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                  <text>&lt;p&gt;The Saturn V was a three-stage launch vehicle and the rocket that put man on the moon. (Detailed information about the Saturn V's three stages may be found&lt;span&gt; &lt;/span&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_first_stage.html"&gt;here,&lt;span&gt; &lt;/span&gt;&lt;/a&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_second_stage.html"&gt;here,&lt;span&gt; &lt;/span&gt;&lt;/a&gt;and&lt;span&gt; &lt;/span&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_third_stage.html"&gt;here.&lt;/a&gt;) Wernher von Braun led the Saturn V team, serving as chief architect for the rocket.&lt;/p&gt;
&lt;p&gt;Perhaps the Saturn V’s greatest claim to fame is the Apollo Program, specifically Apollo 11. Several manned and unmanned missions that tested the rocket preceded the Apollo 11 launch. Apollo 11 was the United States’ ultimate victory in the space race with the Soviet Union; the spacecraft successfully landed on the moon, and its crew members were the first men in history to set foot on Earth’s rocky satellite.&lt;/p&gt;
&lt;p&gt;A Saturn V rocket also put Skylab into orbit in 1973. A total of 15 Saturn Vs were built, but only 13 of those were used.&lt;/p&gt;</text>
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&lt;p&gt;A Saturn V rocket also put Skylab into orbit in 1973. A total of 15 Saturn Vs were built, but only 13 of those were used.&lt;/p&gt;</text>
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&lt;p&gt;Perhaps the Saturn V’s greatest claim to fame is the Apollo Program, specifically Apollo 11. Several manned and unmanned missions that tested the rocket preceded the Apollo 11 launch. Apollo 11 was the United States’ ultimate victory in the space race with the Soviet Union; the spacecraft successfully landed on the moon, and its crew members were the first men in history to set foot on Earth’s rocky satellite.&lt;/p&gt;
&lt;p&gt;A Saturn V rocket also put Skylab into orbit in 1973. A total of 15 Saturn Vs were built, but only 13 of those were used.&lt;/p&gt;</text>
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                <text>This material may be protected under U. S. Copyright Law (Title 17, U.S. Code) which governs the making of photocopies or reproductions of copyrighted materials. You may use the digitized material for private study, scholarship, or research. Though the University of Alabama in Huntsville Archives and Special Collections has physical ownership of the material in its collections, in some cases we may not own the copyright to the material. It is the patron's obligation to determine and satisfy copyright restrictions when publishing or otherwise distributing materials found in our collections.</text>
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                  <text>&lt;a href="http://libarchstor.uah.edu:8081/repositories/2/resources/60" target="_blank" rel="noreferrer noopener"&gt;View the Saturn V Collection finding aid in ArchivesSpace&lt;/a&gt;</text>
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                  <text>&lt;p&gt;The Saturn V was a three-stage launch vehicle and the rocket that put man on the moon. (Detailed information about the Saturn V's three stages may be found&lt;span&gt; &lt;/span&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_first_stage.html"&gt;here,&lt;span&gt; &lt;/span&gt;&lt;/a&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_second_stage.html"&gt;here,&lt;span&gt; &lt;/span&gt;&lt;/a&gt;and&lt;span&gt; &lt;/span&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_third_stage.html"&gt;here.&lt;/a&gt;) Wernher von Braun led the Saturn V team, serving as chief architect for the rocket.&lt;/p&gt;
&lt;p&gt;Perhaps the Saturn V’s greatest claim to fame is the Apollo Program, specifically Apollo 11. Several manned and unmanned missions that tested the rocket preceded the Apollo 11 launch. Apollo 11 was the United States’ ultimate victory in the space race with the Soviet Union; the spacecraft successfully landed on the moon, and its crew members were the first men in history to set foot on Earth’s rocky satellite.&lt;/p&gt;
&lt;p&gt;A Saturn V rocket also put Skylab into orbit in 1973. A total of 15 Saturn Vs were built, but only 13 of those were used.&lt;/p&gt;</text>
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                <text>A rocket from the George C. Marshall Space Flight Center will carry the first American to the moon, and the deadline is 1970. Because of the Center's expanding role in space, there are increasing requests for information about our activities. This brief historical sketch should help to answer questions about our past, our present, and our hopes for the future.  Marshall Space Flight Center (MSFC) is the largest installation of the National Aeronautics and Space Administration (NASA). The Marshall Center is NASA's agency responsible for large space rockets and related research. MSFC employs about 7500 civil service employees with an annual payroll of more than {dollar}82 million. In addition approximately 4300 contractor employees work for MSFC on the Arsenal, earning an estimated {dollar}43 million. The Center occupies about 1800 acres near Huntsville, Alabama; in this large area are 270 buildings with floor space totalling about 4,000,000 square feet for a real estate and property value of about {dollar}325 million. MSFC's 1966 fiscal year budget was {dollar}1.8 billion. Obviously MSFC has much human and monetary worth behind United States round trips to the moon and beyond. In addition to its size, MSFC is unique because it has a large rocket development team with more than three decades of experience. Prior to the rocket work that dates back to Peenemuende [sic] the world heard little and cared less concerning rockets and space. As a group Marshall has always thought big. It has worked together as a group, and equally well with fellow scientists throughout the Free World, to get the most into space soonest. This is why there is increasing interest in larger and larger rockets and rocket programs from our Center, a fact generating more and more questions about our Center, and in turn generating a "workload" request for this sketch by the Historical Office. We hope that you enjoy our historical sketch, which could as well be entitled "Closer and Closer Views of the Moon and Beyond."  David S. Akens, MSFC Historian.</text>
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                <text>Laboratories -- Astronautics</text>
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                <text>This material may be protected under U. S. Copyright Law (Title 17, U.S. Code) which governs the making of photocopies or reproductions of copyrighted materials. You may use the digitized material for private study, scholarship, or research. Though the University of Alabama in Huntsville Archives and Special Collections has physical ownership of the material in its collections, in some cases we may not own the copyright to the material. It is the patron's obligation to determine and satisfy copyright restrictions when publishing or otherwise distributing materials found in our collections.</text>
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                <text>&lt;a href="http://libarchstor.uah.edu:8081/repositories/2/archival_objects/17473"&gt; View this item in ArchivesSpace &lt;/a&gt;</text>
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                  <text>&lt;p&gt;The Saturn V was a three-stage launch vehicle and the rocket that put man on the moon. (Detailed information about the Saturn V's three stages may be found&lt;span&gt; &lt;/span&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_first_stage.html"&gt;here,&lt;span&gt; &lt;/span&gt;&lt;/a&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_second_stage.html"&gt;here,&lt;span&gt; &lt;/span&gt;&lt;/a&gt;and&lt;span&gt; &lt;/span&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_third_stage.html"&gt;here.&lt;/a&gt;) Wernher von Braun led the Saturn V team, serving as chief architect for the rocket.&lt;/p&gt;
&lt;p&gt;Perhaps the Saturn V’s greatest claim to fame is the Apollo Program, specifically Apollo 11. Several manned and unmanned missions that tested the rocket preceded the Apollo 11 launch. Apollo 11 was the United States’ ultimate victory in the space race with the Soviet Union; the spacecraft successfully landed on the moon, and its crew members were the first men in history to set foot on Earth’s rocky satellite.&lt;/p&gt;
&lt;p&gt;A Saturn V rocket also put Skylab into orbit in 1973. A total of 15 Saturn Vs were built, but only 13 of those were used.&lt;/p&gt;</text>
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                <text>Dr. von Braun's calendars and scrapbooks indicate that these were his personal contacts with President Kennedy, Vice-President Johnson and members of their immediate staff.</text>
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                <text>Is part of: Dr. von Braun / NASA HQ Correspondence July 1968.</text>
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                <text>This material may be protected under U. S. Copyright Law (Title 17, U.S. Code) which governs the making of photocopies or reproductions of copyrighted materials. You may use the digitized material for private study, scholarship, or research. Though the University of Alabama in Huntsville Archives and Special Collections has physical ownership of the material in its collections, in some cases we may not own the copyright to the material. It is the patron's obligation to determine and satisfy copyright restrictions when publishing or otherwise distributing materials found in our collections.</text>
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                <text>The first page contains a typed routing slip. A list of Wernher von Braun's meetings with President Kennedy, the Vice President and members of their immediate staff.</text>
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                  <text>&lt;p&gt;The Saturn V was a three-stage launch vehicle and the rocket that put man on the moon. (Detailed information about the Saturn V's three stages may be found&lt;span&gt; &lt;/span&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_first_stage.html"&gt;here,&lt;span&gt; &lt;/span&gt;&lt;/a&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_second_stage.html"&gt;here,&lt;span&gt; &lt;/span&gt;&lt;/a&gt;and&lt;span&gt; &lt;/span&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_third_stage.html"&gt;here.&lt;/a&gt;) Wernher von Braun led the Saturn V team, serving as chief architect for the rocket.&lt;/p&gt;
&lt;p&gt;Perhaps the Saturn V’s greatest claim to fame is the Apollo Program, specifically Apollo 11. Several manned and unmanned missions that tested the rocket preceded the Apollo 11 launch. Apollo 11 was the United States’ ultimate victory in the space race with the Soviet Union; the spacecraft successfully landed on the moon, and its crew members were the first men in history to set foot on Earth’s rocky satellite.&lt;/p&gt;
&lt;p&gt;A Saturn V rocket also put Skylab into orbit in 1973. A total of 15 Saturn Vs were built, but only 13 of those were used.&lt;/p&gt;</text>
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                <text>"Saturn V S-IC stage engine gimbal actuation system."</text>
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                <text>The actuation system for the Saturn V S-IC stage is described and compared to the Saturn I system. The use of mechanical feedback actuators that result in a significant increase in system reliability and the damping of load resonance is discussed. The unprecedented component sizes and system requirements are cited.</text>
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                  <text>&lt;p&gt;The Saturn V was a three-stage launch vehicle and the rocket that put man on the moon. (Detailed information about the Saturn V's three stages may be found&lt;span&gt; &lt;/span&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_first_stage.html"&gt;here,&lt;span&gt; &lt;/span&gt;&lt;/a&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_second_stage.html"&gt;here,&lt;span&gt; &lt;/span&gt;&lt;/a&gt;and&lt;span&gt; &lt;/span&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_third_stage.html"&gt;here.&lt;/a&gt;) Wernher von Braun led the Saturn V team, serving as chief architect for the rocket.&lt;/p&gt;
&lt;p&gt;Perhaps the Saturn V’s greatest claim to fame is the Apollo Program, specifically Apollo 11. Several manned and unmanned missions that tested the rocket preceded the Apollo 11 launch. Apollo 11 was the United States’ ultimate victory in the space race with the Soviet Union; the spacecraft successfully landed on the moon, and its crew members were the first men in history to set foot on Earth’s rocky satellite.&lt;/p&gt;
&lt;p&gt;A Saturn V rocket also put Skylab into orbit in 1973. A total of 15 Saturn Vs were built, but only 13 of those were used.&lt;/p&gt;</text>
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                <text>desiofthesatus.pdf</text>
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                <text>"Design of the Saturn S-IV Stage Propellant Utilization System."</text>
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            <name>Description</name>
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                <text>Describes the SIV vehicle and its components. Presented at: IRE International Convention.</text>
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            <name>Creator</name>
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                <text>Allen, D. J.</text>
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                <text>Bekemeyer, L. G.</text>
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            <name>Date</name>
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                <text>1962-03-29</text>
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                <text>Saturn project</text>
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                <text>Liquid propellant rockets</text>
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                <text>Saturn V Collection</text>
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                <text>Box 6, Folder 55</text>
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                <text>This material may be protected under U. S. Copyright Law (Title 17, U.S. Code) which governs the making of photocopies or reproductions of copyrighted materials. You may use the digitized material for private study, scholarship, or research. Though the University of Alabama in Huntsville Archives and Special Collections has physical ownership of the material in its collections, in some cases we may not own the copyright to the material. It is the patron's obligation to determine and satisfy copyright restrictions when publishing or otherwise distributing materials found in our collections.</text>
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                <text>&lt;a href="http://libarchstor.uah.edu:8081/repositories/2/archival_objects/16767"&gt; View this item in ArchivesSpace &lt;/a&gt;</text>
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NO. - ----AEROSPACE WELDING STANDARDS

