Payload Vibration Test Results

In order to ensure that the samples survive the expected launch loads, we must ensure that the samples do not move relative to the sample plate. However, we cannot use adhesives, which could affect the sample material properties. Instead, we are using disc springs to prevent relative movement between the samples and sample plate. Since the samples are brittle and of variable thicknesses we will use aluminum support disks underneath the samples to concentrate the compressive load along the edge of each sample, preventing shear stresses in the samples. Using this method, the samples should only be held in compression between the support disk and sample plate lid along their edges.

Therefore, to ensure that the samples do not fail or create debris, we have conducted two rounds of random vibration testing on candidate samples in phase B and plan to do at minimum one more round in phase C. These tests use an engineering model of the sample plate and are conducted at Magellan Aerospace.

Phase B

1st Vibration Test Results

Introduction:

Test Description: The following test shall subject an engineering model (EM) of the Iris (ManitobaSat-1) payload sample plate assembly to the mission’s expected random vibration profile. This test will be used to validate the clamping mechanism used to hold payload samples in place and quantify how much (if any) debris is emitted by the samples during vibrations.

Completed: 7 Sep. 2019

Conducted and documented by: Matt

Resources Required:

Tools: Torque screwdriver, camera, pens and paper for test notes, flashlight, sample storage container(s), cleanroom approved storage box
Hardware and Equipment: Front and rear supports, vibration interface plate, fasteners, vibration table control computer, Kapton tape, super glue, vibration table, accelerometers, the sample plate
PPE: Hearing protection, CSA approved steel-toed shoes, CSA approved safety glasses, cleanroom attire

Verification Activities:

Pass Criteria:

The sample plate EM will pass this test if:

The plate assembly and components have not visibly plastically deformed and the samples have not fractured after random vibration testing in all three axes for both soft and hard mount vibration profiles.
There is no debris created by the samples after random vibration testing in all three axes for both soft and hard mount vibration profiles.
The test input levels match the given test profiles to within +/- 1.5 dB.
The resonance search (sine sweek) shows a major mode frequency shift no greater than +/-5%, and +/-30% for major mode amplitudes.

Test Result Summary:

Random vibration tests were performed on an engineering model of the Iris (ManitobaSat-1) sample plate assembly. These tests were performed to both hard mount and soft stow vibration profiles for all three axes.

After testing, no FOD was observed within the FOD containment box (FCB) but after the assembly was disassembled some materials were found within the sample mounting areas. Most of this material came from a single sample of anthracite coal. Anthracite coal did not survive due to its chemical composition.

A few sub-millimetre metallic flakes were found within the compression discs of several samples but these flakes were in a sealed area and it is unlikely that they could become liberated from the assembly during or after launch.

results

Table 1: Tested Samples

2. Sample Plate Assembly Preparation:

The test article was prepared with eleven EM payload samples, as listed in the table below. The twelfth sample supplied by our science PI, saponite, was not included in this test due to an error in the sample’s compression disc design.

The samples were placed within their assigned wells, as noted in Figure 1, with a 0.4 lb wave disc spring and compression disc below each sample. The sample plate lid was then installed and all fasteners were tightened to their pre-assigned torque values (5 in-lb for all 2-56 fasteners and 10.6 in-lb for 4-40 fasteners).

3. Test Article Installation:

At Magellan Aerospace on August 28th, the interface plate was installed onto the vibration table in accordance to our test procedures. The plate was installed in the Y-Axis orientation. As recommended by our Magellan contact, the ½-13 fasteners holding the plate down were fastened to 600 in-lb.

The next day (August 29^th), the sample plate assembly and FCB were installed onto the interface plate in accordance to our test procedures. Prior to testing, the FCB was wiped down with isopropyl alcohol and what we had thought were dust-free kimwipes; however, after testing was completed we discovered that we had used a non-dust-free wipe. The assembly and FCB were inspected for FOD under UV light and no FOD was found.

