressure--psia 616 700
firewall,off centerin order to preventinterference Throat area--sq in. 31.8
with the propellantfeedlinesandto allowroomfor Combustion chamber volume--
cu in. 616.5
otherequipment.
Characteristic chamber length
All first-stagepropellanttankscontainedbafflesto (L*)--in. 19.4
preventvortexing.Baffledesignwasvery similarto Thrust chamber expansion ratio 5.5
thatof Viking,the onlychanges beingthe additionof Thrust coefficient (Cf) 1.42
an extravaneanda slightincrease in baffledepthin Characteristic exhaust velocity
(c*)--fps 5750
the LOX andkerosene tanks. Peroxidetank baffles Turbine speed--rpm 31,000
werethe sameas Viking. The purposeof the inlet Turbine exhaust pressure--psia 30
baffleon the peroxidetankwasto preventpressuriza- Gimbal deflection in pitch or
tiongasfromstrikingtheperoxide directlyandcausing yaw plane--deg _+5
Thrust vector alignment
frothingor bubbling. tolerances:
All propellanttankswereventedto theatmosphere Distance from center of
engine mounting
duringpropellantservicingandthroughout the count- points--in. 0.0625
downsby normallyopenventvalves.Theventswere Angular deviation from
engine geometric axis----
lockedclosedelectricallyjust prior to launchby re- deg 0.4
motelyoperatedsolenoidpilot valves.All threetanks Thrust chamber support
had mechanicalventsto relieveoverpressurization. frequency---cps 30
TheLOX andfuelventreliefsweresetat30.1___ 1.5 Engine package dry weight--lb 425
Engine package wet weight--lb 450
psig and 21 ----- 1.5 psig, respectively. The peroxide Oxidizer--Liquid oxygen, Federal Specification BB-0-925,
vent relief was adjustable. Type II
Fuel--Kerosene, Shell Oil Co., Jet Fuel, Grade B, No. 16185,
Pressurization system--Helium was selected as UMF
the pressurization gas because of the tremendous ÷1
weight advantage that it offered. Considerations of Hydrogen Peroxide--BECCO, 90 --0%
leaking and handling had little bearing on its choice.
The engine package was located below the peroxide
The helium was contained in two high-pressure
compartment firewall and was attached to the airframe
spheres, manufactured by the A. O. Smith Company;
at four thrust structure attachment points. The thrust
these were located in the aft section just below the fuel
structure assembly consisted of four identical thrust
tank. The high-pressure gas was regulated to a lower
struts and two actuator support struts, welded together
value by a single-stage, dome-loaded, normally closed,
and supported around a central hub assembly. Four
solenoid-operated regulator, which supplied pressure to
support brackets on the thrust struts supported the
all the propellant tanks and pneumatically operated
turbopump.
valves. Orifices in the fuel and LOX tank lines further
The thrust chamber assembly was attached to the
reduced the regulated helium pressure. Average tank thrust structure by means of the gimbal ring and yoke
pressures are shown in Fig. 16. assembly. The gimbal ring attached to the bottom of
Engine package--The General Electric X-405 the hub on the thrust structure b_, two gimbal bearings,
rocket engine (Fig. 17) is described in the manufac- while the yoke assembly was attached to the gimbal

41
/
/ /.. /'/

/ /

/
/
/ /

/' , //

( 4 )-_ ..... " . LIQUID OX GEN
/_ _ _J AVERAGE PRESSURE, 35 PSlA
C5 _ _ / AVERAGE
WE,GHT,
11,100L8
_ _ _ LAVERAGE TANK VOLUME, 158 FT_

4000 PSIG 4000 PSIG

_l AV VOL, AV VOL,

@
KEROSENE

AVERAGE PRESSURE, 20 PSIA

AVERAGE WEIGHT, 5160 LB
AVERAGE TANK VOLUME, 103 FT3

®
J

AV H_02
PRESSURE -- " @

AV650 WEIGHT,
PSIA @

®® _,,
,

AV 380
TANK LBVOL @
J 4.4 FT _

r<l
\
\
®
\\ ®
®
® \.
\

®
/ /.

\

® ® "®_) ®

Fig. 16 First-Stage PropulsionSystem Schematic
42
PARTS LIST

I. LOX TANK HELIUM FLOW CONTROL VALVE 43. LOX BELLOWS
2. LOX TANK ORIFICE 44. LOX CONTROL VALVE (WITH ORIFICE)
3. LOX TANK 45. FUEL INJECTOR PRESSURE SENSOR
4. FUEL TANK HELIUM FLOW CONTROL VALVE 46. ETHANE FiLL DISCONNECT
S. FUEL TANK ORIFICE 47. ETHANE LINE
6. FUEL TANK 48. TURBOPUMP NOZZLE BOX
7. FUEL TANK OUTLET BAFFLE 49. HYDROGEN PEROXIDE DECOMPOSER AND CATALYST
8. FUEL FEED LINE 50. HYDROGEN PEROXIDE SYSTEM ORIFICE
9. LOX FEED LINE 51, HYDROGEN PEROXIDE FILL AND DRAIN DISCONNEC1
10. LOX FLOWMETER 52. HELIUM AUGMENTATION LINE
11. GEAR CASE BREATHER 53. CHECK VALVE
12. FUEL FLOWMETER 54. MAIN HYDROGEN PEROXIDE VALVE
13. LOX PUMP SEAL PRESSURE SENSOR 55. CAV_TATING VENTURI ORIFICE
14. LOX LINE TEMPERATURE SENSOR 56, HELIUM THRUST AUGMENTATION VALVE
|5, LOX PUMP .57. HYDROGEN PEROXIDE TANK OUTLET DIFFUSER
16. LOX LINE BELLOWS 58. HYDROGEN PEROXIDE TANK
17. FUEL LINE BELLOWS 59. HYDROGEN PEROXIDE TANK INLET DIFFUSER
18. LOX LINE TRANSITION SECTION 60. HYDROGEN PEROXIDE TANK VENT LINE
19. FUEL LINE TRANSITION SECTION 61. HYDROGEN PEROXIDE VENT PILOT VALVE
20. LOX LINE PRESSURE SENSOR 62. HYDROGEN PEROXIDE VENT CHECK VALVE
2). FUEL LINE PRESSURE SENSOR 63. HELIUM LINE PRESSURE TAP
22. FUEL PUMP OUTLET PRESSURE SENSOR 64. HELIUM FILL CHECK VALVE
23. FUEL PUMP 65. HELIUM FILL DISCONNECT
24. LOX FILL AND DRAIN DISCONNECT 66. HYDROGEN PEROXIDE SYSTEM PRESSURIZING VALVE
25. FUEL SYSTEM ORIFICE 67. ROLL JET ACTUATOR PRESSURIZATION LINE
26. LOX PUMP OUTLET PRESSURE SENSOR 68. HELIUM LiNE CHECK VALVE
27. GEAR BOX ASSEMBLY 69. ENGINE CONTROL PILOT VALVES
28. FUEL CONTROL VALVE 70. FUEL FILL AND DRAIN DISCONNECT
29. NITROGEN PURGE CHECK VALVE 71. PRESSURE REGULATOR ADJUSTMENT TAP
30. THRUST CHAMBER NITROGEN PURGE 72. MAIN PRESSURE REGULATOR
31. ROLL JET ACTUATOR ASSEMBLY 73. MANUAL SHUTOFF VALVE
32. ROLL CONTROL JET 74_ HELIUM SPHERE STRAINER
33. FLEXIBLE FUEL LINES 75. HELIUM SPHERE
34. TURBINE NOZZLE BOX PRESSURE 76. FUEL VENT CHECK VALVE
35. TURBINE EXHAUST HOOD PRESSURE 77. FUEL VENT PILOT VALVE
36. LOX INJECTOR PRESSURE SENSOR 7B. FUEL TANK VENT VALVE
37. ENGINE THRUST CHAMBER 79. LOX LINE BELLOWS
38. REGENERATIVE COOLING LINES {FUEL) BO. LOX TANK OUTLET BAFFLE
39. FUEL PRIMING BOSS 81. LOX VENT CHECK VALVE
40. DRAIN PLUG B2. LOX VENT PILOT VALVE
41. THRUST CHAMBER PRESSURE SENSOR 83. LOX TANK VENT VALVE
42. FUEL INJECTOR TEMPERATURE SENSOR

LEGEND

OXIDIZER (LOXI

+_ FUEL (KEROSENE)

..... HELIUM

HYDROGEN PEROXIDE

ETHANE

NITROGEN

Fig. 16 First-StagePropulsionSystemSchematic
43
Fig. 17 First-Stage Engine Package

44
ring by two additional gimbal bearings. The yoke was flexible connections permitted thrust chamber gimbal-
bolted to the thrust chamber prior to attachment to ing without propellant flow interruption.
the gimbal ring. The gimbal ring and yoke assemblies The turbopump was mounted on the thrust structure
allowed maximum thrust chamber movements of -+'5 above the liquid oxygen valve. It contained the turbine
degrees in the pitch and yaw planes, or combinations wheel, two centrifugal pumps, a gear box, a heat
of these movements, to permit thrust vector control. reflector shield, a nozzle box with an attached peroxide
The thrust chamber assembly consisted of a reactant catalyst chamber and an exhaust hood with two
head and a motor body. The stainless steel reactant exhaust stacks. The exhaust hood also had two AN
head injected the propellants into the combustion fittings for helium augmentation line attachments. The
chamber in an atomized condition, achieved by a like- insulated reflector plate was located between the nozzle
on-like style injector (Fig. 18b) with two similar box and the gear case assembly to protect the pro-
streams impinging at an angle of 90 degrees. The six- pellants from the heat. All hot external surfaces of the
teen alternate oxidizer and fuel rings contained a total turbopump assembly were covered with insulation.
of 554 pairs of self-impinging orifices of varying The liquid oxygen and kerosene pumps contained
diameters, drilled in conical recesses on the ring sur- six fully shrouded vanes and were 6.0 and 5.75 inches
faces. Ring No. 1 (in the center) was an oxidizer in diameter, respectively. The oxidizer pump was
ring, while Ring No. 16 was a fuel ring. The outermost equipped with an electrical band-type heater to prevent
propellant ring also contained one hundred twenty thrust bearing freezeup when the pump contained
0.0225-inch-diameter, axially directed, non-impinging liquid oxygen but was not operating. The LOX
"fuel curtain" holes for combustion chamber wall cool- pump, the pump outlet line and the main valve were
ing. The propellant rings were copper-brazed to the insulated to minimize boiloff. The oxidizer pump out-
injector head plate and the injector was bolted to the let line was also connected to the LOX fill, drain and
motor body. disconnect valve at the first-stage tail ring.
Figure 18a shows a cross-sectional view of the in- The hydrogen peroxide decomposer, consisting of
jector. A 100-mesh stainless steel filter basket and a silver screen catalyst bed in a stainless steel cham-
check valve were located in the opening at the top of ber, was bolted to a flange on the turbine nozzle box.
the injector, through which liquid oxygen passed to The peroxide valve attached to the inlet side of the
reach the injector manifold. Kerosene entered from the decomposer, and included a fill and drain port with a
motor body through radially drilled passages in the hand valve attached.
injector. A 100-mesh stainless steel wire filter was Opening and closing of the engine package pro-
wrapped around the injector head to filter the fuel. pellant valves was controlled by regulated helium pres-
The motor body was comprised of inner and outer sure, supplied through four solenoid-operated pilot
shells, separated by a helical baffle, thereby forming valves which were attached to one of the thrust struts
a cooling jacket with helical passages through which the and linked electrically to an engine control unit
fuel was passed on its way to the injector. The inner mounted on the same strut. The engine control unit
and outer shells were made of steel (AMS 6350) of contained all the airborne electrical control elements
varying thicknesses which averaged about 0.125 inch. required for engine start, operation and shutdown.
The steel helices were welded to the inner shell.
Pressurization system operation--The helium
Helical copper fins were positioned between the steel
spheres were pressurized through a tail ring disconnect.
helices around the combustion chamber and throat by
The peroxide system pressurization valve was closed,
brazing to the inner shell. Two brackets were inte-
and the main pressure regulator was energized. This
grally welded to the outer shell to provide connectors
permitted high pressure helium gas to flow through an
for the gimbal actuators. A fuel manifold ring, con-
open hand valve to the regulator where pressure was
taining four fuel line bosses and the fuel system
reduced to 650 __+20 psia. Then, the kerosene tank was
drain tap, was located at the aft end of the motor body.
pressurized, after closing the vent valve and opening its
All surfaces of the motor body except the hot gas side
flow control valve, until fuel pump inlet pressure was
of the inner shell were nickel phosphide coated. The
28.5 _ 1.5 psia. Next, the peroxide tank was pres-
hot gas side was chrome plated.
surized to 650 _ 20 psia by closing its vent valve and
Four rigid fuel feed lines affixed to the aft manifold
were connected through two flexible hoses to the fuel opening the system pressurization valve. The LOX
valve--a normally closed, spring-loaded, pneumatically vent pilot valve was energized, closing the two tank
actuated, sliding sleeve type, with a calibrated orifice in vents. Then, the LOX tank flow control valve was
the valve inlet. A flexible bellows connected the in- opened and the tank pressurized until LOX pump in-
jector to the liquid oxygen valve--a normally closed, let pressure was 59 __+ 2 psia. After the fire signal,
spring-loaded, pneumatically actuated, pintle type, con- proper inlet conditions were maintained by the pump
taining a calibrated spacer for orificing the flow. These inlet pressure switches, electrically linked to open or

45
FUEL MANIFOLD

FUEL INLET

PASSAGES

PROPELLAN_T R NOS

A. CROSS-SECTIONAL VIEW

B. PLAN VIEW

Fig. 18 X-405 Type A Precision Injector
46
close their respective flow control valves to adjust which delayed the valve closing time to 3 ___ 0.5 sec-
tank pressures on demand. onds.

Hydrogen peroxide system operation--Hydrogen Engine ignition sequence--First-stage ignition
peroxide flowed from its tank under positive was initiated by the fire switch, which supplied 28
regulated pressure, through its feed line and a cavitating volts dc to the igniter filament of a pyrotechnic device.
venturi orifice, to the normally closed, spring-loaded, The igniter was positioned in the combustion chamber
pneumatically operated main peroxide valve. A signal below the injector by a wooden dowel, which was sup-
from the engine sequencer energized the peroxide pilot ported by a metal combustion indicator placed across
valve solenoid and allowed pressurization gas to open the exit end of the motor body. Once the igniter
the peroxide valve against spring tension. Peroxide power had been applied, all operations in the starting
flowed through the valve and an orifice to the catalyst sequence were automatic and were controlled by a
chamber, where it was decomposed to a gaseous mix- ground-based engine sequencer unit. Heat from the
ture of oxygen and superheated steam, which then burning igniter melted a fusible link, which tripped the
entered the nozzle box and drove the turbine. Nozzle igniter indicator relay in the engine sequencer. This
box temperature and pressure were 1300°F and 540 opened the LOX valve to preliminary position and
psia, respectively. Nominal turbine speed was 31,000 actuated the ground-based ethane gas supply wdve.
rpm. Power was transmitted from the turbine to the Ethane gas entered the combustion chamber through
gearbox, which drove the LOX, fuel and hydraulic the fuel injector pressure tap at a regulated pressure
pumps. The peroxide decomposition gases collected in of 205 to 225 psig. The ethane combined with the
the exhaust hood and traveled out two exhaust outlets vaporous LOX and burned in the presence of the
to the roll jets. Exhaust temperature and pressure were igniter until kerosene entered the chamber. The fuel
nominally 870°F and 30 psia, respectively. valve open relay in the engine sequencer was energized
1.5 seconds after the LOX valve left the closed posi-
Oxidizer system operation--Liquid oxygen
tion. The fucl valve opened, and approximately two
flowed from the tank through an insulated four-inch
seconds later, kerosene entered the combustion
feed line which passed through the fuel tank to the
chamber. When chamber pressure increased to 23 to
LOX pump inlet. The feed line contained two flexible
28 psia, the combustion indicator and igniter were
bellows to compensate for contraction, and a Potter
ejected from the motor body exit, which tripped an
flowmeter and temperature probe for determining
attached microswitch. The resulting combustion
oxidizer flow rate. LOX was supplied to the pump at
indication signal closed the ethane supply valve and
a pressure of 49 _ 1.5 psia under flow conditions. A
energized the peroxide valve open relay in the engine
signal from the engine sequencer energized a solenoid
sequencer. When the peroxide valve opened, the
pilot valve to allow pressurization gas to crack the
turbine and the propellant pumps started. When
main valve open. LOX flowed to the injector by
oxidizer pump outlet pressure approached normal, the
gravity and tank pressure until the pump started. When
LOX valve moved to full open to develop full engine
the pump discharge pressure approached normal
thrust.
(about 912 psia), the valve pintle was forced open
against the springs, and full LOX flow (about 75.4 Engine shutdown sequence--First-stage engine
pounds per second) entered the injector. At engine shutdown was initiated by exhaustion of either liquid
cutoff, pneumatic pressure from the LOX close oxygen or kerosene. When the pressure at either pump
solenoid pilot valve and the springs forced the valve outlet had decreased to 500 _ 50 psia, the respective
closed. pump discharge pressure sensor switch energized the
cutoff relay. The cutoff relay then de-energized the
Fuel system oper_ttion--Kerosene flowed from
engine control unit, closing the hydrogen peroxide, fuel
the tank through a 3.5-inch feed line to the fuel pump
and oxidizer valves. Figures 51 and 52 illustrate
inlet. The feed line contained a flexible bellows to
typical first-stage chamber pressure decays at shut-
compensate for line movement and side loads, and a
Potter flowmeter and temperature probe for determin- down. The pressure sensors were armed by the pro-

ing fuel flow rate. Kerosene was supplied to the pump gram timer at 127 seconds after liftoff in order to
at a pressure of 25 "+- 1.5 psia under flow conditions. preclude premature shutdowns due to erratic sensor
The pump increased the pressure to approximately 956 operation or minor interruptions in propellant flow.
psia and supplied fuel to the injector at a flow rate of
3. COMPONENT DEVELOPMENT
about 34.5 pounds per second. A signal from the engine
sequencer energized the fuel valve solenoid pilot valve Immediately after award of the subcontract, the
and allowed pressurization gas to open the fuel valve General Electric Company began modification of their

against spring tension. At engine shutdown, the gas existing engine to meet the Vanguard requirements.
was vented through an orifice in the control gas line, The requirement for a gimbaled engine dictated

47
changesin thedesignof thethruststructure, develop- Injector--Injector development testing began in
ment of a gimbalmechanism and relocationof the December 1955. The X-405 prototype injector was
propellantvalvesand feedlines. The selection of a a modified version of that used in the Hermes A-3B,
higher performance propellant combination and the a like-on-like, self-impinging, multihole, stainless steel
requirement to increase burning time from 60 to 150 injector. The modification consisted of enlarging the
seconds necessitated modifications to the existing in- injector holes to reduce the pressure drop and provide
jector and motor body. The existing turbopump had to the best heat transfer conditions, and also to obtain an
be modified to operate for 150 seconds, to provide a optimum reactant ratio of 2.2. Initial tests of the
power takeoff for the control system hydraulic pump, prototype injector resulted in hard starts, repeated in-
and to supply exhaust gases for the roll jets. jector explosions due to combustion instability and
motor body burnthroughs. A variety of design modifi-
Thrust structure--The major problems associated
cations were tested in an attempt to eliminate these
with the thrust structure and gimbal ring assembly
problems.
were attainment of the desired natural frequency and
the prevention of gimbal bearing brinelling and In May 1956, a prototype injector (BA8-255-5A)
permanent set. The natural frequency of the engine was developed which completed 700 seconds of firing
package assembly was increased to an acceptable and displayed smooth starting characteristics and good
limit (35 cps) by relocating the actuator brackets from combustion stability. This was a high drop, matched
the yoke to the thrust chamber outer shell. The propellant velocity, stainless steel injector containing
like-on-like 90-degree self-impinging orifices with 120
brackets were supported on the motor body by a
flange which stiffened the outer shell and minimized nonimpinging orifices (0.022-inch diameter) in the
outer fuel ring. It was combined with three prototype
the possibility of "oilcanning." The yoke was lightened
motor bodies and tested for a total of 3,300 seconds,
until its deflection approximated that of the gimbal
while determining the effects of ___ 5% mixture ratio
ring under load. Spherical gimbal bearings were in-
variation, oxidizer exhaustion, fuel temperature of
stalled in lieu of the original needle-type roller bearings
120°F, variation in fuel and LOX valve operating
to compensate for deflection differences and eliminate
brinelling of the bearing shafts. times, engine gimbaling and 120°F engine compart-
ment temperature. At the completion of these tests, the
Turbopnmp--The outer diameter of the fuel pump
prototype injector design was released for production.
impeller was reduced and the fuel line metering orifice
From September to December 1956, four produc-
enlarged to decrease the turbine shaft horsepower out- tion engine packages containing injectors of the BA8-
put, in order to prevent turbopump operation from 255-5A type were assembled and tested in the pro-
limiting engine thrust. This permitted nominal turbine duction test stand. The first unit experienced a non-
speeds at nozzle box pressures below 550 psig, and damaging hard start. It also demonstrated low overall
also reduced the hydrogen peroxide flow rate by at specific impulse and mixture ratio, due to fuel leak-
least 0.1 pound per second. ing into the combustion chamber past the injector and
Hydrogen peroxide system--The initially designed motor body sealing joint. A copper lip-sear gasket was
inserted between the motor body and the injector bear-
hydrogen peroxide catalyst bed, the main hydrogen
ing surfaces on subsequent engine packages to
peroxide valve, and the peroxide valve inlet orifice
eliminate this problem. The thrust chamber of the
were changed in the prototype engine package to avert
second engine package was scored twice in two tests.
nozzle box bulging and decomposer casing ruptures.
Prior to testing the third production engine package,
These failures occurred during development testing
the injector fuel curtain holes were enlarged to 0.028-
because of excessive pressure surges during initial
inch diameter. This engine package experienced a
peroxide flow. The surges resulted, in part, from the
hard start which destroyed the injector, motor body
high pressure drop across the decomposer, which per-
and thrust structure. The fourth engine package
mitted spontaneous initial decomposition of the experienced two thrust chamber burnthroughs
peroxide. This condition was remedied by replacing during testing. Figure 19a is a typical example of the
the roll-up catalyst screen bed with one composed of type of injector failure that occurred during develop-
70 laminated flat silver screens separated by 10 stain- ment testing.
less steel screens, and by replacing the original sharp- Due to these failures, all assembly and testing of
edged orifice at the peroxide valve inlet with a production thrust chambers was discontinued, and a
cavitating venturi in order to suppress initial lockup thrust chamber improvement program was implemented
pressure flow. The reduction in peroxide flow due to to obtain a precision injector and a reliable motor
decreased turbine shaft horsepower output also helped. body. Fifteen injectors with six variations in design
The original peroxide valve experienced trouble with were tested during the period January to April 1957.
closing time, and was replaced by another design. Of all the injectors tested, only one did not score a

48
Fig.19a. First-Stage Injector Showing Typical Failure

Fig. 19b. Motor Body Showing Inner Shell Burnthrough
49
motor body. This injector, designated M-17, had a After failure of the three production engine packages
total run time of 1410 seconds. Injector M-17 was in December 1956, a series of thrust chamber tests
of the same design as BA8-255-5A except that it had were performed with motor bodies containing thermo-
0.025-inch diameter fuel curtain holes in the outer couples. The major deficiencies found in the original
fuel ring, and each hole of the impinging pairs of fuel motor body design were that it contributed to injector
and LOX orifices in the outer four rings was counter- failures by impeding fuel flow, that combustion chamber
sunk on the upstream side to better balance the pro- cooling was marginal and that quality control of the
pellant flow. A second injector which had a good manufacture was poor.
history was UNMA-76A, which scored a motor body Flakes of cadmium broke loose from the liquid side
during its first test, then operated successfully for a of the inner shell and deposited on the fuel filter screen,
total of 904 seconds. Injector UNMA-76A was thus reducing fuel flow to the injector. This resulted
similar to BA8-255-5A, except that it had 0.025-inch in high reactant ratios and generally produced either
diameter radial cooling holes around the periphery of burnthroughs due to LOX impinging on the combustion
the outer fuel ring. chamber wall, or loss of injector rings due to instability
Attempts to duplicate injector M-17 failed, due to within the injector. Flaking occurred at combustion
inadequate quality control of subcontracted injector chamber hot spots which exceeded the melting point
components. Many of the injectors received by General of the cadmium coating (610°F). This problem was
Electric were rejected prior to testing, due to erratic eliminated by plating the coolant passage with a high-
spray patterns, off-center or burred propellant orifices, melting-point corrosion-preventing material, nickel
or misalignment of impinging orifices. phosphide, instead of cadmium.
A reliable injector finally evolved during April 1957, The problem of marginal combustion chamber cool-
as a result of intensified quality control. A prototype ing was eliminated by inserting three equally-spaced
injector (M-29A 1 ), designatcd "Type A," successfully 1/16-inch thick copper fins in each of the helical flow
completed 14 consecutive 150-second firings with- passages around the throat and combustion chamber.
out motor body damage, for a total accrued time of Adding the fins increased both the effective area of
2100 seconds. This injector was similar to type BA8-
fluid film contact and the fluid velocity, thereby increas-
255-5A, with the same propellant distribution and
ing the rate of heat transfcr and rcducing the inner wall
number of orifices, but differcnt orifice diameters. It
temperature of the coolant passage by about 100°F.
had countersinks in the outer four propellant rings.
Improved quality control eliminated improper welds,
It also contained 120 nonimpinging curtain cooling
motor bodies being out of round, wall thickness being
holcs (0.0225-inch diameter) in the outer fuel ring.
out of tolerance, and improperly drilled bolt holes in
The performance with injector M-29A1 was exccllent
the castellated ring used for attaching the injector to
--average thrust was 28,000 pounds and overall specific
the motor body.
impulse was 253 seconds. The Type A design was
released for production. A 100-mesh stainless steel filter screen was wrapped
The use of precision tooling for fabricating injector around the injector fuel inlets to catch any metal chips
rings, close quality control, and a flow test device for that might be trapped in the motor body. The hot gas
quantitatively measuring ring performance prior to as- side of the inner shell was chrome plated to prevent
sembly in an injector permitted repeated duplication of corrosion and to minimize carbon formation. The ex-
the precision injector for production engine packages. ternal surfaces of the motor body were coated with
Motor body--The original motor body was also a nickel phosphide to prevent corrosion.
modification of the Hermes A-3B design. It consisted During April 1957, a prototype X-405 motor body
of two steel shells separated by helical passages through containing the above improvements was combined with
which fuel flowed for regenerative cooling. The coolant the Type A precision injector for the successful 14-
passage surfaces and the exterior of the motor body firing, 2100-second operation previously described.
were cadmium plated to prevent corrosion. This prototype thrust chamber was released for pro-
Motor body testing began in December 1955, con- duction. The first flyable X-405 production engine
current with injector testing. The wall thickness at the package was shipped on 27 April 1957.
exit end of the inner shell had to be increased from Starting technique--Service use of the X-405
I/8 to 3/16 inch to prevent the bulging that occurred engine brought forth just one additional major problem
during development tests. As previously described, that should properly be classed as development. This
numerous burnthroughs and scorings of the inner shell was the destruction of TV-3 at launch, which was at-
occurred in the convergent section of the thrust cham- tributed to the engine starting technique originally used,
ber and at the throat. Figure 19b is an example of the and resulted in the development of a radically different
type of inner shell destruction that was experienced. system. Details are given in Chapter VIII, Section B.

50
Propellant Jeed and pressurization system--The as a basis for early design studies, in keeping with the
major problems encountered during development test- program philosophy of using available hardware.
ing of the propellant feed and pressurization system System concept---To assure a reasonable accelera-
were with the main helium regulator and the liquid tion at the separation of the second stage from the first,
oxygen vent valve. (See Ref. 28.) a nominal thrust of at least 7500 pounds was required.
Repeated failures of the main helium regulator oc- The most optimistic foreseeable uprating of the Aero-
curred during early testing of the pressurization mock- bee-Hi predicted the attainment of a vacuum thrust of
up. The types of failure experienced were: leakage less than 6000 pounds. Another deficiency of the
past the seal in the dome loader, which resulted in poor Aerobee-Hi design was its 15-inch tankage diameter.
regulation; and failure of the seal at the outlet port, Since the Vanguard configuration required approxi-
which allowed leakage when the regulator was in a mately twice this diameter for the second stage, new
de-energized or closed position. Failure of the dome tooling and possibly new manufacturing techniques
loader seal occurred due to adjusting the regulator with would be required. Thus, it became increasingly evi-
pressure at the inlet. This difficulty was eliminated by dent that the existing Aerobee-Hi design would not
placing a hand valve upstream of the regulator, which meet Vanguard requirements without considerable
stopped gas flow to the regulator while it was being modification.
adjusted. The hand valve had to be opened to check The system design was therefore reconsidered from
regulator adjustment under flow conditions, Failure the standpoint of weight optimization. Three versions
of the outlet port seal was attributed to damage sus- were studied: a turbopump system: a pressurized sys-
tained by the impact of high velocity foreign particles tem utilizing cold helium and a heat exchanger; and a
which entered through the regulator inlet. The addition pressurized system utilizing helium gas heated by a
of a filter screen at the inlet eliminated this problem. solid propellant gas generator within the helium storage
Another regulator failed in full-open position and container. The turbopump system was the lightest
allowed unregulated gas to enter and rupture the hy- because it afforded the use of light gage tankage. This
drogen peroxide tank. Recurrence of this type of fail- system was rejected, however, because of reliability
ure was prevented by the addition of a 750-psi relief considerations and the likelihood of development prob-
valve on the dome loader and the insertion of a stain- lerns. The heated helium system was the lighter of the
less steel porous filter in the dome inlet gas line. two pressure-fed systems and was ultimately selected.
The main problem associated with the LOX vent
Propelhmts--The Aerobee-Hi propellants (red
valve was improper operation due to excessive helium
fuming nitric acid and 65:35 aniline-flirfuryl alcohol)
leakage. Excessive dome bleed port leakage was preva-
produced a characteristic exhaust velocity of only 4700
lent throughout development testing of the pressuriza-
fps, compared to 5100 fps that could be attained with
tion mockup. The cause was traced to seal damage
red fuming nitric acid (RFNA) and unsymmetrical
from the ramming effect of high pressure gas at the
dimethylhydrazine (UDMH), which also are hyper-
pressurizing port. A small check valve was inserted at
golic. UDMH was selected instead of hydrazine be-
the pressurization port, which decreased the incoming
cause of its more favorable storage and handling
gas velocity and minimized seal damage.
characteristics. The oxidizer (RFNA) was chosen as
the coolant for the regenerativcly cooled thrust cham-
C. SECOND-STAGE PROPULSION ber because of its superior heat capacity. Later studies
1. BASIC DESIGN DECISIONS indicated that white fuming nitric acid (WFNA) should
be used instead of RFNA because WFNA has a higher
Specific impulse, burning time and thrust chamber boiling point and would therefore provide greater cool-
gimbaling were the primary factors influencing the ing capacity. Later in the program, it was decided to
selection of a liquid-propellant rocket for the Vanguard use an inhibitor, hydrofluoric acid (HF) in the acid
second stage. Reliability of operation, particularly en- in order to reduce its corrosive properties. Therefore,
gine starting, was considered of paramount importance, white inhibited fuming nitric acid (WIFNA) was used
since the second stage did not have the option avail- in all flight firings.
able to the first stage of shutting down in the event of
Subcontract mcard---A purchase order was issued
a malfunction during the starting transient.
to Aerojct-General Corporation on 14 November 1955
In order to achieve maximum reliability for start-
ing at altitude, a hypergolic propellant combination was for the design, development and manufacture of the
selected. A pressure-fed system was considered more Vanguard second stage in accordance with a Martin
desirable than a turbopump system because its rela- Development Specification (Ref. 18). The contract
tive simplicity offered potentialiy more reliable starting covered the complete propulsion system because it was
and operation. Both of these features were available felt that a pressurized system required very close inte-
in a modified version of Aerobee-Hi, which was used gration of all components in order to achieve an opti-

51
@
/
\

PROPANE
INITIAL PRESSURE, 240 PSIA
WEIGHT, 11 LB

J'

UDMH PRESSURE, ®
330 ± 10 PSIG
WEIGHT, B94 LB
ANK VOLUME, 18,3

HELIUM
PRESSURE
1630 ± 15 PSIG

SPHERE
VOLUME,

®

@
®
®
®
®
I ®

@

Fig. 20 Second-Stage
Propulsion
SystemSchematic
52
PARTS LIST

I. PROPANE SYSTEM PRESSURE TAP
2. PROPANE SYSTEM VENT VALVE
3. PROPANE TANK
4. PROPANE TANK FILL DISCONNECT
5, PROPANE HAND BLEED VALVE
6. HELIUM-PROPANE PRESSURE REGULATOR
7. FUEL TANK {UDMHJ
8, HELIUM SPHERE
9. HEAT GENERATOR ASSEMBLY (HGA)
10. IGNITER SQUJB IIGN)
11. OXIDIZER TANK (WIFNA)
12. OXIDIZER TANK DRAIN FITTING
13. FLOWMETER
| 4. FILTER
15. OXIDIZER FLEXIBLE FEED LINE
16. PRESSURIZATJON .SYSTEM CONNECTION TO PITCH AND YAW CONTROL .SYSTEM
17. PITCH AND YAW SOLENOID VALVES
)8. OXIDIZER OVERFLOW DRAIN FITTING
19. PRESSURE TRANSMITrER SERVICING CONNECTION
20. PRESSURE TRANSMITTER
21. CONTROL SYSTEM FILL CONNECTION

22. OXIDIZER THRUST CHAMBER VALVE POSITION SWITCHES ITVS_ AND TVS_)
23. OXIDIZER THRUST CHAMBER VALVE (OTCV)
24. RESTRICTOR CHECK VALVE
25. BURST DIAPHRAGM
26. OXIDIZER BALANCING ORIFICE
27, OXIDIZER TEMPERATURE TAP
28, OXIDIZER ULLAGE BLEED FITTING
29. OXIDIZER ULLAGE BLEED FLEX LINE
30, OXIDIZER PROBE
31. OXIDIZER FILL RECEPTACLE
32. OXIDIZER FILL FLEX LINE
33. OXIDIZER COOLING JACKET OUTLET PRESSURE TAP
34. OXIDIZER COOLING JACKET INLET PRESSURE OR TEMPERATURE TAP
35. OXIDIZER INJECTOR PRESSURE TAP
36. THRUST CHAMBER DRAIN FITTING
37, THRUST CHAMBER ASSEMBLY
38. NOZZLE CLOSURE DIAPHRAGM
39. FUEL INJECTOR PRESSURE TAP
40. THRUST CHAMBER PRESSURE TAP

41. THRUST CHAMBER PRESSURE SWITCH (TPS)
42. FUEL VALVE BLEED FLEX LINE
43. FUEL VALVE BLEED (DISCONNECT)
44. FUEL THRUST CHAMBER VALVE [FTCV)
45. FUEL BALANCING ORIFICE
46. FUEL LINE TEMPERATURE TAP
47, FUEL FILL AND DRAIN CHECK VALVE [FFCV) [DISCONNECT)
48. FUEL FLEX FEED LINE
49. FUEL THRUST CHAMBER PILOT VALVE (FTCPV)
50. CONTROL ORIFICE
51. FTCPV VENT FLEX LINE
52. FTCPV VENT CHECK VALVE
53. FTCPV VENT FITTING
54. OTCPV FLEX LINE
55. OXIDIZER THRUST CHAMBER PILOT VALVE IOTCPV]
56. PRESSURE TRANSMITTER BLEED
57. OXIDIZER LINE TEMPERATURE TAP
58. OTCPV PRESSURE LINE
59. OXIDIZER TANK PRESSURIZATION LINE
60. FUEL FEED LINE
61, HELIUM PRESSURIZATION LINE
62. FUEL TANK PRESSURIZATION LINE
63. HELIUM SPHERE PRESSURE SWITCH IHPS,I
64. PRESSURIZATION SYSTEM CONNECTION TO ROLL CONTROL SYSTEM
65, FUEL TANK PRESSURE TAP
66. FUEL TANK VENT AND POROUS BLEED PLUG
67, PROPELLANT TANK PRESSURE SWITCH (HPS2)
6B. FUEL TANK PRESSURIZATION CHECK VALVE (PCV)
69. BYPASS HELIUM SHUTOFF VALVE IBHSV]
70. OXIDIZER TANK VENT AND POROUS BLEED PLUG
71, OXIDIZER TANK PRESSURE TAP
72. OXIDIZER TANK PRESSURIZATION CHECK VALVE (OCVI
73. REGULATOR VALVE IRV)
74. HELIUM SPHERE PRESSURE TAP
75. HELIUM FILL CHECK VALVE [HFCV) IDISCONNECT)
76. 3-WAY HELIUM-PROPANE SOLENOID VALVE
77. ROLL JET SOLENOID VALVES (2 CLOCKWISE, 2 COUNTERCLOCKWISE)

LEGEND

OXIDIZER (WIFNAI

FUEL IUDMHI

HELIUM

PROPANE

HYDRAULIC OIL

Fig. 20 Second-Stage Propulsion System Schematic
53
mum design from the standpoint of weight, propellant arrangement. This configuration also provided addi-
utilization, reliability and performance. Since delivery tional separation of the hypergolic propellants.
of the first unit was due in one year, plans called for
Pressurization system--The helium sphere was
the use of as many existing components as possible,
pressurized to 1630 ± 15 psig through an umbilical
although it was already apparent that a new thrust
disconnect just prior to launch. The solid-propellant
chamber and tankage would have to be developed. The
heat generator (see Chapter IV, Section F) was in-
schedule was not considered unrealistic, as the design
stalled in the helium sphere by means of a boss on the
approach was conservative and did not involve much
outside surface. As originally designed, decay of helium
improvement in the state of the art. Aerojers broad
sphere pressure to 1400 -+- 50 psig, several seconds
experience, particularly with Aerobee-Hi, was expected
after ignition, actuated a pressure switch (HPS1)
to permit rapid completion of the development program.
which ignited the heat generator. In the final configura-

2. SYSTEM DESCRIPTION tion, the heat generator was ignited at first-stage sepa-
ration. Sufficient energy was added to the helium
The general arrangement of the second stage is
during the burning time of the heat generator (approxi-
shown in Fig. 12, and a schematic diagram is shown
mately 100 seconds) to maintain the propellant tank
in Fig. 20. The Aerojet-General Model AJ10-37
pressures throughout flight.
liquid-propellant system is described by the manufac-
Pressurizing gas flowed from the helium sphere to a
turer's Model Specification (Ref. 19). It used white
single-stage spring-loaded regulator (Fig. 21) which
inhibited fuming nitric acid (WIFNA) as oxidizer and controlled propellant tank pressures to 330 __+ 10
unsymmetrical dimethylhydrazine (UDMH) as fuel, psig. In order to provide positive lockup, the regulator
at a nominal mixture ratio (O/F) of 2.8. The engine (RV) was manually closed prior to system operation
operated for approximately 120 seconds at a minimum and was electrically opened by a rotary-solenoid-
rated thrust of 7500 pounds in a vacuum. Other perti- actuated trip mechanism during the engine starting
nent design parameters are listed in Table 8. sequence. Pressurization of the propellant tanks before
The tankage was comprised of three type AISI 410 launching was accomplished by opening a solenoid-
stainless steel sections, welded into an integral assem- operated bypass valve (BHSV), which was controlled
bly providing compartments for fuel, helium and oxi- by a pressure switch (HPS_) sensing propellant tank
dizer. Central location of the helium sphere permitted pressure.
a relatively light unit because the differential pressure The gas downstream of the regulator and bypass
acting on the helium sphere was less than for any other valve divided and flowed through propellant tank check

Table 8. Second-Stage Propulsion System Design Parameters

Minimum Nominal Maximum
Total impulse in vact, um--lb-sec 894,000
Thrust in vacuum--lb 7500
Characteristic exhaust velocity (c*)--fps 5000
Oxidizer flow rate--lb/sec 21.0
Fuel flow rate--lb/sec 7.5
Mixture ratio (steady-state, static test)_O/F 2.744 2.80 2.856
Thrust chamber pressure--psia 200 2O6 212
Thrust chamber throat area--sq in. 21.66
Design thrust coefficient in vacuum (Ct) 1.75
Thrust chamber nozzle area ratio 2O
Gimbal deflection in pitch or yaw planes--deg ±3
Thrust vector alignment tolerance (maximum deviation of nozzle
centerline from tankage centerline when thrust line of action
is parallel to tankage longitudinal axis)--in. I/8
Thrust chamber support frequency---cps 30
Propulsion system weight (excluding Martin components) :
Dry-- lb 386
Loaded-- lb 3760
At burnout--lb 448
Propulsion system envelope:
Diameter--in. 32.092
Length-- in. 191.0
Propellant tank ullage volume (below fill boss)--percent 1
Design propellant outage and residuals--lb 45
Tank volumes, capacities and pressures--see Fig. 20
Oxidizer--Inhibited white fuming nitric acid (WlFNA), MIL-N-7524B (USAF)
Fuel--Unsymmetrical dimethylhydrazine (UDMH), MIL-F-25604

54
Fig. 21 Second-Stage Helium Pressure Regulator Valve

valves to the individual propellant tanks. The primary thrust chamber cooling jacket. Oxidizer flowed through
function of the check valves was to prevent propellant alternate tubes to the end of the divergent cone, where
vapors from mixing, but the oxidizer check valve also the flow was again manifolded and returned through
served to prevent the acid vapor from attacking the the remaining tubes. The flow was again manifolded
nylon poppet of the regulator. Downstream of each before entering the tubes which comprised the combus-
check valve was a porous tank vent plug which allowed tion chamber. After leaving the cooling jacket, the
slow bleeding of propellant tank pressure, thus prevent- flow was collected and continued to the burst dia-
ing pressure buildup due to thermal expansion of the phragm housing. Opening the oxidizer valve at igni-
propellants. Another function of the porous plugs was tion caused the acid in the thrust chamber cooling
to bleed the propellant tank pressure from about 345
jacket to become pressurized (from tank pressure) until
psia at liftoff to 330 psia at second-stage ignition, in
the oxidizer burst diaphragm ruptured at 110 "4- 20
order to maintain design differential pressures.
psig, allowing oxidizer flow into the injector and then
Oxidizer system--WlFNA flowed from two tank into the thrust chamber. The purpose of using a burst
outlets through l lA-inch flexible hoses to the oxidizer diaphragm at the cooling jacket outlet was to permit
thrust chamber valve (OTCV), which was mounted rapid engine starting by eliminating the time lag for
on the thrust chamber. Each feed line contained a
acid to fill the cooling jacket tubes.
Potter flowmeter and an /n-line, finger-type, 30-mesh
Oxidizer fill and ullage bleed lines were connected
screen. The oxidizer valve was a dual-pintle valve
to the thrust chamber just upstream of the burst dia-
actuated by a self-contained hydraulic system (which
phragm. Filling was accomplished by flowing oxidizer
provides more positive action than a gas system). The
back through the thrust chamber cooling jacket and
hydraulic accumulator was pressurized by regulated
propellant feed lines into the tank. The oxidizer burst
helium pressure when the oxidizer thrust chamber pilot
diaphragm housing also contained a flow-balancing
valve (OTCPV) was energized. Hydraulic fluid then
orifice used to establish proper oxidizer flow rate.
flowed through a restrictor check valve, which pro-
vided the pressure required to open the main valve and Oxidizer probes were installed in both oxidizer feed
controlled the opening and closing times. Closing was lines just downstream of the oxidizer valve, Each probe
accomplished by relieving the helium pressure through consisted of a platinum wire prong extending into the
OTCPV. Two position switches were mounted on the acid flow and insulated from the probe body by teflon.
oxidizer valve, at 27% (TVS1) and 78% (TVS.,) of An electrical current flowed from the probe through the
full valve travel. acid to ground; a decrease in this current, caused by
Rigid dual feed lines continued downstream of the helium gas bubbles upon oxidizer exhaustion, initiated
oxidizer valve until the flow was manifolded in the the engine cutoff signal.

