RELLCOMM

,
L

INC.
-.

DATE:
FROM:

SUBJECT: D e e c r i p t i o n

Structures

-

of S-11 Stage Case 320

April 20,

1967

T. H. Crowe

ABSTRACT

T h i s memorandum provides a d e s c r i p t i o n of t h e S - I 1 s t a g e s t r u c t u r e i n s u f f i c i e n t d e t a i l t o enaple the reader t o a s s e s s t h e irnpzct of major pr3biems and changes t o t h e s i r u c ture.

(NASA-CR-154767) DESCRIPTION OF 5-2 S T R G E STRUCTURES (Eellcomm, I n c - ) 17 p
00/15

~79-72173
Unclas
12561

Available to NASA Offices and Research Centers Only.

SUBJECT:

D e s c r i p t i o n of 3-11 Stage S t r u c t u r e s - Case 320

DATE:
FROM:

A p r i l 2 0 , 1967 T. H. Crowe

MEMORANDUM FOR FILE

In - troduction The purpose of t h i s memorandum i s t o provide a d e s c r i p t i o n of t h e S - I 1 s t a g e s t r u c t u r e i n s u f f i c i e n t d e t a i l t o enab1.e t h e r e a d e r t o a s s e s s t h e impact o f major; prc7blema and changes t o t h e s t r u c t u r e . F i g u r e 1 i s a n exploded view showing t h e p r i n c i p a l O components of t h e s t r u c t u r e : t h e forward s k i r t , LE2 tank, L X tank, t h r u s t s t r u c t u r e and a f t s k i r t , and t h e a f t i n t e r s t a g e . An exploded view showing some of t h e d e t a i l s of' c o n s t r u c t i o n of t h e S-11 s t a g e a r e shown on F i g u r e 2. The dry weight of t h e S-11-1 s t a g e i s approximately 90,000 pounds and t h e dry weight of t h e a f t i n t e r s t a g e i s 14,000 pounds. Aft I n t e r s t a g g The a f t i n t e r s t a g e i s a c y l i n d e r 219 i n c h e s long of 7075 aluminum. I t i s of semi-monocoque c o n s t r u c t i o n w i t h e x t e r n a l h a t s e c t i o n s t r i n g e r s r i v e t e d t o t h e s k i n . The s k i n and s t r i n g e r s a r e supported by i n t e r n a l r i n g s . The aft r i n g has p r o v i s i o n f o r t h e f i e l d s p l i c e f o r mating w i t h t h e S - I C s t a g e . The f'orward r i ~ g t n e mating Sace f'sr a t t a c h i.s ment t o t h e S - I 1 a f t s k i r t . The a f t i n t e r s t a g e has two separat i o n p l a n e s , one 23 i n c h e s forward of t h e a f t r i n g and t h e o t h e r a t t h e forward r i n g . A door p r o v i d e s a c c e s s t o t h e i n t e r i o r and c u t o u t s i n t h e s t r u c t u r e provide f o r u m b i l i c a l connections. Eight mounting b r a c k e t s a r e prsvided f o r a t t a c h ment of u l l a g e r o c k e t s . Figure 3 d e p i c t s the a f t i n t e r s t a g e under c o n s t r u c tion. Aft S k i r t and Thrust S t r u c t u r e The a f t s k i r t and t h r u s t s t r u c t u r e a r e i n s t a l l e d on t h e S - I 1 a s a n i n t e g r a l asserr~bly. The a f t s k i r t i s a c y l i n d e r 87 i n c h e s long. I t i s of semi-monocoque c o n s t r u c t i o n w i t h e x t e r n a l h a t s e c t i o n s t r i n g e r s r i v e t e d t o . t h e s k i n . The s k i n and s t r i n g e r s a r e
Available. t o NASA Offices and Ficsearch Centers Only.