Figure 1: Sample Layout

4. Soft-Stow Testing:

We began testing the soft-stow vibration profile with the Y-axis. No instrumentation was performed for this test, aside from the control accelerometer, and we did not perform sin sweeps before or after the random vibration profile. After the test was completed, we opened the lid of the FCB and inspected the test article for FOD using a UV light source. No FOD was observed and the lid was re-installed.

After the Y-Axis soft-stow test was complete, we proceeded to the X-axis test. The interface plate was unfastened from the vibration table and rotated 90 degrees and then refastened. The control accelerometer was re-installed and the random vibration test was performed. After the test was complete, the article was again inspected under UV light and no FOD was found. Afterwards, the FCB lid was re-installed.

After the X and Y axis tests were complete, the interface plate was removed and the vibration table was re-configured for Z-axis testing. After the table was rotated, the interface plate was re-installed. At this point, we realized that there was no access port in the FCB for passing accelerometer wires through and so the lid was removed and the technician drilled a ½” hole into the lid. The lid was cleaned, and we proceeded to instrument the test article as seen in the figure below.

Note that the accelerometer installed at the gnomon mounting point was originally intended to be mounted to an aluminum sample stand-in. This stand-in was not manufactured, and so we decided to place the accelerometer near the centre of the plate, where the most deflection was expected.

The Z axis test was performed, with sin sweeps before and after the soft-stow random vibration profile. Sin sweeps were performed at 1 g from 20 to 2000 Hz at 4 octaves per minute. After the post-random vibration sin sweep was completed, the lid was removed and the test article was inspected under UV light, with no FOD detected.

5. Hard Mount Testing:

The test article was kept in its Z-axis test configuration and the FCB lid was reinstalled. The Z mount hard-stow random vibration test was then performed, again with sin sweeps before and afterwards. These sin sweeps were performed to the same 1 g intensity, 20 to 2000 Hz frequency range, and same 4 octave per minute frequency rate. After the post random vibration sin sweep, the FCB lid was removed and the assembly was inspected under UV light with no FOD being detected.

After Z-axis testing was completed, the interface plate was removed and the table was re-configured for X and Y axes testing. The accelerometers were removed from the test article and the article was again inspected for any FOD that may have been created when the instrumentation was removed. No FOD was detected under UV or standard lighting.

We proceeded to do Y-axis hard mount testing, without sin sweeps. After the test was complete, the test article was inspected under UV and standard lighting with no FOD detected.

Finally, we performed our X-axis hard mount test. This test had to be aborted two times due to accelerometer over-voltage readings by the vibration table control computer. We observed that there was insufficient strain relief on the control accelerometer and so added more strain relief and waited approximately 15 minutes before re-testing. After this, the test proceeded as intended and no FOD was found during post-test inspection.

6. Post Test Inspection:

After all vibration testing was complete, the test article, FCB, and interface plate were moved to an inspection table. The FCB/test article assembly was removed from the interface plate while carefully looking for any debris that could fall out from the mounting holes. No debris was found and the FCB/test article assembly was placed on a previously cleaned anti-static mat.

The assembly was again visually inspected and we found some long white fibres on the side wall of the FCB. At this point, our technician informed us that we had used a non-dust-free wipe and this is the likely source of the contamination. No materials in the sample plate or FCB had white fibres and so it is highly unlikely that this debris was liberated from our test article.

Next, the test article was removed from the FCB and placed separately on the mat. Afterwards, the bottom of the FCB was inspected and no FOD was observed. Finally, the FCB was wiped down using isopropyl alcohol and dust-free kimwipes and the wipes were examined. No decolourization or debris was observed on the wipe.

Finally, the test article itself was inspected for FOD visually and then using the same isopropyl alcohol/kimwipe method with no FOD observed. After this, the test article was carefully packaged in kimwipes and placed into a plastic bag for transportation back to the University of Manitoba STAR Lab.

7. Post Test Tear-Down:

After carrying the test article back to the UM STAR Lab, the sample plate assembly was disassembled on a cleaned anti-static mat. First the sample plate lid was removed and inspected for FOD, both visually and then by wiping the lid down with kimwipes and isopropyl alcohol and then inspecting the wipe for FOD. No FOD was found through this inspection; however, some scratch marks were observed from where the fasteners were installed.