55
Fuel system--UDMH flowed from the fuel tank
signal when chamber pressure initially rose to 140 psia,
through a 1¼-inch rigid line running down through and another when chamber pressure decayed below
a conduit on the outside of the tankage until it en- about 130 psia.
tered the engine compartment. The UDMH fill dis-
Engine ignition sequence---Ignition of the second-
connect fed into this line. Inside the engine compart-
stage engine was initiated by a signal from the first-
ment, the rigid line connected to a Potter flowmeter.
stage chamber pressure sensor, or its backup timer.
Downstream of the flowmeter, a flexible line led to the
This signal energized the oxidizer pilot valve
fuel thrust chamber valve (FTCV) which was mounted
(OTCPV), which started opening the main oxidizer
on the thrust chamber. A flow-balancing orifice was
installed in the valve inlet. valve (OTCV). Tank pressure caused rupture of the
oxidizer burst diaphragm, and acid began to flow into
The fuel valve was actuated by UDMH pressure,
the chamber. When the oxidizer valve reached 27%
which was controlled through the solenoid-operated
open, a valve position switch (TVS_) provided a signal
UDMH pilot valve (FTCPV). Fuel valve opening was
to trip the helium regulator (RV) and to actuate the
accomplished by venting the actuating piston cavity
fuel pilot valve (FTCPV) which, in turn, opened the
through FFCPV, thereby providing an unbalanced
main fuel valve (FTCV). Fuel and oxidizer ignited
UDMH pressure to open the valve. The valve was
hypergolically in the thrust chamber and, as chamber
closed by de-energizing FTCPV, thereby providing
pressure increased, the nozzle closure diaphragm was
equal UDMH pressure to both sides of the actuating
blown out. Physical separation of the first stage (ini-
piston and allowing a spring inside the piston to close
tiated by TVS,) broke a ground connection through
the valve. A vent check valve was added to prevent
the interstage disconnects, which caused the helium
liquid UDMH in the actuation circuit from boiling off
heating charge to ignite. Within 0.5 seconds after igni-
during flight. Opening and closing time of the UDMH
tion signal, 90% of rated chamber pressure was
valve was controlled by an orifice in the pilot valve
attained. This ignition sequence was involved in the
vent.
first-stage separation sequence, as described in Sections
Thrust chamber--The thrust chamber was of E and G of this Chapter.
welded aluminum tube bundle construction, with 162
Engine shutdown sequence--Second-stage shut-
tubes (3/16-inch outside diameter) in the combustion
down was initiated by exhaustion of either propellant.
chamber and 258 tubes (1/4-inch outside diameter)
In the case of fuel exhaustion, the cutoff signal was
in the divergent cone. The combustion chamber was
generated by the thrust chamber pressure switch (TPS)
wrapped with 0.031-inch square stainless steel wire to
when chamber pressure decayed to about 130 psia. In
provide hoop tension strength (Fig. 22). The 20:1
the case of oxidizer exhaustion, the resistance change in
area ratio divergent cone, which had relatively low
either oxidizer probe, as helium entered its feed line,
pressures, was strengthened by intermittent aluminum
would generate the cutoff signal. In either case, the
bands, tack-welded to the exterior of the cone. Design
cutoff relay de-energized the pilot valves, causing the
operating chamber pressure was 206 --¢- 6 psia. The
main propellant valves to close. The second-stage shut-
throat area was 21.7 square inches. The thrust cham-
down signal also performed other vehicle functions, as
ber was gimbal mounted to the aft end of the oxidizer
described in Section G of this Chapter.
tank through a "monoball" spherical bearing, which
permitted universal engine deflections. Attitude control systems--The second-stage pro-
The injector (Fig. 23) was a one-on-one impinging pulsion system was intimately involved with the Martin-
type, having 72 pairs of orifices arranged in circular supplied second-stage attitude control jet systems,
rows of 36 each, with the oxidizer rings being outer- which are described in Chapter IV, Section A. The
most. The orifice diameters were 0.120 inch for oxi- attitude control jets were also used as vents for the
dizer and 0.055 inch for fuel. Twenty-four additional entire helium system when depressurization of the tanks
0.031-inch diameter, axially directed, nonimpinging was required.
fuel orifices comprised the innermost ring. 3. COMPONENT DEVELOPMENT
A frangible aluminum disc was cemented in the
divergent cone to maintain sea level pressure in the The configuration was established and basic compo-
combustion chamber for altitude starting. This "nozzle nent design was conducted for several months before
closure diaphragm" was 0.010 inch thick, chem-milled testing could be started. Major development programs
to 0.0062 inch near the edges so that it would fail at a were undertaken for the injector, thrust chamber and
chamber pressure of 22 psig, if the bond did not fail tankage.
first. The remaining ring was ejected in one piece as Development of minor components, such as pro-
the chamber pressure increased. pellant valves, heat generator, nozzle closure and en-
Thrust chamber pressure at the injector face was gine controls, proceeded more or less according to plan
sensed by a pressure switch (TPS), which provided a and did not present any major difficulties. In the case

56
Fig. 22 Second-StageEngine Package
57
Fig. 23 Second-StageInjector Assembly

of the helium regulator, a backup development of a This one-on-one impinging injector displayed smooth
different type valve was pursued for a time, but was starting and excellent combustion stability throughout
dropped when the original Aerojet design appeared to its development. At first, its performance was slightly
be satisfactory. lower than that of the showerhead, but continued de-
velopment increased the characteristic exhaust velocity
In)ector--Injector development began in December
to values consistently above 5000 fps. One of the main
1955, with plans for a square-grid showerhead as the
problems associated with this injector was that the high
primary design and a one-on-one impinging type as a
velocity fuel streams tended to pierce the oxidizer
backup. Early tests to determine the effect of mixture
streams, producing an oxidizer-rich mixture at the cen-
ratio variation over a wide range were conducted with
ter of the combustion chamber and a fuel-rich condi-
6.5- and 5-inch diameter showerhead injectors. Per-
tion near the wall. This condition was finally rectified
formance was generally good, with characteristic ex-
in December 1956 by adding a ring of axially directed,
haust velocities greater than 5000 fps usually achieved.
nonimpinging fuel orifices in the center of the injector.
Testing of prototype showerhead injectors started in During the development program, 48 modifications of
May 1956. Characteristic exhaust velocity was about
the basic one-on-one impinging design were tested in
9% below theoretical. In addition, hard starts were 196 firings, using uncooled, water-cooled, and re-
experienced on injectors having low pressure drops.
generatively cooled thrust chambers. An apparent in-
Continued difficulties with hard starts, combustion in-
crease in c* of 1 to 2% was noted in firings using
stability and low performance led to an intensified test regeneratively cooled thrust chambers, because the un-
program on the showerhead injector. Further develop-
cooled and water-cooled nozzles experienced greater
ment of the basic showerhead injector was terminated throat area increase due to thermal expansion.
in August 1956, when the accelerated program did not
Thrust chamber--The primary thrust chamber
produce the desired improvement. A total of 83 firings
design used tubes of 5052 aluminum, hand-welded and
was conducted on 33 modifications of the basic design,
wrapped with stainless steel wire. Mar-brazing instead
using both aluminum and steel injectors. Several other
of hand welding, 6061 tubes and fiberglas wrapping
configurations were rejected without being fired, on the
all were investigated but did not prove feasible. A
basis of water flow pattern tests.
steel thrust chamber was designed, fabricated and
Because of the problems encountered with prototype tested as a backup in case the aluminum chamber could
showerhead development, it was decided to investigate not be adequately cooled.
the possibility of scaling up the 6.5-inch diameter-type Testing of experimental (nozzle area ratio of 5)
YLR-63 showerhead injector that had provided good aluminum regeneratively cooled thrust chambers began
results in early testing. Problems encountered with in July 1956. By the end of September, 45 tests of
this injector and its modifications were high oxidizer durations up to 149 seconds had been conducted on
pressure drop and high rates of heat transfer. A total five thrust chambers. One chamber using an impinging-
of 40 firings was made on 14 modifications of this in- type injector had accumulated a total of 498 seconds
jector. Addition of fuel film cooling produced some without any signs of erosion or burnthrough. Further
promising results, but in October 1956, a decision was development of the stainless steel chamber was ter-
made to use the one-on-one impinging-type injector. minated. Development of the prototype aluminum

58
thrustchamber wascontinued withtestsatvariousmix- sealingof incipienterosionfailures--thiswasusedin
ture ratiosandchamber pressures, andwasconsidered qualification testing,but neverona flightchamber.
tobecomplete in January1957. Tankage--AISI 410 stainless steel was selected as
Reasonable success in prequalification testsled to the primary tankage material because of Aerojet's
initiationof the formalthrustchamberqualification previous experience in forming and welding this mate-
testprogramin May 1957.In June,a series of failures rial. Type 17-7PH stainless steel also was investigated
of thrustchamber coolanttubeswasexperienced. Four because its higher strength offered the prospect of a
chambers developed internalleaksafter327,240,364 substantial weight saving. This investigation was dis-
and278seconds of accumulated firingtime. Thefail- continued in August 1956, in order to concentrate all
ureat 240seconds wasattributedto locallossof cool- effort on the type 410 tankage.
ingduetofailureof a thrustchamber drainfitting.The Considerable difficulty was experienced during early
otherswerediagnosed astubeerosionfailures. tankage fabrication. Approximately 50% of the helium
Thrust chambertube erosionfailuresapparently sphere and propellant tank domes were scrapped dur-
werecaused by a combination of conditions.Mostoc- ing the drawing process. Some of the causes of failure
curredwith high performance injectors;earlyin the were thin sheet stock, local thinning during drawing,
program,wheninjectorperformance waslow, nofail- difficulties with cleaning and annealing, and scratches
uresoccurred.The tubewall temperature remained because of galling in the die.
well belowthe meltingpoint,but undoubtedly was Changes in drawing dies and manufacturing proce-
high enoughto causesomesoftening.Onelikelyex- dures improved fabrication to the point where several
planationwastheUDMHstreams piercingthroughthe complete prototype tankages were manufactured. The
oxidizerstreamsandimpingingon thewalls.Mostof first two prototypes failed during proof testing, and
the erosionoccurredin the regionswhereUDMH some minor design changes were made. In November
might haveimpingedon the walls;in fact, Fig. 24 1956, three more tankage failures occurred. All five
showsthat the failuresaregenerallyin line with the failures were in tankages fabricated by one particular
insidepairsof orifices.The phenomenon is still not subcontractor to Aerojet. The causes of these failures
well understood, but fuel impingement on the walls were excessive brittleness due to carbonization during
mayhavecausederosionby thewearingactionof the annealing: and poor welding. As a result of the fail-
fluid or hot gas,by causinglocal hot spots,or by a ures, the entire heat treating process was reviewed. The
combination of both. It wasalsosuggested that the cleaning procedures were improved, and a new heat
HF inhibitorin the oxidizermayhavehadsomeero- treat procedure was instituted, involving a double tem-
siveeffect.Gapsbetween tubesapparently contributed per at 825°F in an air atmosphere with argon inside
to the erosionprocess,causinga characteristic thin- the tanks. Stress corrosion investigations led to the use
ning of the sidesof the tubesinsteadof thecrest,as of HF as an inhibitor in the oxidizer.
shownin Fig.25. Another result of these difficulties was that an alter-
Sincea chamberlifetimeof something lessthan278 nate tankage design proposed by the A. O. Smith Com-
secondswasconsidered inadequate, an improvement pany was implemented as a backup for the original
programwasimmediately instituted.Variouscoatings design. The A. O. Smith approach involved the use
weretested,includingzirconiumoxide,Devcon,elec- of a separate forged ring instead of weldments to form
trolyzedchromium, anodized aluminumhardcoatand the juncture between the helium sphere and the pro-
tungstencarbide. The mostpromisingresultswere pellant tanks. Similar construction was used at the
exhibitedby the tungstencarbidecoatingappliedto tank wall junctures of the fuel tank forward dome and
the oxidizer tank aft dome. A. O. Smith tankage was
thethrustchamber wallsby theLindeCompany.This flown on the SLV-4 and SLV-6 vehicles.
chamberlastedfor morethan400seconds. Resultsof
Successful completion of the structural loads, cycling
othercoatingsvariedfrom actualacceleration of the
and burst tests led to the conclusion that tankages were
erosionprocess(Devcon)to unsatisfactory adhesion acceptable for flight use. Four production propulsion
(zirconiumoxide). The steelthrustchamber,which units were delivered between April and August 1957,
hadaccumulated over600seconds of firingtimewith- following successful completion of acceptance tests.
out anyevidence of erosion, represented a possible final On 6 May 1957, a leak developed between the
recourse but wouldhaveinvolvedweightandschedule helium and oxidizer tanks of the prequalification unit.
penalties.Injectormodifications, atthatlatedate,were Investigation disclosed a stress corrosion failure and a
evenlessdesirable. laboratory program was undertaken to evaluate the
Finally,in October1957,the aluminumchamber problem. On 6 July 1957, the helium sphere of the
with tungstencarbidecoatingwas.selected, and all qualification test tankage ruptured due to stress corro-
flight thrustchambers beginningwith TV-5 wereso sion. The tankage had been exposed to liquid WIFNA
coated.A patchingtechnique wasdevisedto permit for a total of 40 hours, of which 45 minutes were at

59
Fig. 24 Cutaway of Second-StageThrust ChamberShowing Tube ErosionFailure
60
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ZZ.__

0o., _

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_° Z .__
u_ im
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oR_

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61
full working pressure. Additional testing indicated that separation; but repeated attempts to achieve satisfac-
stress corrosion failures were caused by exposure of tory operation of this arrangement were unsuccessful.
the sphere to liquid acid while fully pressurized, and that Failure of the test program led to another analytical
stress corrosion lifetime was short and unpredictable. approach which used Nike data for a nozzle area ratio
An intensive analytical and experimental investiga- of 16, adjusted to give a thrust coefficient for a nozzle
tion developed a new heat treat process, using a tem- area ratio of 20. Based on these studies, a thrust coef-
pering temperature of 600°F instead of 825°F, which ficient of 1.75 was considered reasonable for the Van-
guaranteed 8 hours lifetime in the stress corrosion en- guard second stage, and was approved by all concerned
vironment. It was also demonstrated that a reduction in the Model Specification (Ref. 19).
of 20 to 30% in the stress level would achieve the
Flight Development--A considerable amount of
same result with the original heat treat.
further development of this system was found to be
All undelivered tankages were retempered at 600°F.
necessary and was accomplished during the Vanguard
Three of the already-delivered units were subsequently
flight program. These activities are documented in
flown (TV-3, TV-3BU and TV-4), using an initial
Chapter VIII, Section C.
helium sphere pressure of 1365 psig instead of 1630
psig, at the price of a small performance tail-off during
the latter portion of the burning time. No further diffi- D. THIRD-STAGE PROPULSION
culties were experienced with stress corrosion of the
A solid-propellant rocket motor was a natural choice
second-stage tankage during the program.
for the Vanguard third stage, primarily because of the
Thrust coeOicient--Sea level firings of an altitude decision for spin stabilization rather than conventional
thrust chamber do not provide representative thrust guidance, but also because of its relatively small size
data. In order to calculate the vacuum thrust of this and simplicity. The performance requirements gen-
system, therefore, it was necessary to multiply the erated by the early design studies and the stage optimi-
product of throat area and chamber pressure by a zation were expanded into a Martin Development
"thrust coefficient" (Cf) which would account for noz- Specification (Ref. 20). The two best proposals pro-
zle expansion effects and all losses due to nonparallel duced in an industry-wide competition were those of
flow, friction, cooling, etc. Early design calculations, the Grand Central Rocket Company and the Allegany
based on an average ratio of specific heats of 1.2, indi- Ballistics Laboratory. Since the requirements repre-
cated that a corrected vacuum thrust coefficient of sented an advance in the state of the art, and the two
1.741 could be attained. Substantiation of this value best proposals were based on radically different ap-
was to be accomplished by static test firings into a proaches to the problem, it was decided to authorize
supersonic diffuser, in order to eliminate nozzle flow parallel development programs by these two agencies.

Table 9. Third-Stage Motor Design Requirements

GRAND CENTRAL ALLEGANY BALLISTICS
REQUIREMENT 33-KS-2800 MOTOR X248 MOTOR

Motor weight, not to exceed: 433 lb 507 lb
Velocity increment imparted to 22.1-1b payload (horizontal,
drag-free, in vacuum), not less than: 14,182 fps 17,100 fps
Maximum acceleration imparted to 22.1-1b payload, not to
exceed: 35 g 50 g

Thrust and spin axes each aligned with principal axis (axis of
dynamic balance), within: 0.0003 rad (0.017 deg)

Storage and firing temperature range: +30°F to +130°F +40°F to +I00°F
Vibration input: 2 gfor2 hrat Rough road test (250 miles
resonant frequencies over secondary roads) in
lieu of vibration tests

Accelerations: Longitudinal axis, 7 g; Transverse axis, 2 g; Rotational, 20
rad/sec/sec
Rain: Two hours, in accordance with specifiication MIL-E-5272A
Salt Spray: Exposure in accordance with specification MIL-E-5272A
Relative Humidity: 100% for 10 days, as per specification MIL-E-5272A, Pro-
cedure II.
Ignition: Reliable ignition under vacuum conditions

62
1. GRAND CENTRAL ROCKET COMPANY MOTOR generating igniter, activated by two electrically fired
The Grand Central approach used a steel motor case, Hercules SD2A7 15-second delay squibs, and a styro-
with a GCR polysulfide-perchlorate case-bonded pro- foam erodable nozzle closure with a center plug de-
pellant grain. The major design requirements and signed to blow out at a chamber pressure of 20 to 27
special environmental criteria are listed in Table 9. psia. The remaining portion of the erodable closure
maintained chamber pressure produced by the gas-
Description--The Grand Central 33-KS-2800
generating igniter until the propellant grain was fully
rocket motor configuration is described in detail in the
ignited.
manufacturer's Model Specification, Ref. 21, and is
depicted in Fig. 26. It was a case-bonded, solid-pro- Development--The GCR motor development pro-
pellant motor with an integral igniter. The chamber ceeded in five steps, each step producing motors ap-
was 410 stainless steel with a nominal thickness of proaching the desired delivery configuration as the
0.030 inch. The chamber was lined with 91LD Re- required lead time of the manufacturing techniques
frasil and rubber lining material, with glass cloth lami- permitted.
nate used as additional insulation at the locations of Type I motors were heavy-walled, 15-inch diameter
the grain star points. The nozzle was SAE 1020 steel scale models used to determine interior ballistics and
with an insulating lining of "Rokide A" aluminum ignition requirements. Seven of these motors were
oxide in the expansion cone and a graphite insert at fired. None failed, but pressure irregularities would
the throat. have caused failure of light-walled motors in several
A polysulfide and ammonium perchlorate composite instances.
propellant, designated GCR-201C, was used. The Type II motors were heavy-walled, full-size models
grain was cast-in-case, with an internal-burning, star- and were also used to determine ballistics and ignition
shaped port. Polyvinyl acetate cement was placed at characteristics, but now in full scale. Twelve motors
the star points to inhibit grain cracking under thermal were fired, of which seven suffered component failures
stress. or irregularities which would have caused failures in
The ignition system consisted of a slow-burning gas- lightweight motor cases. Fuel liners separated from

57.38 =!

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Z __\'x_'/_ 91 LD AND RUBBER
LINERPLUS
PROPELLANT--x /1__i_,I_ GLASS CLOTH AT STAR POINTS

_POLYVINYL AC_ATE CEMENT

A-A

Fig. 26 Third-Stage Motor (33KS-2800)-- Grand Central Rocket Company

63
four of the cases, and three nozzles burned through. Description--The final configuration of the ABL
X248 A2 rocket motor is shown in Fig. 27. This pro-
The ignition characteristics were successfully deter-
mined with these motors, resulting in satisfactory de- pulsion system was a case-bonded, solid-propellant
velopment of the igniter and erodable nozzle closure. motor with an integral igniter. The chamber was con-
Type III motors simulated those which were to enter structed of epoxy resin-impregnated, filament-wound
qualification testing as closely as the short lead time fiberglas with a nominal thickness of 0.055 inch. A
permitted. Ten Type III motors were fired to obtain layer of cellulose-acetate cloth was bonded to the inner
data on internal ballistics, overall performance, pre- surface of the fiberglas case, acting as a bonding surface
and as an insulator. A contoured rubber insulator
dicted performance and choice of case bonds. Three
failures occurred--the chamber burned through in one covered the aft half of the chamber. Glass cloth was
motor and the nozzles burned through on two others. used for additional insulation in certain areas, notably
the forward dome.
Type IV motors were intended for delivery, but pre-
qualification test results indicated that the mass ratio The propellant grain was a cast-in-case internal-
was too low to produce the required velocity increment. burning type using an ABL double-base propellant,
Weight saving studies were instituted to correct this. designated BUU. The grain was a single-perforated,
Thirty-five static firings were made, and six failures four-slot design with hemispherical head and aft ends.
occurred when four reused and two new nozzles burned Four additional smaller slots were added to obtain the

through. proper burning surface. Case bonding was accom-
Type V motors resulted from the weight saving plished by the use of cellulose-acetate cloth and a case
studies. These motors entered prequalification tests, bonding lacquer. The forward end of the grain was
where eleven of them were fired. Three failures oc- pierced by a cellulose-acetate tube to accommodate the
curred due to insufficient insulation of the nozzle resonance suppressor shaft. A phenolic asbestos reso-
graphite throat, so the insulation was redesigned. nance suppressor paddle was attached to the head end
Cracking from thermal stress was found at the propel- of the motor, through the cellulose-acetate tube, and
lant grain star points, so the star points were coated extended into the propellant grain port.
with polyvinyl acetate cement to inhibit cracking. These The igniter assembly consisted of high impulse pro-
motors then entered qualification testing (see Chapter pellant strips, an ignition charge of boron and potas-
V, Section C). sium nitrate pellets (BKNO:_), two 7 x 7-inch stainless
steel mesh cages to hold the ignition charge, and two
2. ALLEGANY BALLISTICS LABORATORY MOTORS
electrically actuated Hercules SD2A7 15-second delay
The ABL approach to the Vanguard third-stage squibs. The high impulse propellant strips were bonded
design was a "plastic" (resin-impregnated, glass-fila- to the forward end of the resonance suppressor paddle
ment-wound fiberglas) motor case, with a high-energy in two pieces, one on each side. The cagcs with the
double-base ABL propellant. However, technical de- BKNO_ charges were mounted, one on each side of the
velopment problems were encountered which made it paddle, aft of the propellant strips. The 15-second
evident that this unit, the JATO X241 A! (39-DS- delay squibs extended into each ignition charge. Each
2400), would not be operational in time to meet the squib also had a small ignition charge of crushed
Vanguard schedule. BKNO:, covering the active end of the squib. Addi-
In June 1957, the Navy, recognizing the importance tional propellant, having the same composition as the
to solid rocketry of the fiberglas rocket case, author- propellant grain, was bonded to the paddle aft of the
ized ABL to suspend work on the Vanguard motor as BKNO:; cages in eight strips, four on each side.
such, in order to concentrate on solution of the basic The igniter leads extended through a r_ozzle closure
problems which had been uncovered. These problems made of styrofoam coated with an aqueous rubber
were eventually resolved, and in February 1958, ABL latex solution. The closure was then bonded to the
was authorized to develop and qualify a dimensionally nozzle throat insert to hermetically seal the chamber.
similar but higher performance motor, for use as an The nozzle consisted of a glass-filament-wound ex-
advanced Vanguard third stage and in other space
pansion cone, with a liner of asbestos-impregnated
vehicle applications. phenolic and a graphite cantilevered throat. The
This motor, originally designated JATO X248 (40- entire throat section was contained within the motor
DS-3000), was designed to an NRL specification, Ref. chamber.
22, which was similar to the original Vanguard
The motor attachment fittings were of aluminum
specification except for increases in weight, velocity
and consisted of a spin shaft forward, a ring adapter
increment, and maximum acceleration, and some mod-
for attaching the nozzle to the case, and a torque ring
ifications to the environmental criteria, as shown in
at the nozzle exit for attaching the motor to the vehicle
Table 9. The nomenclature of the Vanguard version
spin table.
was later changed to JATO X248 A2 (38-DS-3100),
see Ref. 23. Development--Development of the ABL X248

64
PI
iii iii
0
0

z
w

I..-
z
.,,_1
w

0

0
z
0
o 0
0

z
0 o
t-- II
U --'
1,1.1

I
0
0

M
d_

o

/

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a

! -.F f-_ _.i)

_Du
_0_

I_ I_ I,.I,.

T

65
utilizedthe technology learnedfromtheoriginalVan- on the tail frame of the vehicle. To avoid possible
guardcompetition.One of the majordevelopments delays in the launching operation, an improved launch
towardattaininga successful motorwasthechoiceof stand was designed midway in the program, to permit
properinsulation.Success wasobtainedby usinga launching in ground winds up to 35 mph by providing
silica-loaded rubberinsulatorin the aft part of the retractable support arms. Both launch stands are
motor and designingthe propellantgrain so that a described in detail in Chapter VI, Scction A.
portion of the insulatorwas consumed during the Launch clearance studies--Vehicle tolerances
burningphase.Originally,a rubberinsulatorof uni- that could adversely affect the Vanguard launch were
form thicknesswasemployed, but later a machined made up of three basic parameters: ( 1 ) vehicle vertical
insulatorwas incorporated, wherethe thickness was alignment with respect to the launch stand, (2) lateral
greaterin the areasof the propellantslotsandless shift of the center of gravity with respect to the vehicle
elsewhere, therebyreducing theweightof theinsulator centerline, (3) angular misalignment of the first-stage
and improvingthe massratio. Burn-throughs of the engine thrust vector. These tolerances were originally
casesoccurredin a numberof development firings estimated and later modified to reflect operational
andthe insulatorthicknesses wereadjusteduntil this experience and changes in the engine manufacturer's
conditionwascorrected, specification of thrust vector misalignment. Bending
A seconddevelopment of importance wasthe use of the vehicle due to wind forces caused a lateral cg
of a cantilevered nozzle,with the entirenozzlethroat shift and, by inducing a gyro error, produced an engine
contained insidethemotorcase.Thenozzleconfigura- deflection which acted as a thrust misalignment.
tion was tested by many development firings to Empirical formulas were determined for these condi-
demonstrate itsabilityto withstand damage. tions by measuring the vehicle deflection when exposed
A reliableignitionsystemwasthe objectof an ex- to ground winds. Bending of the vehicle and resultant
tensivetestprogram,includingconfigurations withthe lateral cg shift due to temperature differential between
igniteraspart of thenozzleclosureandaspartofthe opposite sides did not contribute to thrust misalign-
resonance suppressor paddle.The finalconfiguration, ment because the differential changed slowly and the
with the igniteras part of the resonance suppressor, gyro and motor position were nulled just prior to
fulfilledtheignitionrequirements bestandwasincorpo- launch.
ratedin themotor. Early studies of the launch phase considered that
ThirteenABL X248motorsweretcstedatsimulated first vehicle motion took place at liftoff. The allowable
altitudein a vacuumwindtunnelfacilityat theArnold launch wind velocities for test vehicles were calculated
Engineering Development Center,Tullahoma,Tenn. bascd upon this assumption. Further analysis, however,
Fourfiringsweremadeto studyignitionproblems, and indicated that a critical force was present prior to lift-
indicatedreliableperformance of thefinalignitercon- off, in the form of vehicle pitch motion due to wind
figuration.Threemotorswerefired to evaluatethe loads, misalignments, engine gimbaling, and discon-
insulatorandresultedin development of thecontoured nect forces. Moreover, when springs were used to
insulatordiscussed above.Three firings were made as restrain the swingaway arms of the stationary launch
part of the X248 qualification program, to demonstrate stand, the spring forces and spring unbalance moment
reproducible performance in motors which had been contributed to the initial toppling motion of the vehicle.
subjected to environmental testing. Three motors were The equations of motion for the latest study were
subsequently fired in a study of residual thrust after those of a rigid body moving in a vertical plane. A
burnout.
specified point on the rigid body (the hinge point) was
E. SEPARATION constrained to move in a specified path (a vertical
straight line the height of the pins) until a certain
1. LAUNCH altitude was reached, above which the vehicle acted as
System selection--Operational missiles are re- a free body. Because the equations of motion used by
quired to fly under almost any environmental condition. the computer did not employ coefficients of drag and
The Vanguard was considered to be a research tool, lift, the aerodynamic side force was independently
which permitted reductions in launch environment determined for these coefficients as a function of wind
capabilities in favor of increased vehicle performance. velocity. The first-stage engine thrust was a function
The original launch stand for the first half of the pro- of time. Investigations of various thrust buildup curves
gram permitted the first-stage engine thrust chamber experienced in test vehicles showed that clearance was
to extend down into the stand. This eliminated the insensitive to small variations of thrust buildup. The
need for an extended vehicle skirt structure but in- liftoff weight was conservatively assumed larger than
curred a launch wind limitation of about 17 mph. An the predicted liftoff weight.
additional saving of weight and a simplified operation The studies indicated that the allowable ground
was realized by locating most of the vehicle disconnects wind of 17 mph for launch from the fixed stand was

66
limited by the clearancebetweenthe enginenozzle design was a fundamentally simple starting system.
andeitherthepipestructureof thelaunchstandwhich Past experience in the industry led to the selection of
supported the swingawayarmsor theLOX disconnect a hypergolic propellant combination and a pressure-
fitting. The relationship
of theseprotuberances
to the feed system. In addition, a specification limit was
centerlineof the stationarylaunchstandis shownin established which required that the second-stage thrust
Fig.28. For theretracting launchstand,thetrajectory buildup time from ignition to 90% of rated value
of the vehiclewith a 35-mphwind fell within the would not exceed 0.5 second, and from l0 to 90%
design curve. However, it was possible to collide with would not exceed 0.2 second.
the umbilical tower if certain tolerance conditions oc- Environmental conditions--It was decided early
curred. Launch was therefore restricted to wind condi- in the program that two of the environmental condi-
tions of less than 28.5 mph, when the wind was toward tions which would contribute to successful ignition
the quadrant containing the tower. were the retention of sea level ambient pressure in the
chamber and the maintenance of positive acceleration
2. FIRST-STAGE SEPARATION
on the propulsion fluids throughout the prior flight and
For a remote start at altitude, as was the case with during the critical ignition period. Pressure was main-
the second stage, it was considered important to have tained in the combustion chamber by a nozzle c]osure
a simple and rapid starting technique, a separation sys- installed before launch. The separation sequence
tem that produced environmental conditions conducive adopted for Vanguard assured continuous positive
to reliable starting, and a physical separation which acceleration of the fluids by programming second-stage
caused no damage or disturbance to the second stage. ignition prior to separation, during a period when
Engine starting requirements--One of the pri- thrust was still being produced by the first-stage engine.
mary objectives of the second-stage propulsion system The thrust shutdown characteristics of the first-stage

RETRACTING LAUNCH STAND
7O

6O

V,,v -- 21 MPH -_ Vw ---- 23.5 MPH j////J,/
5O

4O
Z
m

3O

2O

10

J
/ //
12 16 20 24 28 32 36 40 44 48

X (IN.)