//d3

FOR THE MINUTES OF THE MEETING OF AMEIUCAN ORDNANCE ASSOCfATION
I

The term "Welding Standard" is one which must be qualefied since
there are many dfjfferent classifications. There are, for example, welding

,

standards for bridge and building construction, automotive manufacturers,
machinery manufacuurers, and, of course, space vehicle manufacturers.

To

each of the functional segments of an organization, producing welds to meet
the requirements

vr

a welding standard has a different meaning:

(1) to

engineering, it is a necessary requirement to fulfill the design function;

(2) to manufacturing, it means additional operations, precise dimensional
tolerances, elaborate tooling and pre-production test sampling; (3) to
quality control, 5t is the responsibility to select inspection points within
the manufacturing operations and to apply NM: methods to insure that the
product meets engineering requirements; and (4) to top management, producing

'

welds to meet the requirements of a weld standard means much higher costs.
Fundamentally, the'basic objective of any welding application is
to obtain a weld which will perform the function for which it: was designed.

The problem then, in establishing an aerospace welding standard, is one of
determining what parameters must be controlled and the limits of acceptability
'

to meet the design function.
If perfect welds could be produced consistently with 100% reliability,
the problem would be solved. This is not possible, of course, since a
perfect weld would be one having absolutely no defects and having 100%
joint efficiency based on mechanical, metallurgical, and physical properties.

�Thds means thas realistic welding standards must be established which
require a minimum level of performance based on what engineering can
tolerate and what manufacturing can produce.

Even though the present welding

standard is based on this philosophy, the. question still arises, "Is the
high quality required by this standard really necessary?"

In reviewing

the product history, the answer is quite evident.
From the first missiles and rockets constructed, many failures which
occurred during proof testing of the components have been traced to poor
quality welds. Natueally, with each incident, engineers became educated
as to the type and magnitude of defects which can be tolerated; thus, the
standard is modified to correct the deficiences.
As an example of failures which have occurred in the past, Figure 1
shows a portion of a weld from a missile propellant tank,whichexhibits
transverse weld cracks.