Next, each sample was carefully removed from the assembly and inspected for damage using an inspection microscope. After the sample itself was inspected, the compression disc was removed and first inspected and then wiped down using an alcohol-soaked q-tip. Finally, the wave disc spring at the bottom of the sample well was removed and the well itself was inspected and wiped down. All inspections with the microscope were recorded.

The results of these inspections are summarized in the table below, but a few trends were noted:

· Impressions from the lid and/or compression disc were left on many of the samples

· Some residue was present on the lip of the compression discs where they were in contact with the samples.

· Sample compression discs for AW558 and AW559 (lunar mare simulant) had two small sub-millimetre metallic flakes inside them. Science PI, Dr. Ed Cloutis, was contacted to help identify their source and confirmed these were flakes from the graphite that coated the samples. As these flakes were found on the inside of the compression discs, it is unlikely that they could become liberated from the payload assembly during or after launch.

· One sample (AW563 Anthracite Coal) had several pieces liberated from it, held within and on the compression disc, hanging off the sample itself, and in the sample well. As none of this debris was found in the FCB or on the outside of the sample assembly, it seems that the assembly was able to contain this FOD. Alternatively, the material may have been partially attached to the sample and became detached during disassembly. This sample was the thinnest one tested (0.8 mm) so it is hard to say if the FOD was caused by the sample material, previous undetected damage, or insufficient material thickness.

Figure 2.1: Graphite Flake from AW559

Figure 2.2: Loose material on AW563

8. Post Test Summary and Lessons Learned:

In total, 11 samples including 7 distinct sample types, were tested under random vibrations using both the Nanoracks hard mount and soft mount test profiles. Sample AW563 produced significant FOD and samples AW558/559 produced two small metallic flakes of FOD. However, the FOD released from AW558 and AW559 were likely due to the sample’s graphite coating.

Based on the material liberated from AW563, we will not be including anthracite coal samples in the Iris (ManitobaSat-1) payload. The other sample candidates will be re-tested with the graphite coating fully removed.

Additionally, the lip size of the supporting compression discs will be increased to reduce the stress concentration on the samples to reduce the residue which formed between the samples and the compression disc where they touched. Finally, to aid in post-test inspections, we will take pre-test photographs of both sides of each sample for comparison.

2nd Vibration Test Results

Introduction:

Completed: 10 Oct. 2019

Conducted and documented by: Matt

Resources Required:

Tools: Torque screwdriver, camera, pens and paper for test notes, flashlight, sample storage container(s), cleanroom approved storage box
Hardware and Equipment: Front and rear supports, vibration interface plate, fasteners, vibration table control computer, Kapton tape, super glue, vibration table, accelerometers, the sample plate
PPE: Hearing protection, CSA approved steel-toed shoes, CSA approved safety glasses, cleanroom attire

Verification Activities:

Pass Criteria:

The sample plate EM will pass this test if:

The plate assembly and components have not visibly plastically deformed and the samples have not fractured after random vibration testing in all three axes for both soft and hard mount vibration profiles.
There is no debris created by the samples after random vibration testing in all three axes for both soft and hard mount vibration profiles.
The test input levels match the given test profiles to within +/- 1.5 dB.
The resonance search (sine sweek) shows a major mode frequency shift no greater than +/-5%, and +/-30% for major mode amplitudes.

Test Result Summary:

The following test report details the second set of vibration tests, including post-testing inspection, for the Iris (ManitobaSat-1) geological payload samples. Four samples, including three sample-types, were successfully vibration tested to the Nanoracks hard-mount test profile shown in Table 2. Tests were performed in X, Y, and Z axes without damage to the samples, as summarized in Table 3.