Fig. 28 ClearanceCurves for Stationary and Retracting LaunchStands

67
engine were favorable for this type of sequence, and no explosive bolts) in several ways. The top half of the
additional complication in the form of thrust augmenta- explosive bolt was retained by a steel bolt extending
tion and/or controls was needed. through the legs of the channel surrounding the ex-
During the period between second-stage ignition and plosive bolt head; smaller fragments were stopped by
separation, a large volume of high temperature gas an aluminum shield riveted to the separation plane
stiffener frame. The bottom half of the bolt was re-
was produced in the interstage compartment. These
gases required venting through blast doors to prevent tained by the flame shield installed over each explosive
damage to local hardware and to keep compartment bolt to protect the explosive bolt assemblies from
pressure at an acceptable level. An insulating blanket impingement of second-stage exhaust prior to separa-
tion.
on top of the first-stage LOX tank dome was also re-
quired as protection against the second-stage engine The fragmentation problem caused rejection of the
flame impingement, which could have caused LOX original concept of separating the first and second
tank rupture. stages by means of primacord. Tests demonstrated
that the heavy charges of primacord necessary to
Sequence--Shutdown of the first-stage engine was
sever structural members resulted in high velocity
initiated by one of the two pump discharge pressure
metal fragments, which would have perforated the
sensors, which detected exhaustion of LOX or kerosene
aluminum second-stage thrust chamber. An adequate
and energized the cutoff relay, which then performed
shield would have been excessively heavy; therefore,
the engine shutdown by removing power from the
the explosive bolt system was far superior in this
propellant valves. In addition, the cutoff relay ignited
respect.
explosive latches in the interstage compartment to al-
low the spring-loaded hinged blast doors to open. A Analysis and tests--The separation of the two
third function of the cutoff relay was to energize the stages was analyzed on the analog computer and de-
helium thrust augmentation valve, which permitted monstrated by mockup tests. The analog study showed
residual first-stage helium to flow into the roll control that the reactive force on the first stage due to the
system at shutdown of the peroxide steam-generating exhaust of the second-stage engine was an important
system. This augmentation was necessary to maintain factor in successful separation. This force caused a
roll control during the separation, mainly to counteract significant deceleration, which increased the relative
the moment produced by the turbine deceleration. separation rate. In addition, the results of the study
A sensor in the first-stage engine sensed when cham- showed that there would not be any interference (col-
ber pressure dropped to 60 psia (3000 pounds of lision) between stages, even under the most adverse
thrust), and then initiated the second-stage ignition sig- conditions. The mockup tests demonstrated that the
nal. A backup timer initiated this signal 1.0 second after operation of various components (such as blast doors,
first-stage cutoff if the primary system failed to operate. explosive bolts, etc.) was satisfactory.
A sensor in the second-stage engine initiated the stage A series of short-duration firing tests was conducted
separation signal when chamber pressure reached 140 at the Aerojet-General Corporation with a test engine
psig (5500 pounds of thrust), 0.35 to 0.50 second after and a mockup of the separation compartment. The
second-stage ignition signal. A backup system operated tests verified that the engine compartment temperatures
by the oxidizer valve (78% open) initiated separation and pressures were within safe limits. The tests also
approximately 0.3 second later, if the primary system qualified the adequacy of the LOX dome insulation
failed. For the SLV-6 and TV-4BU vehicles, the blanket to protect the LOX tank during the ignition-to-
primary separation signal was given earlier by the separation time sequence (Ref. 29).
oxidizer valve (27% open), and backup signals were Delayed second.stage ignition study--Engineering
initiated by the chamber pressure sensor and the was completed on an alternate separation system which
oxidizer valve (78% open).
was to be used in the event that the flight system proved
The separation signal energized two relays to det- inadequate (see Ref. 14). In this system, the explosive
onate the six double-ended explosive bolts which held bolts separated the stages and then retrorockets on
the first and second stages together. For increased the first stage and booster rockets on the second stage
reliability, each bolt had two independently wired provided about three feet of clearance between the
detonators, either of which was capable of breaking stages before the second-stage engine was ignited.
the bolt. Physical separation of the two stages then
An analog study was made to determine the number
resulted from the combined effects of pressure in the
of retrorockets needed, whether the first-stage control
interstage compartment, second-stage thrust and im-
system could maintain proper vehicle attitude until
pingement of second-stage exhaust on the first stage. separation, and whether the second stage would ex-
Fragmentation protection--The vehicle was pro- perience an excessive angle of attack after separation.
tected from damage (caused by fragments from the The final design employed three large retrorockets

68
with410poundsof thrustandtwoboosterrocketswith table, which was mounted on a spherical self-aligning
45 poundsof thrust,andresultedin 32.5inchesof bearing, was prevented from rotating prior to spinup
clearance.The studyalsoindicatedthe adequacy of by a shear arm and shear pin engaging a drive pin in
the controlsystemsto performtheir functionsduring the table.
thisperiod. Separation sequence--A signal from the ground
Electricaltestswereconducted to verify the time or the airborne coasting time computer initiated the
sequenceof eventsbetween the first-stageengineshut- spin-up and separation sequence. This signal ignited
downsignalandthesecond-stage ignitionsignalforthe the two spin rockets mounted on the periphery of the
delayedsequence. Qualificationtestingof the retro- table, started a 1.5-second delay timer to ignite the
rocketwasconducted by theAtlantic Research Corpo- retrorockets and shut off the second-stage control jet
ration, and a series of tests conducted at The Martin systems, and started a 15-second powder train to ignite
Company demonstrated successful separation of the the third stage. The initial thrust of the spin rockets
aerodynamic shields covering the nozzles of the retro- sheared the pin restraining spin table rotation. Con-
rockets. It was never found necessary to install the tinued burning of these rockets spun the table and
delayed-ignition separation system in a vehicle. motor to a speed of approximately 185 rpm. During
this time, the satellite was prevented from rotating by
3. NOSE CONE JETTISON
the spider arms, which engaged the forward bearing
The nose cone was attached to the second stage by housing and rode in longitudinal tracks on the second
two diametrically opposed canopy-type hinges. Each stage.
hinge was locked in place with a hinge pin and an After the first 45 degrees of table rotation, the third-
L-shaped toe. The cone separation plane divided the stage powder train ignition wires were severed by a
nose cone longitudinally through Quadrants I and III. wire cutter mounted on the table. After one revolu-
An explosive-actuated bolt latch pin locked the tip of tion of the spin table, two triggers mounted on the
the cone, and an explosive bolt surrounded by a com- second-stage bulkhead were positioned. At two
pression spring locked the body of the cone. The latch revolutions of the table, these triggers engaged two
pin and explosive bolt were actuated simultaneously by levers on the spin table which sheared the pins retain-
an electric signal to unlock the nose cone and free the ing the motor, leaving the third stage free within the
compression spring. The spring imparted an impulse second stage. This sequence required about 1.2
to the separated sections of the nose cone, rotating seconds. At 1.5 seconds after spin rocket ignition,
them outward about the hinges to jettison the cone two retrorockets mounted on the exterior of the second
from the vehicle. This impulse was sufficient to ensure stage were fired, decelerating the second stage and
that the longitudinal acceleration would not cause the achieving separation. At the same time, the pitch/yaw
cone halves to snap back into the closed position. Pro- and roll jets were cut off to ensure minimum second-
tection from fragment damage was provided by a stage movement during the separation sequence. The
cylindrical shield fitted around the explosive bolt. release of the spider arms at separation allowed the
Analysis--Beyond the angle at which the accelera- satellite to rotate on the bearing.
tions of the nose cone cg normal to the vehicle axis Separation clearance analysis--To ensure success-
go to zero, a tension force was required at the hinge to ful third-stage separation, the second-stage shell which
hold the cone half to the vehicle. Since the hinge was surrounded the third-stage motor had to retract ap-
not designed to apply to this kind of force for more proximately five feet longitudinally without contact.
than 55 degrees of motion, the disengagement angle The disturbing factors of interest were those which
occurred as soon after 55 degrees as the normal induced relative motion between the second and third
accelerations changed sign. This was determined to be stages when the third stage became unrestrained.
61 degrees. Further calculations revealed that the nose These included manufacturing tolerances in the motor
cone halves would not present any problems of collision cg and principal axis location, retrorocket alignment
with the second stage following their disengagement. errors, retrorocket thrust and burning time variations,
disturbances from non-simultaneous ejection of the
4. THIRD-STAGE SEPARATION spider arms, and residual second-stage vehicle motions
The third stage of the Vanguard rocket had no from the control system.
guidance system, but was spin-stabilized. The third- A large number of computations was necessary to
stage motor was contained in the forward shell of the solve the equations of motion of the third-stage separa-
second stage (see Fig. 12). The aft end was mounted tion for a given set of initial conditions. Since the
on a spin table and the forward end was restrained study was made for several vehicles and several dif-
from transverse motion by four jettisonablc "spider" ferent sets of initial conditions for each vehicle, it was
arms. The third-stage nozzle was clamped to the spin decided to program most of the problems on the IBM-
table by two sets of shear pins and collars. The spin 701 computer then available. Approximate hand

69
methodswereusedto computethe effectsof several velocity of the vehicle at the time of retrorocket igni-
additionaldisturbancestendingto producethird-stage tion were not included in the equations of motion. The
wobbleandtranslation. solution of the equations and the resulting locus of
Testing(seeChapterIV, SectionH) andanalysis rocket shields with respect to the third stage showed
that there would be at least 100 feet clearance between
of an earlyconfiguration,whichtaperedto a 26-inch
externaldiameterat the forwardend of the second the shields and the third stage.
stage,disclosedthatonly a smallmarginof clearance
waslikely, if any of the variables
consideredshould F. ORDNANCE
assume a maximumtolerance.The configuration was
modifiedto maintaina constant32-inchdiameterall Ordnance components were used in the Vanguard
separation sequences, in the second-stage helium heat-
thewayto thenoseconeseparation plane.Thislatter
ing system, and provided the explosive force for the
configurationwas the only one flown (exceptin
destruct system.
TV-2, whereno third-stage separation
wasplanned).
Explosive bolts--The six explosive bolts used to
5. RETROROCKET COVER CLEARANCE connect, and later to separate, the first and second
The retrorockets were fired 13.5 seconds before stages were ordinary 4130 steel bolts, center-bored to
receive electrically initiated explosive detonators. For
the firing of the third stage, and imparted a velocity of
increased reliability, two independently-wired Dupont
approximately 80 fps, directed forward at a minimum
E-77 detonators, either of which could sever it, were
of 11 degrees from the vehicle centerline, to the aero-
sealed into each bolt.
dynamic shields that protected these components dur-
The explosive bolt used in jettisoning the nose cone
ing flight through the atmosphere. After the third
was similarly designed, and incorporated the same dual
stage was ignited, it passed the jettisoned rocket
actuation feature, but was made of aluminum and used
shields. It was therefore necessary to investigate the
possibility of collision. Since only the relative motion two Dupont X210 detonators.
between the rocket shields and the third stage needed Explosive latches--The first-stage blast doors and
to be considered, the effects of gravity and the actual the nose cone halves were held in place, and later

END CAP

BONDING DISC

IGNITION BOOSTER STRIPS

4.749

1.530
DIAMETER

NOZZLE COVER

SS SHIM WASHERS
IGNITER SEALING GLAND

4130 STEEL CHAMBER NOZZLE PLUG

GRAPHITE NOZZLE INSERT
MOUNTING BRACKET PROPELLANT GRAIN

Fig. 29 Cutaway of IXS-50 Spin and Retro Motor

70
released, by Conax explosive latches. Components additives in small amounts. The igniter contained
used for the two applications were identical except for powdered magnesium, potassium perchlorate and poly-
a reflective chrome finish applied to the nose cone isobutylene, actuated by an Atlas electric match.
latches to inhibit the absorption of thermal radiation. The spin motors had a reflective chrome finish to
The latch pin was driven to the open position by pres- reflect radiant heat in order to prevent operating
sure on an attached piston from the explosion of an temperature of the rockets from being exceeded. The
electrically initiated squib. For increased reliability, retro motors were protected from aerodynamic loads
each latch contained two squibs, wired in parallel, and heating by a protective insulating fairing of Haveg
either of which was capable of actuating the latch pin. asbestos-impregnated phenolic (Fig. 30). The forward
portion of the fairing was a removable nose cone
Spin and retrorockets---Spinup of the third stage
which was blown off by the retro motor exhaust gases
and deceleration of the second during the separation
upon ignition. The cone was designed so that it was
sequence of these two stages was accomplished by
ejected at an angle of approximately 11.5 degrees to
small solid-propellant rocket motors designed and
the vehicle centerline and away from the vehicle skin.
manufactured by the Atlantic Research Corporation,
Since the fairing also insulated the retro motors, a
in accordance with a Martin Development Specifica-
reflective finish was not required, and a zinc-chromate
tion, (Ref. 24). These motors, designated 1-XS-50,
finish was used.
are described in the manufacturer's Model Specifica-
The development of the spin and retro motors was
tion, (Ref. 25) and are shown in Fig. 29. They
based upon existing propellants and hardware manu-
nominally produced 50 pounds of thrust for one sec-
facturing techniques. Large numbers of static test fir-
ond, and had a maximum length of 4.85 inches, a
ings were made to establish the reproducibility of per-
diameter of 1.510 _ 0.032 inches, and a maximum
formance over the operating temperature range of
weight of only 0.70 pound. The rocket chamber and
+20°F to +130°F, as well as for vacuum ignition
nozzle were 4130 steel, and the solid-propellant grain
characteristics.
was a separately machined type, bonded to the forward
end cap of the chamber. The propellant consisted of Helium heat generator--Part of the second-stage
ammonium perchlorate, resin, plasticizer and other propulsion system furnished by Aerojet-General was

f BODY, INSULATION POD

--- FELT DISC

HI,

_x'xX-- END PLUG
f

ec0oJ
X I -q_\A"

EPARATION "7
1
r.t'3 \t I J

2.53 DIA

_A

Fig. :30 Retrorocket Aerodynamic Cone and Insulation Assembly

71
the heat generator unit. The function of this unit was engine start, cutoff and separation; second-stage igni-
to provide additional energy to the helium pressuriz- tion, hydraulic system operation and cutoff; nose cone
ing gas in the form of heat from the in-flight burning jettison; third-stage spin, separation and ignition; and
of a solid-propellant charge. This was essentially a vehicle destruct.
weight-saving device, in that the initial helium sphere Primary power was supplied from two 20 ampere-
pressure could thereby be kept to a lower value, re- hour silver-zinc batteries, one in the first stage and
ducing the structural weight requirements. one in the second stage in order to keep the second-
This device, cylindrical in shape, contained two stage battery weight to a practical minimum level.
cast-molded solid-propellant grains actuated by an The flight batteries supplied power to an aircraft-
ignitcd assembly of two electrically fired squibs em- type rotary inverter which, in turn, powered the trans-
bedded in a black powder charge. Hot gas flow into former-rectifier B+ power supply. Two additional bat-
the helium sphere was controlled by four gas ports in teries were provided for the first- and second-stage
the heat generator. The propellant grains were a telemetering systems. The first-stage telemetry battery
cylindrical, end-burning type, of polyurethane and also supplied power to the first-stage command system,
ammonium nitrate composition. Functionally, the unit while the second-stage telemetry battery supplied power
had a nominal burning rate of 0.115 inch per second to the radar beacon. The electrical system parameters
and a chamber pressure of 1000 psia. Dimensionally, are given in Table 10.
the unit had a nominal diameter of 2.5 inches and an
overall length of 31.0 inches, with a nominal wall thick- 1. PRIMARY 28-VOLT D-C POWER SUPPLY
ness of 0.090 inch. The unit was made of corrosion-
The two sources considered for 28-volt d-c power
resistant steel.
were batteries or a generator driven by a monopro-
Destruct system--The destruct system consisted of
pellant such as hydrogen peroxide. Batteries were
multiple strands of explosive primacord, installed in
selected, since they had a definite weight advantage for
the external conduits along the fuel and oxidizer tanks
the short use period required. The specific outputs of
of the first and second stages. About 140 feet of
thermal, lead-acid, nickel-cadmium-alkaline, zinc-
primacord (five strands pyramided) were used on the
mercuric oxide, and silver peroxide-zinc-alkaline bat-
first stage, and about 50 feet (four strands side-by-
teries were examined. A comparison of operating
side) on the second stage.
characteristics of the two types having highest outputs,
The primacord consisted of a 100-grain-per-foot
i.e., the zinc-mercuric oxide (30 watt-hours per pound)
explosive core of Pentaerythoritetetranitrate (PETN), and the silver peroxide-zinc alkaline (40 watt-hours
contained within a moisture-proof Hycar rubber jacket.
per pound), showed the first to have a lower operating
Initiation of each primacord circuit was provided by
efficiency at high rates of discharge.
either of two electric detonators, connected to inde-
The most practical main power supply for the Van-
pendent electrical circuits. Dupont E-81 instantaneous
guard vehicle therefore appeared to be the silver
detonators were used for both oxidizer tank destruct
peroxide-zinc-alkaline-type battery. The batteries
systems, while Dupont D-IB-3 two-second-delay det-
chosen were manufactured by the Yardney Electric
onators were used for both fuel tank systems. The
Corporation. Each battery had a 20-ampere-hour
detonator assemblies were equipped with shorting
capacity and was composed of 20 HR-20 silver cells,
plugs, which remained attached until plugged into the
each having a nominal voltage under load of 1.4 volts.
vehicle destruct panel. The lead wires were just 6
These batteries were light, weighing approximately one-
inches long to minimize possiNe interception of stray
fifth as much as a lead-acid battery of equal capacity.
RF current.
They had low internal impedance, which provided
There was relatively no danger in the handling or
good voltage regulation with varying loads; a flat
installation of primacord, since it cannot be set off by
discharge curve, keeping the voltage relatively con-
friction, sparks, stray electric currents or any ordinary stant with flight time; and a small amount of free
shock. It can be exposed to temperatures of 200°F
electrolyte, minimizing spillage problems. They were
for an indefinite period without danger or damage.
rechargeable, permitting usage during ground checkout
Loose PETN dislodged from the cord, however, is a
and static firings to determine actual battery perform-
high explosive sensitive to friction, and should be
ance prior to flight firing, and had proven reliability
avoided at all times.
in actual usage on other vehicles.

G. ELECTRICAL 2. A-C INVERTER

The electrical circuits provided operational control Static inverters were procured and tested early in
of the following: power generation and distribution; the program. Results indicated that cost and time
propellant servicing and pressurization; first-stage would not permit satisfactory development. Therefore,

72
Table 10. Electrical System Parameters

First Stage Second Stage
Hight Battery:
Volts 28 28
Capacity, amp-hr 20 20
Telemetry Battery:
Volts 28 28
Capacity, amp-hr 5 5
Instrument Reference Battery, volts 5
Inverter (3-phase) :
Volts 115
Frequency, cps 400
Capacity, volt-amps 250
Maximum Allowable Voltage Modulation 0.5%
Transformer-Rectifier (B+ Supply) :
Volts 150
Capacity, watts 15
Telemetry Systems:
Modulation System PPM/AM PWM/FM
Carrier Frequency, mc 238.5 231.5
Power, watts 35 15
Channels 15 43

Radar Beacon (C-Band) AN/DPN-48(c)
Interrogation Frequency, mc 5490
Transmitting Frequency, mc 5555
Command Control:
Receivers AN/FRW-59 AN/FRW-59
Recorder NRL E4680 NRL E4680
FM Radio Frequency, mc 410 410
Sensitivity, #v 5 5
Minitrack (Satellite) :
Frequency, mc 108
Power, mw 10

a conventional aircraft-type rotary inverter was especially commutator performance and temperature
selected. The Leland SE-10-3 inverter was chosen rise. The results of these tests showed satisfactory
over others because tests indicated that its voltage commutation and the ability of the inverter to operate
modulation (less than 0.5%) met the requirements of for approximately 15 minutes before overheating. The
the control system. This inverter was capable of sup- decision to pressurize the inverter container was made
plying 250 va at a power factor of 0.8 when connected in order to ensure inverter operation for the entire
for 115-volt, three-phase delta operation, with a voltage flight period of Vanguard, since 15 minutes of operation
regulation of 109 to 121 volts and a frequency regula- were considered marginal.
tion of 380 to 420 cps.
The unit was a rotary motor-generator with a 3. COMPONENTS
laminated yoke assembly, having a common shaft for
Relays and timers--There were 32 relays and
the armature and motor. The prime mover was a
timers used in the vehicle electrical system. All were
compensated compound-wound d-c motor having a
hermetically sealed from the effects of moisture and
pole face winding for stabilizing the operation. Noise
filters were included in both the d-c input and a-c out- altitude. Each relay or timer demonstrated satisfactory

put lines. Two built-in carbon pile amplifiers furnished performance under the temperature, shock and vibra-

automatic voltage and frequency regulation by con- tion conditions imposed by the Vanguard vehicle. In
trolling the current in the a-c motor winding for voltage addition, the electrical operating characteristics and

control and in the shunt field of the motor for frequency capacity were proven adequate in a functional mockup
control. The frequency could be adjusted by means of the electrical system. The types used were:
of an internal rheostat. An external adjustable 16--Hart four-pole double-throw. Contacts rated
rheostat was also provided to permit manual setting
for 10 amperes resistive at 28 volts.
of the a-c voltage.
5--Union Switch and Signal six-pole double-throw.
This inverter satisfied the environmental require-
Contacts rated for 5 amperes resistive at 29 volts.
ments of standard drawing MS25093-1 and specifica-
tion MIL-I-7032D. One inverter was checked for 2--Filtors four-pole double-throw magnetic latch.

performance characteristics at extremely high altitudes, Contacts rated 2 amperes resistive at 26.5 volts.

73
2--Filtors two-pole double-throw. Contacts rated 2 stalled to meet the requirements of MIL-W-8160,
amperes resistive at 26.5 volts. except for high temperature applications (200°C)
3--Cutler-Hammer 1-pole single-throw. Contacts where teflon wire in accordance with MIL-W-16878A
rated 50 amperes, 27.5 volts (MS24140-1). was used. The ambient temperature wiring (up to
4--Wheaton Timers, two 5 to 195 second adjustable 105°C) was a nylon-jacketed thermoplastic-insulated
timers, one 1-second timer, one 1.5-second timer. copper wire, identified as MC| 58740. This wire met
the requirements o[ MIL-W-5086. The high tempera-
Switches--Seven switches were used in the elec-
ture wire was identified as MCI 58756, and was
trical system, of which three operated during flight.
teflon-insulated copper wire which met the require-
The others were used during ground testing only. The
ments of MIL-W-16878 type E or EE. The smallest
three flight switches were all MS24331 first motion
size wire used was 22 gage and the largest 4 gage.
(ice breaker type) switches. These met thc require-
ments of military specification MIL-S-6744 and in
4. SYSTEM OPERATION
addition were scaled to meet the immersion test of
Procedure I of MIL-E-5272. The contacts were rated The propulsion fire panel, the ground servicing
at 4 amperes resistive. The test switches were all panel and the electrical monitoring panel located in
military standard toggle switches; three were AN3027-3 the blockhouse were used in conjunction with remote
switches and the other was an MS25068-3. All test junction racks in the equipment house to service and
switches had contacts rated for 20 amperes resistive. fire the vehicle. A block diagram of system operation
is shown in Fig. 31. A resume of all electrical sequen-
Connectors--There were approximately 100 elec-
cing is given below for completeness. Sequences are
trical connectors used in the electrical system and as-
sociated interconnecting wiring within the vehicle. repeated elsewhere in the report insofar as they affect
the operation of the various systems.
More than 80% of these were required to connect
with various electrically operated components such. as Prelaunch--Up to five minutes before launch, the
valves, motors, solenoids, etc. For example: vehicle was supplied with 28 volts d-c from a ground
23 were required to connect with components of power source. The control system, and consequently
the first-stage propulsion system; the inverter, was energized when power was applied
14 with components of the second-stage propulsion to the second-stage bus when the control switch was
system; closed in the second stage. During W|FNA servicing,
21 with components of the controls system; and the oxidizer probe resistance was periodically monitored
22 with range safety and destruct system com- to ensure the physical and electrical integrity of the
ponents. probes.

The different types of connectors used were: At approximately T-6 minutes, the second-stage
hydraulic pump motor was energized from ground
50 Military Standard type or MS modified for
power to check out the second-stage contrql system and
potting;
to arm the second-stage pressurization system. At
26 Titeflex connectors;
T-5 minutes, the rotary selector switch on the pro-
*21 Bendix miniaturized connectors;
pulsion fire panel was placed in the first arm position.
2 Cannon type K connectors;
This operation put the first-stage battery on the first-
* 11 Winchester type M connectors;
and second-stage busses and also armed the first-stage
*6 Amphenol type 165 connectors;
firing circuits. The fire signal could not be initiated
I Cannon type GMA 140-pin, solenoid-disconnect
unless the batteries were connected to the vehicle
type connector.
busses.
All connectors had 20-ampere contacts except those
First-stage pressurization began at T-2 minutes,
marked with an asterisk, which were miniaturized con-
at which time the hydraulic pump motor switched to the
nectors with 7.5-ampere contacts. All connectors were
second-stage battery. The peroxide and fuel tanks were
potted to relieve strain on the soldered connections
pressurized automatically, with the fuel tank having the
and to resist moisture, except the Titeflex connectors,
capability of being manually overpressurized. At
which used individual wire collets around each wire to
T-60 seconds, the first- and second-stage batteries
achieve the same results. The interstage and first-stage
were paralleled. The helium and cooling air umbilicals
disconnects were all Titeflex plugs, where the use of
dropped at T-45 and T-30 seconds, respectively. The
teflon insert material gave a degree of resistance to
LOX tank vents, which had been periodically cycled to
nitric acid .and to the relatively high temperatures
ensure proper operation, were then closed and the
encountered.
LOX tank was manually pressurized at T-20 seconds.
Wiring--The wiring used for interconnecting Once the fire signal was initiated, the LOX tank main-
electrically operated components was selected and in- tained pressure automatically. If the need arose, the

74
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75
heliumpressureof all tanks and spheres could be Also, the helium heater squibs were ignited. When
dumped. Ground cutoff opened all tank vents. chamber pressure reached 70% of full thrust, a backup
separation signal was sent. Another backup separation
Launch--When the first-stage fire switch was
signal was given when the main oxidizer valve opened
operated at T-0, the electrical umbilical dropped and
78% of full open.
the firing sequence began. If all the propellant valves
Second-stage flight--At approximately 172 sec-
were closed, and if the combustion and ignition in-
onds after liftoff, the program timer energized a relay
dicators were properly installed, the firing sequence
which detonated the explosive bolt and latch to jettison
continued, resulting in operation of the ignition relay
the nose cone. Second-stage cutoff, which could be
in the ground sequencer. The igniter contactor then
initiated by the exhaustion of either propellant, was
closed and applied 28 volts dc to the pyrotechnic
armed at 240 seconds by the program timer. If fuel
igniter. The resulting flame burned through the fusible
exhaustion occurred, the resultant decrease in chamber
ignition indicator link, signalling the main oxidizer
pressure was sensed by the thrust pressure switch. This
valve and ethane valve to open. Approximately 1.5
energized the cutoff relay, which de-energized the pilot
seconds after the oxidizer valve started to open, the
valves and caused the main propellant valves to close.
fuel main valve opened. When combustion chamber
If oxidizer exhaustion occurred, it was sensed by an
pressure reached approximately 23 psia, the combus-
electrical resistance probe in either oxidizer feed line,
tion indicator opened, which shut off ethane flow and
which gave the cutoff signal through a transistorized
signalled the peroxide valve to open, starting the
circuit. The second-stage cutoff signal also armed the
turbopump. Certain functions, such as ignition, valve
pitch and yaw attitude control system for coasting
openings and combustion indication, had to occur
flight, armed the third-stage firing circuits, and started
within a specified time, as controlled by timers in the
a 20-second timer to de-energize the hydraulic pump
ground sequencer, otherwise cutoff would have been
motor. The fifth pitch rate was activated at 400 sec-
given automatically. Liftoff occurred when thrust ex-
onds by the program timer.
ceeded vehicle weight, actuating first motion switches
which started the program timer and the coasting time Third.stage separation--Upon receiving a spinup
computer. and ignition signal from the coasting time computer,
the qommand timer, or the program timer, the third-
First-stage flight--The program timer activated stage spin and ignition relay closed, energizing the spin
the first four pitch rates consecutively at 10, 24, 45, motors, the 15-second powder train to ignite the third-
and 112 seconds after liftoff. At 127 seconds, the pro- stage motor, and the 1.5-second separation timer. The
gram timer energized two relays in the second stage separation relay energized the retro motors to separate
to arm first-stage cutoff, second-stage ignition and the second and third stages 1.5 seconds after the
nose cone jettison. Normal first-stage burning time was spinup signal was initiated. At this time also, the
approximately 140 seconds. When the fuel or LOX pitch, yaw and roll attitude control systems were
pump outlet pressure switches sensed exhaustion of de-energized.
either propellant, first-stage cutoff occurred through
Payload separation.--Payload separation from the
closing of the propellant valves. Residual helium in
third stage after burnout was initiated on several flights
the spheres and peroxide tank was vented through the
by a mechanical timer that was armed by the high
roll jets to provide roll control during the period from
accelerations (about 30 g) during third-stage burning.
first-stage cutoff to second-stage separation. The blast
The range of timer settings used was from 0.5 to 5
doors in the interstage area unlatched to relieve the minutes.
compartment pressure during the second-stage start
sequence. The first-stage chamber pressure sensor or 5. DEVELOPMENT TESTS
its backup (a one-second timer which started at first- Mockup tests--The electrical system mockup
stage cutoff) gave the second-stage ignition signal and which utilized actual vehicle wiring and components,
armed second-stage roll control. was operated to simulate a vehicle flight from first-stage
First-stage separation--Once the second-stage ignition to third-stage ignition, including actual inter-
sequencer received the ignition signal, the second-stage stage connector separation. Test results indicated that
oxidizer pilot valve opened the main oxidizer valve. battery capacity and wiring were adequate even under
the worst conditions.
When the main oxidizer valve opened 27%, stage
separation was initiated by the detonation of six double- Interstage connector tests--A test was run on the
ended explosive bolts. The fuel pilot valve was also interstage connectors to explore the effects of separat-
energized by this signal, causing the fuel main valve to ing connectors in a vacuum with power supplies on
open. At the same time, the main helium regulator both sides of the connectors and with loads simulating
was tripped electrically, so that second-stage propellant those on TV-3. The test was successful in that no
tank pressures were maintained under flow conditions. apparent arcing was visible during separation, and

76
examination
of both sections
indicatedthat nonehad differential relay shutdown system was designed and
occurred. developed to give a cutoff signal to the second-stage
Flame impingement tests--The LOX dome engine as soon as the probe shutdown system sensed
oxidizer exhaustion. The system consisted of an oxi-
impingement test at Aerojet determined the effects of
the separation process on the electrical connectors, wir- dizer probe in each oxidizer line and a differential
ing and components located in the interstage area. relay circuit which would become unbalanced and give
Results indicated that the wiring and electrical compo- engine cutoff when both probes had sensed oxidizer
nents should be protected with several wraps of teflon- exhaustion. The system depended upon an increase in
impregnated fiberglas tape, which were incorporated. resistance of the oxidizer probe (probe tip to the wall
of the oxidizer line), once liquid oxidizer flow no
6. DEVELOPMENT PROBLEMS longer existed. When the resistance of both probes
Moisture and condensation---Moisture and con- started to increase, the current in the sensing winding
densation adversely affected the vehicle high impedance of the differential relay decreased, which in turn gave
circuits at terminal strips and connectors, since the the cutoff signal.
potting compound did not adhere to teflon wire. The Further development testing with the second-stage
terminal strips and some of the connectors in these engine showed that there could be a relatively large
circuits were eliminated and the splices were encapsu- time difference between the exhaustions of the two
lated in Scotchcast. All connectors (except Titeflex) oxidizer lines. This new input required the probe-
that had teflon wires were scotchcasted and the Tite- differential relay system to be capable of giving the
flex connectors were protected with fluorolube grease. cutoff signal when either probe sensed oxidizer exhaus-
In the final vehicle, all compartments were continuously tion. Careful evaluation of this requirement indicated
purged with dry nitrogen until the gantry was retired. that the differential relay could give an inadvertent
In addition, all terminal strips were treated with glyptol cutoff signal because of its low drop-out characteristic.
to minimize effects of moisture and condensation. In view of this deficiency, the differential relay was
Relay sequence--As originally designed, the relay replaced with a transistor relay circuit.
sequence in the Aerojet propulsion sequencer unit could The final shutdown system (probe-transistor sys-
prevent giving the cutoff signal to the second-stage tem) was capable of giving the cutoff signal when
engine. The basic problem was that, within established either probe sensed oxidizer exhaustion. The probes
relay tolerances, the pull-in transfer time of the cutoff were employed as before, except that they were wired
relay (the time from opening of the normally closed so that either probe could give the high resistance sig-
contact to closing of the normally open contact) could nal to the transistor circuit which gave the cutoff signal.
The transistor circuit consisted of two transistors and
be greater than the drop-out time of another relay
which armed the cutoff relay coil. This was eliminated a fast-acting relay; the transistors were employed as
by making cutoff relay operation independent of the on-off amplifiers which drove the relay. In addition,
drop-out time of the arming relay. arc suppression circuits were added to reduce induced
voltages to a level that would not adversely affect
Thrust pressure sensor switch--The thrust pres-
the relay contacts and the transistors in the Aerojet
sure sensor (TPS) switch in the second-stage propul-
sequencer.
sion system sensed and reacted to the pressure of the
second-stage engine thrust chamber. It was used to Inverter frequency drift--Inverter frequency
initiate a back up separation signal for first and second drift was a problem during ground checkout on the
earlier vehicles. This problem was attributed to failure
stages on rising pressure and to shut down the second-
of regulating tubes and to carbon dusting. The tubes
stage engine (sensing fuel exhaustion) on decreasing
pressure. During engineering evaluation of the TPS were replaced by silicon diodes, while alt components
in the inverter frequency and voltage control circuitry
and the propellant tank pressure switch (HPS_, same as
TPS except for pressure setting) a number of switches were treated with glyptol to preclude effects of carbon
dusting.
performed erratically and did not operate within speci-
fied tolerances, especially after being subjected to a
vibration environment. Further investigation revealed H. MECHANICAL
dirt and chips of metal within the switch's working There were two significant mechanical systems util-
mechanism, maladjusted stops and incorrect mounting. ized on Vanguard, the first-stage roll jets and the third-
Later tests showed that properly cleaned and adjusted stage spin mechanism.
switches performed within specification. Each TPS and
HPS_ switch was thereafter inspected before, during, 1. FIRST-STAGE ROLL JETS
and after exposure to a vibration environment specified System selection--Movable fin stabilization of the
for the Vanguard. first stage in the roll axis was considered but abandoned
Oxidizer exhaustion cutoff--An oxidizer probe- in favor of individually controlled jet reactors because

77
of the weightsavingadvantages, simplicityof vehicle The centering mechanism was designed to put the cen-
design,and requirement for roll controlin regions tering spring in compression for any roll jet position,
where dynamicpressurewas low or nonexistent. resulting in a positive, quick-action return to center
Originally,the first-stage
roll controlstabilization sys- and good damping.
temwasto haveconsisted of peripherally
mounted jets System tests and development--The initial roll
fedby a separate gassupply.However, a largeamount jet design employed a ball bearing joint on which the
of fuelandstorage spacewouldhavebeenrequiredto jet can rotated. Tests revealed that extreme friction and
supplythesubstantial correcting momentrequireddur- binding in the roll jet bearing and seal prevented the
inglaunchandat maximumdynamicpressure. Steam mechanism from meeting the response requirement
fromthe hydrogen peroxide turbinewasexpelledwith because of differential expansion of the parts when
considerable force duringthe entirefirst-stage flight. subjected to the 800°F turbine exhaust. A redesign
It wasdecidedto harness thisdeveloped thrustfor roll incorporated a floating labyrinth seal of aluminum
controlmoment. bronze composition, and a three-bearing, track-roller
System description--The turbine exhaust was design. The rollers were designed to center the jet by
ducted through flexible bellows to two rotatable spher- riding on the exterior surface, and were, therefore,
ical-shaped roll jet nozzles, placed 180 degrees apart on removed from the 800°F environment. The friction
the periphery of the tail can (see Figs. 12 and 32). problem was essentially eliminated and the response
These were actuated in unison so that the individual requirement was met, as substantiated by subsequent
thrusts combined to form a rolling couple. The nozzles test and flight data.
had three positions: neutral, where the exhaust was Systems testing of the roll control system was ac-
pointed aft, and -+- 45 degrees (see Fig. 32). There was complished by use of the first-stage roll mockup. Items
no valving on the exhaust system; the nozzles operated such as thrust, response and nozzle position were
from start until shutdown of the peroxide system. When monitored during the tests. Test results generally sub-
the nozzles were not required for roll correction, they stantiated design predictions. Many helium control
were pointed aft, augmenting the thrust of the first- valves were rejected during ground tests because of
stage thrust chamber. Since the available correcting leakage. This leakage was caused by small bits of line
moment was substantially larger than the maximum wall scale and the level of contaminant in the helium
predicted disturbing moment, system stability was im- as purchased. These very fine contaminants would
proved by deflecting the nozzles through only 45 de- have had no effect on most valves but were sufficiently
grees instead of the maximum 90 degrees. In this coarse to scratch the optically fiat sealing surfaces in
manner, the most advantageous combination of system these valves. The condition was remedied by installing
damping and overshoot was realized, and the relatively paper micronic filters at the valve inlets.
long delay between hard-over in one direction and
2. THIRD-STAGE SPIN MECHANISM
hard-over in the other direction was substantially
reduced. System seler'tian--Several methods of spinning the
Movement of the roll jets was accomplished by a third stage to a minimum of 150 rpm were considered
pair of on-off actuators, powered by helium pressure during the Vanguard design phase. The spin could be
and controlled by pneumatic four-way, three-position imparted before launch, during flight, or just prior to
valves which responded to signals from the roll gyro. separation, but the effect of spinup on other vehicle
Each of the actuators contained two single-acting pis- functions had to be considered. In addition, a maxi-
tons, a solenoid-operated three-position valve, a cen- mum allowable spin of 1000 rpm was established by
tering spring, and linkage to convert linear piston third-stage structural considerations.
motion to rotary motion of the nozzles. A disconnect The third stage would have to be rotated to about
and two check valves were used so that the actuators 1250 rpm on the ground to ensure 150 rpm at third-
could be operated without energizing the propulsion stage separation. This was above the allowable spin
system. The design of the first-stage roll jet actuator rate of the third stage, and would have introduced a
was governed by the available 640-psi helium source large gyroscopic effect during first and second-stage
and by maximum response requirements that the jet flight. A helix screw was considered, wherein the third
actuate from neutral to 45 degrees within 80 millisec- stage would be initially locked in place, then spin down
onds and return to neutral within 110 milliseconds. the helix during some high acceleration portion of the
The jet was also required to pass steam at 800°F with- flight, and rotate freely at the end of the helix thread.
out binding during the 140 seconds of first-stage flight. Weight and space considerations, however, ruled out
Since the pistons of the actuator were bottomed in the this method. Weight also ruled out the use of a turbine
neutral position, it was not necessary to compress resi- driven by helium, ram air, or solid propellant gas
dual helium to start the actuator, which resulted in generators.
quicker starting and required less pneumatic power. The potential energy of a leaf spring wound on a

78
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79
drum was also considered as a source of the rotational these tests, the satellite separation time and expected
energy needed. Premature rotation would be prevented final spin rate of the satellite were determined.
by a cam, held in place by a fuse link which could be
melted by an appropriate electrical signal. Sufficient I. HYDRAULIC
spin could also be imparted to the third stage by the
ignition of two small solid propellant spin rockets The gimbaled first- and second-stage Vanguard en-
mounted tangentially on a revolving spin table. The gines were positioned by electrohydraulic transfer
spring actuation method weighed about 2.5 pounds as valves and actuators in response to gyro commands.
compared to about 1.5 pounds for the spin rocket The transfer valves used on Vanguard were similar to,
design. Since the reliabilities of both systems were but had higher performance characteristics than those
considered excellent, the lighter spin rocket design used on Viking rockets. They were chosen largely be-
was chosen. cause of their good reliability and performance on
Viking. Relief valves and constant displacement pumps
System description--A description of the hardware
were chosen to maintain system pressures in the first
and its operation may be found in Chapter IV,
and second stages, since they were simpler and lighter
Section E.
than the available alternative of variable volume pumps.
System tests and development--A mockup was
1. SYSTEM DESCRIPTION
constructed to test the third-stage spin and separation
system. The mockup consisted of the following: a First stage--Design system parameters and a
tapered second-stage shell (top diameter, 26 inches), schematic of the final first-stage hydraulic system con-
including retrorocket installations and weights to simu- figuration are given in Fig. 33. The major components
late second-stage mass and moments of inertia at of the system were the pump, a pneumatically
burnout; a simulated third stage suspended in a man- pressurized accumulator, a system pressurized reservoir,
ner to allow spin; and the third-stage spin and separa- a high pressure relief valve which maintained system
tion mechanism mounted in the second-stage shell. In pressure between 1600 and 1700 psi during normal
addition, a stroker motor was utilized to give a low- operation, a low pressure relief valve for thermal pres-
frequency, low-amplitude pitch/yaw oscillation to the sure relief, a filter, and the engine pitch and yaw hy-
second stage to simulate motions during separation. draulic actuator assemblies.
The tests indicated that spin and separation could be The first-stage pump was driven by the hydrogen
accomplished with this configuration. Collisions did peroxide turbine through a gear linkage, thus utilizing
occur between the stages on the last three runs. How- an available power source which eliminated the need
ever, this was alleviated by increasing the top diameter for an electric motor. The first-stage pump was a
of the second-stage shell and locating the retrorockets seven-piston constant-displacement pump rated for 1
at the center of percussion of the empty second stage. gpm flow at 1500 rpm. It was operated at 3900 rpm
The bearing housing on which the satellite was and delivered about 2.9 gpm flow to the system. When
mounted permitted the satellite to attain a rotation of this flow was not required by the actuators, it was
about 150 rpm prior to satellite separation from the ported directly back to the return line by a high pres-
motor. On several of .the vehicles, it was desired to sure relief valve. The fluid supply for the first-stage
limit the satellite spin rate to 60 rpm. Since the initial pump was contained in a reservoir which was pres-
spin rate of the third stage was 180 rpm and that of surized by system pressure. This "boot-strap" type of
the satellite was zero, it seemed feasible to obtain the reservoir was chosen because the pump required a
desired spin rate by merely separating the satellite from relatively constant back-pressure of about 37.5 psi for
the third stage at the proper time. Precision bearings proper operation. The position of the actuators was
were evaluated and sets were chosen that had low controlled by the electrohydraulic transfer valves
enough friction characteristics to keep the satellite spin (series 900 Moog Valves) which responded to attitude
rate below 50 rpm until after burnout of the third error signals from the gyros. As a gyro sensed a pitch
stage. These bearings were cleaned and assembled or yaw vehicle error, it initiated a signal to the cor-
into housings designed as one piece to ensure the close responding transfer valve, which ported high pressure
concentricity of the bearings themselves. A spacer was oil to the correct side of the double acting actuator
added between the bearings to distribute the thrust piston. The wiper rod of a linear follow-up potenti-
loading during third-stage burning (maximum of 650 ometer was connected to the moving end of the
pounds) equally between the bearings rather than al- actuator, and fed back an indication of engine position
lowing one bearing to support all the load. After to the control system summing point.
assembling the housing, it was-necessary to determine, The first-stage hydraulic system was operated by a
through testing, the friction level of the assembly ground hydraulic source up to liftoff to provide a
under loads that would be imposed during flight. From means for adjusting engine position prior to launching.