Radiographic examination of the welds in this tank

revealed porosity in excess of specification requirements. Prior to this
failure, there were no requirements for 100% radiographic inspection.
quality control of these welds was based on the establishment of welding
schedules which produced welds to meet the specification requirements.
Then the operator and equipment were relied upon to produce the same weld
quality in the production part.
Upon completion of the failure analysis, it was concluded that the
failure resulted from very low ductility in the weld, with porosity being a
contributing factor.

That is, the weld could not plastically deform with

thgt base material without failure. This is an example of a defect resulting from
dissimilar mechanical properties between the base material and filler metal.

�Thus, in order to have a complete welding standard, the mechanical
properties 0f.a welded joint must be defined and controlled.
Corrective action for this failure was to modify the welding standard,
incorporating a different filler metal and, in addition,-arequirement was
imposed for 100% radiographic inspection of all subsequent welds to insure
that porosity w~uldbe within specifications.
As another example, Figure 2 shows a failure in ground support
equipment (54-in&amp;

diameter water line flange-to-pipe weld) which occurred

during cyclic pressure proof testing. The crack shown here initiated at
the toe of the weld as a result of undercut.

The undercut was noted to

be more severe on the side of the forged flange, which happened also to be
the weaker material.

This, of course, necessitated tightening the allowable

undercut requirements for steel weldments in certain ground support equipment.
The above examples illustrate typical defects which have caused failure
and which must be controlled to insure weldment reliability. Without
attempting to define or describe in detail all of the parameters which
form a welding standard, the following may serve as a generalized description:
a.

Metallurgical Compatibility of Base Material and Filler Material
A filler metal must be selected which is metallurgically compatible
with the base material.

The filler metal should not present a

metallurgical discontinuity (i. e. , formation of brittle phases)
which could cause premature failure, nor should there be a high
electro-chemical potential.difference between the weld and base
metal which would invite corrosion. Stress corrosion characteristics
of the deposited filler metal must also be considered in the selection.

�b, Nechahical Properties of the Welded Joint
In order to have a high degree of confidence in the mechanical
properties of a weldment, a 1arge.amountof data must be obtained
and statistically analyzed. If, for example, the ductility or
tensile strength of the weld is below that of the base material,
the des$gners may compensate by increasgng the thickness of the
weld joiht.
c. Welding Brocess
~tandarazationon a particular welding process must be based
on its adaptability to the product and the quality of weld which
can be produced. Subsequently, the welding procedure must be
docum@nted, listing allowable variations for each variable in the
proce4s.

Joint preparation and fit-up tolerances must be

established to maintain good weld quality and consistent
mechanioal properties. Simultaneously, and in combination with
the det-ination

of mechanical properties, acceptance limits

for both internal and external defects must be established.
Having in mind the parameters which must be controlled, the next
objective is to establish what tools will be used to insure control.
a.

Research and Development
Through research and development, the optimum filler wire for the
specific application may be determined together with the optimum
welding process, joint design, mechanical properties, defect
limitations, etc.

�b.

Measurement of Dimensional Tolerances
The component p a r t s must be dimensionally i n s p e c t e d t o i n s u r e
p r o p e r f i t - u p and proper joint p r e p a r a t i o n .

P o s t weld inspection

of dimensions i s necessary t o i n s u r e t h a t metal d i s t o r t i o n h a s
n o t renPered t h e p a r t unusable,

c.

Visual I n s p e c t i o n
V i s u a l i n s p e c t i o n , a v e r y important t o o l , i s i n continuous u s e
b e f o r e , d u r i n g , and a f t e r t h e welding operation.

d.

Sampling
Often i t i s b e n e f i c i a l , o r even necessary, t o make pre-production
and/or post-production samples which a r e s u b j e c t e d t o d e s t r u c t i v e and
n o n d e s t r u c t i v e t e s t s f o r g r e a t e r assurance of t h e q u a l i t y w i t h i n
t h e product.

e.

Radiography
Radiography i s g e n e r a l l y considered a p o s t weld i n s p e c t i o n t o o l
f o r determining i n t e r n a l q u a l i t y .

f,

Penetrants
Most s u r f a c e d e f e c t s which a r e not v i s i b l e t o t h e naked eye can

,

g.

be d e t e c t e d by p e n e t r a n t i n s p e c t i o n .
Magnetic P a r t i c l e
This i n s p e c t i o n t o o l i s used w i t h magnetic m a t e r i a l s f o r d e t e c t i n g
s u r f a c e o r s l i g h t l y subsurface d e f e c t s .

h.

Ultrasonic
U l t r a s o n i c i n s p e c t i o n may be used f o r both s u r f a c e and i n t e r n a l
defects.

�i, Eddy :Current
Eddy current inspection, also, may be used for surface and internal
defects.

It is obvious that no one of the above tools, by itself, could assure.
a high quality weldment.

In almost all instances, at least three of the

above tools are used: namely, (1) research and development, (2) measurement
of dimensional twlerances, and (3) visual inspection.

Determining a welding standard for the major structural material used
in the S-IC booster stage of the Saturn V vehicle, as discussed below,
will serve as a guide for determining a welding standard and for illustrating
the use of several of the tools.' The platerial used was aluminum alloy
2219-T87. Folluwing the selection of type 2319 filler metal as .the optimum
commercially available filler, welds were made in 1/4, 1'/2, 3/4, and 1-inch
thick plates using both the consumable and nonconsumable electrode processes in the flat, vertical,' and horizontal welding positions.
Discontinuities,such as weld undercut and joint misfit (root openings
and misalignment), were introduced purposely to establish tolerable limits.
All panels were radiographed, noting both internal and external defects in
the weld. Figure 3 shows an example of internal defects which were
tested to evaluate their effect on strength properties, This is a mild
example, for many of the weldments contained a vast amount of internal
defects.

Ultrasonic inspection was also performed for correlation to

radiographic defects and for determination of the sensitivity of ultrasonic
testing.

�T e n s i l e sgecimens and specimens f o r m e t a l l u r g i c a l examination were
s e l e c t e d from Ehe welded panels t o i n s u r e ample r e p r e s e n t a t i o n of a l l
t y p e s of d e f e c t s ,

L a t e r , t h e mechanical p r o p e r t i e s were compared t o t h e

recorded d e f e c t s , and d e f e c t l i m i t a t i o n s were e s t a b l i s h e d .

If the strength

of a specimen having a s p e c i f i c type and magnitude of d e f e v t dropped
below t h e strenggh s c a t t e r f o r sound welds, t h a t magnitude of d e f e c t was
considered unacceptable f o r s t r u c t u r a l q u a l i t y weldments.
Among t h e i n t e r e s t i n g r e s u l t s were t h e l o c a t i o n and s i z e e f f e c t of
p o r o s i t y o r i n c l u s i o n s on weld s t r e n g t h .

Very l a r g e d e f e c t s l o c a t e d i n

t h e c e n t e r of t h e weld had l e s s e f f e c t upon s t r e n g t h than small d e f e c t s
along t h e f u s i o n l i n e , which i s t h e usual path of f a i l u r e when t h e weld
reinforcement i s not removed.