These tests were conducted using the flight-configuration mounting system in a sealed container to trap any emitted FOD. All four samples survived and no FOD was detected.

results

Table 3: Sample Summary

Table 2: Nanoracks Hard-Mount Test Profile

2. Lessons Implemented from 1^st Vibration Testing:

Pre-testing images were taken of all samples to allow for a before/after comparison.
The clamped area of each sample was increased to the outer 1 mm, from the previous 0.5 mm, to reduce the stress concentration on the samples.
Anthracitic coal was removed from the list of potential samples due to its poor performance during the first round of testing.
The outer layer of graphite, a remnant of the vacuum sintering process, was removed from both sides of the samples.

3. Testing:

3.1. Pre-test Inspection:

Before testing began, each sample was imaged to observe any existing damage and to allow for before/after comparisons as summarized below. During inspection, it was found that one of the samples, AW559 (lunar mare simulant), did have its graphite coating removed from the rear of the sample. As such, this sample was not tested.

Sample

Top

Bottom

Notes

AW555 (olivine)

Note ‘scar’ of light colouration on the sample bottom.

AW556 (olivine)

Sample damaged during assembly, not tested.

AW558 (lunar mare simulant)

Some scratches present on sample top.

AW559 (lunar mare simulant)

Sample rejected due to excess graphite.

AW564 (pyroxene)

Some pitting on sample top.

AW565 (pyroxene)

Some graphite present (silver colouration on the rear side); however, sample was deemed acceptable for testing.

3.2. Sample Plate Integration:

The samples (excluding AW559) were integrated into the sample plate assembly as follows:

All samples were wiped down with a dry kimwipe.
All other components were cleaned with isopropyl alcohol and kimwipes.
The samples were installed as follows:
1. A 0.4 lb-f disc spring was placed into the bottom of the sample well.
2. The custom-machined compression disc (specific for each sample) was placed into the well.
3. The sample was placed into the well on top of the compression disc.
The sample lid was placed onto the assembly and all fasteners were loosely installed.
The fasteners were fastened to their specified torque levels.

During the fist integration attempt, sample AW556 was damaged as the fasteners were tightened. Due to this damage, AW556 was removed and the unit was re-assembled. AW556 was not vibration tested.

3.3. Sample Vibration Testing:

The sample plate assembly was brought to Magellan Aerospace for vibration testing. The assembly was mounted within the FOD Containment Box (FCB) and mounted onto the vibration table using an interface plate.

The vibration testing procedure was as follows:

Pre-Test Activities:
1. Clean the FOD containment box and wipe down the sample plate assembly using kimwipes and isopropyl alcohol (avoiding the areas near the samples themselves to prevent contamination.
2. Mount sample plate assembly and FCB onto the interface plate.
3. Install the FCB lid.
X-Axis Testing:
1. Mount the interface plate to the vibration table.
2. Perform hard-mount random vibration test.
3. Remove FCB lid and inspect the assembly visually and with a UV light.
4. Remove the interface plate from the vibration table.
Y-Axis Testing:
1. Mount the interface plate to the vibration table.
2. Perform hard-mount random vibration test.
3. Remove FCB lid and inspect the assembly visually and with a UV light.
4. Remove the interface plate from the vibration table.
Z-Axis Testing:
1. Reconfigure the vibration table into the Z configuration.
2. Mount the interface plate to the vibration table.
3. Perform hard-mount random vibration test.
4. Remove FCB lid and inspect the assembly visually and with a UV light.
5. Remove the interface plate from the vibration table.
Transport the full assembly (including interface plate and FCB) to the University of Manitoba STAR Lab for inspection.

No FOD was observed during post-test visual and UV light inspections.

Figure 3.1: Sample Plate Under UV light after X-Axis Testing

Figure 3.2: Sample Plate Under UV light after Y-Axis Testing

Figure 3.3: Sample Plate Under UV light after Z-Axis Testing

Figure 3.4: Sample Plate Assembly in FCB Mounted on Interface Plate before vibration testing

4. Inspection:

The sample plate assembly was transported from Magellan Aerospace, where vibration testing took place, while the plate was still mounted within FOD containment box (FCB) with the vibration interface plate attached. With the full test-assembly still in place, there were no openings in the FCB that could allow FOD to escape.