80
LEGEND:

1. HYDRAULIC PUMP
2 3 2. CHECK VALVE
3. RESERVOIR
4. RELIEF VALVE
5. ACCUMULATOR

I 6. TRANSFER VALVE
7. PITCH AND YAW SERVO ACTUATOR
8. FILTER
9. DISCONNECT
10. LOW-PRESSURE RELIEF VALVE

SUPPLY AND DRAIN

i PRESSURE

RETURN

FLEXIBLE HOSE

El E]

HYDRAULIC SYSTEM DESIGN PARAMETERS

MAXIMUM ENGINE BIAS LOAD 600 FT-LB

MAXIMUM ENGINE DEFLECTION RATE 30 DEG/SEC

MAXIMUM ENGINE DEFLECTION ACCELERATION 4.8 DEG/SEC 2

ENGINE MOMENT OF INERTIA 26.8 SLUG-FT 2

PUMP CAPACITY 2.9 GPM

ACCUMULATOR VOLUME 0.26 GAL

RESERVOIR CAPACITY 0.82 GAL

PRESSURE 1750 PSIA

Fig. 33. Eirst-Stage Hydraulic System Schematic

81
The ground hydraulic source was connected to the caused by rocket engine thrust misalignments and gim-
vehicle through two disconnects which separated at bal bearing friction. A secondary purpose of the test
liftoff. A more detailed description of the first-stage was to determine the effect of "cold" (85°F) and
hydraulic system is given in Ref. 13. "hot" (160°F) hydraulic fluid on the frequency re-
Second stage--A schematic of the final second- sponse of the control system. Frequency response
stage hydraulic system configuration is given in Fig. results indicated that bearing friction loading increased
34. The major components of the system were the the phase lag of the system and caused the response
pump, a pneumatically pressurized accumulator, a to peak at a lower frequency than the unloaded system.
spring-loaded reservoir, a high pressure relief valve The tests run with "cold" oil resulted in slightly noisy
which maintained system pressure between 1000 and frequency response data, while the system response
I I00 psi during normal operation, a filter, check using "hot" oil was considerably quieter. The applica-
valves, and the engine pitch and yaw hydraulic actua- tion of maximum expected bias loads of 550 foot-
tor assemblies. pounds resulted in a null shift of 0.2 degrees in the
A highly reliable electric-motor-driven, nine-piston, hydraulic servo. Transient response tests indicated that
constant displacement pump was chosen to drive the with the inclusion of bias loading and bearing friction
second-stage hydraulic system. With 28 volts dc ap- effects, the vehicle was able to recover from one-degree
plied, the motor pump drew 35 amperes and delivered gyro error steps.
0.875 gpm flow to the system. When this flow was Battery paralleling--In early vehicles, large elec-
not required by the actuators, it was ported to the trical transients caused by battery paralleling occurred
return line by a high pressure relief valve. The fluid slightly prior to the critical first-stage burnout transient.
supply for this pump was contained in a spring-loaded These electrical transients resulted in fairly large en-
reservoir, which compensated for thermal expansion of gine and vehicle motions, and hence structural load-
the oil and maintained a back pressure on the order of ing. A combined bias load, 28-volt electrical transient
37.5 psi. This reservoir was chosen over the "boot- test was undertaken, utilizing the dynamic engine
strap" type because the pump was relatively insensi- mockup and two analog computers to simulate aero-
tive to back pressure. The position of the actuators dynamic and structural flight conditions. Test results
was controlled by electrohydraulic transfer valves indicated that the effects of the combined predicted
(series 900 Moog Valves) in response to gyro initiated maximum electrical transient and bias load effects were
signals, as in the first-stage system. within the capabilities of the structure.
The second-stage hydraulic pump was turned on six
Hydraulic oil contamination control--A hydrau-
minutes prior to liftoff, to prevent in-flight starting
lic oil contamination control program (reported at
transients. This caused the second-stage engine to
length in Ref. 26) was instituted early in the Vanguard
"follow" the gyro signals throughout first-stage flight.
program because the electrohydraulic transfer valve
Disconnects were provided in the system for use during
was known to be vulnerable to contaminant in the hy-
testing when a ground hydraulic source was employed.
draulic oil. A test program was initiated to determine
A more detailed description of the second-stage hydrau-
what level of contamination the transfer valves could
lic system is given in Ref. 13.
safely tolerate for the effective life of the rocket (test-
2. SYSTEM DEVELOPMENT ing plus firing), and to determine how this level could
be maintained. Tests were also performed on various
Breadboard testing of both the first- and second-stage
filters to determine their effectiveness. While these
hydraulic systems indicated successful component op-
tests were in progress, an interim contamination control
eration. Performance tests were run on the first-stage
pump to determine the flow characteristics for various program was instituted to protect rockets about to go
into production. The acceptable contamination level of
pump speeds and outlet pressures. Performance tests
fluid in the vehicle systems and test carts was defined
were run on the second-stage pump to determine the
as "B" grade of the Allison contamination method,
speed, flow, voltage, current and discharge pressure
which was used as a standard.
relationships. Tests were performed on both first- and
second-stage transfer valves to determine the flow The test program indicated the amount of contami-
versus differential current relationships. Detailed infor- nant tolerable to the system and that the most effective
mation on hydraulic system development testing may means of measuring fluid contaminant was by particle
be found in Ref. 14. counting. Contamination control facilities were set up,
Bias load tests--Bias load tests were conducted, based upon the test findings, both in the factory and at
using the first-stage dynamic engine mockup, to inves- Cape Canaveral. The incorporation of Rigimesh woven
tigate the frequency and transient responses of the metal screen-type filters into the hydraulic systems was
first-stage pitch and yaw control systems with simu- a result of test findings which disclosed that the pre-
lated actuator loads. These loads represented moments viously used paper filters were not only inadequately

82
LEGEND:
1. HYDRAULIC PUMP
2. CHECK VALVE
3. RESERVOIR
4. RELIEF VALVE
5. ACCUMULATOR
6. TRANSFER VALVE
7. PITCH AND YAW SERVO ACTUATOR
8. FILTER
9. DISCONNECT

SUPPLY AND DRAIN

m PRESSURE

RETURN

FLEXIBLE HOSE

O O

HYDRAULIC SYSTEM DESIGN PARAMETERS

MAXIMUM ENGINE BIAS LOAD 283 FT-LB
MAXIMUM ENGINE DEFLECTION RATE 20 DEG/SEC

MAXIMUM ENGINE DEFLECTION ACCELERATION 1.6 DEG/SEC 2
ENGINE MOMENT OF INERTIA 9 SLUG-FT 2
PUMP CAPACITY 0.875 GPM
ACCUMULATOR VOLUME 0.26 GAL
RESERVOIR CAPACITY 0.39 GAL
PRESSURE
1050 PSIA

Fig. 34. Second-Stage Hydraulic System Schematic

83
filtering the oil, but were actually contributing fibrous cycles) from either one or two radars, and retrans-
contaminant to the system. mitted pulses (at 5555 megacycles) for radar detection.

Antenna systems--The command system and track-
3. RANGE SAFETY
ing system antennas were designed to provide adequate
The Vanguard range safety system provided engine coverage to ensure that the UHF radio command sig-
cutoff and vehicle destruct capabilities to permit imme- nals and radar tracking signals would be received at
diate termination of a flight if range safety criteria any point along the powered flight trajectory, with the
were exceeded during any period from first-stage en- vehicle in any flight attitude. The command antenna
gine ignition to the end of second-stage powered flight. system was composed of two arrays; one in the first
No destruct system was provided for the third stage stage and one in the second stage. Each array con-
since re-entry tempe/'atures would destroy the stage sisted of two antennas connected together with coaxial
in any case. cable, such that one antenna was 180 degrees out of
Two separate and independent UHF command sys- phase with the other. The antennas were used in pairs
tems, capable of terminating flight from the ground and in order to obtain greater coverage than would be pos-
compatible with the standard Atlantic Missile Range sine with one antenna alone. Each individual com-
(AMR) flight termination system, were flown in Van- mand antenna was a 50-ohm external-notch type hav-
guard: one set in the first stage and one set in the ing elliptical polarization.
second. The only components common to the two sys- The Martin C-band antenna system developed for
tems were the antenna, the destruct package and their Vanguard was composed of one cross-slotted flush-
direct connections. The airborne systems were de- mounted wave guide antenna located in the second
signed to provide a reliable destruct system with a stage. The antenna was a 5-inch long section of non-
minimum possibility of inadvertent flight termination. standard size wave guide, whose axis was mounted
parallel to the axis of the vehicle. The antenna was fed
1. AIRBORNE SYSTEMS
from a coaxial to wave guide junction. A quarter-
Electronic equipment--All electronic equipment wave length step transformer in the wave guide matched
was supplied by the Government. The airborne portion the slot impedance to the impedance of the coaxial
of the range safety system was composed of two AN/ junction. The C-band antenna system originally con-
ARW-59 command receivers, two of NRL's transistor- sisted of a four-antenna array, spaced at 90 degrees
ized decoders, an AN/DPN-48(c) C-band beacon, around the periphery of the vehicle. At the request of
command cutoff and destruct circuitry, and beacon NASA, radiation pattern measurements were made on
and command antenna systems. dual and single C-band antenna arrays, and results
The AN/ARW-59 is a UHF radio receiver that indicated a better gain coverage in the region of in-
contains circuits which accept the frequency-modu- terest with the single antenna. In addition, the severe
variation in gain experienced with the four-antenna
lated, 410-megacycle, radio control signals (if these
array did not exist. The single antenna was success-
signals are at a level of 5 microvolts or greater), de-
fully flown on SLV-4, -5 and TV-4BU. Four antennas
modulate these signals, and pass the resulting audio
were used on SLV-6 because of the more northerly
content to the E4680 decoder. The decoder contains
flight azimuth. This antenna system was adopted intact
audio filters for separating the audio output of the for usage on the Thor-Able vehicle.
receiver into the proper control channel, and provides
Destruct system--The destruct system consisted of
an "on-off" switching function for each channel. The
multiple strands of primacord placed inside the exter-
command receivers and decoders constituted the air-
nal conduits of the fuel and oxidizer tanks of both the
borne command systems. Command system No. 1 was
first and second stages. The exploding primacord
in the second stage and could provide flight path trim- would rupture the tanks to accomplish propellant dis-
ming commands as well as range safety commands. It persion. The firing voltage would be applied to all
was powered by the second-stage, 28-volt d-c bus. detonators simultaneously. The detonators that ignited
Command system No. 2 was in the first stage and was the primacord along the fuel tanks had a two-second
used only for range safety commands. It was powered pyrotechnic time delay in order to rupture the fuel
by the first-stage telemetering battery. tanks a short time later. This delay feature was incor-
The AN/DPN-48(c) C-band beacon was included porated to preclude rapid mixing of the oxidizer and
in the vehicle for range safety purposes to provide, at fuel and thus minimize a potential high order explo-
all times during powered flight, position information sion. Two detonators were used in each primacord
which was compatible with the tracking system utilized package to increase reliability. Further details of the
at AMR. It was a pulse-type receiver-transmitter that ordnance components of this system are given in Chap-
responded to single-pulse interrogation (at 5490 mega- ter IV, Section F.

84
2. GROUND SYSTEMS unit, by manual operation of the ground service panel
cutoff switch or by momentarily holding the master
Radar tracking data, a prime source of information
switch on the propulsion fire panel in the emergency
for range safety decisions, were obtained from the two
position.
AN/FPS-16 radars which tracked the AN/DPN-48 (c)
beacon in the vehicle. The AN/FPS-16 (XN-1) is 3. ADDITIONAL DEVELOPMENT TESTS AND
located at Patrick Air Force Base (PAFB) and the PROBLEMS
AN/FPS-16 (XN-2) is located at Grand Bahama
Island (GBI). Output information from both of these Command antenna--The conical radiation pattern
radars was fed to the IBM-704 computer at Cape measurements of the command array were taken to
Canaveral. Data from either could be used for com- check the design and to determine the coverage and

putation of predicted impact points. These inputs, plus gain of the antenna in any direction. Radiation patterns
the data from the telemetry-ELSSE system, the optical of various combinations of the number, phasing and
trackers and the vertical wire skyscreens were used by location of the antennas were recorded in order to

the range safety officer in making his decisions. determine the configuration giving the optimum angular
coverage. The best combination was found to be an
The AN/FRW-2 radio command transmitters were
array of two antennas located at Quadrants II and IV,
equipped to send cutoff and/or destruct signals if the
and fed from a coaxial tee through unequal lengths of
range safety officer's situation analysis indicated that
cable, one cable being one-half of a wave length longer
the vehicle was exceeding a range safety limit. The
than the other.
specific command desired would be transmitted on one
of ten separate channels by frequency modulating the C-band antenna--Initially, it was difficult to tune
transmitter with selected audio tones. The ground- the C-band antenna to meet VSWR limits. Capacitance
transmitted signal would be received and demodulated was added to the antenna in the form of teflon spacer
by the airborne AN/ARW-59 receiver and applied to washers in the feed connector to make impedance more
the input of the decoder, where audio filters would resistive.
separate the signals and each tone would actuate a
relay corresponding to the command to be initiated. K. INSTRUMENTATION
Channels 1, 2 and 5 were controlled solely by the
Instrumentation in the vehicle and on the ground
range safety officer. Signals received on the range
provided information required for prelaunch testing
safety channels took precedence over any other control
and for establishing flight performance, as well as a
signals. The ground signals had to be transmitted in
basis for analysis of any malfunctions which occurred.
sequence: channels 1 and 5 (arm and cutoff) first,
then channels 1 and 2 (destruct). When the decoder 1. TELEMETRY SYSTEMS
in either stage detected an "arm" signal, it provided an
Three telemetry systems were used to supply a maxi-
output which closed the arm relay, applying power to
mum of instrumentation for the test vehicle program.
the cutoff or destruct relays in the decoder. The
A PPM/AM (Pulse Position Modulation)"system, de-
"cutoff" signal (given simultaneously with the arm sig-
veloped by NRL and successfully flown on the Viking
nal) closed the cutoff relay in the decoder and op-
program, was used for first-stage propulsion and con-
erated the destruct power relay, which armed destruct
trols measurements. A PWM/FM (Pulse Width Mod-
relays if the liftoff switch was in flight position. The
ulation) system was used for gathering data on the
cutoff relay in the decoder also supplied voltage to the
second stage. An FM/FM (Frequency Modulation)
first- and second-stage radio cutoff relays. The radio
system was utilized in the second stage for gathering
cutoff relay opened the third-stage firing circuit and
high frequency data from both the first and second
applied voltage to the Aerojet flight sequencer in the
stages. A second PWM/FM system was used in the
second-stage firing circuit. The cutoff relays for either TV-1 vehicle to obtain data from an instrumented
engine were electrically latched-in, and therefore needed
nose cone. The satellite launch vehicle instrumentation
only a short-duration signal which could be immediately
was somewhat reduced from that for the test vehicles.
followed by the "destruct" signal. When the ground-
A PPM/AM system was used for first-stage perform-
transmitted destruct signal was given, the decoder
ance data and a PWM/FM system for second-stage
destruct relay was energized. This applied voltage to data.
the destruct relays, closing them and firing the destruct
RF radiated power for the FM carriers was between
detonators. 12 and 15 watts, which afforded excellent reception,
Engine cutoff could be accomplished while the ve- in some cases up to 1200 miles line of sight. The AM
hicle was on'the launch pad by a manual cutoff signal carrier radiated approximately 35 watts during pulse
from the fire switch on the propulsion firing panel, by a transmissions. Quadraloop antennas were employed,
cutoff signal from the General Electric ground sequence which gave a fairly omnidirectional pattern. The an-

85
tennas were machined to a wedge or fin shape from temperatures of corrosive media were to be sensed,
a block of stainless steel, and then stress relieved to the sensing thermistor was placed in a thin aluminum
better withstand aerodynamic heating. casing. Noncorrosive media were sensed by the un-
Sensing devices, in most cases, provided outputs com- covered thermistor to minimize temperature lag. The
patible with the telemetry systems, (i.e., 0 to 5 volts probes developed by Bendix were found to have ex-
input). Very little signal conditioning equipment was tremely long response times because the thermistor was
used, except for demodulators for the gyro signals and enveloped in a plastic covering. Consequently, the
frequency converters or counters for use with the flow- probes developed by Aero Research, which featured
meters. The airborne power source for the instrumenta- much faster response times, were utilized. These probes
tion and telemetry system was separated from the have since found acceptance in the rocket field for the
primary vehicle power source. The instrumentation measurement of propellant temperatures adaptable for
power supply consisted of silver cell battery packs use with telemetry.
which furnished 28 volts de.
Pressure transducer calibrations--Difficulty was
Radiation patterns of various combinations of the experienced in repeating pressure transducer calibra-
number, phasing and location of telemetering external tions in the field similar to those obtained during factory
notch antennas were recorded in order to determine
checkout. This problem became more acute as time
the configuration giving the optimum angular coverage. progressed. Investigation disclosed that the basic source
2. TEST AND CALIBRATION PHILOSOPHY of error was a discrepancy in the various pieces of
calibration equipment. At the same time, it was also
All end instruments received their primary calibra- found that the transducers shifted calibration slightly
tion in the Quality Control receiving and inspection over a period of time. By instituting more rigid con-
laboratory. After installation in the vehicle, instrument trol over expired time between calibrations and a more
calibrations were spot-checked. The instruments were effective method of keeping the test equipment in cali-
again spot-checked against the original calibration at bration, the number of rejections for these reasons was
the launch site. All instruments out of tolerance were drastically reduced.
rejected and replaced.
Phase-sensitive demodulators---C o n s i d e r a b 1e
3. SPECIAL PROBLEMS trouble was experienced throughout the program with
the phase-sensitive demodulators used for conditioning
High pressure measurements--A special line of
the gyro signals for adaptation to telemetry. The ini-
pressure transducers, developed by Rahm Instruments
tial units developed were extremely sensitive to a temp-
and the U. S. Gage Company, solved the high pressure
erature environment above 120°F, and high rejection
measuring problem in extremely corrosive media such
as WIFNA and UDMH. These transducers consisted and failure rates resulted. A new and improved unit
of specially welded stainless steel bourdon tubes with was capable of operating in temperatures up to 185°F.
the media present inside the bourdon tube. The case However, a few critical components in these units
caused more than a normal number of failures. The
was designed to withstand the media and pressure with-
out damage to any other component in the event of critical areas of the demodulator were redesigned, re-
bourdon tube failure. These transducers featured good placing critical components with those of higher temp-
performance for average pressure measurements under erature rating and paralleling some diodes to reduce
all expected environmental conditions, but were not of the current flow in critical areas. These changes con-
much benefit in studying transient responses. siderably reduced the number of failures, and a reliable
unit was the end result.
High temperature measurements--Nose cone
Antenna ionization--Ionization breakdown of the
skin temperature measurements were obtained with
small "postage stamp" resistance wire gages developed PWM/FM antenna was experienced in the earlier ve-
by Aero Research, Incorporated. The gage consisted hicles. The antennas were relocated away from the
of a small platinum wire gage bonded to a very thin second-stage roll jets to reduce propane gas exhaust
strip of steel (about the thickness of a sheet of paper) effect. The teflon insert was also redesigned to increase
which was then fastened to the surface of the nose cone. breakdown distance.
Temperatures in the region of 2000°F could be
recorded. L. SYSTEM AND PAYLOAD
INTEGRATION
Propellant temperatures--Propellant temperature
measurements during flight in different types of media Physical integration of the various systems into the
and different temperature ranges presented another complete Vanguard vehicles (space provisions, elimi-
problem. A series of temperature probes were de- nation of interferences, etc.) was the specific responsi-
veloped by Aero Research and Bendix-Friez, utilizing bility of an Integration Group within The Martin Com-
thermistors as the sensing elements. In cases where pany. Functional integration of the individual systems

86
Fig. 35 SLV-4 Satellite

87
was accomplished by the closely knit nature of the mechanism for separation from the third stage after
Vanguard Project organization, whereby each group burnout) were mounted atop this bearing. Some of
was responsible for the correct functioning of its hard- the satellites were prcwided with a dish-shaped heat
ware in the integrated vehicle. This overlapping of shield (shown in Fig. 35) to protect the payload from
responsibility provided double checks of integration heat radiated by the hot third-stage motor case at or
problems in the important areas, and contributed near the time of burnout, and from the exhaust products
greatly to the success of the Vanguard. of the spin motors during separation.
Design of the satellite payloads was accomplished Space provisions were made within the nose cone
bv the Naval Research Laboratory (and, later, by
for the retracted satellite antennas. A ground-supplied
NASA), with the single exception of the early vehicle
cooling air system was provided for the payload com-
performance inputs by The Martin Company which
partment, to ensure that satellite outer shell tempera-
established the sphere diameter. A shaft was provided
at the nose of the third-stage motor, upon which was ture would never exceed 30°C prior to launch. Liaison

mounted a low-friction bearing for attaching the cen- was maintained with the satellite designers at NRL
tering spider arms (see Chapter IV, Section H). and NASA, to ensure the resolution of mutual prob-
The Government-furnished satellites (including the lems (e.g., satellite spin rates after separation).

88
V. RELIABILITY
A. REQUIREMENT (3) A prototype hydrogen peroxide decomposer
completed 50 runs for a total operating time of
Budgetary and schedule restrictions dictated the 7500 seconds.
scope of the Vanguard reliability program. The philo-
The engine was qualified as a system in accordance
sophy is best described in the wording of the Design
with an approved General Electric specification, Ref.
Specification (Ref. 3, paragraph 3.1.10):
27, by successfully completing eight consecutive static
"Reliability--The vehicle shall be designed and firings for a total accrued burning time of 900 seconds.
components selected on the basis of available reliabil- One firing was preceded by a three-hour "cold hold"
ity data to ensure reliability consistent with the state of with all propellants loaded. Engine gimbaling was
the art. Reliability studies and statistical testing to satisfactorily demonstrated during two of the firings.
establish such data shall not be required." Two oxidizer and three fuel exhaustion shutdowns
were accomplished in this series, and satisfactory per-
B. ENVIRONMENTAL CRITERIA formance was demonstrated with "+'5% variation of
liquid oxygen flow. Performance and repeatability
An environmental study was undertaken during the within specification limits were conclusively demon-
early stages of the system design to define the antici- strated by these tests. No hardware damage occurred,
pated environmental climate for the Vanguard vehicles. nor were there any component failures or replacements
The primary sources for this study were data from during the qualification program. The qualification
Viking and Redstone missile flights and Specification engine later successfully completed a 200-second firing
MIL-E-5272A. Information on the spectrum of the after 8 hours "cold hold" with all propellants loaded.
engine forcing functions was gathered from the engine
First.stage propellant ]eed and pressurization
manufacturers, based on preliminary test firings. The
system--An operational mockup of the complete
initial results of the study were used as a basis for com-
first-stage propulsion system, less the engine package,
ponent and system selection. Modifications were.con-
was subjected to qualification tests (Ref. 28). The
tinually made to these criteria as the program
planned program was not fully completed because the
progressed and as additional information became
mockup was damaged due to a malfunctioning pressure
available from analytical, experimental or flight data.
regulator. However, adequate information was
Figure 36 presents a summary of the end result of this
obtained to functionally check out the system and
refining process.
verify the production test specifications, the helium roll
thrust augmentation system, the method for adjusting
C. COMPONENT AND SYSTEM
the main helium regulator, and the proper LOX
QUALIFICATION filling technique.

Qualification tests were performed on all new com- Structural integrity of the individual tanks (LOX,
ponents and systems of the vehicle to demonstrate fuel and hydrogen peroxide) was verified by proof
their compliance with applicable specifications. Where and burst pressure tests on prototypes. The structural
off-the-shelf hardware was used, previous qualification integrity of the vendor-supplied helium spheres was
data were accepted insofar as they were compatible verified by pressure cycling, proof pressure testing,
with Vanguard requirements and criteria. and burst testing prototype vessels. All fuel lines and
high pressure plumbing were proof pressure tested.
First-stage engine package--Extensive qualifica-
Verification that the LOX tank forward dome could
tion tests were made by the manufacturer on individual
components of the X-405 engine. Among the more withstand actual external temperatures and pressures
important results were: during first-stage separation was demonstrated by LOX
dome impingement tests at Aerojet (Ref. 29).
(1) A prototype thrust chamber, injector and
The scope of the qualification tests of all vendor
motor body successfully completed 14 con-
secutive firings using a pressure-fed system. components used in the propellant feed and pressuriza-
Total accrued burning time on this particular tion system is presented as a part of Table 11.
thrust chamber was 2100 seconds. Second-stage propulsion system--Although com-
(2) A prototype turbopump successfully com- plete qualification testing was not performed on each
pleted 15 hot runs for a total accumulated time component, functions were tested under anticipated
of 2250 seconds. critical environments (see Table 11). In addition,

89
Table I!. Propulsion Component Environmental Test Program-Vendor Supplied

0

t:

A. First Stage

Solenoid Pilot Valve (LOX, fuel) V V V V V V V V V
Helium Sphere X X X X X X 0 0 O
Vent Valve (fuel) V V V V V V V V V
Plug VaNe (H:O.,) Linden Tool X X X X X X X 0 O
X-405 Rocket Engine Qualified per GE Qualification Test Spec DR-E-586--d
Exhaust Pipe Insulation Blanket V O O V O O O O O
LOX Dome Insulation Blanket O V V O V V V V O
Pressure Sensor V V V V V V V V V
Pressure Sensor V V V V V V V V V
Pressure Sensor V V V V V V V V V
Helium Sphere Strap Assy O O O O O O O O O
Coupling V-Band O O O O O O O O O
Bellows (steam) V V V O V V V V V
Bellows (fuel) V V V O V V V V V
Bellows (LOX) V V V O V V V V V
Disconnect (N:) V V V O V O V V O
Disconnect (He) V V V O V O V V O
Disconnect (fuel) V V V O V O V V O

Valve--3-Way (He) O O O O O O O O O

Valve_-Check (He) V V O O V V V V O
Valve--Check V V O O V V V V O
Valve---Solenoid V V V V V V V V V
Valve--Solenoid Progressive Research X X X X X X X X X
Relief Valve (H=O:) V V V V V V V V V
Pressure Regulator (He) V V V V V V V V V
Solenoid Valve V V V V V V V V V
Vent Valve (LOX) V V V V V V V V V

B. Second Stage
Propane Disconnect V V V O V O V V O
Propane Bleed Valve O O O O O O O O O
Roll Jet Solenoid Valve V V V V V V V V V
Tumble Jet Solenoid Valve V V V V V V V V V
3-Way Helium/Propane Solenoid Valve V V V V V V V V V
Propane Relief Valve V V V V V V V V V
Helium/Propane Regulator V V V V V V V V V
Propane Heater Blanket O O O O O O O O O
Helium Pressure Regulator (RV) V V -- V V V O V V
Heat Generator (HGA) V V V O O O O O O
Position Switch (TVS,, TVS2) V V O V V O V V V
Pressure Switch (TPS, HPS=) V V O V V -- O V O
Oxidizer Valve (OTCV) V V O O O O O V V
Oxidizer Pilot Valve (OTCPV) V V O V V O O V V
Fuel Valve (FTCV) V V O O O O O V V
Fuel Pilot Valve (FTCPV) V V O V V O O V V
Helium Bypass Valve (BHSV) V V O V V O O V V
Electrical Sequence Unit V V O V V O O v V
Helium Disconnect V V V O V O O V O

V = Vendor tested.
0 = Requirement satisfied by design criteria.
X = Not required.

90
91
functional tests were conducted on mockups of various flight failures were foreghadowed during the second-
subsystems. Extensive structural testing and corrosion stage qualification tests. These problems were not
testing were accomplished on complete tankages and ignored--field procedures were developed and modified
tankage sections (see Chapter Ill, Section F). to guard against such malfunctions. Operational ex-
The thrust chamber was qualified as a component by perience indicated, however, that complete reliability
accumulating a total of 738 seconds of firing time on a requires correction of observed deficiencies by design
single thrust chamber, utilizing a tungsten-carbide rather than by procedural changes.
coating on the inner wall. A total of 13 runs of Third stage--The qualification program for the
various durations from 10 to 118 seconds was made Grand Central 33-KS-2800 included tests of 32 motors
under conditions of high and low mixture ratio, high (see Table 12). Thirty motors were individually
and low chamber pressure, and high and low tempera- tested for certain environmental conditions and then
ture soak prior to liring. The thrust chamber coolant fired successfully to observe the effects of the environ-
jacket be-an_ to leak because of tube erosion failures ment on motor performance. Two motors incurred
after about 280 seconds of accumulated firing time, and nozzle damage as a result of sequential salt spray,
patching was required before each of the subsequent humidity and rain tests, and were not fired. In order
runs.
to preclude such failures on delivered motors, all noz-
Qualification of the complete propulsion system was
zles were packed in hermetically sealed containers with
required by an approved Aerojet specilication, Ref. 30.
desiccant for shipment and storage.
Four attempts to qualify the system for 540 seconds,
The qualification test program of the Allegany
using prototype hardware, ended in failure after 352,
173, 305 and 271 seconds, due to three cases of thrust Ballistics Laboratory X248 consisted of the firing of
chamber erosion and one of tank failure due to stress 14 motors which had been subjected to sequential
environmental tests in such a manner as to ensure that
corrosion (see Chapter 1V, Section C). Use of the
several motors would be tested at each condition
tun,gstc-
,,, ",-carbide chamber coating and the associated
(Table 13).
patching technique, together with a new tankage tem-
pering temperature, permitted satisfactory completion Aging tests were also conducted on both GCR and
of the system qualification test. A total of 567 seconds ABL motors. As of this writing, a storage life has been
was accumulated on a single thrust chamber and tank- demonstrated for the GCR motor of at least 24 months,

age during eight runs, including three for full duration. and for the ABL motor of at least 8 months.

Thrust chamber patching was used after 549 seconds. Spin and retro motors--The spin and retro
Although thc system qualification test was considered motors (Atlantic Research 1-XS-50 rockets) success-
acceptable, it was not entirely trouble-free. There fully passed qualification tests (Table 14) including
were isolated instances of failure of the regulator to reproducibility of performance, vacuum ignition, and
trip, clogging of the oxidizer filter screens, and leaky environmental tests in accordance with Ref. 24. Retro
fuel and oxidizer tank check valves. In retrospect, it is motor aerodynamic fairing ejection tests were also
apparent that some "scrubbed" field operations and made.

Table 12. GCR 33-KS-2800 Qualification Test Program

TEST NUMBER OF MOTORS TESTED

Thrust Alignment All motors with altitude nozzles
Statistical Performance 12
]_emperature Cycling 6
Acceleration 2 + 4 motors
from temperature
cycle tests for
total of 6
Altitude Ignition
Rough Handling and Drop
Truck Shipment
Rain, Humidity and Salt Spray
Total motors tested = 32

NOTE:
One additional empty ease was static tested to destruction.

92
Ordnance---Ordnance components such as explo- tests performed on these systems and their components
sive latches, bolts and primacord were certified by the are shown in Table 15. Certain environmental require-

manufacturer as qualified to the manufacturer's specifi- ments were satisfied by design criteria; for example, the

cation. Certain ordnance components had to be sub- controls can, a sealed pressurized container, did not

jected to additional tests to qualify for the Vanguard require any formal humidity or altitude tests. Addi-

environment. Some components were ignited under tional qualification tests, such as the controls cooling
vacuum conditions of about 3 x 10 4 millimeters of air test, and a complete description of the tests shown

mercury; other samples were ignited after exposure to in Table 15, may be found in Ref. 14.

liquid nitrogen at about --300°F. Electrical system--Standard electrical units that

Guidance, control, hydraulic and mechanical had already been qualified to Government procurement

systems--The principal environmental qualification specifications were used throughout the Vanguard re-

Table 13. ABL X248A2 Qualification Test Program

QUALIFICATION MOTOR NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

1. Hydrotest X X X X X X X X X X X X X X
2. Pressure Test X X X X X X X. X X X X X
3. Dynamic Balance X X X X X X X X X X
4. Thrust Alignment X X X X X X X X X X
5. Rotational Acceleration X X X X X X X X X X
6. Humidity Test X
7. Rainfall Test X
8. Salt Spray Test X
9. Thermal Cycle X X X X
10. Vacuum Fire X X X
11. Lateral Acceleration X X X
12. Rebalance and Alignment X
13. Longitudinal Acceleration X X
and Centrifuge Fire
14. Longitudinal Spin-Fire X X
15. 250 ° F Soak Test X
16. Storage Evaluation X X

Table 14. ARC I-XS-50 Spin and Retro Motor Qualification Test Program

All
Thrust Alignment
12
Statistical Firing
Statistical Firing with Sea Level Nozzles 13

Thermal Cycling (high to low) 3

Thermal Cycling (low to high) 3

Pressure Test and Altitude Ignition 7

Vibration and Shock 6
3
Drop Test (one each at 130°F, 70°F, 0°F)
Rain 2
2
Humidity
2
Salt Spray
3
Acceleration, 7g Longitudinal
(one each at 130°F, 70°F, 0°F)
3
Acceleration, 2g Transverse
(one each at 130°F, 70°F, 0°F)
Acceleration, 20 rad/sec 2 2
Rotational at 70°F
Nozzle Seal Modification 8

Static Fired at 130°F 23

Static Fired at 70°F 29

Static Fired at 20°F I0

Total Motors in Test Program 131

93
hicle,with theexception
of timersandflightbatteries. Instrumentation,---All new components developed
All standardunits andthe timer weresubjected to for the Vanguard were thoroughly tested and qualified
additionaltests(seeTable 15) to satisfyVanguard to the expected environmental conditions. All other
requirements. Extensive
testingwasperformed on the instrumentation components were either tested or
flight battery, which was built specifically for Vanguard certified on a similarity basis before use in the pro-
requirements. gram.

Table 15. Guidance and Control Components-Environmental Test Program

Vibration

1. Guidance System
Gyroscope Assembly V M O V V O V
Coasting Time Computer V M V MV MV O O
Program Timer MV M MV MV MV MV O O

2. Control System
Pitch-Yaw Amplifier M M M M M M O O
Roll Amplifier M M M M M M O O
Slave Relay Chassis M M M M M M O O
Auxiliary Chassis M M M M M M O O
Regulated B+ Supply M M M M M O O

3. First-Stage Hydraulic
Servo Package M M O M M M O
Pump V V V MV MV MV V
Reservoir M M O M M M O
Relief Valve MV MV V MV MV MV V
Accumulator M O O MV MV M O
Filter M O O V V O O

4. Second-Stage Hydraulic
Servo Package M M O M M M O
Pump V M V V MV MV MV V
Reservoir M M M O M M M O
Relief Valve MV M MV O MV MV MV 0
Accumulator M O 0 MV MV M 0
Filter M 0 0 V V O O

5. Mechanical
Roll Jets M 0 0 M O 0 M
Roll Jet Pneumatic Valve V V V V V V V

6. Electrical
50-amp SPST Power Contactor M M V V V V V
4PDT Latching Relay M V V V V V V
2PDT Relay V V V V V V V
4PDT Relay M M M M M M V V
5- to 195-see Adjustable Timer V V V V V V V
Time Delay Relay (1 sec V V
and 1.5 sec) V V V V V V V
6PDT Relay V M V V V V V V
20 A-H Flight Battery M M M M M M M
250 VA Rotary Inverter M V V M V M M
2PDT Liftoff Switches M V M V V V M

7. Range Safety
C-Band Beacon Antenna M M M O O O
Command Control Antenna M M M O O O
Telemetry Antenna M M M O O O

M--Martin tested
V--Vendor tested
O--Requirement satis/ied by design criteria

94
D. COMPONENT AND SYSTEM and dynamic balancing of the motors about the spin
ACCEPTANCE TESTING axis in a specially designed fixture.

Acceptance tests were performed on the major Van- Guidance and control, electrical and hydraulic
guard components and systems to ensure that flight --Acceptance tests were performed on all guidance
and control system components prior to installation
hardware measured up to the standards of the qualifica-
tion test articles. in the vehicle. All important performance parameters
of the gyroscope reference system, coasting time com-
First.stage propulsion--Each production engine puter and program timer were checked by the vendor
package was acceptance tested in accordance with an prior to shipment to Martin. The electronic autopilot
approved General Electric specification (Ref. 31). units, such as the pitch amplifier, etc., were thoroughly
Acceptance was based upon successful completion of bench tested after fabrication. Some of the more im-
two consecutive 150-second static firings, without com-
portant performance characteristics checked on all
ponent malfunction or change. Repeatability of per-
units as a prerequisite to acceptance were:
formance within applicable specifications and accurate (1) Gyroscope reference system--drift under vibra-
orientation of the thrust vector were also required. tion, cross-coupling, reaction torques, mass
The complete propulsion system was functionally unbalance, pitch program and transfer func-
checked after assembly of the engine package with its tions.
tankage, propellant feed and pressurization systems. (2) Coasting time computer--coasting time ac-
These checks included leakage, electrical and pneu- curacy for various velocities and velocity
matic functional tests of each component. The first- potentiometer telemetering accuracy.
stage static firing in the field (see Chapter VI, Section (3) Program timer--timing accuracy checks, load
B) really constituted final acceptance of this system for tests and effects of vibration.*
flight. (4) Pitch/yaw and roll amplifiers--frequency re-
Second.stage propulsion--All components were sponse, linearity, gain, jet deadspot and jet
acceptance tested to Aerojet specifications prior to hysteresis.
installation on a production unit. Each complete 15) .Controls can--frequency response, gains,
Aerojet system was subjected to a 60-second static linearity, jet deadspot, jet hysteresis, remote
firing to demonstrate proper functioning of all com- centering, pitch program rate resistance and
ponents and adequate system performance, in accord- effects of vibration on the complete assembly.
ance with an approved Aerojet specification (Ref. 32). (6) Inverters (Leland 250-VA)--voltage modula-
The system was decontaminated and inspected after tion.
the acceptance test firing. (7) Hydraulic actuators--leakage, piston stroke,
Following assembly of this system with acceptance- evidence of binding or chattering and frequency
tested Martin components into a vehicle second stage, response.
the entire system was functionally checked for leakage, * A special reliability program was started in July
electrical continuity and component operation during 1958, to increase program timer reliability and decrease
a simulated flight sequence. Provisions were available the number of failures in ground checkouts, due mainly
for static firing of the second stage in the field, but to relay malfunctions. The reliability program con-
were used only on TV-3, TV-3BU and SLV-3 (see sisted of performing the following additional tests dur-
Chapter VI, Section B). ing the program timer acceptance test: relay load test;
vibration of 15 minutes in each plane at qualification
Third-stage propulsion and ordnance--This specification levels; time check; and five additional
type of component does not readily lend itself to a relay load tests.
functional type of acceptance test. For small ordnance
items such as detonators and squibs, which were de-
E. VEHICLE ACCEPTANCE TESTING
livered in relatively large lots and certified by the
manufacturer, samples of each lot were fired under The primary goal throughout fabrication and as-
simulated vacuum conditions (approximately 10 -4 mm sembly was the delivery of a vehicle that was ready for
Hg) to determine acceptability of the lot. flight. Voluminous test specifications were prepared to
Third-stage motor acceptance was based upon the formalize the procedures. Testing was designed to
documentation of rigid quality control during manu- confirm integrity with a minimum of aging. Sub-
facture, firing of samples from each batch of propellant components were tested prior to assembly wherever
mixed, and visual inspection, weighing and measuring practical, to maximize the possibility of a successful
each motor after final assembly. The measurements system checkout. Backup and alternate systems were
made consisted of checking critical dimensions, also checked, but not necessarily in the simulated flight
geometric determination of the thrust axis alignment sequence.