supported by i n t e r n a l r i n g s . The s k i r t i s a t t a c h e d t o t h e b o l t i n g r i n g a t t h e forward end and t o t h e a f t i n t e r s t a g e a t t h e a f t end. F i v e LH2 l i n e s a r e routed from t h e bottom of t h e LH2 t a n k down t h e e x t e r i o r of t h e s k i r t , through t h e s k i r t and down t h e t h r u s t s t r u c t u r e t o t h e engines. The LOX f i l l and d r a i n l i n e i s a l s o routed through t h e s k i r t and thrust structure. The t h r u s t s t r u c t u r e i s a c o n i c a l frustum w i t h a forward diameter of 396 inches, a n a f t diameter of 210 i n c h e s 1 and a l e n g t h of 1 1 i n c h e s . The frustum i s a t t a c h e d t o t h e i n t e r i o r of t h e a f t s k i r t 61 i n c h e s a f t o f . b o l t i n g r i n g i n t e r f a c e with t h e s k i r t . The frustum i s made up o f e x t e r n a l hai; s e c t i o n s t r i n g e r s r i v e t e d t o t h e s k i n . The s k i n and s t r i n g e r s a r e supported by i n t e r n a l r i n g s . The f o u r outboard engines a r e mounted on t h e a f t r i n g . A t each engine a t t a c h p o i n t a r e two longerons t o a s s i s t i n shearing t h e engine loads i n t o t h e t h r u s t s t r u c t u r e . The c e n t e r engine i s mounted on a c e n t e r e n g i n e support assembly c o n s i s t i n g of f o u r honeycomb sandwich t y p e beams joined a t t h e s t a g e c e n t e r l i n e by a machined f i t t i n g . The outboard ends a r e a t t a c h e d t o t h e t h r u s t s t r u c t u r e cone. The LH2 feed l i n e s a r e a t t a c h e d t o t h e e x t e r i o r of t h e cone a s a r e v a r i o u s components of t h e e l e c t r i c a l , measurement, c o n t r o l and o t h e r s t a g e subsystems. F i g u r e 4 i s a p i c t u r e of t h e assembly during manufacture. Heat S h i e l d The h e a t s h i e l d I s designed t o p r o t e c t t h e s t a g e b a s e a r e a from h e a t i n g due t o r e c i r c u l a t i o n of engine exhaust g a s e s . It i s of f i b e r g l a s s honeycomb c o n s t r u c t i o n p r o t e c t e d by a n a b l a t i v e c o a t i n g . I t i s a c i r c u l a r p l a t e 210 i n c h e s i n diameter w i t h c u t o u t s f o r each engine. F l e x i b l e s i l i c a c l o t h c u r t a i n s a r e a t t a c h e d between t h e c u t o u t s and t h e engines. I t i s l o c a t e d 54 i n c h e s a f t of t h e engine gimbal plane and i s suspended from t h e t h r u s t s t r u c t u r e . F i g u r e 5 i s a s k e t c h of the heat shield. L X Tank O The L X tank. i s a n e l l i p s o i d a l c o n t a i n e r of 2014 O aluminum formed by j o i n i n g an a f t and a forward bulkhead by a c i r c u m f e r e n t i a l weld. I t s volume i s 11,108 cu. f t . The forward bulkhead i s known a s t h e common bulkhead because i t i s common

t o t h e L $ and LOX t a n k s . The j o i n t i n c o r p o r a t e s a r i n g f o r F a t t a c h i n g t h e t a n k t o t h e LH2 t a n k b o l t i n g r i n g . The a f t bulkhead of t h e t a n k i s made up of 12 g o r e s and a c e n t e r c i r c u l a r s e c t i o n welded t o g e t h e r . Attached t o t h e c e n t e r of t h e a f t bulkhead Is a sump. The sump h a s i n i t f i v e L X o u t l e t l i n e s , one f i l l and d r a i n l i n e and a n a c c e s s O manhole. F i g u r e 6 d e p i c t s an a f t bulkhead being assembled. The forward o r cornnion bulkhead i s of honeycomb sandwich c o n s t r u c t i o n w i t h i n s u l a t i o n sandwiched between p l a t e s of aluminum. The two p l a t e s a r e each made up of 12 g o r e s and a c e n t e r c l r c u l a r s e c t i o n welded t o g e t h e r . P r o v i s i o n i s made I n t h e bulkhead f o r purging and a l.eak d e t e c t i o n system. I n t h e bottom of t h e t a n k i s a cruciform a n t i - v o r t e x baffle. Three s l a s h b a f f l e r i n g s a r e s u p p m t e d by s t r u t s i n t h e s t a n k . A mast n e a r t h e c e n t e r of t h e t z n ~ u p p o r t s a p r e s s u r i z a t i o n d i s t r i b u t o r and t h e LOX vent l i n e s . Cutouts a r e provided f o r t h e p r e s s u r i z a t i o n g a s i n l e t , and t h e vent l i n e o u t l e t .
LH,C Tank