The sample inspection area was prepared by cleaning all surfaces with kimwipes and isopropyl alcohol. An inspection microscope was used to observe and record sample conditions. The microscope plate was wiped down between inspections to avoid cross-contamination.

4.1. Inspection Part 1: FCB and Sample Plate Assembly Inspection:

The FCB lid was removed and the inside was visually inspected. No FOD was found.
The sample plate was removed and both the sample plate assembly and FCB were visually inspected. No FOD was found.
The inside of the FCB was wiped down with kimwipes and isopropyl alcohol. After each wipe, the kimwipe was observed for FOD. No FOD was found.
The exterior of the sample plate assembly was wiped down with kimwipes and isopropyl alcohol. After each wipe, the kimwipe was observed for FOD. No FOD was found. NOTE: the samples themselves, and the area immediately surrounding them, was not wiped down to avoid contaminating the samples with isopropyl alcohol.
The sample plate lid was removed and both the lid and area underneath were visually inspected for FOD. No FOD was found.
The sample plate lid was wiped down with kimwipes and isopropyl alcohol. After each wipe, the kimwipe was observed for FOD. No FOD was found.

Figure 4.1: Sample Plate Assembly as Removed from FCB

Figure 4.2: Sample Plate Assembly with Lid Removed

Figure 4.3: Sample Plate Lid Bottom Side

Figure 4.4: FOD Containment Box Interior

4.2. Inspection Part 2: Sample Inspection Procedure:

For each of the four samples, the following procedure was followed:

The sample was removed from the assembly using tweazers and visually inspected, including both the top and bottom along with the edges.
The sample was then viewed under the inspection microscope and a photo was taken of both sides.
The sample’s supporting compression disc was removed from the assembly and viewed under the inspection microscope. A photo was taken as well.
The compression disc was wiped down with a q-tip and isopropyl alcohol. The q-tip was then inspected for signs of FOD.
The disc spring was removed from the sample well and wiped down with a q-tip and isopropyl alcohol. The q-tip was then inspected for signs of FOD.
The sample well was wiped down with a q-tip and isopropyl alcohol. The q-tip was then inspected for signs of FOD.
The inspection microscope plate was wiped down with a kimwipe and isopropyl alcohol. The kimwipe was then inspected for signs of FOD.

4.3. Sample Inspection Results:

There were some visible marks where the sample lid had compressed the samples, but as seen in Table 4 no cracks, loose material, FOD, or other damage was observed. There were no signs of FOD during the sample inspection process. A scratch was observed in sample AW555, as seen in Figure 3. However, after reviewing the pre-testing images, this scratch was present before testing began. No visible signs of crack propagation around the scratch were found.

Figure 5: Sample AW555 Scratch

Sample

Top

Bottom

Compression Disc

AW555 (olivine)

AW556 (olivine)

Not tested

AW558 (lunar mare simulant)

AW559

Not tested

AW564 (lunar mare simulant)

AW565 (pyroxene)

Phase C

3rd Vibration Test Results

Introduction:

Test Description: The following test shall subject an engineering model (EM) of the Iris payload sample plate assembly to the mission’s expected random vibration profile. In this test, the duration will be increased to 120 seconds and test level will be increased to +3 dB relative to the Nanoracks hard-mount test level for qualification. This test will be used to validate the clamping mechanism used to hold payload samples in place and quantify how much (if any) debris is emitted by the samples during vibrations.

Completed: December 18, 2020, and December 21, 2020

Conducted by: Ali, Jaime, and Stephanie (second group testing only)

Documented by: Ali

Resources Required:

Tools: Torque screwdriver, camera, pens and paper for test notes, UV light, sample storage container(s), tweezers, Q-tips
Hardware and Equipment: Front and rear supports, vibration box, vibration interface plate, fasteners, vibration table control computer, Kapton tape, vibration table, the sample plate
PPE: Hearing protection, CSA approved steel-toed shoes, CSA approved safety glasses, cleanroom attire

Verification Activities:

Pass Criteria:

The sample plate EM will pass this test if:

The plate assembly and components have not visibly plastically deformed and the samples have not fractured after random vibration testing in all three axes for hard mount vibration profiles.
There is no debris created by the samples after random vibration testing in all three axes for hard mount qualification test profiles.
The test input levels match the given test profiles to within +/- 1.5 dB.