95
Acceptance
testingof the completedvehicleswas static firing in the field. The static firing contributed
accomplished in both horizontal (stages physically system pressure and flow data, but the expulsion test
separated) and vertical (vehicle erected) positions. data were not applicable because special engine
The factory and field test equipment and procedures orificing was used to simulate combustion chamber
were identical, insofar as possible, to maintain person- pressure.
nel familiarity (many on the field crew had helped
fabricate and test the initial vehicles at the factory), to F. RELIABILITY FOLLOW-UP
help correct procedure inconsistencies and to pinpoint
troublesome areas. Much of the extensive checkout Close liaison was maintained for correcting hard-
equipment was supplied by the Polarad Electronic ware discrepancies. Each design group responsible for
Corporation. a Vanguard subsystem was in daily communication
with its field counterpart by telephone and via direct
Horizontal tests--The horizontal phase of factory
teletype (TWX). Problem areas and corrective
acceptance testing began with checks on each individual
measures taken were documented by the latter means.
system in each stage. The stages were then electrically
The more formal channel for liaison and reliability
mated and further tested as a unit. These "marriage"
follow-up was the "Discrepancy and Trouble Report"
tests included checks of the power adjustment and
system, which was used to record discrepancies, mal-
polarity, gyro linearity, drift and noise, jet deadspot,
functions and potential problem areas. Copies of these
time delay and phase angle, control system frequency
forms were screened for problems requiring immediate
response, program timer, coasting time computer and
action. A Corrective Action Team, consisting of mem-
command control system.
bers from engineering, manufacturing, quality and pro-
Vertical tests--Upon satisfactory completion of all curement, met periodically to review each discrepancy
horizontal tests, the vehicle was erected and aligned report and initiate or verify corrective action. (In the
in the vertical test fixture (Fig. 37), which was majority of cases, the less formal channels described
specially built to accomplish these tests. Individual above had already resolved the problem, but the team
system acceptance tests were made, and operation of action constituted a final follow-up.)
the spin table and satellite bearing were checked,
There were three instances during the Vanguard
using a dummy third-stage motor. The final Vertical
program of extraordinary effort in the area of reliabil-
Interference Test checked out the integrity of the
ity follow-up; these are described below.
entire rocket system, including sequencing functions
and the electrical, guidance, control and range safety TV-.-3BU--Following the flight failure of TV-
systems. The rocket was then disassembled, final pro- 3BU (February 1958), which was attributed to a
pulsion-pneumatic and general checks and cleanups spurious electrical signal in the control system, an
were made and a final wiring inspection was conducted. intensive effort was made to strengthen quality control
The vehicle was painted, weighed, packed and shipped of the remaining vehicles, with emphasis on electrical
on a special trailer to Cape Canaveral. wiring. Additional personnel were assigned to quality
control supervision and to the origination and follow-up
Second.stage rejuvenation--The second stages of
of Service Trouble Reports (forerunners of the Dis-
the SLV-4, SLV-5, SLV-6 and TV-4BU vehicles
crepancy and Trouble Report mentioned above).
were not sent directly to the field, but were air-lifted to
Access to vehicles and vehicle compartments in the
Aerojet-General for rejuvenation to ensure clean, flight-
factory and hangar areas was restricted. Tool pro-
ready systems. Rejuvenation consisted of forward and
cedures and process handbooks were emphasized. The
back-flushing the thrust chamber, water-flow testing
system of solder certification was revised to more rigid
the thrust chamber using laboratory instrumentation,
skill requirements and personnel were recertified.
disassembly, cleaning, replacement of seals, reassembly Special checks were instituted for problem areas. An
and acceptance testing of all components. independent Martin inspection team, including engineer-
After rejuvenation, SLV-4 and SLV-5 were static ing personnel, reviewed the wiring integrity of each
fired, and SLV-6 and TV-4BU were expulsion tested, subsequent vehicle prior to acceptance. The next ve-
using WIFNA in the oxidizer system and water in the hicle, TV--4, produced the first Vanguard satellite
orbit in March 1958.
fuel system. The primary purpose of these static firings
or expulsion tests was to demonstrate satisfactory Goett committee--Late in 1958, the National
operation of the oxidizer probe shutdown system. The Aeronautics and Space Administration assumed re-
tests also served as functional checks of the pressuriza- sponsibility for the Vanguard program. Although the
tion and propellant feed systems, although the sub- next vehicle (SLV-4) was ready on the launching
sequent disassembly for decontamination more or less stand, operations were suspended while a comprehen-
invalidated the systems check here as well as after sive review of the entire program was conducted. An

96
Fig. 37 Vertical Test Tov;er

97
eleven-man committee of independent rocket experts, G. OBSERVATIONS ON RELIABILITY
headed by Mr. Harry Goett, of NASA, found that there
The reliability program laid down for Vanguard
were no major deficiencies in the rocket design, but
was the maximum effort compatible with the overrid-
made valuable suggestions for improvements in vehicle
ing considerations of cost and schedule, and included
reliability. SLV-4 produced the second Vanguard
the following essential elements of today's more formal
satellite orbit in February 1959.
reliability programs.
8LV---6--Following the malfunction of the second- (1) Application of realistic engineering criteria in
stage helium regulator in SLV-6 (June 1959), a new the selection of components and systems.
operational approach was taken, involving total (2) Establishment of an environmental description
quality assurance control of the rocket areas and access early in the design phase of the program.
to the rocket, as well as more rigid control over test- (3) Revision of the environmental description to
ing of flight components and spares. This system was reflect test and flight experience.
instituted with receiving inspection of the rocket in the (4) Qualification of hardware consistent with the
hangar area. Vertical testing, change work and access environmental criteria.
into and about the complex were subject to the same (5) Repeated testing to demonstrate hardware
safeguards, plus inspector surveillance of the work done capability.
in each accessible area of the rocket. Although a cer- (6) Corrective action and follow-up control to
tain amount of operational difficulty was introduced, resolve hardware discrepancies uncovered by
the results associated with this concept of "100% in- equipment usage.
spection" were considered worthwhile, in that higher The principles were sound, though their applica-
confidence existed in the rocket's readiness for flight tion was limited. This program was adhered to, not
than on any previous operation. The next vehicle, without human errors, but to the fullest extent con-
sistent with the project's environment. It is a matter
TV-4BU, produced the third Vanguard satellite orbit
of record that the original Vanguard overall reliability
in September 1959.
goal of at least one orbit in six attempts was more than
The extent to which the three completely successful
achieved. The final tally was three orbits in eleven
Vanguard satellite launchings were influenced or made
attempts, including one for seven in the originally
possible by the extra reliability follow-up activity specified time span of the IGY. Following the two-
described above is a matter of opinion. It is evident, month suspension of launching activities late in 1958,
however, that intensive reliability follow-up is a factor the remaining four vehicles produced two satellite
that cannot be ignored in a program of this kind. orbits.

98
VI. FIELD OPERATIONS
A. LAUNCH COMPLEX perature-controlled air to the satellite and the guidance
and controls units.
Vanguard vehicles were launched from Complex 18A
Fire fighting systems--The CO2 system served
at the Atlantic Missile Range (AMR), Cape Canaveral,
two functions: first, as a fire prevention, by being ex-
Florida. The basic site (Figs. 38 and 39) consisted
pelled into the first-stage tailcan area immediately
of a concrete main equipment house, a movable
after shutdown of a static firing; and second, as an
gantry, a working platform with launch stand and an
extinguisher in the same area if required during static
umbilical tower. The working platform incorporated
or launch countdown. A water fire extinguisher sys-
a 90-degree flame deflector tube that was cooled during
tem, with fixed position nozzles, was mounted on top
a firing by a water flow of about 3,000 gallons per
of the working platform for extinguishing fires at the
minute. An auxiliary equipment house, located about
base of the vehicle in the platform area. The UNOX
a hundred feet from the stand, was used to house the
fire extinguishing system (NRL supplied) had rotating
first-stage firing control and several cooling air units
swivel nozzles mounted on poles at diagonal corners
(i.e., compressor, heat exchanger, dehumidifier, etc.).
of the concrete pad for extinguishing fires anywhere
Adjacent to the area was the concrete blockhouse,
in the pad area, including the working platform.
which protected personnel during firings and was the
center of all remote control operations. The block- LOX disconnect gro,nd unit---The entire opera-
house was connected to the launch stand and the tion of LOX filling, topping, draining and dumping was
equipment houses by an underground trench which accomplished through a single disconnect, mounted
carried wiring and plumbing necessary to remotely to the launch stand, which mated with the vehicle
test and launch the vehicle. A LOX storage facility, fill unit. A microswitch attached to the ground half of
consisting of two large Dewar tanks, with a pres- the disconnect was in physical contact with the shut-
surized vehicle servicing system, was located behind the off valve in the vehicle. Thus, a positive indication of
main equipment house. A photograph of the vehicle the valve position was electrically signaled to the
mounted on the launch stand is shown in Fig. 40. blockhouse to ensure that the vehicle LOX valve was
closed before takeoff. A valve in the ground half of
1. GROUND SERVICING SYSTEMS the disconnect permitted precooling and dumping.
Ground servicing systems were installed on the com- 2. GROUND SUPPORT EQUIPMENT
plex to supply and service the Vanguard with pro-
pellants, pressurization and purging, and to provide Specialized ground support equipment was required
temperature conditioning and fire prevention or ex- at the Vanguard complex to support stati6 and flight
tinguishing capabilities. Remotely operated systems firings and to permit extensive vehicle testing. The
accomplished the filling, topping, draining and dump- more significant of these equipments are described
ing of LOX and supplied ethane gas for first-stage below.

engine starting. Hydrogen peroxide and kerosene were Vehicle handllng--Dollies were provided for trans-
supplied from trucks. A helium system was connected porting vehicle stages. They were constructed to have
to the vehicle for pressurizing the first- and second-stage minimum deflection, permitting the use of castered
helium spheres, and also provided pressure to operate wheels for maximum maneuverability. Hoist slings
various ground servicing LOX, kerosene and CO, employed for the erection of vehicle stages allowed the
control valves. A nitrogen system was installed for stages to be rotated between the horizontal and vertical
purging the first- and second-stage engine tanks, first- positions. The third-stage motor sling was made of
stage thrust chamber, tail can and peroxide compart- nonsparking webbing material to ensure maximum
ments. Nitrogen was also used to actuate various safety. Hoist doors (specially designed replacements
ground servicing helium, LOX and ethane control for the large structural doors of the equipment com-
valves, the LOX disconnect ground unit, and the partment) were used with the second stage to maintain
second-stage helium umbilical disconnect. Other sec- structural integrity during erection. Snubbers secured
ond-stage, gantry-mounted systems included a UDMH the vehicle to the gantry during high wind conditions.
fill and drain, a WIFNA fill, drain and emergency Gantry shielding was added to protect both vehicle
dump and a tank flushing water system. Liquid pro- and personnel from abnormal weather conditions. A
pane filling was accomplished manually. A cooling Greer unit supplied hydraulic pressure for launch
air system was installed to provide dehumidified, tem- stand operations.

99
M
-1
E

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s
m
I

m

100
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o

E
0

S

i
I

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t

lOl
Launch stands--The original launch stand was disconnects remained engaged until separated by the
made by the Loewy Hydropress Division of the vehicle liftoff.
Baldwin-Lima-Hamilton Corporation, and provided
Guidance and control equipment--The basic
launch capability up to a ground wind speed of 17 miles
guidance and control ground support equipment con-
per hour. This stationary launch stand was a structure
sisted of various monitoring, testing and power supply
built up with tubular steel members mounted on the
panels. A gyro panel was used to control gyro opera-
working platform about 10 feet above the launch
tion and to monitor signals and torque currents. A
pad ground level. The base of the vehicle was sup-
controls monitoring panel checked engine motions,
ported on the launch stand by four "acorn" fittings
hydraulic pressure and power supply voltage. This
mounted on "swingaway" arms. The first-stage thrust
panel also monitored all jet operations, program timer
chamber extended 52 inches down into the structure
of the stand. reset and running, and coasting time computer reset.
It controlled the operation to remotely center the
As the vehicle started to move vertically out of the
engines, to start the second-stage hydraulic pump motor,
launch stand, the swingaway arms were rotated upward
and to operate the first-stage roll jets. A controls tester
and outward by 75-pound counterweights acting on
panel was provided for checking the coasting time
one-foot moment arms. Two 150-pound springs were
computer and all channels of the program timer; it
mounted on each of the four swingaway arms to
was also used to initiate command signals to the ve-
restrain the arms until the vehicle had risen one inch.
hicle guidance system. A signal generator panel tested
The springs were restrained from further expansion by
the frequency responses, jet hysteresis and jet time
displacement limit devices. Steel pins, centrally
delays. Switching provisions were included in this panel
located on each acorn fitting, prevented undesirable
for selecting the system and type of signal to be sup-
lateral motion of the vehicle base until the electrical,
plied. Power supply panels generated power necessary
hydraulic, helium and propellant disconnect fittings
for the test equipment, including B+ voltage and 60
had disengaged.
cps a-c voltage. A remote junction panel served as a
Midway in the flight program, it was decided to junction for wiring between the vehicle and the block-
increase the allowable launch wind condition. A
house.. Part of the metering circuit and relays required
retractable launch stand was designed and built by for testing and launching were also contained in this
The Martin Company to provide a launch capability panel.
up to ground wind speeds of about 35 miles per hour.
Figure 41 illustrates the retractable launch stand in Propulsion equipment--Ground equipment di-

both the launch and retracted positions. The retracting rectly associated with the propulsion systems included
launch stand was similar to the stationary launch a considerable amount designed for specific purposes
stand up to the top of the base of the parallelopiped and used for "local" testing. A regulator adjustment
section. Four retracting arms, which were hinged at the panel was required to set the first-stage main helium
regulator. A portable pressure sensor panel was used
top of this section, supported the vehicle base 6.64
to check the vehicle gas pressure sensors to ensure
feet above the working platform, or 4 inches higher
than on the stationary stand. When the vehicle rose that they were within proper operating ranges. Another
1.75 inches, a switch triggered the retracting motion of portable functional test panel indicated gas pressure
the support arms. Hydraulic cylinders forced the re- levels in the vehicle propellant tanks and gas storage
spheres. A second-stage functional pressure panel ap-
tracting arms to rotate about their hinge points, provid-
plied appropriate gas pressures to functionally check
ing outward and upward motion of the support points.
components and sense pressures of the second-stage
The position of the vehicle-supporting acorn fittings
was the same as on the stationary stand. Several of the pressurization system. A hydrostatic flush panel con-
disconnect fittings, however, were relocated onto the trolled the filling, draining, and gas pressure during
the water-flushing of second-stage tanks. An oxidizer
retracting arms.
probe tester monitored the oxidizer probe electrical
A feature of the retracting design was that the ve- resistance.
hicle initiated retraction of the support arms by its
own vertical motion, and the time of retraction was be- Electrical The basic electrical ground support
tween 0.3 and 0.5 second. The arm retraction was equipment consisted of a propulsion fire panel to
control power to the vehicle, to initiate pressuriza-
based on a triangular linkage principle, rotating over
tion of the first stage, to drop umbilical connections
dead center, thereby providing an absolute locking
and to start the first-stage firing sequence. The ground
feature while the vehicle was at-rest on the stand.
service panel was provided to remotely pressurize the
Another important characteristic was the adjustable first- and second-stage helium spheres, to service the
swivel design of the launch stand disconnects to ensure vehicle with LOX, to manually increase the fuel and
proper alignment to the vehicle disconnects. These LOX tank pressures, to dump propellants and to con-

102
/

Fig. dO Vanguard Vehicle During Prelaunch Operations

103
trol the propane heater. Two remote junction racks of the heat generator were accomplished as required.
contained relays and timers used in conjunction with The final hangar test, prior to vehicle erection, was the
the propulsion fire panel and the ground servicing panel Horizontal Functional Test (HFT), which was similar
for remote control of vehicle firing, servicing and power to the horizontal electrically mated tests performed in
transfer. An ordnance checkout panel containing flash- Baltimore. The destruct system primacord and the
bulbs and associated circuitry simulated squibs and second-stage nozzle closure were installed after the
detonators for vehicle tests. A separation simulator, HFT.
consisting of cabling and quick-disconnects, was used Prestatic tests--Prior to arrival of the vehicle at
to electrically simulate separation of the vehicle stages the launch pad, a complete ground service test of the
during vertical tests. Other simulators of first- and sec-
complex was performed. This included such items as
ond-stage propellant valves and pilot valves provided the LOX disconnect leakage test, launch stand con-
a check for automatic sequencing in various propulsion- ditioning tests and the azimuth alignment of the launch
electrical tests. An electrical monitoring panel was
stand. The vehicle was then erected on the stand (using
required to monitor the first- and second-stage battery a dummy third stage) in preparation for the static
running time and to check out the oxidizer probe firing. After alignment, a thorough check was made
resistance prior to liftoff. to verify the compatibility of the rocket to the launch
Cooling air system--The cooling air system auto- stand, to ground service equipment, to blockhouse
matically controlled the mixing of proportionate controls, and to instrumentation. The telemetry sys-
amounts of dehumidified supply and refrigerated air tems were also checked. Vertical tests were then per-
to temperature condition the satellite and various guid- formed to prove that all systems of the rocket were
ance and control components. The flexibility of the ready for a first-stage static firing. The first stage was
design, using two refrigeration units in parallel, allowed passivated, the turbopump lubricated, instrumentation
the air to be temperature-controlled by either or both calibrated, and the first-stage igniter installed. A visual
of the refrigeration units. general inspection of the entire vehicle was then per-
Ground instrumentation---Numerous land line formed by quality control and engineering personnel.

measurements were necessary for operation and count- First-stage static firing--The primary purpose of
down procedures. Such measurements as tank pres- the static firing was to qualify the first stage for flight
sures and temperatures, combustion chamber pressures, by verifying engine package compatibility with its pro-
servicing temperatures and pressures were needed for pellant feed and pressurization systems, by demonstrat-
fueling, static firing and flight readiness checks of the ing the propulsion system performance, reliability and
vehicle. These items were monitored in the block- repeatability and by demonstrating satisfactory opera-
house on visual panel meters or recorded on strip tion of all subsystems and components. The static
chart recorders. The weight recorders measured and firing was conducted with range support and tested the
recorded vehicle weights and provided thrust indica- propulsion, electrical and control systems in a
tions during static firings and before liftoff in flight simulated 50-second first-stage flight. All residual
operations. propellants were drained from the first stage after the
No specialized automatic or semi-automatic checkout static firing, the hydrogen peroxide tank was flushed
equipment was employed for the instrumentation and and passivated, the thrust chamber was cleaned and
telemetry systems. Standard test and calibration equip- decarbonized and the LOX injector was flushed and
ment was used, except for a special pressure cart used dried. There was also a post-static visual inspection
for calibrating pressure transducers. of the vehicle and launch stand. After acceptance of
the static firing data, all ground-based instrumentation
B. FIELD TESTING was removed from the vehicle.

Hangar tests--Hangar operations at Cape Cana- Second.stage static firing--A capability existed
veral started with receiving inspection of the vehicle for static firing the second stage at Cape Canaveral,
by Martin quality assurance personnel. The primary but this was done on only three Vanguard vehicles.
objective of the hangar tests was to ensure complete The question of whether or not the second stage should
system integrity of the vehicle prior to erection at the be static fired in the field was controversial. A firing
complex area. These tests were performed in accord- was desirable to verify satisfactory propulsion system
ance with checkout procedures that were similar to start and operation, and to provide additional system
those used in horizontal tests at Baltimore. The tests pressure and flow measurements. However, the pro-
included functional and operational tests of all com- cess added approximately ten days to the field opera-
ponents: pressure; leakage; electromechanical; controls tion because a separate erection of the second stage was
and guidance; instrumentation and range safety checks. involved, and the system verification was at least
Incorporation of minor changes and checking the fit partially invalidated by the necessary post-static decon-

104
Fig. 41 The Vanguard Break-Away Launch Stand
105
taminationprocedures.In addition,flow separation azimuth tolerance were given. Discussions of power-
withinthe altitudenozzleduringsealevelfiringspre- off conditions and the expected effects of a destruct
cludeddetermination of thrustfor performanceevalua- explosion were included in Ref. 34.
tion, and associatedside forces producedsevere Supplementary range safety reports (e.g., Ref. 10)
vibrationandbuffetingof the thrustchamber. included the effects of performance parameter varia-
Thefirsttwounitsin thefield(TV-3 andTV-3BU) tions on range, the behavior of the vehicle during the
initial launch phase and the wind shear criteria for
werestaticfired, thenthe practicewasdiscontinued.
However,second-stage difficultiesencountered
in the flight.
TV-5, SLV-1andSLV-2flightscausedreinstatement Launch azimuth studies--Studies were made to
of the requirement for SLV-3. The SLV-3 static determine the extreme allowable values of the nominal
producedsideforcesof suchseveritythatoneof the launch azimuth such that the vehicles would remain
thrustchamberactuatorlugswascracked.This re- within range of ground-based electronic stations, and
suitedin thedecision,for SLV-4 andup,to substitute would not require the use of the command control
a "rejuvenation"programat Aerojetfor thefieldstatic system. A three-sigma lateral deviation (assumed to
firing(seeChapterV, Section E). be a _--+-5 degree shift in launch azimuth) in the most
unfavorable direction was permitted on each of the
Prelaunch preparations--The preparations for
above requirements. On the basis of the above
flight consisted of thorough alignment checks, instru-
premises, and by inclusion of minimum, nominal and
mentation calibrations and system functional tests,
maximum variations in performance, the launch
culminating in the Vertical Functional Test (VFT),
azimuth for a most southerly trajectory was determined
which was patterned after the Vertical Interference
to be 107.5 degrees. Similarly, 48 degrees was
Test at the factory. It was conducted with range
determined as the most northerly course.
support and was in effect a dry run of the entire
countdown and flight. The Flight Readiness Test Command control charts--Command control
(FRT), conducted after a thorough visual inspection charts were furnished to be used as a guide in determin-
by quality and engineering personnel, was similar to ing the need for pitch or yaw commands to the vehicle
the VFT, but was necessarily less comprehensive be- during flight. An IBM-704 digital computer, with
cause the rocket was almost completely "buttoned up." C-band radar tracking data as input, was used to con-
A minimum of handling was permitted after the FRT vert real time coordinates to impact points, which were
in order to preserve the rocket's established integrity then plotted in real time on the control charts. The
for flight. The vehicle then entered final servicing and command lines on the charts were constructed such
launch operations. that if a command (one degree per second rate for
four seconds) arrived at the rocket four seconds after

C. RANGE SAFETY CONSIDERATIONS the plotting pens became parallel to any of these lines,
the resulting change to the vehicle's motion would
Information was required prior to flight to ensure prevent the need for destruction of the vehicle by the
proper interpretation of real time flight data received Range Safety Officer. If at any time the plotted impact
by the Range Safety Officer. Studies to obtain point exceeded the predetermined limits set by range
pertinent information were completed for each Van- safety, the flight would be terminated. Vehicle trim
guard vehicle. commands were to be used only for range safety pur-
Perjormance predictions--Range safety reports poses, as described, and never to "steer" a vehicle
(Ref. 33 is typical of such reports) were prepared that that was not in danger of command destruction.
presented time histories of speed, altitude, ground
range, flight path angle, accelerations, thrust, propellant D. FLIGHT LOADING AND
weights and gross weights for minimum, nominal and PERFORMANCE PREDICTIONS
maximum performance of each vehicle. Trajectory
1. FLIGHT LOADING
variations included the maximum expected deviations
in the ground plane from the intended flight azimuth, Maximum total impulse from the first- and second-
the variations in ground range versus altitude and stage propulsion systems was sought by minimizing
speed versus time, and the maximum lateral angles outage (usable residual propellant at burnout). The
through which the velocity vector could turn in the absolute magnitude and sensitivity of all relevant
event of malfunction. Range and altitude versus parameters were studied to determine what was neces-
time and range versus altitude were provided for all sary to keep flight performance within acceptable
three stages. Estimates of the three-sigma impact con- tolerances. In general, the main factors which in-
tours for the first and second stages on a ground plane fluenced outage were operating mixture ratio and quan-
and the locus of impact points with a _ 5 degree flight tities of loaded propellants.

106
Mixture ratio--Prediction of the flight mixture vehicle weight recorder. Additional LOX was loaded
ratio began with accurate determination of the mixture aboard to compensate for that lost by boiloff between
ratios that were measured in acceptance tests and lock-up and the fire signal, and also for the weight of
static firings. All data sources, including Potter flow- ice that formed on the outside of the tank during load-
meters, loaded and residual propellant weights, pro- ing. Topping was continued as late in the countdown
pellant temperatures and system pressure drops, were as possible to minimize boiloff losses. The specific
evaluated; the static mixture ratio and its accuracy gravity was controlled by venting the tank to one
were determined. (Flight mixture ratios differ slightly atmosphere and allowing the LOX to boil and reach
from static mixture ratios because predictable accelera- equilibrium.
tion and additional heating effects cause slight varia- The hydrogen peroxide was weighed prior to load-
tions in propellant flow rates.) Variations occurred in ing. The loaded weight was checked by means of the
these and other parameters such as tank pressures, vehicle weight recorder. The third-stage inert parts
propellant temperatures and specific gravities, starting and the loaded motor were weighed by the manufac-
and stopping losses, and system pressure drops, all of turer.
which contributed to the mixture ratio "tolerance" or
uncertainty. The one-sigma deviation in mixture ratio 2. DRY WEIGHT
was estimated to be 2% for the first stage and 1.5%
The assembled vehicle was weighed after manufac-
for the second stage.
ture in Baltimore. Subsequent additions and changes
Outage The operating mixture ratio may be high were carefully weighed. The total weight was checked
or low, with theoretically equal probability. It was by the weight recorder readings before and after ve-
therefore desirable to minimize the outage at both hicle erection.
extremities of the mixture ratio tolerance. Figure 42
illustrates how loading for the expected mixture ratio 3. PROPULSION SYSTEM PERFORMANCE
would result in unequal outages at the mixture ratio PARAMETERS
tolerance limits. Figure 42 also shows how the outage
The predicted performance and the possible varia-
could be equalized and the maximum amount actually
tion in performance of the numerous components
reduced by intentionally loading for a slightly different
involved in the first- and second-stage propulsion sys-
mixture ratio. Thus, for the Vanguard first stage, an tems were estimated from flight results, static and
overload of 38 pounds of fuel decreased the maximum acceptance test results and engineering judgment. The
outage (within a one-sigma deviation) from 215 to complete system performance then was expressed by
135 pounds. Similarly, second-stage maximum outage the nominal, minimum and maximum values of the
was reduced from 39 to 21 pounds by a 7-pound flow rates, characteristic exhaust velocity, propellants
UDMH overload. consumed for power and propellant outage.
The nominal outage was at the tolerance limit of
Expected propellant loading--The propellant
the mixture ratio. Outage for maximum vehicles
loading of each Vanguard vehicle was calculated in-
occurred at the predicted mixture ratio. Minimum ve-
dividually, based on measured tankage volumes,
hicles had oxidizer outage at twice the mixture ratio tol-
expected operating mixture ratio, offload or overload,
erance. The propellants consumed for power were the
expected propellant specific gravity, and predicted
loaded propellants minus the starting losses, stopping
losses (starting, stopping, trapped and boiloff). Total losses, trapped propellants, boiloff and outage.
available propellants were maximized by overflowing
Third-stage per/ormance--Performance of the
the limiting tank.
third-stage rocket motor was based on the measured
Actual propellant loading--A volumetric loading weight of the flight motor, the satellite payload weight
method was developed which permitted loading the and the specific impulse based on statistical perform-
vehicle within 0.7% (three-sigma) of the desired ance data obtained from static firings conducted during
weights. This method consisted of filling the propellant the motor qualification test programs. The motor
tanks to overflow and then draining back a small burnout weight was considered to be the inert parts
quantity of ullage to establish the desired load. The weight. This assumption was adequate in the case of
required accuracy was achieved by careful calibration the GCR rocket motor; however, the ABL rocket
of the tank at the factory and by accurate determina- motor was constructed such that approximately 7
tion of the specific gravity and temperature of the pounds of rubber insulation would be consumed. This
actual flight propellants in the field. This method was effectively decreased the specific impulse by approxi-
used to fill the WIFNA, UDMH and kerosene tanks. mately four seconds for performance predictions, and
The LOX was loaded by weight as determined by the also decreased the burnout weight by 7 pounds.

107
2.6 I I
TARGET MIXTURE RATIO
O/F "- 2.111

I
_._ LOX OUTAGE
-'---'._ FUEL OUTAGE

fJ

7

0 2 3 4

MIXTURE RATIO; VARIATION FROM TARGET [%)

Fig. 42 Variation of Outage with First-Stage Mixture Ratio

4. PERFORMANCE PREDICTION the field a day or two before launch. The difference be-
tween these results and the data from which range
Vehicle performance data for the Estimated Per-
safety provisions had been made were generally con-
formance Reports (Refs. 35, Vols. I and 1I, and 36)
sidered negligible from the range safety standpoint and
and for the Range Safety Reports (e.g., Refs. 33 and
no modification was made.
10) considerably predated the launch. Late changes
and the results of the first-stage static firing were in- Expected perJormance--The conservatism of the
cluded in "post-static" maximum, nominal and mini- maximum, nominal and minimum performance ap-
mum performance predictions which were delivered to proach was shown by a subsequent method of per-

108
formancepredictionwhich consideredthe system of the cooling blanket. This change greatly improved
performance from a probabilitystandpoint(seethe the operation and allowed second-stage propellants
Appendixof this report). "Expected"second-stage to be loaded prior to the actual range time countdown.
apogeealtitudesand velocities,as predictedby the Liquid propane, UDMH and WIFNA were serviced
probabilitymethod,arecompared to actualflightre- in that order. Propane was gravity-fed until the tank
sultsandto themaximum, nominalandminimumper- overflowed. UDMH and WIFNA were serviced from

formancepredictionsin Fig. 43. This expected special trailers which incorporated their own pumps and
performance is seento agreecloselywith the actual a control panel as well as the refrigerating equipment
performance of all vehicleswhichachieved successful used prior to SLV-4. The volumetric loading of each
second-stageflight. propellant was checked against launch stand weight
recorder readings. The remaining preparations for the
formal countdown included instrumentation prepara-
E. LAUNCH OPERATIONS
tions, electrical cleanups and controls cleanups.
Launch preparations were started after the Flight
Flight countdown--The formal range countdown
Readiness Test, generally two days before flight (F-2 was begun five hours before launch, and was a closely
day), and included turbopump lubrication, setting of
coordinated operation involving personnel of the
ethane and nitrogen pressures, peroxide load prepara- Atlantic Missile Range, the NRL-NASA Vanguard
tion, Dewar tank servicing and cooling air system
Operations Group (VOG), Martin and various sub-
maintenance. The third-stage motor and other
contractors. VOG personnel checked out the satellite
ordnance items were assembled and resistance-checked
and the electronic and range instrumentation, as well
at the AMR solid propellant storage area and installed
as maintaining overall coordination for the operation.
in the vehicle. The third stage and the retrorockets
The Martin Company was responsible for preparation
were aligned after installation. and launch of the vehicle. A complete sequence of
The Vanguard flight firing countdown was split into
operation of both vehicle and ground functions is
two separate parts, occurring on successive days, to presented in Ref. 37. A summary of the more signifi-
reduce the number of continuous working hours re-
cant operations during the final countdown follows.
quired of supporting personnel. Operations on the day
preceding flight included checks on propulsion system Time
pressures, satellite, launch stand water, UNOX,fire (minutes)
fighting system and range hold fire circuit. The nose T-255 Satellite turned on and checked
cone and helium heat generator were installed. T-235 Radar beacon checked
Ordnance was armed and resistance-checked. T-225 Electronic instrumentation checked
T-210 Range sequencer checked
Flight day preparations--The final operation
T-205 Hold fire circuit checked
started approximately eighteen hours before launch,
with checks to ensure that the various systems were in T-180 Cutoff and destruct system checked
T-160 Destruct system detonators installed and
operating order and the vehicle was ready to be serv-
armed
iced with propellants. Prior to propellant servicing,
the first-stage helium spheres were pressurized to 1500 T-135 Igniter and combustion indicator assembly
installed
psig to ensure that the main propellant valves were
closed and to provide pressure for adjusting the main T-120 LOX servicing preparations
helium regulator and pilot pressure for component T-95 LOX servicing
actuation. Kerosene was the first propellant to be T-65 Gantry retired
serviced and was pumped directly from a truck. Then T-45 One-hour built-in hold which was designed to
hydrogen peroxide, which had been batch-mixed on allow completion of outstanding items
F-2 day, was serviced from a special drum by a pump. T-40 Launch stand area cleared
The loaded peroxide temperature was monitored as a T-35 Igniter arming
safety measure to detect any reactivity. T-30 IBM impact/apogee predictor ready (704
Second-stage propellants were originally cooled prior
computer and associated equipment)
to servicing, in order to maximize the propellant loads.
T-25 All personnel in blockhouse or retired to
The 60°F temperature limitation and the removal of
fall-back area
the second-stage insulation or cooling blanket at the
T-20 Instrumentation on internal power
time of gantry retirement caused considerable opera-
T-15 First-stage helium sphere pressurized to 4000
tional difficulty, particularly in the event of long holds
or flight postponement. For SLV-4 and up, the pro- psig.
T-10 Check wind condition at blockhouse, preload
pellant temperature limitation was raised to 90°F,
which eliminated precooling the propellants and use second-stage helium sphere to 400 psig.

109
T-6 Secondstagepressurized,second-stage
hy- T-100 Peroxidetankpressurized
draulicpumpon T-60 First- and second-stageflight batteriespar-
T-5 XN-I radaralignedon vehicle alleled
T-4.5 Gyros freed and commandcontrolsystem
checked T-45 Second-stage heliumumbilicaldropped
T-30 Coolingair umbilicaldropped,LOX vent
Time valvesclosed
(seconds) T-20 LOX tankpressurized
T-180 Telemetry, radarbeacons,command receivers T-10 First-stageheliumtoppingstopped
on internalpower;tailcannitrogenpurgeon T-0 Fireswitchclosed,
electrical
umbilicaldropped
T-175 Flamedeflectorcoolingwateron Liftoff occurred about 6 seconds later and was desig-
T-120 Kerosene tankpressurized nated T + 0.

80

60

m
MAXIMUM
PERFORMANCE
I--
<
I--
¢,O 40 k, •
U.I

<
20
ILl
O
O ACTUAL
a..
PERFORMANCE
<
iii
O 0
<
F--

6
Z
O
¢J
iii
--20
¢,O

W
NOMINAL
PERFORMANCE
111
tX.
X --40
iii

O LEGEND:
¢,w
u
• TV-4
Z --60 • TV-5
o_
I-- • SLV-1
< • SLV-4
ttl • TV-48U
r_

--80
MINIMUM
PERFORMANCE
• Ir
&

--100 4
-- 200 --800 --400 0 400 800

DEVIATION FROM EXPECTED SECOND-STAGE APOGEE VELOCITY (FPS)

Fig. 43 Comparisonof Predicted end Actual Second-Stage Apogee with Expected Vanguard Performance

110
VII. VEHICLE
FLIGHT ANALYSIS
A flight analysis of each vehicle is documented at
length in the series of Vanguard flight analysis reports
(Refs. 38 through 51). This Chapter presents a flight
summary and vehicle trajectory, aerodynamic and
structural performance.

111
A. FLIGHT SUMMARY

Flight

Vehicle
Objectives Results

TV-O Primary: to evaluate the performance All objectives were met except evalua-
of the internal telemetry system, to tion of coasting-flight attitude control.
Lat, nched 8 December 1956. evaluate the launching complex, and to During powered flight, the performance
Martin Viking No. 13, a liquid-pro- become familiar with the operations, of all components was either satisfac-
pellant single-stage rocket, was redesig- range safety and tracking systems of tory or superior. The vehicle reached
nated TV-0 and fired as the first Van- the AFMTC rocket range. an altitude of 126.5 stat mi and range
guard Test Vehicle. Secondary: testing of the Vanguard of 97.6 star mi. Rocket-borne instru-
Minitrack transmitter and evaluation mentation and telemetry systems per-
of the coasting flight attitude control formed excellently; ground instrumenta-
system. tion coverage was adequate.

TV-I Primary: to flight test the Vanguard All test objectives were met. Flight
third-stage prototype for spin-up, sepa- operation and performance of all
Launched I May 1957, ration, ignition, and propulsion and powerplant systems were very good.
A two-stage test vehicle. The first stage trajectory performance. The vehicle was properly controlled
was the Martin Viking No. 14 slightly Secondary: further evaluation of throughout flight to an altitude of 12l
modified for Vanguard objectives. The ground handling procedures, techniques stat mi and range of 451 stat mi.
second stage was a prototype solid pro- and equipment, and in-flight vehicle in-
pellant Vanguard third stage, built by strumentation and equipment.
Grand Central. The second-stage pay-
load was an instrumented nose cone.

_/-2 Primary: to evaluate the Vanguard All test objectives were met. Perform-
launch system and the flight perform- ance of all components throughout
Launched 23 October 1957. ance of the first-stage propulsion sys- flight was superior. This test confirmed
A Vanguard prototype consisting of a tem, the second-stage retrorocket system that the first stage operated properly
live first stage _Martin tankage and and the third-stage spin-up system, at altitude, conditions were favorable
and to obtain data on the first and
the General Electric X-405 liquid pro- for successful separation of the first
second-stage structural characteristics.
pellant engine), a simulated (but inert) and second stages, launch stand clear-
Secondary: to evaluate equipment, test ance for the condition of low surface
second stage and an inert third stage.
procedures, first-stage handling, and the winds was no problem, there was
SHF (C-band) beacon and radar structural integrity throughout flight.
equipment. The test also demonstrated dynamic
compatibility between the control sys-
tem and the structure.