For a given s i z e c a v i t y o r i n c l u s i o n , the

s t r e n g t h of a t e n s i l e specimen decreased a s t h e d e f e c t approached t h e normal
p a t h of f a i l u r e o r t h e f u s i o n l i n e .
Another magnitude of p o r o s i t y which caused considerable l o s s i n
s t r e n g t h , as k l d u s t r a t e d i n Figure 4 , i s macro p o r o s i t y l o c a t e d along
t h e fusion line,

This might be d e t e c t e d by radiography, depending on t h e

f u s i o n zone geolaetry.

I n t h i s p a r t i c u l a r i n c i d e n t , it was d e t e c t e d

because of i t s o r i e n t a t i o n , b u t , i n o t h e r i n s t a n c e s where i t i s not
p a r a l l e l t o t h e beam of X-rays, it i s not detected.

I n one of t h e welded

p a n e l s , t h e s t r e n g t h of t h e specimens ranged from 40 t o 44 K s i , w i t h t h e
exception of two specimens, one being 33 and t h e o t h e r 35 K s i l o c a t e d
s i d e by s i d e .

There was no explanation f o r t h e l o s s i n s t r e n g t h ; t h e

f r a c t u r e s appeared normal t o t h e naked eye, but upon examination a t 20

�power m a g n i f i c a t i o n , very f i n e p o r o s i t y was q u i t e evident over t h e e n t i r e
f r a c t u r e surfkce.

Lack of p e n e t r a t i o n , t o t h e degree shown i n Figure 5 , was n o t d e t e c t a b l e by normal radiographic procedures.
d i d d e t e c t t h i s magnitude of d e f e c t .

U l t r a s o n i c i n s p e c t i o n , of course,

I n Figure 6 , t h e degree of incom-

p l e t e penetratzon i s very small but s e r i o u s l y lowers t h e s t r e n g t h .

In

t h i s c a s e , it was not d e t e c t e d by u l t r a s o n i c s o r , a t l e a s t , could n o t
be resolved.

TMs unpenetrated zone i s s i m i l a r t o a forge weld because

of t h e h e a t from welding and t h e pressure from shrinkage,
t h e r e was a l o s s i n s t r e n g t h .

Nevertheless,

Magnified views of t h i s zone show how

g r a i n s have a tendency t o grow a c r o s s t h e unpenetrated l i n e which i s no
l a r g e r than a g r a i n boundary,
Figure 7 shows t h e l o s s i n s t r e n g t h a s . a r e s u l t of incomplete
penetration.

It i s obvious from t h e s e d a t a t h a t incomplete p e n e t r a t i o n

cannot be t o l e r a t e d ; t h u s , methods f o r p o s i t i v e i d e n t i f i c a t i o n must be
developed.

T h i s d e f e c t i s p r e s e n t l y being c o n t r o l l e d by t h e e s t a b l i s h m e n t

of welding schedules recording t h e c u r r e n t , v o l t a g e , t r a v e l speed, and
w i r e f e e d speed necessary t o a s s u r e complete p e n e t r a t i o n ;

F u r t h e r , pre-

production test samples a r e made and checked before each production weld,
One p o s s i b l e method f o r p o s t i n s p e c t i o n c o n t r o l i s t h e use of a
modified square b u t t j o i n t wherein a shallow groove i s machined down t h e
c e n t e r of t h e a b u t t i n g p l a t e s , a s shown by t h e j o i n t c r o s s - s e c t i o n i n
F i g u r e 8.

If p e n e t r a t i o n i s n o t complete, a void i s p r e s e n t a t t h e c e n t e r

of t h e p l a t e which i s d e t e c t a b l e by radiography.

8

This i s i l l u s t r a t e d i n

�Figure 9.
(i.e.,

Id was found t h a t grooves, w h o s e . t o t a 1 width equal t o .O4O-inch,

.020-inch deep i n each p l a t e ) , would s h r i n k t i g h t and would not be

d e t e c t e d by radiography.

P r e s e n t l y , s a t i s f a c t o r y r e s u l t s 'can be obtained

w i t h a 0.030-Anch deep by 1 / 3 T width groove i n t o each a b p t t i n g edge.
R e l i a b i l i t y o r c t h e j o i n t h a s not been f u l l y e v a l u a t e d , but f u r t h e r t e s t i n g

i s being conduoced.
I n c o n s i d e r i n g radiography a s a t o o l f o r i n s p e c t i n g weldments i n
t h i c k p l a t e aluminum a l l o y s , i t was p o s s i b l e t o d e t e c t p o r o s i t y approximately 1%of t h e m a t e r i a l t h i c k n e s s and undercut of t h e same magnitude.
Defects which could not be r e l i a b l y d e t e c t e d were micro p o r o s i t y , l a c k
of p e n e t r a t i o n , l a c k of f u s i o n ( i . ' e , , t h e t i e - i n between t h e f i l l e r metal
and t h e base m e t a l ) , and t i g h t cracks o r c r a c k s which were not p a r a l l e l
t o t h e beam of X-rays.

Radiography, of course, i s only one t o o l f o r

i n s u r i n g a high q u a l i t y weld, and i t s l i m i t a t i o n must be defined Eor each
application.

This c e r t a i n l y i n d i c a t e s t h a t more than one i n s p e c t i o n t o o l

i s necessary t o p r o p e r l y e v a l u a t e weld q u a l i t y .

Similar definition,of

l i m i t a t i o n s can, and should, be obtained f o r each of t h e i n s p e c t i o n t o o l s
f o r a given a p p l i c a t i o n .
I n summary, an a e r o s p a c e welding standard must encompass (1) m e t a l l u r g i c a l c o m p a t i b i l i t y of base metal and f i l l e r m e t a l , (2) mechanical

proper-

ties of t h e welded j o i n t , and (3) t h e welding process ( d e f e c t l i m i t a t i o n s ,
s t a n d a r d i z a t i o n of equipment, e t c , ) .

The t o o l s a v a i l a b l e f o r i n s u r i n g

h i g h q u a l i t y have been reviewed, and i t h a s been shown why t h e h i g h q u a l i t y
welds a r e necessary.

�Although welding i s not the only i t e m which can cause the f a i l u r e
of a v e h i c l e , i t i s a f a c t that poor welds'can be a s o l e cause.

The

succeae of agaoa vekLcle structures dependslargely upon the quality af

welding and tihe completeness of the welding standards.