Test Result Summary:

The following test report details the third set of vibration tests, including post-testing inspection, for the Iris geological payload samples. A total of 18 samples were successfully vibration tested to the Iris hard-mount qualification test profile shown in Table 4. The test level was started at -3 dB relative to Nanoracks hard-mount test level for 15 seconds, then increased to 100% of Nanoracks hard-mount test level for 15 seconds, and finally, it was increased to +3dB relative to Nanoracks hard-mount test level. Tests were performed in X, Y, and Z axes.

During pre-test inspection, it was found that three of the samples, AX268, AX311 and AX134, had some scratches. As such, these samples were tested separately on another day. In this report, we categorized samples into two groups based on the day they were tested. The first group consisted of 15 samples and the second group consisted of the 3 aforementioned samples.

These tests were conducted using the flight-configuration mounting system in a sealed container to trap any emitted FOD.

All the samples passed the tests successfully based on the test criteria. However, debris were found at the bottom of five wells.

Table 4: Iris Hard-Mount Qualification Test Profile

2. Testing:

2.1. First group pre-test Inspection :

Before testing began, each sample was imaged to record any existing damage and to allow for before/after comparisons as summarized below. The following table shows the first group samples top and bottom.

Sample ID

Sample Name

Sample Support

Top

Bottom

AX128

1 - OBR - 007 (obsidian)

UMS-245

AX271A

UCF/DSI CI (CI1 simulant)

UMS-231

AX123

TRO203 (troilite)

UMS-230

AX265

Tatahouine-VR (diogenite)

UMS-227

AW565

PYX023 (pyroxene)

UMS-235

AX126

OOH003 (goethite)

UMS-228

AX308

MET01 (iron meteorite)

UMS-248

AX302

Admire Olivine (pallasitic olivine)

UMS-236

AX312

MET01 + PYX023 (mesosiderite simulant)

UMS-244

AX305

Murchison-MS (CM carbonaceous chondrite)

UMS-238

AX292

Chelyabinsk-VR (ordinary chondrite)

UMS-234

AX307

NWA7059 (ureilite)

UMS-240

AX259

Chergach-VR (H chondrite)

UMS-247

AW559

BAS600 (lunar mare simulant)

UMS-225

AX262

Mbale (L chondrite)

UMS-226

2.2. Second group pre-test Inspection:

Before testing began, each sample was imaged to record any existing damage and to allow for before/after comparisons as summarized below. Three samples were separated from the other samples due to test operator concerns in generating debris. The isolated samples were tested after inspection of the main sample group, following the same test procedures. The three samples are shown below.

NOTE: The test operators reached out to the science team during the first day of testing for their opinion on the isolated samples. C-TAPE expressed no concern over the samples, and explained that it was difficult to remove material without removing sample volume.

Sample ID

Sample Name

Sample Support

Top

Bottom

AX268

NWA 114444 (lunar highland)

UMS-229

AX311

NWA 974 (E chondrite)

UMS-243

AX134

1 - MID - 001 (pillow basalt with glass)

UMS-241

2.3. Sample Plate Integration:

The samples (excluding AW559) were integrated into the sample plate assembly as follows:

All samples were wiped down with a dry kimwipe.
All other components were cleaned with isopropyl alcohol and kimwipes.
All sample wells were cleaned with isopropyl alcohol and Q-tips to remove debris and remaining particles from the previous test.
The samples were installed as follows:
1. A 0.4 lb-f disc spring was placed onto the bottom of the sample well.
2. The custom-machined compression disc (specific for each sample) was placed into the well.
3. The sample was placed into the well on top of the compression disc.
The sample lid was placed onto the assembly and all fasteners were loosely installed.
The fasteners were fastened to their specified torque levels.