Primary: to launch into orbit a mini-
TV-3 Less than one second after liftoff, the
mal (6.4-in., 4-1b) satellite. This satel- first-stage engine lost thrust because of
Launched 6 December 1957. lite was to determine atmospheric den- an improper engine start. The vehicle
sity and the shape of the earth, to
The first complete Vanguard test ve- settled back on the launching stand and
evaluate satellite thermal design param-
hicle with three live stages. This was exploded.
eters and to check the life of solar
to have been the first flight firing of the
ceils in orbit.
second-stage propulsion system and the
complete Vanguard guidance and con- Secondary: to test and evaluate all ve-
hicle stages and systems.
trol system.

TV-3BU
After 57 seconds of normal flight, a
Identical to those of TV-3. control system malfunction caused loss
Launched 5 February 1958.
of vehicle attitude control. Vehicle
A backup vehicle identical to TV-3.
breakup occurred only after an angle
of attack of at least 45 degrees had
been exceeded.

112
FLIGHT SUMMARY (¢onf)

Vehicle Improvement

Engineering Achievements Deficiency Corrective Action

Attitude control was lost at burnout Extreme care was used on the next ve-
Successful receipt of Minitrack signals
when the auxiliary peroxide jet control hicle (the last Viking to be fired) to
throughout flight demonstrated the
system (peculiar to Viking) did not ensure successful operation of the con-
practicality of the design for satellite
telemetry and tracking purposes. function. trol jet system. Measures were taken to
prevent hardware corrosion. Count-
down procedures for Viking and Van-
guard vehicles were revised to include
actual operation of the control jets.

Excellent correlation between tracking,
telemetry and predicted data indicated
that the retrorocket separation tech-
nique and the use of spin stabilization
for flight path control of the solid
propellant stage were signal successes.
Aerodynamic heating data demon-
strated that the maximum design tem-
perature limitations of antennas and
the nose cone were conservative.

The first flight attempt with the Van-
guard external configuration carried a
4000-1b payload to an altitude of 109
stat mi and to a downrange distance of
335 stat mi, as planned. Excellent
pitch/yaw control through the atmos-
phere demonstrated practicality of gim-
baled engine control with no stabilizing
fins at the base of the rocket. First-
stage powered flight roll control dem-
onstrated the adequacy of the twin roll
jets using turbopump exhaust products.

The improper engine start was traced The minimum allowable fuel tank pres-
directly to a low fuel tank pressure sure head was increased a.bout 30%.
which was responsible for a low fuel Provisions were made for manual over-
injector pressure prior to the start of ride of the regulator to assure that this
turbopump operation. A low fuel in- condition could be met. Fourteen
jector pressure allowed some of the static and flight firing starts, identical
burning contents of the thrust cham- to the TV-3 start except for the in-
ber to enter the fuel system through creased minimum allowable pressure,
the injector head. Fire started in the were subsequently made without inci-
fuel injector before liftoff, resulting in dent.
destruction of the injector and com-
plete loss of thrust immediately after
liftoff.

Spurious electrical signals caused first- Parallel wiring was installed for all
This flight provided unique information
for evaluation of Vanguard structural stage engine motions in the pitch plane, critical control system wire runs be-
starting 57 seconds after liftoff. These tween stages. The mounting panel for
design methods. An analog simulation
of the TV-3BU breakup transient was engine motions developed dynamic controls hardware was strengthened to
made, using controls and servo hard- structural loads which, coupled with a reduce vibration. Close quality control
ware, and simulating elastic structure rapid pitch-down that superimposed air was maintained, along with continued
loads of about the same magnitude, review and redesign of wiring and con-
and aerodynamic loads. The calculated
time and location of structural failure, caused the vehicle to break up at the nections. There was no recurrence in
as well as the vehicle response to the aft end of the second stage. flight of spurious signals to cause de-
spurious engine deflection, were practi- structive engine motions.
cally identical with these measured in
flight. This correlation substantiated
the validity of Vanguard structural de-
sign procedures and philosophy.

113
FLIGHT SUMMARY (cont)

Flight
Vehicle
Objectives Results

l_t-4 Identical to those of TV-3 and TV- TV-4 placed 57 lb (a 4-1b payload and
3BU. the 53-1b third-stage motor case) in an
Launched 17 March 1958. orbit estimated to last at least 1000
The third complete Vanguard configu- years. The initial orbit had a perigee
ration test vehicle, identical to TV-3 of 406 stat mi, an apogee of 2465
and TV-3BU. stat mi and a period of 134 min. The
guidance system produced an overall
error of less than one degree in satellite
injection angle. The Minitrack oscil-
lator, operating on solar battery power,
is still functioning after two years in
orbit.

TV-S Primary: to launch into orbit a fully- Flight was normal through second-
instrumented, 20-in., 21.5-1b "X-ray and stage burnout, but the second-stage
Launched 28 April 1958. environmental" satellite. This satellite shutdown sequence was not completed
The final test vehicle, which differed was to study maximum variations in electrically, which prevented arming of
from a production satellite launching the intensity of solar X-ray radiation the coasting flight control system and
vehicle (SLV) only in the greater de- in the 1 to 8 A wave length bands, separation and firing of the third stage.
gree of instrumentation. and to make certain space environment Second-stage performance was below
measurements. nominal, but combined first- and sec-
Secondary: to verify the complete ve- ond-stage performance was somewhat
hicle performance. better than nominal.

SLV-I To launch into orbit a fully-instru- Successful operation and performance
mented, 20-in., 21.5-1b "Lyman-Alpha" were achieved throughout flight, except
Launched 27 May 1958. satellite. This satellite was to study at second-stage burnout. At that time,
First production satellite launching ve- solar "Lyman-Alpha" radiation and to a disturbance caused loss of attitude
hicle. make certain space environment meas- reference of the pitch gyro so that the
urements, and was identical to the remainder of the flight was controlled
X-ray satellite of TV-5 except that it to a false reference. The third stage
covered the 1100 to 1300 A wave was launched at an angle of approxi-
length bands. mately 63 ° to the horizontal, thus
precluding a satisfactory orbit.

SLV-2 To launch into orbit a 20-in., 21.5-1b The second-stage propulsion system
"X-ray and environmental" satellite shut down after 8 sec of burning, so
Launched 26 June 1958. identical to that of TV-5. that the velocity was low and the third
stage was never armed for firing. As a
normal result of the premature shut-
down, second-stage propellant tank
pressures exceeded design values, prov-
ing the structural integrity of the tank-
age.

SLV-3 To launch into orbit a 20-in., 23.3-1b The flight was normal (or better) in
"cloud cover" satellite. This satellite all respects, except that second-stage
Launched 26 September 1958. was to measure the global distribution performance was well below minimum
and movement of cloud cover and to predicted. The burned-out third stage
contribute to the basic knowledge of and the satellite reached an altitude of
the earth's energy budget. about 265 stat mi, but the velocity was
about 250 fps short of the 25,000 fps
required to orbit. The satellite was pre-
sumably destroyed during atmospheric
re-entry some 9200 stat mi downrange.

114
FLIGHT SUMMARY (cont)

Vehicle Improvement

Engineering Achievements Deficiency Corrective Action

The objective of launching an earth
satellite during the IGY was accom-
plished 21/2 years after inception of the
program. It was accomplished by a
vehicle originally intended for flight
test purposes only, the first time the
Vanguard second stage was ever sepa-
rated and ignited in flight. The flight
also demonstrated the practicality of
the use of strapped-down HIG gyros
for guidance and of the Vanguard
technique for first-stage separation
without auxiliary thrust.

The second-stage shutdown sequence The contact that could result in de-
was not completed because a relay energizing the relay that arms the sec-
(K2) did not "latch in" electrically ond-stage separation and third-stage
after being energized by the second- firing circuits was removed. The pur-
stage thrust chamber pressure switch. pose of this contact had been to open
This was due either to a design de- a bypass valve permitting greater flow
ficiency in the relay sequencing (K1- of helium from the propellant tanks to
K2) or to an in-flight component the control jets during coasting flight.
malfunction within the relays. Flight analysis showed that this feature
could be eliminated.

SLV-I carried 75 lb (a 22-1b satellite Attitude reference was lost at second- In addition to the thrust chamber pres-
stage burnout because of a disturbing sure switch (TPS) shutdown, an oxi-
and the 53-1b third-stage rocket case)
to an altitude of about 2130 stat mi moment, probably caused by structural dizer probe shutdown capability was
and to a downrange distance of about failure of the second-stage thrust cham- provided for subsequent vehicles. The
5860 stat mi. The satellite flew for 20 ber as a result of high frequency com- oxidizer probe was designed to initiate
bustion instability at shutdown. This an earlier shutdown than the TPS sys-
min and was in the space environment
phenomenon can apparently occur dur- tem in the case of oxidizer exhaustion,
long enough to be of significant scien-
tific value. Micrometeorite impacts ing oxidizer exhaustion shutdowns if thus preventing the conditions that lead
were measured over a large altitude the fuel valve is not closed rapidly to combustion instability.

range. enough.

A restriction in the second-stage oxi- "Pickling" procedures were imple-
mented for removal of heat-treat scale
dizer feed system, and the resulting low
oxidizer flow rate, was probably caused from the interior of the second-stage
oxidizer tanks. Arming of the TPS
by heat-treat scale from the oxidizer
tank walls collecting at and partially shutdown was delayed about 25 sec to
clogging the filter screen in the feed preclude shutdown due to slow thrust
line. The low oxidizer flow rate kept build-up.
the chamber pressure below the level
necessary to continue engine operation
after the cutoff system was armed.

A restriction in the second-stage fuel The Buna-N helium fill hose was re-
feed system, and the resulting low fuel placed by a flexible metal hose. All
flow rate, was probably caused by con- second-stage tanks were "pickled" to
tamination from the fuel tank partially completely remove heat-treat scale. All
clogging the fuel injector. The low fuel second-stage thrust chamber assemblies
flow rate produced inefficient burning were returned to Aerojet-General for
and a total impulse from the second complete reconditioning. Testing pro-
stage that was about 20% below the cedures were changed to minimize the
nominal predicted. The contamination necessity for breaking into the propul-
was believed to be Buna-N rubber par- sion system and to prevent contamina-
ticles inadvertently introduced during tion of any kind.
prelaunch testing.

115
FLIGHT SUMMARY (cont)

Flight
Vehicle
Objectives Results

SLV-4 To launch into orbit a 20-in., 23.7-1b SLV-4 placed 71.5 Ib (23.7-1b payload
"cloud cover" satellite identical to that and 47.08-1b third-stage motor case) in
Launched 17 February 1959. of SLV-3. an orbit estimated to last at least 200
years. The initial orbit had a perigee
of 346 stat mi, an apogee of 2063 star
mi and a period of 125.9 min. The
guidance system produced a negligible
overall error in injection angle of 0.02 °
_ 0.2 °.

SLV-5 To launch into orbit a fully instru- Second-stage pitch attitude control was
mented, 13-in. diameter "magnetometer" lost during first-stage separation. The
Launched 13 April 1959. satellite and an expandable (30-in.) resulting tumbling motion in the pitch
aluminum sphere. The satellite was to plane aborted the flight.
determine if the predicted St6rmer-
Chapman ring current exists and to
improve our knowledge of the earth's
magnetic field. The expandable sphere
was to supply information on upper air
density.

SLV-6 To launch a 20-in. diameter, 23.g-lb There was a rapid decay of tank pres-
"radiation balance" satellite into an sures immediately after second-stage
Launched 22 June 1959. orbit witla a relatively high inclination ignition. Abnormally low flow rates
angle (about 48 degrees) to the and chamber pressures resulted, ac-
equator. This satellite was to measure companied by combustion instability.
the direct radiation of the sun, the About 40 sec later, the helium sphere
radiation reflected from the earth and exploded due to unrelieved buildup of
the long-wave radiation emitted by the pressure by the heat generator.
earth and its atmosphere. The trajectory was accurately modified
from a launch azimuth of 100 ° to a
flight azimuth of about 48 ° by the use
of in-flight roll programming just after
launch.

TV-4BU To launch into orbit a fully-instru- TV-4BU placed 94.6 lb (52.25-1b pay-
mented, 52-1b "magnetometer, X-ray load and 42.3-1b third-stage motor
Launched 18 September 1959. and environmental" satellite. This pay- case) in an orbit estimated to last at
This vehicle incorporated the Allegany load combined the scientific objectives least 50 years. The initial orbit had a
Ballistics Laboratory X248 A2 solid of the TV-5 and SLV-5 satellites. perigee of 317 stat mi, an apogee of
propellant motor as the third stage in 2326 stat mi and a period of 130 min.
place of the Grand Central motor used The guidance system produced a
in previous Vanguard vehicles. negligible overall error in injection
angle of 0.05 ° _+ 0.2 °.

116
FLIGHT SUMMARY (cont)

Vehicle Improvement

Engineering Achievements Deficiency Corrective Action

A full-sized satellite was successfully An undesirable satellite tumble rate of A thin metal sleeve was placed in the
launched seven weeks after the official approximately 15 rpm about an axis separation hardware to prevent such
end of the IGY. Two weeks after almost normal to the spin axis was binding for SLV-5 and SLV-6. The
launch, the separated third-stage motor superimposed on the existing spin rate separation spring was restrained at the
case was found to be in a higher- of less than 1 rpm about the spin axis. third-stage side, rather than being a
energy orbit than the satellite, which This apparently occurred during sepa- free body between the stage and pay-
was the first detected flight evidence of ration of the satellite from the burned- load.
significant residual thrust in the third out third-stage motor case, The major
stage after burnout. Further evidence contribution to the observed tumble
was discovered in the TV-4. SLV-1, rate was attributed to interference be-
and possibly the SLV-3 and TV-4BU tween the spring and a sharp shoulder
flights. on the separation device.

Unusually large side forces acted on The primary first-stage separation sig-
the second-stage engine nozzle during nal was changed so that separation
the first-stage separation sequence, pre- would be initiated 0.1 to 0.3 sec earlier.
sumably caused by nozzle flow separa- A check valve was added in the hy-
tion as back pressure built up in the draulic system to reduce the rate of
interstage compartment. This condition engine deflection due to any over-
lasted longer than normal because of a powering force on the actuator. Pre-
nearly 0.3-sec delay in stage separation. cautions were taken to prevent exces-
The actuators were overpowered and sive or nonuniform accumulation of
the engine driven hard into the limit nozzle closure adhesive on the thrust
stops, causing the pitch actuator lug to chamber wall.
fail in tension.

The successful use of in-flight roll pro- The second-stage main helium pressure The regulator was modified to prevent
gramming to rotate the flight azimuth regulator that controlled the flow of mechanical binding, provided with a
some 52 degrees from the launch azi- pressurizing gas to the propellant tanks protective cover and subjected to spe-
muth demonstrated the practicality of apparently opened only partially when cial flow checks prior to flight. A
this technique on the first attempt. energized during the ignition sequence. back-up energizing signal for regulator
Completely successful operation of the operation was installed.
first stage occurred with better than
nominal performance for the eighth
consecutive time.

The third orbit achieved by the Van-
guard program was accomplished about
nine months after the end of the IGY,
four years from the inception of the
program. A total of four out of the
six scientific experiments originally
planned for Vanguard were placed in
orbit. This flight also demonstrated the
remarkable accuracy of the Martin
probability method of performance pre-
diction. As a result, it can be shown
that this vehicle would be expected to
launch a 100-1b payload into a 180-
mile perigee orbit.

The Vanguard vehicle is considered "operational" inasmuch as a thorough analysis of the
TV--4BU flight was the first such effort on Vanguard that resulted in no significant vehicle
change recommendations. It is considered a major engineering achievement to have developed
an "operational" multistage space vehicle after a program of 14 flight firings.

117
B. VEHICLE TRAJECTORIES were a result of unusually high wind shears encountered
at these times. In fact, the wind profile measured pre-
The ability of the Vanguard flight plan and tra- ceding the SLV-1 launch was considered marginal, as
jectory to achieve the necessary orbit injection condi- evaluated by the current wind shear criteria. Maximum
tions was demonstrated three times (TV-4, SLV-4 dynamic pressures averaged about 600 psf and occurred
and TV-4BU). Command control capability was about 78 seconds after liftoff, generally near the 39,000-
maintaind throughout the critical portions of all Van- foot altitude (see Table 16). This value exceeded the
guard flights, and range safety requirements in general early design maximum dynamic pressure of 590 psf
were fulfilled. Impacts of the various stages were because final first-stage engine performance exceeded
always in safe areas, and impacts of all nonmalfunc- that which was expected to be the maximum during the
tioning stages were within predicted areas. Measured early design phase.
trajectory parameters at significant trajectory events are
presented for the Vanguard flights in Table 16. Aerodynamic heating--Skin temperature measure-
ments on the nose cone and along the length of TV-2,
Azimuth control--All vehicles deviated slightly to and motor compartment and internal equipment
the south of the launch azimuth, primarily because of measurements on the test vehicles verified the conser-
the earth's rotation (coriolis effect). Most of the vatism of the design temperatures. The peak measured
remaining deviations, which could not be predicted in temperature at a station 47 inches aft of the theoretical
advance, were accounted for by the effects of measured cone tip was 234°,F compared to a design value of
winds and thrust misalignments. The small remnant 750 ° . Moving aft, the margin between design and
was attributed to gyro heading misalignment. Flight actual temperature decreased approximately as follows:
values at second-stage burnout that may be considered nose cone, 500°F; truncated cone, 100°F; tail can,
typical are given for SLV-3. The vehicle was 1.1 90°F. Compartment and internal equipment tempera-
degrees south of the 107.5-degree launch azimuth at tures measured on the test vehicles were also much less
second-stage burnout, of which 0.6 degree was expected severe than those for which the equipment was de-
from the Coriolis effect. The combined effects of signed.
measured winds and thrust misalignments accounted
Wdnd shear criteria--The wind profile was
for 0. l degree, and 0.3 degree was caused by a roll jet
measured before all Vanguard flights and evaluated
malfunction which rotated the pitch plane three degrees
with the existing wind shear criteria to determine
between 105 seconds and first-stage burnout. The
whether the vehicle could fly without exceeding design
remaining 0.1-degree deviation was attributed to gyro
limits. There were no excessive wind shears during
heading misalignment.
flight countdowns, although conditions were considered
Pitch control--The attitude pitch programs were marginal before the SLV-1 flight, when a wind shear of
inserted as planned. All pitch programs successfully 12.7 fps per 1000 feet of altitude was measured
produced near zero-lift trajectories. The injection angles between 24,000 and 32,000 feet four hours before
of the succesful flights were well within the ± 1.2- launch. The maximum limit between these altitudes
degree (three-sigma) tolerance, indicating the adequacy was 13 fps per 1000 feet, according to the criteria then
of the spin-stabilized attitude control of the third stage in use. Wind shears aloft preceding the SLV-5 flight
and the overall guidance system performance. were even more severe, but they were considered satis-
factory in terms of revised wind shear criteria.
C. AERODYNAMICS
Wind.induced oscillation spoilers--The rubber
Ten successful Vanguard firings, through the regime spoilers mounted on the second stages of all Vanguard
where aerodynamic forces were significant, have proven vehicles appeared to perform their function, as there
the validity of the aerodynamic design procedures. were no periodic oscillations of significant amplitude
noted prior to any flight or static firing. The times of
Angle o] attack---Calculated angles of attack,
based on best estimates of flight performance and the spoiler peel-off for the TV-4 and SLV-3 flights were
measured wind profile, were in good agreement with later than desirable to keep aerodynamic drag and roll
disturbances to a minimum. Considerable additional
the angles measured on the TV--4 and TV-5 flights,
lending confidence to the values calculated for later effort was expended to develop an installation procedure
that would ensure early peel-off times. Motion pictures
vehicles. The angle of attack for all vehicles at maxi-
of the early portions of the SLV-4 flight showed that
mum dynamic pressure was always within a safe limit.
all twelve spoilers peeled off as intended.
The largest calculated value of 5 degrees occurred dur-
ing the SLV-1 and SLV-5 flights. This compared to Launch wind criteria--The winds during the
the maximum allowable angle of 5.5 degrees (which TV-3 launch came closest to maximum allowable con-
was later changed to 7 degrees as more information dition, being only 3 miles per hour less than the limit
became available). The 5-degree angles of attack of 17 miles per hour with the original fixed launch

118
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119
stand. Surface winds for the SLV-3 and SLV-5 differ during the first portion of the transient because
launch were as large, but were not considered signifi- no flight trim angle was included in the simulation
cant, since the retractable launch stand had been study.
incorporated with allowable surface winds of 35 miles Stations 327 to 358 were the longitudinal stations at
per hour. which the failure limit moment was exceeded. A bend-
ing moment time history that resulted from the simula-
D. STRUCTURE tion engine motions was obtained for this area (see
Fig. 44). Failure was expected at about 61.7 seconds
The performance of the Vanguard structure, as but could have occurred any time after 60.5 seconds
indicated by telemetered flight data, demonstrated that because of the neglected static trim moments. The
the design criteria, except for the conservatism in aero- simulation study indicated failure within about 0.1
dynamic heating, were reasonable and sufficiently second of the time of actual failure and in the approxi-
accurate. There were no known structural failures in mate region where it occurred. Failure was not
flight, except in cases of component or system mal- predicted in any other region.
functions. Such a correlation is particularly significant in that
a new philosophy was developed during the Vanguard
Differential pressures across skins--Calculations
design. This design philosophy, as previously noted, is
were made to determine the magnitude of air bleeding
embodied in the use of the control system, through
through joints and other small openings during ascent.
otherwise detrimental structural feedback, to control
Telemetered measurements (the first of this kind
the loads and the bending moments which the vehicle
known to have been made) on TV-2 and TV-4 (Refs.
would normally develop in flight. Experimental verifi-
40 and 43) verified these theoretical calculations given
cation of this philosophy was extremely important if
in Ref. 12.
its application to future designs were to be effected.
InJormation gained ]rom the Iailure oJ TV- Controls bay panel--Telemetered data indicated
3BU--Experimental verification of many of the a high vibration environment at the controls bay panel
parameters entering into the structural analysis was
in the second stage. However, the high indicated g
obtained during the ground vibration survey of the
levels 47 seconds before ignition on TV-3BU, coupled
complete Vanguard vehicle structure; however, no
with 30 g's recorded prior to burnout on the successful
experimental verification had been obtained for the
TV-4 flight, must cause the recorded accelerations to
complete system analytical representation upon which
be viewed with care. Improvements were incorporated
the dynamic load calculations were based. The TV- in later vehicles that precluded the possibility of an
3BU flight failure (see Chapter VIII, Section A) pro- adverse vibration environment. These included stiffen-
vided the opportunity for determining the validity of the ing the structure to raise the natural frequency, spray-
system analytical representation. The telemetry data ing the inside of the controls can with insulating
gained from the flight before breakup showed vehicle lacquer and changing the major wiring cable to the
and engine motions similar to cases analyzed to predict
pitch servo amplifier.
the dynamic bending moment contributions to the
design bending moment envelope. ProoJ o_ design, second.stage tankage--Two
aborted flights (SLV-2 and SLV-6) may be con-
A program correlating the flight data of TV-3BU
sidered as exceptional structural tests of the second-
with the theoretical analyses was undertaken to estab-
stage tankage. On SLV-2, ignition of the heat genera-
lish the accuracy of the analyses and to obtain failure
tor in the second-stage helium sphere, coupled with
predictions for comparison with the actual flight failure.
premature cutoff of the engine, caused unusually high
Control, servo and engine hardware were used, while
system pressures which were near (within 89 to 95% )
the elastic structure and aerodynamic loads were
the design burst pressures of the helium sphere and
simulated by analog techniques (see Ref. 52). The
propellant tanks. However, there was no indication of
engine pitch deflections were externally commanded
structural failure prior to atmospheric re-entry. On
to follow the TV-3BU flight transient motion that oc-
curred from 57.35 to 57.51 seconds. The one-second SLV-6, rupture of the second-stage helium sphere,
oscillation that followed arose from the first elastic caused by a malfunction of the helium pressure regu-
lator, occurred only after the differential pressure be-
mode through structural feedback, since the external
tween the sphere and the tanks had built up to more
command to the engine during this time was zero. All
than 115% of the minimum design burst pressure.
subsequent spurious pitch engine motions were ex-
ternally commanded to produce the remainder of the Second.stage actuator support lugs--The maxi-
simulated flight. The correlation of the simulation with mum tension load imposed on the second-stage engine
the flight motion is shown in Fig. 44. The actual actuators during the first-stage separation sequence of
engine deflection and the simulated engine deflection SLV-5 occurred when an overpowering force of about

120
11,000pounds(computed fromtheenginemotionrate Theenginelugsweremadeof 6061aluminum alloy
of 146degper sec) drovethe engineinto the stops and,asoriginallydesigned, wereto havea heattreat
in the pitch-updirection.Whenthe enginehit the conditionof T6 (maximumstrength).Weldingof the
stops(assuming that all components of the actuation injector assembly to the thrust chamber,however,
systemwere still within the elasticrange), the causedthe lugs to becomeoveragedand to have
totalload,includingimpactforces,wasbetween 12,000 strengthpropertiesbetween0 (soft) andT4 (inter-
and16,000pounds,whichwassufficient to fail either mediate).Lugsin this conditionwouldbe adequate
the actuatoror the enginelugs. Recordsfrom the for the limit designloadof 2500poundsbut would
actuatorfollow-uppotentiometer afterthe enginehit be expected to yield (0.2% permanent set) at about
the stop,maintenance of hydraulicpressure andcon- 3000poundsandfail at about8000poundstension.
tin ed enginethrustindicatethatonlytheendof the Modifications to thefirst-stage
separation
sequence for
a_._uatoror the connecting lugson the enginecould SLV-6 andTV-4BU (seeChapterVIII, SectionE)
havefailed.Fortensionloads,theenginelugwasthe reducedthe loadson the actuatorlugsto acceptably
weakestlink andwouldbeexpected to fail first. safevalues.

PITCH GYRO /I
T 4 ill II
2
Z

0
a 0
_.. ,." -_-- _-_ ... y, s _ ------
FLIGHT
SIMULATED

1
iii
LU

O ENGINE PITCH DEFLECTION
iii
¢-.,
J | I ,d
I I
- ! #

0
1 V'
1 /1"X
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f\ ,,'_

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FLIGHT
------ SIMULATED

400,000
Z
STRUCTURALI NOMINAL SKIN THICKNESS _ '_
JL
LIMIT ._MINIMUM SKIN THICKNESS
zW 200,000

O
^,.A A A
O 0 v
Z V v
I/ V
-
CALCULATED BENDING MOMENT

AT STATION 358
-- STRUCTURAL FAILURE-

_-200,000 ! .... _ n i

56.8 57.2 57.6 58.0 58.4 58.8 59.2 59.6 60.0 60.4 60.8 61.2 61.6

FLIGHT TIME, SEC
Fig. 44 Time Histories of Vehicle Bending Moment Resulting from Abnormal Engine Pitch Motions, TV-3BU

121
122
VIII. SYSTEMS
FLIGHT ANALYSIS
Important system flight analysis results are sum- until 720 seconds, the termination time for program
marized below. More detailed studies may be made timer operation. The loss of information from this
if desired by referring to the series of Vanguard flight channel could have been the result of a sticking micro-
analysis reports (Refs. 38 through 51). switch. This signal loss complicated the data reduction
process somewhat but was in no way detrimental to
A. GUIDANCE AND CONTROL the flight of the vehicle.

Airborne third-stage firing system--The airborne
The adequacy, integrity and reliability of the
third-stage firing system initiated the third-stage spinup
Vanguard guidance and control system was demon-
and firing sequence on all three of the successful satel-
strated by the accuracy of vehicle trajectories on all
lite launches and also on SLV-1. Telemetry records
flights and the small satellite injection angles achieved
indicated proper coasting time computer operation on
on the orbits. A graphical summary of flight per-
all flights. Flight firing operations, as well as pre-
formance of the major components and systems is
launch tests, all demonstrated that the airborne third-
given in Figs. 45 and 46 for TV-4 through TV-4BU.
stage firing system was a reliable and accurate unit.
1. AIRBORNE GUIDANCE Coasting time errors, based on the difference be-
tween the actual coast time and the coast time cal-
Gyroscope re/erence system--There were no in-
culated from the telemetered coasting time computer
dications of any gyroscope reference system malfunc-
velocity, were all less than 2.5 seconds. Typical error
tions throughout the program. Pitch rate information
values were 2.4 seconds on TV-4BU, 1.3 seconds on
was telemetered as a function of pitch torquer voltages,
SLV-4 and 0.7 second on SLV-1. The coasting time
from which the rates could be derived. Ripple in the
mechanism was not started on TV-5 because a second-
torquer voltages prevented an exact determination of
stage burnout signal was not received from the second-
the pitch rates. However, the maximum and minimum
stage engine sequencer. The timing arm did not start
rates, derived from the maximum and minimum
on SLV-2, SLV-3 and SLV-6 because vehicle velocity
torquer voltages, always bracketed the prescribed rate,
was less than the minimum required to start the
thus indicating that pitch rates were nominal.
mechanism.
A further check on the accuracy of the pitch pro-
gram rates and, indeed, of the entire guidance and con- 2. GROUND-BASED THIRD-STAGE FIRING SYSTEM
trol system, was obtained as a result of the trajectory The independent ground-based backup third-stage
match program (see Chapter IX, Section B). The fact firing system was actuated on five Vanguard flights and
that the match data so closely followed the predicted appeared to function reliably. Third-stage ignition was
trajectories was another excellent indication of the successfully initiated by the ground-based system on
accuracy of the gyro system as a control reference and SLV-3, with an indicated coasting time error from the
as part of the vehicle guidance system. ideal of 3.2 seconds, which was somewhat large, but
Program timer--Performance of the program still well within tolerances. The actuation signals were
timer in flight is given in Fig. 47. The specification received by the SLV-4 and TV-4BU vehicles, but were
tolerance for pitch rate insertion times was _ 0.10 merely exercises to check the hardware since the air-
second. The maximum deviation occurred on TV-5, borne system had already given third-stage ignition.
when the fourth pitch rate came through 0.07 second A ground-based attempt was made on SLV-1, but
late. Deviations of 0.10 second for the second-stage did not succeed because of a faulty command receiver
arming signal occurred on SLV-1 and SLV-2 flights. (see Chapter VIII, Section J). However, unknown to
The time tolerance for this function was + 2.0 sec- ground personnel because of a temporary telemetry
onds. The average error for all functions on all flights loss, the airborne system functioned properly. A
was 0.03 second. ground signal was also sent on SLV-2, but was
The only instance of a program timer failure in flight blocked because the second stage did not burn long
occurred on TV-4, for which the 10-second telemetry enough to arm the third-stage firing system.
timing signal was lost after 460 seconds of flight. The Slight modifications to the ground-based system were
signal returned at 650 seconds and continued normally made during the Vanguard program. The smoothing

123
,,, *BATrERY PARALLELED AT T-60 SEC
u MAXIMUM PREDICTED ROLL

•z oll
,_
I , P ICTED T UST

U
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I I ! ! ii
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IJ'l I/_ -- "i
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z
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TV-4 TV-5 SLY-1 SLY-2 SLY-3 SLV-4 SLY-5 SLY-6 TV-4BU
VEHICLE

Fig. 45 First-Stage Controls Performance

124
NOTES:

1 NO TELEMETRY DATA DURING COASTING FLIGHT.
2 COASTING FLIGHT SYSTEM NOT ARMED.
3 NO DATA DUE TO POWERED FLIGHT MALFUNCTION.

._--__ PREDICTED THRUST

i_ o 2 i
I t I _
_ PREDICTED THRUST

!7-ii ,--i ,-i" -
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ZO TV-4 TV-5 SLV-I SLV-2 SLV-3 SLV-4 SLV-5 SLV-6 TV-4BU

VEHICLE

Fig. 46 Second-Stage Controls Performance

125
process of the radar data was improved. Capability 2.1 cps. The amplitude of the oscillation varied from
was added for a backup direct firing command after 0.5 to 0.9 degree peak-to-peak. This engine oscilla-
spinup had been initiated by either system. In addition, tion represented a limited instability in the autopilot
a second-stage burnout signal was transmitted to the loop, but never affected overall pitch and yaw control.
computer operator from a person watching several The engine oscillations generally began in the interval
real-time telemetry channels, an improvement over the between 100 and 120 seconds and continued until first-
previous method of watching the impact point. stage burnout.

Launch transient--Vehicle and engine motions
3. FIRST-STAGE PITCH AND YAW CONTROL associated with launching were relatively small, with
the exception of TV-4, as shown in Fig. 45. An
The operation of the first-stage pitch and yaw con-
engine correction of 2.5 degrees right (in yaw) resulted
trol system for TV-4 and all subsequent vehicles is
from a 1.3-degree left vehicle error at liftoff on TV-4,
summarized in Fig. 45. Typical vehicle motions and
when one swingaway arm of the launch stand did not
controls reactions are shown in Fig. 48.
release properly. This transient motion was sufficient
TV--3BU mal/unction--The only flight failure in to excite first bending mode oscillations (about 3 cps)
the guidance and control system occurred on the TV- which were damped out within 3 seconds, indicating
3BU flight. The pitch and yaw control system operated effective control of structural feedback. Control dur-
satisfactorily for the first 57 seconds of flight, as in- ing the launch transient was considered excellent in
dicated by telemetered data. At that time, spurious view of the adverse conditions.
first-stage engine motions in the pitch plane produced Maximum dynamic pressure--Control through
large dynamic structural loads on the vehicle. These the maximum dynamic pressure region of first-stage
loads, coupled with a rapid pitch down of the vehicle flight, where the airloads could be high, was excellent
(which developed large air loads), caused a major in all cases. Engine deflections required to correct for
structural failure at the aft end of the second stage vehicle attitude errors ranged from 0.5 degree to 1.5
(see Chapter VII, Section D). Each abnormal engine degrees on most flights. Engine deflections of about 2
pitch movement that occurred was accomplished with degrees were required for pitch and yaw control of
maximum engine-down rate, indicating a hard-over SLV-1 because of the unusually high wind shears
hydraulic transfer valve. The second-stage engine did aloft. However, pitch and yaw control was adequately
not follow the spurious motions. To produce such a maintained during this transient.
condition would require a malfunction in the first-stage
servo-amplifier or in interconnecting wiring associated 4. FIRST-STAGE ROLL CONTROL
with the first-stage pitch follow-up potentiometer, servo-
First-stage roll attitude control was adequately main-
amplifier, or hydraulic valve. A malfunction involving
tained on all flights by the two rotating jet nozzles.
the follow-up potentiometer circuitry appeared most
System performance is summarized in Fig. 45.
likely and was most probably caused by a broken or
open circuit somewhere in the associated wiring. The SLV-3 roll jet real/unction--The only instance
corrective action consisted of increased quality control of a partial first-stage roll control systetn malfunction
and the use of redundant interstage wiring, as discussed occurred on SLV-3 flight where, after 106 seconds of
in Chapter V, Section F and in Ref. 42. flight, the up-left roll jet stuck in a 30-degree clock-
wise position. This caused the down-right jet to cycle
Thrust misalignments--Engine thrust misalign- at a rate of 2.5 cps in order to maintain vehicle roll
ments were present to a degree on all flights, as in-
control. The up-left jet deflection gradually decreased
dicated in Fig. 45. The thrust misalignments were
to an angle of about 7 degrees at first-stage burnout,
almost invariably in the pitch-up and yaw-right direc-
with a concurrent decrease in the cycling rate of the
tions, and were generally greater in yaw than in pitch. down-right jet to about 1 cps. The maximum roll atti-
Maximum misalignments present on any flight were 0.5 tude error of 5.7 degrees during this malfunction was
degree yaw-right on SLV-2 and SLV-3. However, the
attained at 106 seconds. Thereafter, until first-stage
average misalignment was only 0.3 degree in yaw and burnout, roll attitude was maintained within 3.4 degrees
0.15 degree in pitch. These relatively small misalign- by the rapid counterclockwise cycling of the down-
ments were not considered detrimental to vehicle con- right jet.
trol.
Roll jet thrust--First-stage roll jet thrust, calcu-
Propellant sloshing--Propellant sloshing in the lated from vehicle inertias, jet-on times and roll gyro
tankage, initiated by vehicle motions, caused engine rates at 80 seconds flight time, was consistently lower
oscillations as indicated in Fig. 45. The frequencies than the predicted thrust level (Fig. 45). Although
of the oscillations varied, vehicle to vehicle, from about thrust was consistently low, it was always more than
1.8 cps to 2.5 cps. The predicted slosh frequency was adequate to maintain roll control. For example, the

126
NOTE:

+0.00
1. TIMES SUBJECT TO TELEMETERING ACCURACY OF SEC.
--0.05

2. 0 NO REQUIREMENT FOR FUNCTION.

3. @ FUNCTION NOT TELEMETERED.

. n
TV-4BU
°' I
--0.1
0 i m

0.1

SLV-6 0 1 m - __ n ® I
--0.1 i

°.11
SLV-5 0 " • m .. @

--0.1

u

sly-4 ,,,,- 0.1 1
o • -- - |
<
g -o.1
u
u

Z< 0.1 ]
m
"l- SLV-3 Q 0
I,LI
> .i
_ --0.1
Z

sLv-2 Zg
O
0.1
o ]
• n • II I ,
z
2 -o.1 j
o.1] m • • • n
SLV-1 0

--0.1 I

TV-5
°.,
0
1 • nm m ®
--0.1 j

TV-4
°'1
--0.1
0
• J • ®too J
m

t I i I I I i
1st 2nd 3rd 4th 5th SECOND- NOSE
STAGE CONE
PITCH RATES ARMING SEPARATION

Fig. 47 Program Timer Operation

127
thrust at 80 seconds on TV-4 (the vehicle with the engine motions and resultant vehicle motions, however,
lowest roll jet thrust) was 68 pounds, which repre- were rapidly damped out and adequate vehicle control
sented a 200-foot-pound correcting moment capability. was maintained.
The maximum roll disturbing moment encountered dur- The engine transients at second-stage ignition resulted
ing this flight was only 33 foot-pounds, which was one- from a combination of causes. At first-stage separa-
sixth of the magnitude of available correcting moment. tion, loss of first-stage servo loads and changes in
Disturbances of similar magnitudes were experienced battery voltage (on vehicles TV-4 through SLV-5
by other vehicles, with a maximum roll disturbance of where the dynamotor-filter combination supplied B-t-
50 foot-pounds occurring on SLV-4 (Fig. 45). to the autopilot) resulted in autopilot B+ transients,
The lower than predicted roll jet thrust levels can and hence in engine motions. The overpowering
probably be attributed to leakage in the roll jets. The moments from the nozzle flow separation resulted in
thrust levels were improved on the last two flights by additional large engine deflections. Steady-state engine
using a new tool to form the flanges of the jets, which deflections following separation were caused by engine
resulted in smoother flanges and tighter fits. thrust misalignments.