�FIGURE 1

Transverse Weld Cracks i n Aluminum Alloy Weldrnen't

FIGURE 2

Longitudinal Crack A t The Toe O f The Weld In A
S t e e l Weldrnent

�FIGURE 3

Radiographic Reproduction Of Weld Test panel

FIGURE 4

Macro-Porosity In Aluminum Alloy Weld Test Panel

�FIGURE 5

Incomplete Penetration Not Detected By Normal
Radiographic Procedures

�(c)

FIGURE 6

200X

Incomplete Penetration Having Overlap Of Heat Affected Zone

�-

50

-

45

-

40

-

35

-

30

-

-

25

-

-

20

-

I

I

I

I

WELDED 2219.787 ALUMINUM ALLOY

@

-

@

-

-

@

"
L
7

0

xX-

r'
0

5

C
e

=:
VI

-*

E

C

-

C

I

3

a

z

=

15

10

-

-

LfGfND:
0-

SOUND WELDS

X-

WELDS WITH LACK OF PENETRATION

I

1

1

%

%

h'

I
1

THICKNESS, INCHES

FIGURE 7

Loss In Weld Strength Resulting From Incomplete
Penetration

�FIGURE 8

Cross-Section Of Modified Square Butt Joint Design

�(b)

FIGURE 9

Weld In Modified Square Butt
Joint Design

50X

�</text>
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                  <text>&lt;p&gt;The Saturn V was a three-stage launch vehicle and the rocket that put man on the moon. (Detailed information about the Saturn V's three stages may be found&lt;span&gt; &lt;/span&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_first_stage.html"&gt;here,&lt;span&gt; &lt;/span&gt;&lt;/a&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_second_stage.html"&gt;here,&lt;span&gt; &lt;/span&gt;&lt;/a&gt;and&lt;span&gt; &lt;/span&gt;&lt;a href="https://www.nasa.gov/centers/johnson/rocketpark/saturn_v_third_stage.html"&gt;here.&lt;/a&gt;) Wernher von Braun led the Saturn V team, serving as chief architect for the rocket.&lt;/p&gt;
&lt;p&gt;Perhaps the Saturn V’s greatest claim to fame is the Apollo Program, specifically Apollo 11. Several manned and unmanned missions that tested the rocket preceded the Apollo 11 launch. Apollo 11 was the United States’ ultimate victory in the space race with the Soviet Union; the spacecraft successfully landed on the moon, and its crew members were the first men in history to set foot on Earth’s rocky satellite.&lt;/p&gt;
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&lt;p&gt;Perhaps the Saturn V’s greatest claim to fame is the Apollo Program, specifically Apollo 11. Several manned and unmanned missions that tested the rocket preceded the Apollo 11 launch. Apollo 11 was the United States’ ultimate victory in the space race with the Soviet Union; the spacecraft successfully landed on the moon, and its crew members were the first men in history to set foot on Earth’s rocky satellite.&lt;/p&gt;
&lt;p&gt;A Saturn V rocket also put Skylab into orbit in 1973. A total of 15 Saturn Vs were built, but only 13 of those were used.&lt;/p&gt;</text>
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                <text>The Army medical contract, grant, and research interest in the bio-science area.</text>
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                    <text>PRESENTED AT TtiE FOURTII INTERNhTlONAL CONFEREI!CE ON FLU!D SEALING HELD I N CONJUNCTION WITH ~ M ~ . 2 4AS1.E
t h AlJNUAL MEETING
IN PIIILE.DELPII!A, MAY 5-9.1969: This paper is thc literary prcpcrty of t l ~ eSociety indicated on the first page. Thc press may summarize frecly from
this manuscript after presentation, citing source; however, publicstion of material constituting more than 2006 of tile manuscript shall bc construed as
a violation of t l ~ cSoricty's rights and subject to appro2riatc I g a l actiori. Manuscripts not to be published by thc Society will bc releascd,in wri!irig for
'publica:lon by otlicr sources. Statcxcnts and opiriions advanced in papcrs arc uridcrstood to be individual expressions of tho author(s) arid not those
'
of t3e Scciety.

AVAILABLE. FROFA: AMEltiCAN SOCIEl-Y OF LUCRICATION CNCINECRS. 838 DUSSE tIICIl\'~A\', PARK ItIDGE, ILl.li&lt;OlS COOGC

�MfALTER J. CIESLII:
Pesco Products, Gedford, Ohio

Tlzc object o j t1z.c leaorit clisctissccl in this yapcr was to
dceelop a rclinblc helitrtn. 60.9 sllnjt scal for rise in an
electric motor-driool, licitlid osygeiz pump on a space
uellicle. Tllc dcvclo~~mcnt
e.orl coocred tests on ttco
basically diflerent jnce scal designs, one raith an atfncllecl
carbon jacc and ille olllcr tvitll o floating lal,$fted carbon jaca Scocral tclloi~stiibration da~npingcleviccs orlcl
unriotrs seal material coinbitzafioru tacre in ticsf iga fcd.

.

hcliuili seal for use in an eIcctric motor driven liquid
oxygcn pump for a n~anncclspacevchicle was tllc objective
of tliis investigation.
PUfAP DESIGN

Elcctric motel--driven, liquid oxygen pumps can be
dcsigndd. with a floodccl, canncd, or scalccl motor. Shaft
scals arc not required in the first t\vo typcs of units, but
oiic or more arc ncccssary with tllc scalcd type motor.
Tlic lattcr type of unit is discussed llcrc togctllcr with
thc tcst work concluclcd in developing a satisfactory
sllah scd.
From the clcsign stanclpoint, thc flooded motor unit is
t l ~ clnost sinlplc. All motor cotnpo~lcnts opcrate in
dircct coritact \\pith the punipccl fluicl and no seals are
rcquirccl. But, from a safcty standpoint; this dcsign could
bc thc most hazardous. IVhilc all matcrials arc sclcctccl
for compatibility \vitll liquicl oxygct~,co~libi.lstionis still
possiblc undcr ccrlaiti conclitiol~s.For instance, in a
si~nulatcdshort circuit test of a motor stator siibmcrgccl
in liquid oxygen, the electrical iiisulalion, part of the
colq~crwindings,'and iron stator Inminations were burncd
away, as slio\vn in Fig. 1. Coinbustion of thcsc matcrials
was tcrniinatccl only wlicn tlic supply of oxygcn was
exhaustccl.
.:
In thc canmcl rtlotor dcsign, usually only thc stator
laininations, windings ancl lcads arc hcrmctically scalcd
witliin a stainless-stccl slicll, thiis l&gt;rcvcntingdircct contact with tlic liquicl osygcn. 111c rotor, howcvcr, is
nor~nallystill submcrgccl clircctly in thc licluicl. In this
dcsign tlic safcty aspccts of t l ~ cstator with its elcctrical
insulation arc itnprovccl.' I.To\vcvcr, t l ~ cprcscncc of t l ~ c .
slainlcss slccl slator sl~cllit1 t l ~ cmotor air gap rccluccs
thc molor clricicnr:y and iticrcascs tlic inolor opcraling
currcn t.
For t l ~ cifnit c;isci~xscdItcrc thc rccluirccl ciirrcnt was
incrcasccl 1 y approsiiiintcly 20 pcrccnt \vhcn a canncd
stator clcsig~lwas tcslccl. This figurc worilcl 11c ftirtl~cr
incrcasccl if llic rolor \\.as also cannccl. ' ,

INTRODUCTION

Liquid ohygcn is one of thc tnorc aclivc cryogenic
fluids. Unclcr propcr conditions.it \\.ill react with tllc
colnnlon coinbustible matcrials, and undcr ccrtaiu conclitions,, such as aclclccl energy input, it will rcact with
mclallic construction materials. l'his is an important
consiclcration in tlic dcsign of cquipmc~ltfor usc in
liquid oxygen applications. It is cspccially important in
the design of rotating macliiucry, for cxainplc eleclric
niotor-drivcn pumps. In this type of equiymcnt the rcsultaut encrgy input cluc i0.a possihlc electrical overload
or mechanical sllock may bc sufiicicnt to initiate a mild
rcaciion or cvcn a violent detonation.
Elcctric motor-clrivcn liquicl oxygen pumps havc
oieratcd succcssfiilly, undcr norn~alconditions, with all
parts complctcly submcrgcd and wcttccl by liqiiicl oxygcii.
13ut in applicatioos which may prescnt a possiblc hazard
to human lifc, tllc safcty aspccts can bc enhanced by
aclditional clcsign precautions. In tlic elcctric rilotor
arc
drivcn ptnnp for instance, evcn thougli all ~n;~terials
sclcctccl for lnaxi~iiiilncornpal ibili ty with liq~iiilosygii~,
thc motor can bc cncloscd in a hcliiun gas incrtccl containcr. A dcsign of this typc, of coursc, will rcqliirc
roiatilig shaft scals. Illc sclcction and testing of a stiital&gt;ld

.