Figure 6.1: Samples placed in the sample plate

Figure 6.2: First group sample plate integration

Figure 6.3: Second group sample plate integration

2.4. Sample Vibration Testing:

The assembly was mounted within the FOD Containment Box (FCB) and mounted onto the vibration table using an interface plate.

The vibration testing procedure was as follows:

Pre-Test Activities
1. Clean the FOD containment box and wipe down the sample plate assembly using kimwipes and isopropyl alcohol (avoiding the areas near the samples themselves to prevent contamination).
2. Mount sample plate assembly and FCB onto the interface plate.
3. Install the FCB lid.
X-Axis Testing:
1. Mount the interface plate to the vibration table.
2. Perform hard-mount random vibration test.
3. Remove FCB lid and inspect the assembly visually and with a UV light.
4. Remove the interface plate from the vibration table.
Y-Axis Testing:
1. Mount the interface plate to the vibration table.
2. Perform hard-mount random vibration test.
3. Remove FCB lid and inspect the assembly visually and with a UV light.
4. Remove the interface plate from the vibration table.
Z-Axis Testing:
1. Reconfigure the vibration table onto the Z configuration.
2. Mount the interface plate to the vibration table.
3. Perform hard-mount random vibration test.
4. Remove FCB lid and inspect the assembly visually and with a UV light.
5. Remove the interface plate from the vibration table.
Transport the full assembly (including interface plate and FCB) to the ASIF in the Magellan Aerospace for inspection.

No FOD was observed during post-test visual and UV light inspections.

IMG_5262.mov

Figure 7.4: Vibration test in Z-Axis

Figure 7.1: First group sample Plate after X-Axis Testing

Figure 7.2: Second group sample Plate Under UV light after Y-Axis Testing

Figure 7.3: Second group sample plate after X-Axis Testing

3. Inspection:

The sample plate assembly was brought to ASIF room in the Magellan Aerospace, while the plate was still mounted within FOD containment box (FCB) with the vibration interface plate attached. With the full test-assembly still in place, there were no openings in the FCB that could allow FOD to escape.

3.1. Inspection Part 1: FCB and Sample Plate Assembly Inspection:

The FCB lid was removed and the inside was visually inspected. No FOD was found.
The sample plate was removed and both the sample plate assembly and FCB were visually inspected. No FOD was found.
The inside of the FCB was wiped down with kimwipes and isopropyl alcohol. After each wipe, the kimwipe was observed for FOD. No FOD was found.
The exterior of the sample plate assembly was wiped down with kimwipes and isopropyl alcohol. After each wipe, the kimwipe was observed for FOD. No FOD was found. NOTE: the samples themselves, and the area immediately surrounding them, was not wiped down to avoid contaminating the samples with isopropyl alcohol.
The sample plate lid was removed and both the lid and area underneath were visually inspected for FOD. No FOD was found.
The sample plate lid was wiped down with kimwipes and isopropyl alcohol. After each wipe, the kimwipe was observed for FOD. No FOD was found.

Figure 8.1: First group sample plate after removing the lid.

Figure 8.1: First group sample plate lid.

3.2. Inspection Part 2: Sample Inspection Procedure:

For each of the samples, the following procedure was followed:

The sample was removed from the assembly using tweezers and visually inspected, including both the top and bottom along with the edges.
The sample was then viewed under the inspection microscope and a photo was taken of both sides.
The sample’s supporting compression disc was removed from the assembly and viewed under the inspection microscope.
The compression disc was wiped down with a Q-tip and isopropyl alcohol. The Q-tip was then inspected for signs of FOD.
The disc spring was removed from the sample well and wiped down with a Q-tip and isopropyl alcohol. The Q-tip was then inspected for signs of FOD.
The sample well was wiped down with a q-tip and isopropyl alcohol. The Q-tip was then inspected for signs of FOD.
The inspection microscope plate was wiped down with a kimwipe and isopropyl alcohol.

3.3. First group:

The following table shows first group samples after vibration test.

No.