Helium augmentation system The helium
Shutdown transients--Engine transients at second-
augmentation system provided additional roll control
stage shutdown were fairly small on all vehicles other
during the interim between first-stage cutoff and separa-
than TV-4 and SLV-1, as shown in Fig. 46. The 2.6-
tion of the first and second stages, at which time roll degree engine yaw deflection on TV-4 was almost in-
disturbances could exceed the correcting capabilities
stantaneous and was rapidly damped out. The hard-
of the second-stage roll jets alone. Thrust levels of the
over engine pitch-down deflection on SLV-1 at shut-
helium augmentation system were calculated on TV-5
down was called for by the control system in response
and SLV-3 to be 117 pounds and 110 pounds, respec-
to vehicle pitch-up motions due to a large external dis-
tively. These thrusts were slightly below nominal, but
turbing moment. The disturbance resulted from engine
were more than sufficient to ensure good roll control side forces such as would have been associated with
during separation. Thrusts could not be determined on a failure of the welds between the thrust chamber tubes
other flights due to characteristic PPM/AM telemetry
caused by an unstable shutdown (Chapter VIII, Sec-
dropouts around first-stage burnout. However, from
tion C). This large disturbance produced a vehicle
roll gyro records (PWM/FM telemetry) it appeared
attitude error of about 75 degrees up. The gimbaled
that helium augmentation thrust was always adequate.
engine was not capable of correcting for the large dis-
Roll program--A roll program chassis was in- turbance since thrust was decaying during this time
stalled in the controls compartment of SLV-6 in order (post-cutoff). The attitude jets regained control of
that an effective flight azimuth of 48 degrees could be the vehicle during coasting flight, but the 12.5-degree
achieved after an actual launch at 100 degrees. The limit of the pitch gyro had been exceeded. Therefore,
chassis fed a signal to the roll torquer, which rotated the control was about a new pitch reference, 63 degrees
the roll gyro reference axis at a rate of 3.07 degrees above the desired reference.
per second counter-clockwise from 5 -+- 0.1 seconds to
Spurious gyro transients--Spurious pitch gyro
22 ___ 0.1 seconds. Roll torquer voltage was not tele-
transients of about one degree were recorded during
metered, but the accuracy of the vehicle flight path indi-
TV-4 flight, commencing at about 236 seconds. The
cated that the torquer rate was correct.
engine response to the gyro signals was normal. The
5. SECOND-STAGE POWERED FLIGHT PITCH/YAW pitch accelerometers indicated vehicle accelerations
CONTROL were in phase with the initial engine deflections rather
than the initial gyro errors. The large gyro error rate
The gimbaled second-stage engine successfully main-
(7.6 degrees per second) would have required a 5000-
tained powered flight pitch and yaw control of the
foot-pound disturbance for 0.1 second. Such a disturb-
vehicle on all flights except on SLV-5, where data
ance would have caused a 0.5-g tail can acceleration,
indicated that an engine pitch actuator lug broke during but there was none recorded. It was concluded that
the second-stage ignition sequence.
the pitch gyro transients were spurious, and were prob-
Ignition transients--The magnitudes of engine ably caused by an intermittent open circuit in the
motions occurring during the second-stage ignition isolation amplifier of the gyro reference system. This
sequence are shown in Fig. 46. Although engine tran- type of malfunction, especially in the feedback loop,
sients were fairly large on several of the flights, pitch could have caused insertion of erroneous gyro signals.
and yaw control was maintained except for SLV-5. An occurrence of this type was not noted on any other
For instance, the engine deflected 1.8 degrees at igni- flight. The TV-4 transient at 236 seconds was sufficient
tion of TV--4 and SLV-2, and may have hit the to induce pitch engine oscillations of about 2 cps, which
mechanical stop in yaw at ignition on SLV-3. These agreed closely with the calculated propellant slosh fre-

128
DIRECTION OF RELATIVE WIND
_- IV
z
_c I
r_ II
III
0 IV

ROLL GYRO

' _
3=
u _i ! i In^i"_IAAkA_AA_A_AA6AI
_ o__ __L 'TvllvvFv4vvyvvlw
I ll_i
PITCH ANGLE OF ATTACK
4

0

Z --4

0
l:::l --8

PITCH GYRO

-2 L_.__L _ DYNAMIC
PRESSURE

L __.lbJ ..... ,. L

V
YAW ANGLE OF ATTACK
4

,/
0 ,,,r
I
I--" --4
r
O
YAW GYRO
2

0

--2
I,--
ii ENGINE YAW DEFLECTION

i _L,__]__.A.,_I _ _..j _1_ _L _._t,.......J......J_,._I J
0

--2
-7_7
--
_, 11]1
:-_!- -Y - " •......-r --
Lt I l
v

0 20 40 60 80 100 120 140 160

TIME (SECI

Fig. 48 Typical Angle of Attack, Vehicle Motions and Controls Reactions During First-Stage Powered Flight

129
quency. The oscillations were damped out within six more detrimental to control than first-stage engine
seconds, and no detrimental effects on vehicle control thrust misalignments because of the gain relationship
were developed. (2.67 degrees of gyro motion per degree of second-
SLV--5 actuator lug ]ailure--The second-stage stage engine motion). Since the gyro error is in effect
engine of SLV-5 exhibited violent pitch and yaw mo- integrated throughout powered flight, the overall
tions, not commanded by the gyros, almost immediately vehicle trajectory of the second and third stages after
after the start of chamber pressure rise, which were second-stage burnout could be adversely affected.
most probably caused by flow separation in the engine The procedures and specifications for second-stage
nozzle (see Chapter VII, Section D and Chapter VIII, engine alignment were reviewed and modified after
Sections C and E). The engine bottomed on the 3.2- the SLV-3 flight to correct for misalignments due to
degree limit stops at least twice, once in the yaw-left structural deflection and alignment of vehicle center of
direction at a rate of at least 55 degrees per second and gravity off the gyro axis. Thrust vector misalignments
again in pitch-up at about 146 degrees per second. This on the next flight (SLV-4) were slight, as is indicated
last pitch rate was high enough to fail the pitch actuator in Fig. 46. However, fairly large misalignments were
lug when the engine hit the stop. in evidence again on SLV-6 and TV-4BU, indicating
After failure of the actuator lug, the normal hose that still tighter control would be warranted on align-
loads in the flexible propellant feed lines probably ment procedures and specifications if there were more
vehicles to be flown.
moved the engine to a position 3 degrees down in
pitch, while the actuator and follow-up potentiometer
returned to zero deflection, as indicated on the tele- 6. SECOND-STAGE POWERED FLIGHT ROLL
CONTROL
metered engine records. The pitch thrust moment
accelerated the vehicle down at about 35 degrees per Powered flight roll control was adequately main-
second. 2 The resulting tumbling motion produced suffi- tained on all second-stage flights, except on SLV-5. In
cient centrifugal force to throw the third stage and this instance, applied roll disturbing moments (see
satellite free of the second stage 5 seconds after separa- Subsection 5) were in excess of the design capabilities
tion. About one second later, the vehicle began to roll, of roll jet correcting moment, and the partial loss of
probably due to a roll moment from the hard-over
roll control was not attributed to the roll control sys-
engine in pitch. The vehicle rolled 25 to 30 degrees tem itself.
initially and was partially stabilized by the propane roll
Roll disturbance--A small, fairly constant disturb-
jets at a roll reference error between 20 and 25 degrees
counterclockwise. ing moment was present during second-stage powered
flight on most vehicles. The disturbance varied in
At about the same time that the vehicle began to
roll, the yaw engine and gyro records, which had been magnitude from 0.1 to 0.5 foot-pounds from vehicle
to vehicle, sometimes clockwise and sometimes counter-
normal, showed that the vehicle yawed right at an
clockwise, but never changed direction on any given
increasing rate. The engine moved hard over in yaw
flight. The disturbance was attributed to" moments
to effect a correction, but was unable to re-establish yaw
attitude control during powered flight. It is believed initiated by propellant vortices forming in the emptying
that this motion was a result of the combined pitch tankage and/or to small misalignments in the tubing
that forms the inside surface of the exhaust nozzle.
tumbling and rolling motions being coupled into yaw,
Other contributing factors might have been small
and possibly failure of either the thrust chamber torque
aerodynamic disturbances and effects of engine thrust
link or the monoball, which would result in engine
rotation as well as linear motion when the yaw actua- misalignments. Roll control was always adequate
tor moved. because of the small magnitude of the disturbance as
compared to the available correcting movement.
Propane was nearing exhaustion at 186 seconds
flight time, whereupon roll control was completely lost TF-5 roll control--Roll control was maintained
and the vehicle began to spin up. Ten seconds later, during powered flight of TV-5. An electrical malfunc-
the vehicle had become spin-stabilized along the longi- tion prevented operation of the three-way roll valve
tudinal axis. The roll rate continued to increase until at second-stage shutdown, so that the roll jet fuel
burnout, when it had reached 170 rpm. supply was not switched to helium for coasting flight, as
would have occurred in normal sequencing. The
Thrust misalignments--Engine thrust misalign-
adequacy of the propane fuel reserve was demonstrated,
ments were present in varying magnitudes on all second-
stage flights, as indicated in Fig. 46. The average mag- since coasting flight roll control was maintained by the
nitudes of the "misalignments were 0.24 degree in pitch propane supply for more than 100 seconds of coasting
and 0.30 degree in yaw. The misalignment compo- flight recorded before telemetering signals were lost.
nents indicated a tendency to lie along the up and right SLV--6 roll disturbance---The problem of low roll
axes. Second-stage engine thrust misalignments were jet thrust never seriously affected vehicle control, since

130
eventhe low thruston SLV-4 (Fig. 46) sufficedto leakage test of the regulator dome was instituted, the
ensureroll controlduringpowered flight. A dangerof regulator setting was increased, and nozzles having
lowthrust,however,waspointedout by thelargeroll smooth throats were provided. The regulator was re-
disturbance which occurredon SLV-6 at first-stage oriented to prevent liquid from entering the sensing
separation. This disturbance,
apparently dueto pivot- port. The propane servicing procedure was also modi-
ingor tippingabouttheinterstage disconnects (Chap- fied to purge liquid propane from the plumbing and to
terVIII, SectionE), produced a highsecond-stage roll ensure attainment of the desired temperature. All of
rateat thetimeof separation of theinterstage discon- these modifications were incorporated on TV-4BU,
nects. A telemetry dropout obscured the flight data and roll system performance in that flight was es-
for about 0.15 second after separation. When tele- sentially as predicted.
metry was regained, the vehicle was rolling clockwise
7. SECOND-STAGE COASTING FLIGHT CONTROL
at about 23 degrees per second. The counterclockwise
second-stage roll jets were on, but the high rate caused Adequate control was maintained on all flights other
the roll gyro to move beyond the telemetry demodula- than TV-5, when the pitch/yaw jets were not energized
tor saturation point (11.6 degrees); therefore, the due to an electrical malfunction, and SLV-6, which
maximum vehicle error could not be determined from malfunctioned during second-stage powered flight.
the telemetry records alone. Phase plane analysis of
Pitch/yaw jet thrust--Pitch/yaw jet thrust was
this roll transient indicated that the maximum roll error
relatively difficult to calculate using vehicle inertias,
attained before the rate was brought to zero was 12.2
jet-on times and gyro rates, due to the small deadzone
degrees. Since the roll gyro gimbal capability, as de-
settings (-+- 0.4 degree) of the control system, and to
termined by preflight bench tests, was 12.5 degrees,
the resolution of the telemetered gyro data. Calcula-
no loss of roll attitude reference was indicated. The
tions on TV-4 yielded 6.0 pounds of thrust per jet
roll jet thrust of 4.6 pounds per jet was about 40%
(excluding the malfunctioning down jet which had 0.1
below predicted. A nominal roll jet thrust of 8.5
pound of thrust). The thrust on SLV-4 and TV-4BU
pounds per jet would have contained the maximum roll
was determined to be about 8.0 pounds per jet, or
excursion to less than 7 degrees. Within 2 seconds
slightly above the nominal 7.2-pound value. Thrust
after separation, the roll jets were able to reduce the
levels on other flights were in the same general range,
roll error below the telemetry demodulator limit and
since coasting flight control was always maintained.
usable data were again obtained. Subsequent roll
oscillations were eventually damped and a limit cycle Roll jet thrust--Roll jet thrust history for the
was established within 10 seconds after separation. coasting flights of TV-4 and subsequent vehicles is
Adequate roll control was maintained throughout the presented in Fig. 46. The trend, as in powered flight,
remainder of powered flight. was for thrust to be lower than the predicted nominal
value. The low thrust of 2.5 pounds per jet obtained
Roll jet thrust---The roll jet thrust history is shown on SLV-4 flight was due to the same items as the low
in Fig. 46. Adequate roll control was always main- thrust during powered flight; a low regulator setting, or
tained, but thrust values were generally below the the failure of one clockwise and one counterclockwise
nominal predicted level of 8.5 pounds per jet through- jet to operate properly. The low thrtlst of 3.5 pounds
out the flight of vehicles up to and including SLV-6. per jet obtained on SLV-2 was believed to be caused
The thrust ranged from 60% low on SLV-4 to 15% by liquid UDMH (considerable UDMH remained in
low on TV-5. The low SLV-4 thrust was attributed to the tank after the early cutoff) being expelled through
low propane flow, due either to a low regulator setting the nozzles along with the helium. The thrust levels
or failure of one clockwise and one counterclockwise on SLV-2 and SLV-4, as on Ell other vehicles with low
jet to operate properly. thrust, did not prevent the system from maintaining
adequate vehicle roll attitude control. The action taken
A test program was conducted after the flight of
after SLV-6 flight (see Subsection 6) resulted in a
SLV-6 to correct the low thrust level. The dynamic
thrust level about one pound higher than the 7.5
mockup that had been used in original system develop-
pounds per jet value predicted for TV-4BU.
ment tests (Chapter IV, Section A) was employed. It
was discovered that leakage of an O-ring seal in the TV-4 pitch-down jet real]unction--The pitch-
helium-propane regulator dome would cause a 25% down jet on TV-4 required 22 seconds of jet-on time
reduction in regulated pressure and thrust at altitude. to correct for a 2-degree up gyro error that existed at
Other possible causes of low roll jet thrust were: failure second-stage cutoff. Similar operation of about 18
of a jet solenoid valve to operate because of low pilot seconds duration occurred about the time of third-stage
pressure; excessive system pressure drop; vena con- separation. This indicated a thrust level of only 0.1
tracta effect at the sharp-edged nozzle throat; and/or pound for the pitch-down jet, which was far below
liquid propane in the sensing port of the regulator. A nominal. Apparently, the down-jet solenoid valve be-

131
camestuckin a partiallyopenpositionduringthe Success of the first stage was attributed to a sound
initialactuationandremained in thispositionthrough- basic design and to the detection and correction of
out coastingflight. Thisconditionwassupported by troublesome items during static firings. Each flight was
thefrequentup-jetactuations to correctfor theresult- preceded by a successful 50-second static firing. Prior
ingdowndisturbance. Dropsin batteryvoltageduring to flight firings, a thorough analysis was made to deter-
the22-and18-second intervalsalsoindicateda 10-to mine the system's readiness for flight. Only after veri-
15-ampload on the battery,whichcouldhavebeen fication of a successful static firing, by data and a
caused by thepitch-downsolenoidusingabout12amps thorough hardware inspection, was the system con-
whilecontinuously attemptingto openthe jet valve. sidered qualified for flight.
The holdingsolenoid,whichnormallyoperatedafter
thevalvewasopen,requiredonly0.4 amp. 1. STARTING TRANSIENTS
Pitch/yawattitudecontrolwasadequate despitethe All vehicles prior to SLV-3 used the original X-
marginalTV--4down-jetoperation.Thevalvesticking 405 "purge-prime" starting sequence, wherein the
may havebeencausedby the DC-11 siliconevalve thrust chamber was primed with kerosene vapor intro-
lubricantreactingwithWIFNAfumesin theheliumgas duced by a flow of nitrogen "purge" gas. The nitrogen
suppliedto the jets. This reactionwouldformcon- entered the system downstream of the fuel valve and
taminatingproducts(silicon dioxide)which would flowed through the engine manifold and regenerative
establishan environmentwhere the valve would cooling passages into the injector. In passing through
probablystick. GR-362lubricantwasusedon TV-5 the manifold, the gas picked up vapors from a small
andup andthetroubledidnot recur. quantity of liquid kerosene placed there for the pur-
SLY-5 coasting flight--The SLV-5 vehicle was pose. This "purge-prime" provided the fuel for the
initial stages of burning until the main flow of kero-
spinning at 170 rpm about the roll axis at second-stage
burnout. Helium was supplied to the roll jets and the sene, released by the opening fuel valve, filled the
pitch/yaw jets were energized when the cutoff signal cooling jacket and reached the injector.
was given. Approximately 70 seconds later, the vehicle The flight failure of TV-3 resulted from a previously
was completely attitude-stabilized, but about some unsuspected deficiency of this starting technique. After
random reference, since all the gyros had exceeded pressurization of the fuel tank, the lockup pressure
their limits during the tumbling and spinning. Attitude at the engine fuel pump inlet was 23.7 psia, well above
control was maintained for an additional 70 seconds, the minimum value of 19.9 psia specified for the X-
at which time the aerodynamic moments caused by 405, but nevertheless at a slightly lower value than for
re-entry into the atmosphere overpowered the jet cor- any previous starting of this engine.
recting moments. Flight analysis indicated the following sequence of
events. The relatively low pressure head on the fuel
B. FIRST-STAGE PROPULSION resulted in slightly late arrival of the main kerosene
flow at the injector, a condition verified by the overly
The first-stage propulsion system operated success- long time (2.33 seconds) from fuel valve open to
fully through burnout, and performed as predicted, in peroxide valve open, and by the excessive decay in fuel
ten of twelve flight attempts. Of the two incomplete flow rate as indicated by the Potter flowmeter. This
flights, one (TV-3BU) was terminated by a malfunc- resulted in the fuel side of the injector being insuffi-
tion in the control system after 57 seconds; until this ciently protected by the mixture of prime-fuel and purge
malfunction occurred, propulsion operation was normal. gas prior to arrival of the main fuel flow, so that com-
The only flight failure attributed to first-stage propul- bustion chamber products (hot igniter gases and
sion was that of TV-3, where an improper start re- vaporous LOX) entered the fuel side of the injector.
suited in loss of thrust and destruction of the vehicle Fire and detonation then occurred when the fuel did
just after liftoff. reach the injector. The damage thus incurred permitted
The reliability of the propulsion system was con- further mixing and burning of the propellants within
clusively demonstrated when it successfully completed the injector. This created an unbalanced condition
its last nine consecutive flights (TV-4 through TV- across the injector face, which caused a momentary
4BU). Performance for all flights was between nominal surge in chamber pressure, structural vibrations and
and maximum predicted. No problems were experi- continued loss of the injector rings. During the time
enced during the shutdown transients as a result of interval of injector failure, sufficient thrust developed
running to propellant exhaustion. Thrust decay during to lift the vehicle off the launch stand. Chamber pres-
shutdown was always rapid and stable, and the engine sure rose until 0.4 second after liftoff, then dropped,
consistently provided low level thrust of sufficient dura- which was indicative of complete loss of the injector
tion to provide positive acceleration to the second stage rings and burnthrough of the combustion chamber.
during its ignition. Approximately one second after liftoff, an extreme

132
structural
vibrationrupturedthefuelfeedsystem
at the pump outlet pressure switch at fuel exhaustion. Figures
fuel valve dispersion cap, which resulted in total loss of 51 and 52 are examples of LOX and fuel exhaustions,
engine thrust. The vehicle rose about 50 inches, then showing valve closing times and typical pressure decays.
dropped back on the launch stand and was completely All shutdown transients were as predicted. There
destroyed. Time histories of chamber pressure and were no propellant valve malfunctions or indications of
LOX and fuel flow rates, with valve opening times, are thrust chamber failures. Thrust decay was rapid and
shown in Fig. 49. The extent of damage to the injector stable regardless of which propellant was exhausted and
is shown in Fig. 50. the engine consistently provided a low level of thrust,
The immediate corrective action taken to prevent sufficient in duration to ensure second-stage ignition
future engine failures during the starting transient was under positive acceleration.
to increase the minimum value for fuel pump inlet All second-stage ignition signals were initiated by the
lockup pressure from 19.9 to 25.5 psia and later to first-stage chamber pressure switch which functioned
28.5 psia, until a more reliable engine start system when the chamber pressure decayed to 60 _ 15 psia.
could be developed. An analysis of engine starts indi- Time for chamber pressure decay to this value was
cated that this increased lockup pressure was adequate within the design limit of 0.5 second.
to compensate for all engine package fuel system pres- 3. PRESSURIZATION AND PROPEttANT FEEO
sure drop variations, and would reduce the time from SYSTEM OPERATION
fuel valve open to peroxide valve open to less than two
Helium regulator--The main problems associated
seconds. A minor modification of the ground electrical
with the regulator were creepage (increase in initial
system provided a fuel pump inlet switch override,
setting during engine operation) and inability to pre-
which allowed controlled over-pressurization of the fuel
cisely adjust the initial regulator settings. Both of
tank after lockup, to ensure meeting this requirement.
these shortcomings resulted in higher thrust than
The effectiveness of this corrective action was borne
predicted because of increased peroxide tank pressure.
out by successful starts on the next fourteen consecu-
Regulator creepage occurred during the TV-2 flight,
tive static and flight firings, after which the new ethane
with a resulting sea level thrust of 29,800 pounds.
system (Chapter IV, Section B) was introduced.
Creepage was attributed to excess pressure buildup in
A new and improved engine starting procedure, the regulator dome. This problem was eliminated
which utilized ethane gas instead of the purge-prime before the next flight by the addition of a constant
vapor, was developed after the TV-3 failure. The bleed vent on the regulator dome. This modification
ethane start was qualified by the engine manufacturer provided thrust control within 1% of the calculated
by successfully completing 41 starts using the qualifica- values for all subsequent flights except SLV-3 and
tion engine with Vanguard vehicle and ground system SLV-5, which were about 2.5% higher than predicted,
hardware. The ethane start demonstrated improved
due to inaccurate regulator settings. Re-evalua-
reliability and repeatability over the purge-prime start. tion of the regulator adjustment panel curve and adjust-
It abolished the previous requirements for wetting the ment of the regulator dome pressure by inc'reased pres-
motor body cooling passages with fuel; priming the sure increments reduced the initial setting tolerances
engine with one quart of kerosene; and purging the to acceptable values for the last two Vanguard flights.
fuel side of the injector with nitrogen five seconds prior
Peroxide Jeed system--The peroxide feed system
to starting the engine. It also prevented the possibility
of random hard starts by maintaining a positive pres- functioned well during all flights (Fig. 53). The feed
sure on the fuel side of the injector until fuel arrived at system line diameter was increased from _/2 to ¾ inch
prior to the TV-2 flight to eliminate the excesssive
the injector, and by eliminating the characteristic
system pressure drop observed during the TV-2
chamber pressure drop which occurred between "fuel
valve open" and "peroxide valve open" with the static firing. Vent valve closing problems experienced
during static firings were eliminated by replacing the
purge-prime start. Vehicle modifications required for
the ethane start were the addition of a tail-ring dis- vent valve pressure probes with a normally open
connect and a feed line containing a check valve. The solenoid valve in the peroxide tank pressurization line;

ethane start system was installed and performed suc- this permitted positive closure of the vent valve prior
cessfully on SLV-3 and all subsequent vehicles. to peroxide tank pressurization. The peroxide system
fill and drain quick-disconnect was replaced by a hand
valve on SLV-1 and later vehicles in order to prevent
2. SHUTDOWN TRANSIENTS minor leakage which had been observed prior to
peroxide tank pressurization.
For all flights except two, the first-stage shutdown
signal was initiated by the LOX pump outlet pressure LOX vent valves--The venting capacity of the
switch upon oxidizer exhaustion. Shutdown signals for liquid oxygen tank was doubled after the TV-2 static
the TV-5 and SLV-2 flights were initiated by the fuel firing by the addition of a second vent valve identical

133
6OO

500

I
/
4OO

B
CHAMBER PRESSURE
¢12
rl

300

ILl
tY
C_

200

100

J
LOX VALVE FUEL VALVE PEROXIDE LOX VALVE LIFT
PRELIMINARY OPEN VALVE OPEN BEGIN OFF
OPEN FULL OPEN

A
8oi
/ .... i /
-- LOX --
/ I /
I /
6O It- _ /_

i,/
A
u

\ ,
-- FUEL I

U.I
I-- 40 L

tI
0

2O:

/

mm

0
-6 -5 -4 -3 0

TIME (SEC)

Fig. 49 Time Historyof ChamberPressureand flow rates DuringTV-3 First-StageStartingTransients

134
Q_

0

.__

135
1000 I

L s LOX PiMP OUTLET

8OO

6OO

--
400
PUMP OUTLET PRESSURE--
SWITCH ACTUATION RANGE

2O0

a-

LU
_v

iii
t t LOX VALVE
LOX VALVE CUTOFF H202 VALVE
a.
START TO CLOSE CLOSED CLOSED

1000

FUEL PUMP OUTLET J

80O

FUEL INJECTOR
_

600

400

200
-0.4 -0.3 0.2 -0.1 0 0.1 0.2

TIME INTERVAL (SEC)

Fig. 51 Typical First-Stage LOX Exhaustion Shut-down Transient

136
1000-" i !

f LOX PUMP

OUTLET,
_ _,._'_PRESSURE __
800 i

INJECTOR

F
60(

CHAMBER - /

40(

200

<
LOX VALVE
LOX VALVE
CUTOFF START TO H_O_ VALVE
CLOSED
iii

::)
_t 4'CLOSE
t
CLOSED
u')
u"J,
iii I000

FUEL PUMP OUTLET

8OO

FUEL INJECTOR -/

600

400

200

0
-0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3

TIME {SEC)

Fig. 52 Typical First-Stage Fuel Exhaustion Shut-down Transient

137
o
O
O

oo
iii
n
b
UJ
1.1.1 iii
m
imM
m m

__ ;.-.r--
L m F --I_ _ "-LI_ '_l- --jg.
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L - --I
I

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d

0

ul
I-- 0
U .<
m E
2
1.1.1 0. I
0 _ L
O.

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m m
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u
i
£
o
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ill

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3]DIN3A

138
to the original. Increased venting capacity was neces- velocities were always above nominal. High perform-
sary in order to reduce the LOX tank pressure to less ance was attributed to the attainment of maximum
than 2 psi prior to pressurization, so that the nominal overall specific impulse and consistently low propellant
LOX temperature requirement (--294.7°F) could be outage.
met. Sluggish and improper vent valve operations
observed during the TV-2 static firing were eliminated Thrust coefficient--Thrust coefficient (C_) is a
by relocating the vent solenoid pilot valve from its measure of nozzle efficiency. Sea level thrust coefficient
cold environment, by adding longer bleed extensions was determined during engine package acceptance
from the valve bodies, and by attaching desiccants to F
tests by calculation from the relationship: Cf -- --
the bleed ports. Failure of the LOX vents to close on P,. A,
the TV-3BU and TV-5 static firings was attributed to Thrust (F) and chamber pressure (P,) were recorded
trim wires installed in the valve inlet restrictor orifices. during acceptance tests, while the throat area (A_) was
Differential contraction between the wires and orifices physically measured before and after each firing. The
at LOX temperatures caused the effective orifice open- altitude thrust coefficient was calculated from the
ings to shrink and reduce the pneumatic gas flow to the accurately determined sea level coefficient by a correc-
valves. Correct orificing without trim wires eliminated tion for the change in ambient pressure. The mean
this problem. No vent valve failures occurred during value of sea level thrust coefficient thus obtained for
flight. the X-405 engine was 1.43. Thrust coefficients were
also calculated from flight data, using "best estimate"
Propellant inlet lines--The wall thickness of the
oxidizer and fuel inlet lines was doubled after the TV-2 flight thrust, telemetered chamber pressure and the
static firing to prevent damage due to pressure surges previously measured throat area. The mean Ct from
resulting from rapid engine valve closure during shut- flight was 1.435.
down. The integrity of these inlet lines was verified Characteristic exhaust velocity--Characteristic
when they were attached to the qualification engine exhaust velocity (c*) is a measure of combustion
package and successfully completed a series of 10 efficiency and injector performance. The character-
engine start tests at the engine manufacturer's produc- istic exhaust velocity on all flights was slightly greater
tion test pit. These tests were performed after the than that calculated during acceptance tests (Fig. 55).
TV-3 flight failure. The mean values were 5760 fps for flight and 5708 fps
for acceptance test.
4. PROPELLANT UTILIZATION
Low propellant outages were achieved during all Overall specific impulse--Specific impulse is the
flights (see Fig. 54) through the practice of precise amount of impulse produced by an engine (in pound-
determination of mixture ratio and propellant loadings. seconds) per pound of consumed propellant. Overall
Propellant outage was conservatively estimated during specific impulse was calculated from the best estimates
the early flights by assuming the most adverse accu- of engine thrust and propellant flow rates (including
mulation of tolerances. As flight experience was gained, peroxide) obtained from a variety of data sources in
it was possible to reduce the spread of expected the flight analyses. The average overall flight specific
tolerances and thus make more realistic predictions. impulse (Fig. 55) varied from 250 to 253 seconds,
The original mixture ratio tolerance spread was reduced which was two to three seconds greater than that
from ±5% to ___2%. obtained during acceptance tests and static firings.
The highest outage experienced, as determined by
post-flight analysis, was 70 pounds of fuel during the
SLV-3 flight. On most vehicles, near-simultaneous
LOX and fuel propellant exhaustions occurred. SLV-2 C. SECOND-STAGE PROPULSION
and SLV-5 were the only other flights with measurable
outages, having 39 pounds of LOX outage and 31
The second-stage propulsion system operated and
pounds of fuel outage, respectively. performed as predicted only on the three flights which
succeeded in placing satellites in orbit. The first two
5. ENGINE PERFORMANCE
flights to carry the second stage, TV-3 and TV-3BU,
The first-stage engine performance was always be- were terminated by first-stage malfunctions. The sec-
tween the nominal and maximum predictions. Burnout ond-stage system performed satisfactorily throughout

139
I

TV-4 I
I
F-
.I
_- PREDICTED
-L__I I

TV-5 i I ' i L_
L---
I i--I "1
I 0 I
SLV-1
I , : i I

I I
SLV-2 ' I J i i
i -I I
_u SLV-3 , j I
"t-
r J L I
i11 --I

SLV-4 '1
r J r-J

SLV-5 , I , !
_/
I--- 1 I

SLV-6

ff _

TV-4BU
I PREDICTED REDICTE[
___ I II I i

72 74 76 78 34 35 36 2.0 2.2 2.4

LIQUID OXYGEN FLOW RATE (LB/SEC) FUEL FLOW RATE (LB/SEC) HYDROGEN PEROXIDE
FLOW RATE (LB/SEC)

j_ __SPECIFICATION -"

TV-4

LIMITS PERFORMANCE
VEHICLE
TV-5 _J

SLV-1 PREDICTED I ' PREDICTED-_
NOMINAL
SLV-2 VEHICLE

U
SLV-3
.,z I
SLV-4 1 , j I

EXPECTED

SLV-5

SLV-6 1
_21 OUTAGE
l I
TV-4BU ._1 r-1 TRAPPED PLUS STOPPINO
LOSSES AND LOX BOILOFF
I I _ I I J '

2.08 2.12 2.16 2.20 2.24 0 lOO 200 3OO 400
MIXTURE RATIO, O/F UNUSED PROPELLANTS (LB)

0 1 2 3
UNUSED PROPELLANTS (%)

Fig. 54 First-Stage Propellant Parameters

140
!
ACTUAL BURNING TIME [SEC)
_- NOMINAL DESIGN
TV-4 144.1 J
I I
TV-5 I 140.7 !
I

SLV-I I I i43.5
I
SLV-2 J 143.4 ]
1
SLV-3 I 1 14o.1 l
,,z,
> f
SLV-4 144.07 J

SLV-5 t _ 140.8 J
I
SLV-6 I'l 144.5 I

TV-4BU 1 I _.144.8

I I I I I
I
27,000 27,400 27,800 28,200 2_,600 29,000 4,120,000 I J
4,200,000 J 4,280,000 '
4,160,000 4,240,000 4,320,000
SEA LEVEL THRUST (LB) TOTAL IMPULSE (LB/SEC)

I-,---PREDICTED _- PREDICTED h----PREDICTED
I I
TV-4 ' I ,] !
I _._I L__
1
i I
TV-5 , I I , J
I I
I

SLV-1 '! ' l l
_ql
I

SLV-2 J ' .I
I
u
_ SLV-3
i

SLV-4 , ! J
C---_ I

SLV-5 L_] I '1
__w| p---,
I

SLV-6 T ] 3i
I ......
I

TV-4BU | . | ! ! J
I I I
I i I I I

248 250 252 254 5600 5700 5800 5900 1.40 1.42 1.44 1.46

SPECIFIC IMPULSE (SEC) CHARACTERISTIC EXHAUST VELOCITY THRUST COEFFICIENT, C
f
(FPS)

Fig. 55 First-StagePerformanceParameters

141
powered flight on two other occasions, TV-5 and by providing an earlier separation signal (Chapter VIII,
SLV-1, but malfunction of the engine shutdown system Section E) and by using check valves in the hydraulic
prevented successful completion of the missions. In system to reduce the rate at which the servos could be
the remaining four flights, malfunctions occurred im- overpowered (Chapter VIII, Section I).
mediately after engine starting. Instrumentation--Nozzle flow separation also
Although the second-stage propulsion system per- caused extreme vibration, probably in excess of 100 g.
formed successfully on only three of nine opportunities, The vibration did not appear to affect operation of the
the design was demonstrated to be basically sound. propulsion system, but did affect the pressure instru-
Relatively minor changes were required to correct the mentation during the starting transients. The injector
deficiencies which led to flight failures. In some cases, and chamber pressure traces for many of the flights
only changes in procedures or ground equipment were were erratic and generally lower than expected (Fig.
required. There was no evidence of any flight malfunc- 56). However, the earlier separation signal used on
tion attributable to thrust chamber erosion or stress
SLV-6 and TV-4BU seemed to provide a more accept-
corrosion of the tankage, which had been major de- able environment, as the transient indications for these
velopment problems. No specific cause of flight failure flights were quite smooth. A vibration test of a typical
was ever repeated. The success of modified Vanguard transducer demonstrated that the wiper would lift away
second stages in other space programs is further indica- from the potentiometer coil under conditions of severe
tion that the design was fundamentally sound. vibration, thereby giving an indication of erratic pres-
sure, always either equal to or lower than the true
1. STARTING TRANSIENTS
pressure.
The validity of assuring reliable engine starting
through the use of hypergolic propellants was dem- 2. SHUTDOWN TRANSIENTS
onstrated-successful ignition occurred on all nine
For all flights through SLV-I, the TPS provided
flights.
the only shutdown signal. The oxidizer probe, origi-
Nozzle flow separation--lgnition of the second- nally planned as the primary system for oxidizer ex-
stage engine caused a pressure buildup in the inter- haustions, had been removed because a malfunctioning
stage compartment until stage separation occurred. or broken probe could initiate premature shutdown.
The level of back pressure was a function of com- The TPS performed satisfactorily on TV-4 and SLV-2,
partment volume, blast door area and the time from but on TV-5, a relay sequencing problem prevented
engine start to first-stage separation. A maximum back delivery of the shutdown signal to the propellant valves
pressure of about 16 psia was possible if stage separa- and the coasting flight arming functions (see Chapter
tion was delayed. The separation signal was normally VIII, Section G).
given by the thrust chamber pressure sensor (TPS)
when chamber pressure reached 140 psia (see Chapter Oxidizer probe--On SLV-1, a high frequency
VIII, Section G). During the short time interval from combustion instability occurred, causing TPS to chat-
ter for 1.5 seconds before the shutdown signal was
ignition to separation, the buildup of back pressure
consummated. During this time, the vehicle experi-
prevented the exhaust gases from completely filling the
20:1 area ratio divergent nozzle. This produced enced a severe pitch-up movement (Fig. 57). Analysis

asymmetrical, random and oscillatory flow separa- indicated that this must have been caused by combus-
tion in the nozzle, which caused side loads that often tion gases escaping through the thrust chamber wall.
were sufficient to overpower the engine servos. Both The thrust chamber probably split in the welds between
flow separation and overpowering of the servos were tubes, due to severe vibration and pressure fluctuations
characteristic of sea level static firings of this engine. induced by the combustion instability; a failure of this
On SLV-5, side loads were much more severe than type occurred on a thrust chamber during a develop-
any previously experienced in flight, and the engine ment test. The probable cause of high frequency com-
was driven hard against the actuator stops, causing bustion instability was intermittent interruption of
failure of the servo mounting lug (Chapter VII, Sec- oxidizer flow into the combustion chamber by helium
tion D) and consequent loss of the vehicle. The reason bubbles which became entrained in the flow upon oxi-
dizer exhaustion.
for unusually severe side loads on SLV-5 could not be
clearly established from the data available. They As a result of this flight failure, it was concluded
could have been caused by some unsymmetrical that oxidizer exhaustion must be sensed, and the system
obstruction in the nozzle (such as uneven rupture of shut down, sooner than was possible with the existing
the nozzle closure), by high or uneven pressure dis- TPS system. Accordingly, various modifications of the
tribution in the interstage compartment, or simply oxidizer probe system were used on all following flights.
from the random nature of the flow separation phe- SLV-2 and SLV-3 used dual oxidizer probe systems
nomenon. The condition was alleviated on later flights which required both probes to sense oxidizer exhaus-

142
2OO
_J

160
.<
a.

v) 120

Q..
/ TV-4
SLV-3
,.n

.<
"r
,,j 8O
I SLV-4
TV-4 BU

4O

_.'T'__T_
0
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6

TIME FROM IGNITION SIGNAL (SEC)

!