.

9rcscntcd.ul lhc Fourt:i In1crna:ionol ~orafc;enceon Fluid Sco!ing
h ~ l in
d conjunction with I:ie 1969 ASLE Annuol hlcc!ing irr
Pliilodcl;~l~io,Pa. This papcr sponsored by flle An~criconSocicly
OF hlccllonicol Engineers.

.

..
.263

.

�flange 10 incllcs in dialnctcr. lirciglit of t l ~ cunit is .
splxosimatcly 15 pounds.
On [he space v'clliclc the unit is fliinge Inounlccl'in a
bottom opening of a liquid osygcn supply lank ar~c1,'cxccpt for the outsidc face of the flange, is totally sub-.
rncrgcd in licluicl oxygen at -2'37°F.This cryogcnic
cooling pcrlnits a lnotor dcsign of smaller size and
\wight and of improvcd cficiency due, to the rctli~ccd
coppcr losses in thc stator windings. Normally, the moior
cavity is incrted wit11 hclium gas at a prcssrlrc of 11
, I:roximatcly 50 psig, but this prcssurc can go as high as.80 .
psig, which is limitcd by the motor cavity rclief valve.

,

SEAL CONSTRUCTION

Fig. I-Elcclric

~ o t o Slator
;

Aller Sirnutoted Short Circuit Test in Liquid
'

Oxygen.

In the sealed motor dcsign all motor parts opcrate
within a housing incrted with prcssurized hclium gas.
This dcsign prcscllts a minimtun safcty hazarcl. An cxample ,of this clcsign is shown in Fig. 2. This is an clcctric motor drivcn licluid oxygen pump unit for use on a
space vehicle. 11ie hclium prcssurizccl motor is separated
from tlic pumpcd fluid by a heliuln seal and a liquid
oxygen scal opcrating in a back-to-back arrangemcnt with
a comnlon ovcrboard vent betwccn them.
I l l e pump unit is clrivcn by a one horscpowcr clcctric
motor o ~ c r a t i n gat 11,000 rpln from a three-phase A.C.,
400 IIz, po\vcr s o ~ u c ca t a supply voltage of approximately 40 17.R.hl.S. lin'c-td-line. Thc unit is approximately
12" long, 4" in clian~ctcrand has an intcgral mounting

Because of the cryogcnic opcrating environment,
elastomcric sealing clcmcnts are not usable. Thercfore,.
an all metal wcldcd bello\vs.seal dcsign is cmploycd as
shown in Fig. 3. This is a cartridge type seal which is
shrink fittcd directly into the aluminum pump housing.
Static scaling is providcd by the seal caltriclgc shrink fit
in the pump housing and by tlle metallic bellows.
A loose or unattached carbon face picce is usccl with
this seal. The back side of the carl~onface piece is lapfittcd to the bellows end platc to provide an cffcctive
static seal at this point. The'clynamic or opcrating surface of thc carbon face is of the gas face typc consisting
of two concentric lands. l l l e inncr land is continuo~a
and performs the pl.cssurc scaling function, wl~ilcthe
outcr is a scgmcntcd bcaring land \vI~ichscrvcs to rcduce
seal facc pressure. Rotation of the carbon face picce is
prcvclltcd by slots, in the O.D. of the carbon face, \vhich
engage with radial kcys located in the I.D. of the scal
cartridge.
Compnrcd to a scal having an integral typc calbon face
piece, the loose facc piccc typc seal 11s thc following
aclvant agcs:

.

1. Seal face distortion due to differential thermal contraction of scal matcrinls is minimized.
2. Vibration damping is achievcd by friction bct\vcen
the face picce and keys.

l'he carbon facc picce opcratcs against a rot:iing ring
clampcd axially on the sllaft and statically scalccl to the
shaft by aluminum compression gaskcts.

V q WrUd Te

brbonN=*\

Fig. 2-Liquid

Oxygen Pump Will1 klc,liu~~i
lncrfcd Motor.

Fig. 3-llcliuni

.

Bellows Seal \Vil!,

I kaI

%I1 LD.

Loorc Carbon Fate.

�Scal

materials arc as follo\\,s:

lcakagc thcn slo\\;ly dccays to so~iicratc bct\vccn tllc

Scal cnrtrirlgc including bcllows-71s Staiulcss Stccl
-P5N carbon .
Carbon f;~ccpiccc
Rotating ring
-]lard cliro~nc
.. . on 440C Stainless
Stccl (Anncalcd)
l l i c 400 scrics stainless stccl is l~scclin prefercncc to'a
300 scrics bccause of its higher Lllcrnial conductivity. Thc
chrome plate tl~ickncssis 0.0015-0.005" as platccl and
0.001" minimun~aflcr lapping.

SEAL CHARACTERISTICS
Significant scal cliaracteristics are listcd in Table 1.
Tlle scal face prcssure of 10 psi consists of 7.5 psi
duc to bellows spring pressure and 2.5 psi resulting from
the 5596 scal hydraulic overbalance at 50 psig hclium
gas opcrating pressure. l l e ma.\imum a l l o ~ a b l cseal
friction torque of 10 oz. in. is governed by thc motor
torquc remaining after all othcr pump rcquirenlcnts have
bccn satisfied. I t &amp; influenced to a large extent by [lie
noto or starting currcnt lililit \vhicIi govclns tlie motor
torque capability.
The maximum pcr~nissiblcseal leakage ratc is 25
stanclard cd)ic inclies pcr minutc (SCIXI) of hclium gas
a t a motor cavity prcssurc of approximately 50 psig.
Actual scal lcakngc expericnccd during testing is about 2
SCIhl dynamically and 20 SCIhI statically, i.e., with tlic
unit non-operating. It is interesting Lo note that the
clynamic leakage is much lo~vcrtlian thc static Icakagc.
Tlic transition from the dynamic to thc static lcakagc
rate takcs place in apPr~si~natcly
10 to 40 seconds a f c r
tlic pump has come to rcst following powcr shut-olf. The
seal lcakagc incrcascs to the pcak static valuc at which
it remains for a pcriod of 30 seconds to 3 ~ninutes.Thc