The LH:, t a n k i s made up of s i x c y l i n d r l c a l s e c t i o n s , a n e l l i p s o i d z l forward b u l k and t h e csmmon-bulkhesd. The volume of t h e LH2 tank i s 36,553 cu. f t . The forward bulkhead and t h e t h e c y l i n d r i c a l s e c t i o n s a r e o f 2014 aluminum covered w i t h external insulation. The c y l i n d r i c a l sectdon.s a r e made up of q u a r a t e r p a n e l s welded t o g e t h e r . The q u a r t e r p a n e l s have i n t e g r a l l o n g i t u d i n a l and c i r c u m f e r ~ e n t i a ls t i f f e n e r s . Riveted t o t h e c i r c u m f e r e n t i a l s t i f f e n e r s a r e 7 i n c h w i d e r i n g s of 2024 aluminum f o r a d d i t i o n a l s u p p o r t . F i g u r e 7 d e p i c t s a q u a r t e r p a n e l d u r i n g f o r n i n g and F i g u r e 8 a completed c y l i n d r i c a l s e c t i o n . The a f t c y l i . n d r i c a 1 s e c t i s n h a s e x t e r n a l t a p e r e d l o n g i t u d i n a l s t i f f e n e r s 25 i n c h e s long t o a s s i s t i n t r a n s f e r r i n g l o a d s from t h e b o l t i n g r i n g t o and which i t i s f a s t e n e d . The b o l t i n g r i n g i s 15 i n c h e s l ~ n g h a s p r o v i s i s n f o r attachment o f t h e LOX tank, t h e a f t s k i r t and t h e LH2 c y l i n d e r . The forward c y l i n d r i c a l s e c t i o n h a s a boss a t t h e fopward end t o which Is b s l t e d t h e forward s k i r t . The forward bulkhead i s welded t o t h l s s e c t i o n .

.

.

The f o r w a r d bulkhead i s c o n s t r u c t e d o f 12 welded g o r e s and a c i r c u l a r s e c t i o n welded a t t h e c e n t e r . Access t o t h e t a n k i s t h r o u g h a manhole i n t h e c e n t e r o f t h e f o r w a r d b u l k h e a d . One f i t t i n g f o r p r e s s u r i z a t i o n and two f o r v e n t i n g a r e p r o v i d e d i n t h e f o r w a r d bulkhead. F i v e f i t t i n g s f o r LEI2 e n g i n e l i n e s , one f o r Lt12 r e c i r c u l a t i o n r e t u r n l i n e , and one f o r f i l l and d r a i n a r e p r o v i d e d i n t h e c y l i n d r i c a l s e c t i o n J u s t f o r w a r d of t h e b o l t i n g r i n g . I n s t a l l e d i n t h e i n t e r i o r of t h e tank i s t h e continuous l e v e l p r o b e and a p r e s s u r i z a t i o n g a s d i f f u s e r .
insulation on t h e c y l i n d r i c a l s e c t i o n and t h e f o r w a r d bulkhead i s e x t e r n a l t o t h e t a n k . I t c o n s l s t s of g l a s s - p h e n o l i c honeycomb c o r e f i l . l e d w i t h isocyana.te foam covered wi-th a Provision n y l o n p h e n o l i c s k i n and s e a l e d w i t h a p l a s t i c f i l m . i s made i n t h e i n s u l a t i o n f o r p u r g i n g and a l e a k d e t e c t i o n s y s tem. I n s u l a t i o n o n t h e b o l t i n g r i n g i s machined b l o c k s ~f p l a s t i c .