200

TV-5
SLV-2

I '% SLV-5 ;
%% SLV-6 /
|

#I •

";,<
_ eo
/
.o /
_- " J t

0
0 2 4 6 8 10 12 14 16

TIME FROM IGNITION SIGNAL (SEC)

Fig. 56 Time Historiesof Second-Stage
ChamberPressure DuringStartingTransient
143
4

7
Z
ENGINE PITCH
DEFLECTIONS

o
O

I.,14
III
Q_

LLJ
c_

Q. PITCH GYRO
w

-4

-8
\
t2

_V,_ WIFNA NO. 2

8
O
..J
14.
_UDMH
FLOW RATE

,.,,:, 5
I--

tTpsICLOSEDI . LPS
_--
ACTOATIOIq--_
I
I
II
I
m m

I I
> 0

300 II

m
g,,)

_. 200 / 'qb, i •

M.I
WIFNA
UDMH INJECTOR
Q.
CHAMBER PRESSURE

100

258.6 259 259.4 259.8 260.2 260.6 261 261.4 261.8
TIME (SEa

Fig. 57 Time History of SLV-! Second-Stage Shut-down Transients

144
tion before the cutoff signal was given. This arrange- Fuel valve--A 0.25-second delay in fuel valve
ment was used to prevent premature cutoff should closing was observed during the shutdowns of TV-4,
either probe malfunction. Several successful test firings SLV-3 and SLV-4. It was deduced that UDMH in
were made with this type of system, but, during the the valve actuation system boiled off because of the
field static firing of SLV-3, some of the thrust chamber near-vacuum ambient pressure in flight. A vent check
coolant tubes burned through at shutdown. It was valve which opened at 10 psig was installed in the pilot
determined that the dual oxidizer probe system some- valve vent line, beginning with SLV-5. This valve
times delayed shutdown because considerable entrain- prevented UDMH boil-off, thus permitting more rapid
ment of helium had to be present for the probes to closing of the fuel valve. The sketch shows a compari-
remain simultaneously uncovered long enough to ener- son of the fuel injector pressures on SLV-4 and SLV-5,
gize the shutdown relay. The dual probe system was indicating the more rapid valve closing on SLV-5.
flown on SLV-3, but UDMH was off-loaded to ensure
a fuel exhaustion which could be safely handled by 3. PRESSURIZATION SYSTEM
the TPS shutdown system. As luck would have it, the
Heat generator--The heat generator ignited and
fuel system became clogged, oxidizer exhaustion did
burned satisfactorily on all flights. However, in TV-5
occur, and the dual probe system operated perfectly.
and SLV-6, it ignited immediately after first-stage
In the meantime, an intensified development program separation instead of at the expected time, several sec-
was initiated to develop a fully reliable oxidizer probe onds later, after decay of the sphere pressure to 1400
shutdown system. The effects of probe location, geome- psig. Tripping the helium regulator during the engine
try, acid constituents, acid temperature, arming time start transient initiated the flow of high-pressure helium,
and vibration were determined. The final configuration causing a pressure transient in the vicinity of HPS1.
consisted of two probes, one in each feed line down- Sometimes the pressure dipped low enough to cause
stream of the oxidizer valve, either of which could sig- actuation of the switch, thus firing the heat generator.
nal shutdown independent of the other. This arrange- This "malfunction" was not detrimental to system op-
ment provided for the possibility of one feed line eration; in fact, on TV-4 and TV-4BU, the heat
exhausting before the other. The probe was modified generator was purposely ignited at first-stage separa-
to prevent internal breaks such as those which led to tion.
its earlier deletion. A transistor network was used in
Helium regulator--The performance of the helium
place of differential relays in order to provide a precise
regulator proved to be rather unpredictable. On five
resistance setting for system operation. This system
flights, the regulated pressure was above or below
was used with success in SLV-4 and subsequent
vehicles. specified tolerances (see Fig. 58). Regulated pressures
as much as 20 psi outside specification limits could
be tolerated, however, as the effect on overall per-
formance was determined to be small.
The regulator opened only slightly, if at all, on the
UDMH INJECTOR PRESSURE
flight of SLV-6. This caused all downstream system
pressures to decay rapidly, after the starting transient,
FLIGHT to less than half of their normal flight values (Fig. 56)
----SLV-5 STATIC with consequent low thrust and combustion instability.
CUTOFF
..... SLV-4 FLIGHT Since the heat generator ignited at first-stage separa-
SIGNAL
400 tion, the helium sphere pressure continually increased
TVS 2
until rupture occurred. Corrective action consisted of
.< I every conceivable precaution to ensure that the regu-
/,L °*°l lator was in operating condition at launch. Minor
e
"' 200 mechanical modifications were made to the rotary
,v

solenoid and tripping mechanism. A protective cover
i11 was provided for the regulator. Improved field pro-
Jo
,,.,_ cedures were instituted, including flow tests and, on
- i_a'l n ! ii,
0
the day of the flight, a check of the trip mechanism
243.4 243.8 244.2 244.6 245.0 just before final torqueing.
TIME (SEC)
A more desirable regulator would have been one
that did not require manual closing, but which would
automatically lock up at the proper propellant tank
pressures. This was recognized early in the program,
and an attempt was made to develop such a regulator,

145
['----'--I TANK PRESSURE

INJECTOR PRESSURE

CHAMBER PRESSURE

(TANK PRESSURE)

---1 _SPEOFICATION
(CHAMBER
LiMiTS:
PRESSURE)

s v_,
SLV-2 /

i
I I

SLV-3
"r
>.

SLV-4

SLV-5

i I
SLV-6

TV-4BU

I I
120 160 200 240 280 320 360

PRESSURE (PSIA)

Fig. 58 Second-Stage System Pressures

146
but difficulty was experienced in achieving satisfactory almost 300 pounds of UDMH remained in the propel-
regulation with heated helium, and the decision was lant tanks. The resulting low second-stage performance
made to use the existing regulator. prevented the satellite from attaining orbital velocity.
The Buna-N rubber particles were inadvertently in-
4. PROPELLANT FEED SYSTEMS troduced into the second-stage tankage during vertical
testing, after the second-stage static firing in the field.
The oxidizer and fuel propellant valves operated
Silica gel particles from a broken drier in the ground
satisfactorily in all flights. On the flights of SLV-2 and
helium system passed through a 4-micron filter and
SLV-3, however, foreign matter caused severe clog- eroded the interior of the Buna-N rubber helium fill
ging in the propellant feed systems, causing failure of
line. The rubber particles entered both propellant
these flights. tanks and the helium sphere. After an unsuccessful
Heat treat scale---On SLV-2, loose heat treat scale attempt to remove these particles with water contain-
lying in the bottom of the WIFNA tank entered the ing a detergent, the UDMH tank and helium sphere
propellant feed lines during the starting transient, and were flushed with toluene and the WIFNA tank with
clogged the oxidizer filter screens. Clogging initially methylene chloride. It was physically impossible to
occurred in only one feed line; then, as scale entered visually inspect the interior of the propellant tanks,
the second line, the clogging in the first line was re- but the clean appearance of the helium sphere led to
lieved somewhat, probably due to the particles breaking the conclusion that the other tanks were clean also.
up and passing through the screen. The oxidizer flow Unfortunately, some of the particles may have been
rate was about 60% of the normal value, and the trapped in the UDMH tank. After the flight, it was
chamber pressure was slightly less than 70% of normal. learned that Buna-N rubber swells in the presence of
Shutdown occurred after about 8 seconds of burning, toluene and then becomes tacky and coheres upon later
when the TPS shutdown system was armed (Fig. 56). exposure to UDMH. It was theorized that the enlarged
Varying degrees of oxidizer screen clogging had rubber particles, having a specific gravity near that of
been experienced during qualification testing. As a UDMH, were agitated from the tank bottom and swept
result, a field procedure had been instituted for water- into the feed line at the start of fuel flow. The timing
flushing the oxidizer tank to remove loose heat treat of the initial clogging (Fig. 56) and the increasing
scale. SLV-2 had a history of scale contamination, restriction throughout powered flight correlate well with
and required 16 flushing operations in the field before this theory.
all the loose scale was apparently removed. The screens Corrective action for this problem consisted of re-
were inspected and cleaned. Following a scrubbed flight moval of the silica gel driers, using a metal helium fill
attempt, the propellant tanks were drained, and about hose instead of rubber and installing an additional 4-
two quarts of water were inadvertently introduced into micron filter at the connection of the hose to the vehicle.
the oxidizer tank during flushing of the pitch/yaw jets.
This water was removed but not before it might have 5. PROPELLANT UTILIZATION
combined with acid adhering to the tank walls to form The feasibility of achieving low propellant outages
a dilute acid solution, which would further remove through the practice of precise determination of mixture
heat treat scale by a pickling action. ratio and propellant loading was demonstrated (see
In order to prevent future malfunctions of this type, Fig. 59) on four flights which experienced no feed
a pickling process was developed to remove the heat system malfunctions (TV-4, TV-5, SLV-1 and
treat scale altogether. The oxidizer tank of SLV-3 was TV-4BU). In the earlier flights, propellant outage was
pickled in the field, using dilute nitric acid. An im- conservatively estimated by assuming the most adverse
proved pickling process, using a sodium hydroxide- accumulation of tolerances. As flight experience ac-
potassium permanganate solution followed by a dilute crued, it was possible to narrow the spread of expected
acid solution, was used to pickle the WIFNA, UDMH deviations and thus to make more realistic predictions.
and helium tanks of SLV-4 and following vehicles. A statistical approach to performance prediction was
Buna-N rubber--The clogging which occurred on finally developed which produced quite accurate results.
SLV-3 was attributed to Buna-N rubber particles which This probability study indicated that 68% of the ve-
hicles should have a mixture ratio variation within
lodged in the fuel injector, clogging about a third to
half of the orifices. The fuel flow rate, after rising to 1.5% of the predicted value. Most of this uncertainty
a normal level, suddenly decreased after one second was attributable to inaccuracy in determining the
to about 85% of normal and then gradually dropped original static firing mixture ratio.
off to 70% of normal. Figure 56 shows the resulting There were high propellant outages on several flights
effects of this on chamber pressure. The second stage due to malfunctions. The radical changes in flow rate
operated for 108 seconds, shutdown occurring upon and the short burning times caused by propellant feed
oxidizer exhaustion. Due to the low fuel flow rate, system clogging on SLV-2 and SLV-3 produced large

147
SPEC LIMITS-- PREDICTED _-PREDICTED
MINIMUM
TV-4 ] ,I •--n I 1 MAXIMUM
,
TV-5 'J0
_EXPECTED
I
SLV-1 'd
• 1.51 ".////////_'//]'//////////_tJ//////J 3200
SLV-2 I L
SLV-3 P I _, -- Elul,'_ol l IIInn v/////_//H/////////4///////_ 300
SLV-4 i •
I

SLV-5 f 'L,
I I j , I i':,,35c
SLV-6 1 I _//////,_/_//////////_//////i 28 O0
mm
"T'V--4BU,
t i_ll I l
'
I I I
L L I

18 22 26 30 2.4 2.6 0 40 80 120 160 200

TOTAL FLOW RATE (LB/SEC) MIXTURE RATIO UNCONSUMED PROPELLANT (LB}
I l |, I I I +
0 1 2 3 4 5 6
UNUSED PROPELLANTS (%)

OUTAGE
OTHER LOSSES

Fig. 59 Second-Stage Propellant Parameters

outages. The high outage of SLV-5 was caused by a in which no malfunctions occurred. Engine perform-
forced vortex over the entire liquid surface in the ance can be divided into two main categories: charac-
WIFNA tank, induced by the fact that the vehicle was teristic exhaust velocity (c*), which is a measure of
spinning out of control. This allowed helium to enter combustion efficiency and injector performance; and
the feed lines and initiate cutoff while considerable thrust coefficient, which is a measure of nozzle effi-
oxidizer remained in the tank. In SLV-6, abnormally ciency.
low propellant flow rates and burning time caused by
Characteristic exhaust velocity--The character-
the helium regulator failure resulted in extremely high
istic exhaust velocity on all flights which operated
outage.
reasonably close to the nominal.mixture ratio (except
The 16.7-pound UDMH outage on SLV-4, although TV-4BU) was about 0.5% low (Fig. 60). This dif-
rather low, deserves comment because this vehicle was ference is well within the accuracy of both static and
off-loaded to favor the probability of fuel exhaustion. flight instrumentation, and some variation in injector
The UDMH load was 12.5 pounds (equivalent to 12/s performance is to be expected. In some flights, the
seconds burning time) less than that required by the reduction could be partially accounted for by an in-
predicted flight mixture ratio. A high oxidizer flow crease in flight mixture ratio to a value farther from
rate in flight caused the mixture ratio to be 4% higher stoichiometric than the static firing value. However, the
than predicted. No fully satisfactory explanation was fact that the value was low by a similar amount in
found for the high WlFNA flow rate. A hypothesis each of five flights appears to be more than a coinci-
that the oxidizer filter screens were inadvertently dence.
omitted provided a good fit for the telemetered data,
One possible explanation for an apparent decrease
but field records and eyewitnesses indicated that the
in c* during flight was an increase in throat area due
screens were properly installed.
to thermal expansion. The acid in the thrust chamber
cooling jacket experienced an estimated 150°F temp-
6. ENGINE PERFORMANCE
erature rise in flight, as compared with 120°F meas-
The second-stage engine performance was somewhat ured in static firings, because the exhaust gases did
less than originally expected, even during the flights not separate from the nozzle walls in flight. Another

148
PREDICTED_ ACTUAL BURNING TIME (SEC)

TV-4
l SPECIFICATION

'i
I
MINIMUM
TV-5 I

SLV-1 II i _--4 r I 2 1. _ _I

I
I TV-5 120.5 I
SLV-2 5000
I
SLV-3 I U SLV-1 116.2 -_
"I" "r .... _i_..
LU
> SLV-4 SLV-3 108.1 } F_PREDI
/
CTED
_
SLV-5 SLV-4 ! 16.3
/

SLV-6 SLV-5 102.7 j ---i I

TV-4BU I TV-4BU 117.4 'Ill'
SPECIFICATION /',
I J I I
5800 6200 6600 7000 7400 7800 8200 400,000I 600,000I 800,000I 1,ooo,ooo
500,000 700,000 900,000
THRUST (LB) TOTAL IMPULSE {LB-SEC)

!
SPECIFICATION MINIMUM --'_

TV-4 -ORBIT

m
TV-5 I NO SECC ,ID-STAGE

) T E[ ATTITUD _ONTROL
SLV- 1 LOST SEC, ND.S AG , _ .

SLV-2 254
OXIDIZER IEEDUNE tl
.(;LOGGED [
SLV-3 221 _-CLO ;GED SECOND-STAGE FUEL
-1-
uJ

SLV-4
ORBIT t

SLV-5 LOST SECOND-STAGE

LOST • SECOND-STAGE I PRESSURIZATION
CONTROLI
SLV-6 i

TV-4 BU ,ORBJT
PREDICTED
J
260 264 268 272 4200 4400 4600 4800 5000 5200

SPECIFIC IMPULSE (SEC) CHARACTERISTIC EXHAUST VELOCITY (FPS)

Fig. 60 Second-Stage Performance Parameters

149
factor that could have contributed to higher thermal D. THIRD.STAGE PROPULSION
expansion in flight was the almost total loss of con-
]. GRAND CENTRAL ROCKET COMPANY MOTOR
vective cooling from the thrust chamber outside walls
to the ambient air. The effect of thermal expansion GCR 33-KS-2800 third-stage motors had five op-
was observed during development testing when it was portunities to fire in flight--on vehicles TV-1, TV--4,
found that an injector fired in a regeneratively cooled SLV-1, SLV-3 and SLV-4. In each of these flights,
thrust chamber had an increase in c* of 1 to 2% the motor ignited reliably and performed satisfactorily.
over that obtained with an uncooled or water-cooled A summary of the predicted and delivered perform-
thrust chamber. ance and weight values for these motors is presented
in Table 17.
The flight c* for TV-4BU was more than 2%
below the expected value (Ref. 51). System pressures Velocity increment--The horizontal drag-free
and flow rates were analyzed (in addition to trajectory velocity increment imparted to the payload by the third-
matching data) in order to verify the accuracy of this stage motor was the only performance item which could
result. Static firing records were re-examined to de- be observed with reasonable accuracy. Other perform-
termine if the predicted value of c* had been in error. ance parameters were calculated from known weights
All studies indicated that the prediction was valid and and the observed velocity increment, or were obtained
that the flight c* was really 2% low. The discrepancy from less reliable indications such as telemetry fre-
was too great to be accounted for by thermal expansion quency shifts. The delivered velocity increments were
of the throat, so various malfunctions were considered slightly below nominal values for each of these motors,
in an attempt to discover the cause. One assumption, but were greater than predicted minimums. The con-
that of a leak from the UDMH injector or injector pres- sistently high nominal predictions are believed to have
sure tap, provided a surprisingly good fit to the data. resulted from lack of information concerning the motor
Such a leak would provide the proper UDMH flow burnout weights. It appears that unburned propellant
rate to fit the near exhaustion of UDMH evidenced in slivers remained at burnout and reduced the total ve-
the shutdown transient, and would also fit the observed locity increments by 100 to 200 fps.
injector pressure, which was 11 psi lower than expected. Specific impulse--The standard formula used to
The resultant low UDMH flow rate into the combus-
evaluate solid propellant motor flight performance
tion chamber would give a high mixture ratio and low (see Ref. 54) is:
total propellant flow rate, which would account for the
I_ -- AV
apparently low c*. If no leak existed, an error must
32.17 In (MJMb)
have been made in the analysis of static or flight test
where Lp "- specific impulse, seconds
data. Instrumentation inaccuracies do not appear to be
AV--drag- and gravity-free velocity increment, fps
a sufficient explanation, because the analysis method
Mi --third-stage mass at ignition
employs several independent data sources, allowing all
Mb --third-stage mass at burnout.
parameters to be evaluated within I%.
Substitution of the best estimate of the drag- and

Thrust coefficient--The first three flights of the gravity-free velocity increment and the ground-
measured values of loaded and empty motor weights
second stage all produced appreciably lower velocity
consistently yielded a calculated flight specific impulse
increments than expected, despite almost nominal c*
one to four seconds below that predicted from statisti-
and the low propellant outages experienced (Figs. 59
cal test data (except in the case of the prototype motor
and 60). An intensified study (Ref. 53) was made of
for TV-1, Table 17B). This low calculated flight
telemetry, weight, and trajectory data in order to de-
specific impulse was directly attributed to unburned
termine the cause of low performance. The thrust
propellant slivers on the order of two to three pounds
coefficient was determined by dividing the best esti-
remaining after burnout under the vacuum condition.
mate of thrust (from trajectory match and accelerom-
These slivers could have been the energy source for the
eter data) by telemetered chamber pressure and
residual thrust discussed below.
known throat area. The investigation indicated that
the actual thrust coefficient was 1.69, about 3.5% Residual thrust_Two weeks after the launch of
lower than the analytically determined value of 1.75, the SLV---4 satellite, the third-stage motor case, which
which had been used for the design. The lower value had been separated from the payload after burnout,
was further substantiated in the flights of SLV--4 was found to have an orbit period about four minutes
and TV--4BU. Studies made by Aerojet-General of longer than that of the payload. A search of the previ-
Thor-Able flights and vacuum chamber tests at AEDC ous orbits revealed that the same phenomenon had
indicated a thrust coefficient of 1.70 ± 0.02 for this occurred on TV--4, and that the SLV-1 motor case
chamber. A thrust coefficient of 1.69 is indicative of had been reported sighted over Kansas, whereas the
an overall nozzle efficiency of about 92%. payload re-entered the atmosphere below India. The

150
existenceand significanceof residualthrust after the motor case was highest. These conditions were
normal burnout with the solid propellant Grand Central consistent with the observed relationships between the
motor was therefore well established. motor and satellite orbits described above. However,
the behavior of the GCR motors after supposed burn-
£hufJing--In the summer of 1958, several GCR
out is still not completely understood.
33-KS-2800 rocket motors were fired at simulated
altitudes of 70,000 to 80,000 feet in a vacuum facility 2. ALLEGANY BALLISTICS LABORATORY MOTOR
at the Arnold Engineering Development Center
(AEDC), Tullahoma, Tennessee. After a motor had The ABL X248 A2 third-stage motor was used on
one Vanguard vehicle, TV-4BU. The motor ignited
apparently burned out, several "chuffs" were observed.
successfully and operated normally, placing a 52.25-
Generally, five or six chuffs occurred over a period of
pound payload into orbit. In this case, the payload and
about three minutes, each lasting approximately 0.2
expended motor were not separated, resulting in a total
second and producing thrust levels as high as 250
satellite weight of approximately 95 pounds. The pre-
pounds. No indications of chuffing could be found in
dicted and delivered performance and weight values
the flight records of Vanguard vehicle TV-I, where
are summarized in Table 17.
the payload was not separated and was instrumented
to sense accelerations of this magnitude. It therefore Velocity increment--The horizontal, drag-free
appears that the near perfect vacuum conditions at the velocity increment imparted to the payload by this
third-stage operational altitude would not support the motor exceeded the predicted value. The X248 was
type of chuffing observed in the partial-vacuum tunnel designed so that portions of the rubber insulating liner
tests. were consumed during the burning phase. For pre-
Outgassing--Further studies and some tests with dicted performance calculations, it was assumed that
the propellant and motor liner materials showed that seven pounds of liner would be consumed. From the
these materials decomposed or sublimated under the flight behavior of the motor, it appears that eight
combined effects of low pressure and high temperature. pounds would be a better estimate. The conservative
Calculations indicated that sufficient material remained estimate of burnout weight is considered the reason
why the nominal predicted velocity increment was ex-
in the chamber to produce the impulse necessary to
ceeded.
explain the observed conditions, and that the major
action and impulse would occur during the first 20 Specific impulse---The flight specific impulse was
minutes after motor burnout when the temperature of calculated in the same manner as for the Grand Central

Table 17. Third-Stage Rocket Motors

A. Weights (in pounds)

INERT PARTS WEIGHT ESTIMATED PAYLOAD
WEIGHT AT EXPELLED AT LOADED SLIVER
VEHICLE IGNITION IGNITION PROPELLANTS LOSS WEIG HT (_)

TV-I_ 378.8 0 186
TV--4 48.41 0.34 381.2 0--3 4.56
SLV- 1 48.27 0.41 382.5 0-3 21.95
SLV-3 47.23 0.43 384.4 0-3 23.91
SLV-4 47.38 0.43 382.3 0-2 23.74
TV-4BU 50.21 0.61 454.6 _ 52.25

B. Performance Comparisons

EFFECTIVE
BURNING TIME SPECIFIC IMPULSE VELOCITY INCREMENT O
VEHICLE (sec) (sec) (fps)
Predicted Actual Predicted Actual Predicted Actual

Tv-I ® 33 33 240 242.2 7,375
TV-4 33 34 238 235.8 16,162 15,950
SLV-1 33 32 238 234.7 14,183 14,075
SLV-3 33 33 239.5 238.1 14,066 14,225
SLV-4 33 33 238 236.5 14,190 14,100
TV-4BU 38 37 251 251.2 14,240 14,390
6)
Includes attachment fittings
®
Prototype motor
®
No sliver loss. Estimated liner weight consumed was 8 pounds compared to 7 potmds predicted.
@
Gravity-free velocity increment.

151
! "I
16o
,
I

I
!
SATELLITE
l,j
:E .... THIRD-STAGE MOTOR
O-
80
120 I /

40/
u

SPIN
RATE

0

SPINUP

1000

----- EXPECTED ACCELERATION
EXPECTED ACCELERATION
:?"
LU
800
1 .....
(SMOOTHED]
MINITRACK ACCELERATION
(SMOOTHED)

6O0
Z
o

/
t--
.<
40O
u
u RESULTANT ACCELERATION
.<

200 i_ "_11_11

•.
ee e eBe,oo,o,
|llmge e. , _a e ,.
-, " " D"
0 °m- "" i

SEPARATION
BURNOUT
SIGNAL IGNITION

28,000
t i t
f

Q.
M.

O
.=4
24,000

20,000
/ THIRD-STAGE INERTIAL VELOCITY
IJJ
> (MINITRACK)

16,000

J
12,000
520 530 540 550 560 570 580 590 600 610 620 630

TIME {SEC)

Fig. 61 Time Histories of Velocity, Acceleration and Satellite Spin Rate During Third-Stage Powered Flight, TV-4BU.

152
motors. Flight results indicated that the effective spe- caused the swingaway arm to hang up until a tension
cific impulse was essentially nominal. force of 2300 pounds pulled the pin free. This re-
suited in binding of the quadrant II disconnects. The
Outgasslng--Observation of the first TV-4BU
,nitrogen, high and then low pressure hydraulic discon-
orbital period, compared to the periods of succeeding
nects, respectively, pulled free under a tension
orbits, indicated an increase of the period from 129.4
load of 300 pounds, about 0.35 second after the acorn
to 130.2 minutes. The additional impulse required to
pin released. The acorn fittings were redesigned for
produce this effect has been attributed to sublimation
TV-5 and later vehicles to provide positive centering of
of the liner material in the motor (outgassing), since
the geometry and amount of propellant remaining in the acorn pins; the alignment procedure was revised to
preclude lateral motions after the pins were centered.
the X248 after burnout is believed to make chuffing of
Aborted launchmretractable launch stand--The
this motor almost impossible. Studies indicated that
conditions in the motor and the materials remaining first attempt to launch a vehicle (SLV-3) from the
retractable launch stand was unsuccessful. The engine
were sufficient to provide the impulse necessary to ex-
plain the change in orbital period. The minimum im- starting sequence was normal; however, the vehicle
settled back on the stand because of a premature shut-
pulse required was 200 pound-seconds, which would
down after only about 0.35 inch of vertical motion.
result in a velocity gain of about 50 fps. An ac-
celerometer kick after payload separation on the first The vehicle "bounced" slightly when it hit the launch
Javelin research vehicle (Honest John, Nike, Nike, stand, as a result of the spring action of the stand and
X248) is taken as additional evidence of residual thrust vehicle tailcan. No structural damage resulted. Inves-
with the ABL X248 motor. Thus, residual thrust, which tigation revealed that the shutdown sequence was not
had also previously been observed on the Grand Cen- initiated by the normal cutoff system but resulted from
tral motor, seems to be a characteristic of solid pro- improper sequencing of the tail plug disconnects (see
pellant motors fired in the space environment. Chapter VIII, Section G).
Following the SLV-3 first flight attempt, three suc-
Case expansion during burning--Both longitud- cessful launches were conducted with the retractable
inal and diametrical expansion of the X248 motor
launch stand performing excellently and the arms fully
cases were observed during static firings, but were not
retracting before the vehicle had risen 10 inches.
considered to be especially significant. Anomalies in
During the SLV-6 launch, however, the retraction of
the satellite spin rate during the flight of TV-4BU
the arms was delayed about 0.4 second, and they were
created new interest in case expansion during burning.
not fully retracted until the vehicle had risen about 23
There was a decided dip in the spin rate of the satellite-
inches. Examination of motion pictures of the launch
motor combination after about 26 seconds of burning
stand indicated that the arm releasing mechanism
(Fig, 61). This dip in spin rate (and partial recovery
worked properly, but the spring-loaded valve which
after burnout) was taken as a strong indication of controls motion of the arms hesitated for 0.4 second
motor case expansion, which would increase the roll
about one-third of the way through its 90-degree
moment of inertia. The presence of a discontinuity at travel. Excessive clearance between the disc and the
about the same time as portions of the propellant burn-
housing of the four-way hydraulic valve allowed the
line reached the case liner had not previously been disc to wobble and score during repeated operations.
established, since time histories of case deflection dur-
The scoring apparently caused sufficient binding to
ing burning had never been made. This expansion overcome the spring force and to cause the observed
could become significant if very precise flight path or
delay. This was in no way detrimental to the flight,
spin rate control were required. However, it was not a since the lateral vehicle motions were so small that the
problem on TV-4BU, as evidenced by the satellite in- engine would have cleared even if the arms had not
jection angle of less than 0.1 degree from the hori- retracted. The valve was replaced and a spacer was
zontal. added to decrease the clearance between the disc and
the housing, reducing the possibility of scoring the disc.
E. SEPARATION The valve actuating spring was also replaced with a
stronger spring as an added precautionary measure.
1. LAUNCH

The launch motions were about as expected for the 2. FIRST-STAGE SEPARATION
measured winds and thrust misalignments. Small dif- There were nine first- from second-stage separation
ferences observed were attributed to gusts, unexpected sequences. Eight of these separations were successful,
disconnect forces and momentary thrust misalignments. even though some minor malfunctions did occur. A
Acorn pin bindmfixed htunch stand--During malfunction during the SLV-5 sequence was the direct
the TV-4 launch, a binding of the quadrant II acorn cause of that mission failure. A representative (TV-
pin sufficient to overpower the separation spring force 4BU) first- and second-stage thrust variation during

153
first-stage
separation
is shownin Fig. 62. First-stage caused solely by engine thrust misalignments and maxi-
thrustdecaywasnormalfor all flights.Initial second- mum roll excursions only slightly greater than the
stagethrustbuildupsarebelievedto havebeennormal deadspot setting of ± 3.0 degrees.
despitesomecontrarytelemetered data (seeChapter
3. NOSE CONE JETTISON
VIII, Section
C) frompressuretransducers.
The nose cone, which protected the satellite during
Delayed separation--The time delay between the
flight through the atmosphere, was separated from the
TPS separation signal and unplugging of the interstage
second stage at 172 seconds after liftoff. Completely
electrical disconnects was 0.18 second, or about three
successful separation was recorded by two sources of
times longer than expected for TV-4, and 0.3 second,
data on all eight vehicles on which separation was
or about five times longer than expected for SLV-5.
initiated. The telemetry system transmitted the initiat-
The telemetered interstage compartment pressure and
ing signal and also a microswitch signal when the nose
propulsion system parameters indicated that separation
cone halves had parted. The Minitrack signal strength
forces of about 15,000 pounds existed. The delay was
not understood since extensive efforts to isolate mal- and frequency also reacted to the absence of the shield-
ing effect of the nose cone and the unfolding of the
functions in the explosive bolts or their circuitry were
satellite antenna.
frtaitless (Chapter VIII, Sections F and G). However,
The second-stage pitch and yaw attitudes were
SLV-6 and TV-4BU, wherein the only change was to
unchanged by the separation of the nose cone, reflect-
give the separation signal earlier, or before a dynamic
ing the symmetry of the separation sequence. However,
environment had built up, separated promptly.
during the SLV-3 separation sequence, a small counter-
Dynamic environment--All vehicles through clockwise roll disturbance about 0.4 second after the
SLV-5 had the second-stage engine exhausting into an separation signal was attributed to a slight binding in
appreciable back pressure, created by the confines of one nose cone hi/age. Normally, the hinge disengaged
the interstage compartment prior to stage separation 0.7 second after the separation sequence was initiated.
(see Chapter IV, Section E). There were numerous Roll control was in no way compromised by this
instances of random thrust vector motion during thrust anomaly.
buildup, due to separation in the vacuum exhaust nozzle
4. THIRD-STAGE SEPARATION
(Ref. 43). The random thrust vector applied moments
on the engine large enough to overcome the servo sys- The Vanguard third-stage separation sequence was
tem and move the engine as much as two degrees on initiated four times by the airborne firing system and
TV-4, against the stop in SI_V-3, and hard enough once by the ground-based system during the Vanguard
against the stop in SLV-5 to fail the pitch actuator lag program. All resulted in satisfactory separations. The
(Ref. 49). The primary separation sequence was third stages were successfully spun up to at least 178
changed for SLV-6 and up, to be given earlier by TVSI rpm. Total impulse of the spin rockets was within the
(oxidizer valve 27% open) in an attempt to reduce specified limits.
the period over which nozzle flow separation might Second.stage spinup--Exhaust gases from the
occur. Precautions were also taken to ensure against third-stage spin rockets impinged on the second-stage
excessive and nonuniform accumulation of adhesive
compartment walls and caused a rolling moment greater
used on the nozzle closure, and a check valve (see than the correcting roll jet moment. This introduced
Chapter VIII, Section I) was installed in the hydraulic a second-stage roll rate on the order of 10 rpm during
system to decrease the rate at which an overpowering third-stage separation. No attempt was made to retard
force would move the engine. this roll rate on any vehicles because analysis revealed
Roll transient--SLV--6--The new early separa- that this spin rate actually increased clearance by more
tion system (see Chapter IV, Section E) used for or less averaging out transient disturbances.
SLV-6 removed the adverse dynamic environment, but TV--4 premature separation and recontact--
was accompanied by rather large pitch, yaw and roll Third-stage spinup for TV-4 was accomplished satis-
motions; in fact, the rolling motion came near the gyro factorily and all hardware performed normally. How-
limit. These motions were probably caused by hinging ever, premature physical separation of the third stage
about the electrical disconnects and tipping due to from the spin table occurred, probably because of one
unequal separation forces. The roll motion was or a combination of: vibrations from the spin rockets;
exaggerated by a deficiency of about 40% in second- pressure buildup underneath the motor by exhaust
stage roll jet thrust (see Chapter VIII, Section A). gases from the spin rockets; and the relatively large
Ensuring a nominal roll jet thrust and placing three attitude error rates. The separation delay time was
guide pins between the first and second stages to pre- therefore changed from 3.3 seconds to 1.5 seconds
vent hinging about the electrical disconnects resulted in after spin rocket ignition, which prevented recurrence
a TV-4BU separation sequence with engine motions of this premature separation.

154
32,000

FIRST-STAGE
CUTOFF,
28,000
SECOND-STAGE
IGNITION SIGNAL
SEPARATION

1'
24,000 SIGNAL (TVSJ

20,000
DISCONNECTS

i,--
16,000 FIRST-STAGE_ QUADRANTS INDICATIONS
e_
-1- THRUST _ I AND IV

12,000

THRUST
_ SECOND-STAGE
8,000

4,000

0
144.0 148.0
144.4 144.8. 145.2 145.6 146.0 146.4 146.8 147.2 147,6
TIME {SEC)
F_. 62 Representative (TV-4BU) First and Second-Stage Thrust During First-Stage Separation

When the TV-4 pitch/yaw control system wasturned tipoff rate of the TV-4BU second stage during retro-
off at third-stage spinup, the stuck-open pitch-down rocket burning (Ref. 51) was believed to have been
tumble jet continued thrusting (see Chapter VIII, Sec- caused by unbalanced retrorocket forces. The increase
tion A). As the third stage spun up, the second stage in rate could have been caused by a nominal difference
between retrorockets. This increase was not detrimen-
was also spun (see above). The second stage had
rotated more than half a revolution and had developed tal to the point of causing collision between stages.
a wobble of better than one degree because of the con- Following the SLV-I launch, one retrorocket shield
was found near the launch site. No adverse effects were
tinued jet thrusting and the reversal in attitude errors.
The third-stage nozzle base hit the second stage just noted, as both rockets ignited properly.

as it was separating, apparently because the premature 5. SATELLITE SEPARATION
separation (see above) sufficiently lengthened the time Every satellite except that of TV-4BU was separated
that the third stage was free inside the second to allow
from the burned out third-stage motor to avoid signal
the second-stage wobble to cause collision. The colli-
interference, to limit the satellite spin rate and/or to
sion was not serious since the TV-4 satellite was
orbit a symmetrical body. A spring-loaded device to
injected with an angular error of approximately 0.8 be actuated after third-stage burnout was supplied with
degree. the satellites to provide a relative velocity of about
SLV-4 control cutoff--On SLV-4, pitch jet three fps between the payload and rocket.
actuations (one up and one down) were recorded TV-4--The satellite of TV-4 was connected to the
between 0.10 and 0.15 second after retrorocket igni-
third stage by a high friction bearing. The satellite and
tion, when the control system was normally de-ener- rocket motor were Spinning with no relative rotation
gized. This malfunction was attributed to one set of between them from four seconds after spinup to satellite
contacts on the 1.5-second delay relay closing about
separation, 75 seconds later. A slight increase in spin
0.20 second after the other set. This time difference
rate during third-stage burning was probably caused by
was within specification and did not affect the stabiliza- transfer of the angular momentum of the burning
tion during separation. gases as they moved from the burn line inward toward
Retrorocket perJormance--An increase in the
155
the centerthroughthe propellantslots.(The nozzle suspicion. SLV-5 experienced a mysterious delay in
throat diameterwas considerably smallerthan the actual separation of the first stage, and unusually
average diameterof the propellantburnline.) There severe flow separation occurred in the second-stage
wasa sharpdecrease in spinrateafterseparation
from nozzle just after ignition (see Chapter VIII, Section C).
thethird-stage motor,whichhassincebeenattributed The behavior of the vehicle could be explained very
to the tie-downstrap attachingthe satelliteto the conveniently by assuming that actuation of the explo-
third-stagemotor. This strap,whenreleased, would sive bolt detonators was delayed for about 250 milli-
tend to straighten.The changein its momentof seconds and that the blast doors failed to open, causing
inertiawouldcausethe strapto rotateat a decreased excessive back pressure in the interstage compartment.
rateandthustanglein the satelliteantenna,resulting Consideration was given to the possibilities that the
in the satellitelosingrotationalenergy. separation delay might have been due to overaged
SLV--4--A tumble rate of approximately 15 rpm detonators, resulting either in a weak detonation or a
about an axis slightly off the equatorial plane was delay in detonator actuation, and that the blast doors
superimposed during separation on the existing pay- may have failed to open due to weak latchpin squibs
load spin rate of less than one rpm about the spin or or LOX tank ice sealing the doors.
polar axis. This tumbling was attributed to a disturb- Nearly half of all the E-77 detonators used for first-
ing moment resulting from the binding of the separating stage separation were removed from Vanguard stores
spring on a sharp ledge. The disturbing moment was at Cape Canaveral and returned to Martin-Baltimore
particularly damaging because of the unexpectedly low for test purposes. These detonators included those of
satellite spin rate which resulted when a despin device the lot from which the SLV-5 detonators had been
operated more effectively at altitude than ground cali- taken. Four explosive bolts were sheared, using only
brations had indicated. A thin metal sleeve was placed one detonator in each bolt, and leaving the opposite
in the separation device for SLV-5 and SLV-6 to pre- bolt cavity empty and not capped. Two annealed
vent binding, and the separation spring was restrained explosive bolts were sheared with these detonators.
to the third stage. A flight shift was also applied to the Times to detonation were measured for six of the
ground calibration tests of the despin device, based detonators wired in parallcl in a mockup of the
on the measured performance during SLV-3 and SLV- vehicle firing circuit. This test was repeated twice.
4 flights. Finally, a bolt was sheared with only one detonator
installed and a detonator alone was fired while both
Post.separation spin drag--The SLV-4 satellite
were subjected to a vacuum of about 5X 10 4 milli-
tumble rate had decayed from 15 rpm to slightly more
than 11 rpm in about two weeks of observation. The meters of mercury. The detonators operated normally
in all tests.
spin rate about the spin axis also decayed from some-
what less than one rpm to about 0.5 rpm. A similar Blast door latchpins and squibs were similarly
decay was also noted on the TV--4 satellite. These de- returned for tests. Tests included firing squibs alone
cays are considered normal and are attributed to the under adverse conditions, and operating a mockup of
energy dissipated by eddy currents generated in the the blast door installation with a thick coating of ice
metallic satellite that is spinning in the earth's magnetic around the doors. All squibs and latchpins operated
field. normally, and the blast doors opened.
Based on the test results, it was concluded that the
Time o] payload separation--The TV-4 and
SLV-I payloads were separated from the third stage E-77 detonators and latchpin squibs were not likely to
have malfunctioned on SLV-5, and that those remain-
approximately 27 seconds after burnout. Residual
thrust, noted in AEDC wind tunnel tests, raised the ing in Vanguard storage at AFMTC were acceptable
possibility of an expended motor being accelerated into for the succeeding flights. Subsequent flight data indi-
collision with the satellite after separation. Satellite cated that these detonators and squibs operated
separation was delayed for approximately five minutes normally. The separation delay on SLV-5 has never
been satisfactorily explained.
in the SLV-3 through SLV-6 vehicles, but (see Chap-
ter VIII, Section D) even this did not remove the con- Prior to flight, two first-stage igniters failed during
the entire program. In one instance, the failure was
cern over possible collision from residual thrusting.
caused by improper installation. In the second case,
Accordingly, the TV--4BU burned-out third stage was
left attached to the payload since the fiberglas case did actual failure of the igniter occurred, apparently
not adversely affect the experiments. because of low order burning of the igniter charge.

F. ORDNANCE G. ELECTRICAL
No failure of any ordnance component is known to A summary of electrical system functions and volt-
have occurred on any Vanguard flight. There was, ages measured during the Vanguard flight program is
however, just one instance where ordnance was under given in Table 18.

156
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Arming and battery paralleling--Battery parallel- because the K2 relay did not latch in after being
ing, first-stage cutoff arming, and second-stage arming energized by the chattering thrust pressure switch
in vehicles through SLV-4 were accomplished by a (TPS) (Ref. 44). This was due either to a design
relay in the program timer at approximately 120 deficiency in the relay sequencing (K1-K2) or to an
seconds after liftoff. For SLV-5 and SLV-6