TA~I.E
I-IIELIUhI

SEAL CIIARACTElXISTICS

1. Scal Operating Spcccl, RPII
2. ,Surface Spccd, ft/rnin.
3. P-V Factor, PSI' Ft/XIin.
4. Opcratiiig h1cdiu111
5. Prcssurc, PSI11

11,000

5

2300
23.600
.I~cliu~n
Gas
50-80

-297

6. l'cmpcraturc, "F

7. Scal 1)cflcction (installed), Inch
8. Axial Load, Lbs.
9. Ikcc Arca, in2: Scaling Land
Ilcaring Land
10. IIydraulic Ovcrbalancc, 9L
11. kace I'rcssurc (Total), PSI
12. Frictiori Torquc (Xluxir~ium),oz in.
13. Friction 111'
14. Facc I'Iittl~css,I1cli\111l
Light Bands
15. . Run-Out (Ilotating I:acc), l'.I.lt., illcli

,

.040-.050
2.5
0.19
0.14
55
.Id
I0
0.10
1-2
0.0005

ski clyna~nicand ~ n a x i ~ n ustatic
~ n rates. Tl~isclinrncteristic is rcpcat~1,leon sticccssivc pump tcsts.
l l i c 1 ~ 1 n iunit
p opcrating lifc rcquirc~ncntis 10 1iou1.s
wllich is nmde up of duty cyclcs each consisting of 20
minutcs of opcratiun follo~vcclby a soak timc of not lcss
than 5 minutcs. \\'car ratcs of scal C O I I I ~ ) O I I C I ~ ~cspcriS
enccd during tcst i1.e as follows:
P5N Carbon Face Piece
Chrome Plate on Rotating Ring

0.00005 in./hr
0.000025 in./lir

.

'

. Ilicsc \%?carrates wcre detcrniincd from three tcsts
with a total run timc of approximately 30 hours. The
ratcs indicate that tlic scal \vill easily surpass the rcquired life requirement.

Numcrous tcsts were pcrformed to dcvelop a scal combination that would meet the rcquired life, leakage, and
torquc requirements. Thc tcsts werc conductcdon scvcral
scal dcsign variations and on various con~binationsof seal
face and mating ring materials. I'ariations in scal facc unit
loading werc accomplisllcd by varying tlic bellows spring
load, seal facc \vidtIi, and hydraulic overbalance. For tcst
purposes, thc scals werc installed in tlie LO2 pun111 prcviously discussed.
The tcsts wcre pcrfor~ncdwith the unit subn~crgcdin
liquicl oxygcn and with thc motor cavity incrtccl with
helium gas at prcssurcs fro111 5 to 130 psig. Tlic tcsts
consisted of rcpeatccl opcrating cycles of 20 millutes cluration. Aftcr each operating cycle, tlic electrical power to
tlie unit was shut off and the unit was allowed to soak
for a minimum of fivc minutes before restart. Static scal
lcakage \!.as measurccl bcforc and aftcr every run, ancl
dynamic lcakagc during each run.

SEAL CONFIGURATIONS TESTED

liyo basically dilferent types of bcllows scals wcre
tcstcd wit11 the dcsign variations shown in Fig. 4 and
Tablc 2. Initial tcsts were pcrformcd with a scal having
an-intcgral carbon facc prcss fittcd in an encl plate weldcd .
to tlic scal bcllo\\~s.1,atcr tests wcrc donc with a scal
having a scparatc unattached floating carbon nose piccc
statically scalccl to thc bello111s end plate by a lappcd fit
as previously dcscribcd.
A bcllowvs scal will] an intcgral car1)on facc ancl no
vibration d:ir~lpcrwas tcsicd first. I~sccssivclcakagc, carbon wcar and chipping of thc carbon filcc at thc O.D.
ancl premature bclloti7s failurc were cspcricncccl wit11 this
scal. Af(er rcmoval fl'om thc pulnp, tlie scal was sul)jcctccl to vibration tcsts at aml)icnt tcnlpcr;~tt~rc
and
founcl to have a bronc1 nntural rcsonnut frequency rangc,
wliicll inclr~clcclthc unit operating spccd. An attcmpt \vas
maclc to shift Ll~isrcsona~itfrcqi~cricyband Ly cllnnging
the 1ir1rnl)crof bcllows convoli~tionsto 7 and also to I 1
from tlic original 9 convolutions. Thcsc cllruigcs did not

�swsrrn IIICCRU
VlORlIlGN I r ' W i R TIE

w1h~504ILQ r t c a

XAL COIFIGUUIIOY

SEU W I ~ HmAnNc cuaon nee A
m

Fig. 4-Seal

Configurations Tesfed.

prove cffcctive, so a vibration clamper spring \\:as aclclcd
to the scal.
l'hc vibration danlper consistcd of a flat steel spring
encircling the bcllows O.D.al&gt;prosinnatcly at the ~ n i d point of its axial Icngth. The spring applied a distri-

TABLE
2-SEAL
VIBRATION
DAB~PER

butcd forcc acting radially inward at the bello\vs 0.11.
This was a fingcr typc spring with lhc fingers cslc~iding
o~itiilardmncl rcaqling against the 1.11. of the scnl casc.
A vibriition tcst of illis seal at aml)icnt teii1pcl;tture
indicatcd that this spring was not vcry cffcctive in clunnping out vibration. Close visual examination of the seal
rcvcalcd that thcrc 'was vcry littlc physical interaction
bctween tlic spring and tlie bcllo\vs. llnis was confirmed
by' the prcscnce of very little hystcrcsis in the load
versus dcflcction calibration of this scal pc;fornncd a t
room tcmpcrature.
The scal design \\.as tlnen furthcr moclilicd to include an
adclitional spring acting around the O.D.of the seal nose
rctaincr plate w l ~ i c lis~ wclclcd to the bcllows. Vibration
tests of this seal indicatcd no natural resonhnce in the
operating spccd mnge. IIowevcr, operatiorla1 tests of the
scal within the unit still rcsultcd in excessive leakage
and chipping of the carl~onnose at the facc 0.13. A load
versus deflection calibration df this scal exhibited a very
widc liystcrcsis. This iilay have camcd hanging up of the
carbon nose rclativc to the mating ring with the consequent poor performance.
A round wire damper spring of approximately square
,configuration was installed in the scal acting betwcen tlle
scal nose retainer O.D.and the scal case I.D. This spring
provcd cffcctive in damping the seal when it was subjcctcd to a vibration tcst at rQoln temperature. An ol&gt;cra:
tional test of the seal \ililhin the unit shoivcd the leakage.
to be within acceptable limits. But addition of the round

VIBR;\TIOX AND LEAKAGE CIIAMCTERISTICS
RESOS,\NT
FREQUEXCY
O F I)ELI.O\VS
sE.4~-.'
(ROOMTE~IPEIIATURE)
,

Seal with Integral CnrLo~ifice Piece
None
173 to 190 Ilz

~ A ~ A N ; S

Excessive lcnkage, premature

bcllo\i~sfailurc,.rcsonant fi-cqucncy rangc includcs operating spccd of 183 cps.