Forward S k i r t The f o r w a r d s k i r t i s made o f 7075 aluminuin s k i n w i t h e x t e r n a l l o n g i t u d i n a l h a t s e c t i o n s t r i n g e r s . The s k i n a n d s t r i n g e r s a r e s u p p o r t e d by f o u r i n t e r n a l r i n g s . The s k i r t i s 137 i n c h e s l o n g . The a f t end b o l t s t o t h e c y l i n d r i c a l p o r t i o n of t h e LH2 t a n k and t h e forward end h a s p r o v i s i o n f o r t h e f i e l d s p l i c e t o t h e S-IVB i n t e r s t a g e .
A d o o r i s p r o v i d e d f o r a c c e s s and c u t o u t s a r e p r ~ v i d e d n * b i l T c 2 1 ;ls++L.L - * J . - - --.u c v 1 . n l l ~ ~ t l ~ ~ ~ a r e mounted o n t h e e x t e r i o r of t h e s k i r t and v a r i o u s subsystem components g n t h e 5 n t e r . i o r . F i g u r e 9 shows a n assembled f o r w a r d s k i r t and some q u a r t e r p a n e l s b e i n g f a b r i c a t e d .
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System Tunnel The s y s t e m s t u n n e l i s l o c a t e d e x t e r n a l l y and r u n s from t h e a f t s k i r t t o t h e f o r w a r d s k i r t . c o n t a i n s c a b l e , p i p i n g , e t c . I t i s c o n s t r u c t e d of s e c t i o n s i n t e r c o n n e c t e d by s u p p o r t s f o r t h e c a b l e s The i n n e r s u r f a c e o f t h e t u n n e l i s i n s u l a . t e d . t o the stage
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fiberglass and t u b i n g .

u'T. H. Crowe
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Figures 1 thru 9 Copy t o ( s e e next page)

Copy t o Messrs. J . G. L. J.

H. F. K. P. T. A. R. C . W. B.
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D i s h e r - NASA/MLD Esenwein, J r . - NASA/MAT F e r o - NASA/IJILV F i e l d - NASA/MLP Keegan NASA/JW-2 Mapp, S r . - NASA/MAP T a y l o r - NASA/MLA

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T. Ackerman Bidgood R , Hagner C. H i t t i n g e r . B. T . Hwarc! J . Z . Menard I D. Nehama J. J . O I C o n n ~ r T. L. P ~ w e r s I . M. Ross W. S t r a c k T. H. Thompson R. L. Wagner A l l Members D e ~ a r t m e n t 1024 Central F i l e s Department 102, Libra r y t.

REE'ERENCES

1. 2.

Model S p e c i f i c a t i o n f o r S a t u r n S - I 1 S t a g e , NAA SID 61-51., 7/2 7/6 3. Model S p e c i f i c a t i o n J - 2 Rocket Engine, Rocketdyne, 7/20/60. S a t u r n S - I 1 General Manual, NAA SM-S-11-01, S - I 1 Von Braun B r i e f i n g , NAA S ~ 6 4 - 2 4 , 2/64. S a t u r n S - I 1 Q u a r t e r l y Reviews 1 t h r o u g h S a t u r n V PUP, MSFC,

3.

10/1/64.

4.
5.
6.

4, NAA, 1963 t o 1967.

8/65.

7.

S a t u r n ?-I1 Systems and A s s o c i a t e d GSE F a m i l i a r i z a t i o n , NAA ST66-18, 12/66.

FORWARD SKIRT 4 SECTIONS

I

COMMON BULKHEAD

,

FORWARD BULKHEAD 12 GORE SEGMENTS & ACCESS

COMMON BULK

I

4 SECTIONS THRUST STRUCTURE 4 SECTIONS

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SECTIONS EACH FABR ICATED IN'QUARTER SECT1 ONS 99" H I G H WITH MILLED SKINS, STRINGERS, & RING FRAMES lNTERNAL 27" H I G H 1 LH2 CYL
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AFT LOX BULKH 12 GORE SEGMENT & 12 WAFFLE SECTIONS BOLTING R I N G 12 SEGMENTS

5 J-2 ENGINES

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AFT' lNTERSTAGE 18.5' H l G H 8 SECTIONS
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CYILINDER 1

STRl NGERS 12 SECTIONS

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FIGURE 2

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FIGURE 3

- AFT INTERSTAGE

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FIGURE 9

- FORWARD SKIRT