Sample

Top

Bottom

Notes

AX128

I-OBR-007 (obsidian)

AX271A

UCF/DSI CI (CI1 simulant)

AX123

TRO203 (troilite)

AX265

Tatahouine-VR (diogenite)

AW565

PYX023 (pyroxene)

AX126

OOH003 (goethite)

AX126 survived vibration testing but was shedding FOD in the sample bag. Note the sample was removed from the flight candidate list.

AX308

MET01 (iron meteorite)

AX302

Admire Olivine (pallasitic olivine)

AX312

MET+PYX023 (mesosiderite simulant)

AX305

Murchison MS (CM chondrite)

AX292

Chelyabinsk-VR (ordinary chondrite)

AX307

NWA 7059 (ureilite)

AX259

Chergach-VR (H chondrite)

AW559

BAS600 (lunar mare simulant)

AX262

Mbale-VR (L chondrite)

3.4. Second group:

The following table shows second group samples after vibration test.

No.

Sample

Top

Bottom

Notes

AX268

NWA11444 (lunar highland)

AX311

NWA 974

(E chondrite )

AX134

I-MID-001 (pillow basalt w/ glass)

3.5. Sample Inspection Results:

No fractures, broken samples or other damage was observed.
There were no signs of FOD in the FOD containment box (FCB).
There were no fractures on the edges of the samples or on their surfaces.
Sample AX126 survived vibration testing (no FOD was detected at the bottom of the well); however, the sample left residue in the sample bag. This is due to the type of mineral it is. As a result, the sample was removed from the flight candidate list.
However, debris was found in 5 wells of samples AX271A, AX126, AX305, AX307 and AX134 as shown in Figure 9. This debris was found just at the bottom of the wells and no debris was found on the sample support. Due to the compression force of the supports on the edge of the samples, very tiny debris came off the samples and fell into the wells through the tiny gap between the support and the well. This debris was captured in the wells, and cannot get out of the wells. Thus, the debris will not harm the mission.
There was discolouration on the edges of samples AX292 and AX307. Preliminary inspection shows that it is due to the compression caused by sample support on the samples.

Based on the test criteria, the samples passed the test successfully.

Figure 9: Debris found at the bottom of a well.

Phase D

4th Vibration Test Results

Introduction:

Completed: July 15, 2021

Conducted by: Ali and Stephanie

Documented by: Ali

Resources Required:

Tools: Torque screwdriver, camera, pens and paper for test notes, UV light, sample storage container(s), tweezers, Q-tips
Hardware and Equipment: Front and rear supports, vibration box, vibration interface plate, fasteners, vibration table control computer, Kapton tape, vibration table, the sample plate
PPE: Hearing protection, CSA approved steel-toed shoes, CSA approved safety glasses, cleanroom attire

Verification Activities:

Pass Criteria:

The sample plate EM will pass this test if:

The plate assembly and components have not visibly plastically deformed and the samples have not fractured after random vibration testing in all three axes for hard mount vibration profiles.
There is no debris created by the samples after random vibration testing in all three axes for hard mount qualification test profiles.
The test input levels match the given test profiles to within +/- 1.5 dB.

Test Result:

The following test report is the summary of last round of vibration test for the Iris geological payload samples. A total of 4 samples were successfully vibration tested to the Iris hard-mount qualification test profile shown in Table 5. The test level was started at -3 dB relative to Nanoracks hard-mount test level for 15 seconds, then increased to 100% of Nanoracks hard-mount test level for 15 seconds, and finally, it was increased to +3dB relative to Nanoracks hard-mount test level. Tests were performed in X, Y, and Z axes. These tests were conducted using the flight-configuration mounting system in a sealed container to trap any emitted FOD. The samples which undergo vibration test are as follows:

AZ005-PYX023
AZ002-SAP105
AW555-OLV003
AZ008- GRP102

All the samples passed the tests successfully based on the test criteria. However, sample AZ008- GRP102 left some residue. Therefore, that sample was removed from the candidate list.

Table 5: Iris Hard-Mount Qualification Test Profile

Figure 10: Sample plate after vibration test.

Figure 11: Vibration test facility at Magellan Aerospace

MAH04668.MP4

Figure 12: Vibration test in Z-axis

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