'

Fingcr Spring at XlidPoint of Dcllows O.D.
Finger Spiing at
Bcllows Slid-Point &amp;
at Carbon Face 0.1).
Round IVire at Carbon Face 0.D.
Inhcrcnt in Dcsign

120 to 205 112
Nonc bctwcen
20-SO0 IIz
560 1Iz

153 to 205 ITz
wit11 ,lo torsional
lo:1d.
Nonc bciwccn 20SO0 IIz with a
t&amp;sionnl load
of S oz. in. applicd to thc
cnr1)on.

Excessive Leakage, Insuficicnt
Damping
Exccssivc L,cakagc, I righ
IIystcrcsis Calibration Curve
Low Lcakagc and Adcquatc
Damping

Low 1-cakagc and Adcq~latc

Dariq&gt;i~ig.
Prictiori damping
ariscs Lctwccn thc slots at
thc ca~.l,onface 0.11. and
thc keys at the scnl casc I.D.

�wirc diunpcr spring incrcasccl tlic scal spriiig r:itc and ~ila'dc
Under tliis conclit ion, ass~i~ili~lg
a tri:uigular I~ydraulicface
inslilliution witliin t l ~ cpurnp fi~irlycritical. For a scal . prcssurc distril~utiot~,
50 percent of tlic scal facc arca is
load of 2.5 Ibs. the scal liad to LC installed with an inioutside and 50 ycrccnt is i~~sidc
thc bcllo\vs mcan cKectial clctlcclioi~of 0.010 to 0.012 inch. Furtl~crirnprovctive dinmctcr. Such a scal is said to have ail ovcrl)alancc
mcnt \\'as, tl~cr~forc,
coi~sidcredclcsirable.
of 50 pcrccnt. %Ilc ;naul cfTectivc or cquivalcnt piston
A basically dilfcrcnt type of bcllo\\s scal was tcstcd ncst.
diameter is npprosimalcly equal to the average gcomctThis scal employccl a scparatc u~lattacllcdcarbon fitc6
ric diameter of the. bellows. In a scal with a 70 pcrccnt
piccc scaled statically to the bcllowvs end plate l?y' a
overbalance, 70 percent of tlic scal facc area is outside
lapped fit. NO addccl vibrittion damping devices wcrc rcof tlie incan cffectivc diamctcr. In tliis scal, tlie total facc
.
quircd with this scal. Leakagc and wcar were rcpcatcdly
pressurc consists of tlic pressure due to the spring load
within acceptable limits. nccausc of a lower scal spring
ancl 70 pcrccnt minus 50 percent or 20 pcrccnt of the
rate, installed scal dcflcctio~lis approsi~natcly0.040 to
scal operating prcssurc. Theorctically, hydraulic scal over0.050 inch for a.seal loacl of 2.5 Ibs. making installation
balance should not be necessary, but practically it comnon-critical. This scal is prcsc~ltlybch~gused in production
pcnsatcs for scal facc mccl~a~~ical
and thermal distortiorls
liquid oxygen pumps. At approximately 50 psig helium
and manufacturing impcrfcctions in facc flatness. \lrhcn
pressure static Icakagc of this seal is fro1113 to 20 SCIhl
the scal must operate ovcr a range of prcssurcs, it must
and dynamic Icakagc is about 2 SCIM.
be hyclraulically ovcrbalanccd suficicntly to keep the
leakage within acceptable liillits at the highest pressure.
During the devcloplnent tests, the scal bellows spring
SEAL FACE PRESSURE
loads were variccl froin approsi~llatelyseven to two pounds,
. .
scal I~yclraulicovcrbalancc from 70 to 46 per cent, and
One of the more important seal pararnetcrs is tllc facc
seal face arcas.fr01110.10 to 0.39 squarc inches. This reprcssurc. Statically, it is duc to the bcllo~vsspring load
suiltcd in seal facc pressures from 40 to 10 psi.
and hydraulic unbalancc. During seal operation, hyclrodyThe highcr values of seal spring load and ovcrbalance
namic loads ancl therinal dislortions also affect thc facc
producccl higher facc prcssurcs. Thc highcr facc prespressurc.
sures resulted in low initial lcakage, but presented conThe spring load must bc adequate to enable the seal
siclcrable wear ancl friction torque problems, and cvcntufacc to follow, ancl to maintain contact with, the scal
ally Iiigll leakagc duc to seal face scoring. At tlic other
rotating ring wit11 its inherent out-of-squarcncss. \Vhcn a
scal facc load extreme, wvhile wear and friction torque
scal is to be operalee1 at a single pressurc only, the spring
were lo\\ very little scaling was achieved. At ovcrbalload alonc could bc uscd, \vitll a liydraulically balanced
anccs of 50 pcr ccnt or Icss, scal lcakage was very erratic.
scal, to achic've acceptable scal performance.
Best over-all results wcrc oblainccl with a seal spring
In a ' hydraulically balancccl seal tllc hyclraulic forces
load of 2.5 Ibs., an ovcrbalance of 55 per ccnt, and a
tcnding to load and unload tllc seal face arc equal and
resultant seal face pressurc of 10 psi. Seal Icakagc, frictllc facc prcssurc is due to the bcllo\vs spring load only.
tion torque and facc wcar wcrc within acceptable limits.

3-PROPEI~TIES
O F SEAL h.lATERIt\IS
TAI~LE

BTU-IN

~IATERIAI.

F0 - El'

UECU
.
,

TIIEIL\IAL
ESP~~SSION EIARDSESS
In./ln./FO @ 70°F
Goor

1000
261 (Rc 22)
251 (Sc 20)
2200 to 2.100

~uriistcn
- Carbidc (KSO1)
(Nickel Ililldcr)

.'

'

I

'

(Bcrrylco 25)
P5N
(Purc Carbon Co.)
G39.
(U. S; Crap!\itc Co.)
P2003
(Purc Carl)on Co.)

Sclcroscopc 100
220 approx.

Sclcroscopc SO

�TABLE4-SUMMARY

OF SEAL TEST RESULTS
Wear Rate

Seal
face
herial

Rotating
Ring
hlaterial

Intcgral Carbon Face Typc Scul
1
C39 Carbon Chrome on
30.1
2
Chro~ncon

3
4
"

5

P2003
Carbon

S

P5S
Carbon

9

.

'

1

10
11
12

I.
.

13
14

Tungsten
Diselenide
Silver
Tefon

'

5

Over
Balance

Face
'Area
Inch2

'

%

Run
Time
Hr
Min

Xone

3.2

70

0.18

20

4

1
3

Seal
Face
In./Hr

Rota:ing
Ring
In./Hr

Seal
Operating
Press.
psig

Leakage
Std In.3/Min.
Static
Dynamic

0.004

(1)

5

'

01

(2)

(1)

.

40

0.00015

(2)

40
5
130

0.000S

0.010

,130

. 36

130

225

130

Light wear, erratic seal, high leakage
P2003 carbon is hygroscopic and not
suitable for cryogenic use.
High leakage

1.8

70

0.18

18

Round
Wire
Round
IVire

2.6 '

70

0.18

41

1.3

55

0.18

17

2

27

Chrome i n .
440C
P2003
,
CnrSon
P5S
Carbon

Round
\Yire
Round
Wire
Round
Wire

2.6

70

0.18

41

4

00

(2)

(2)

3.1

70

0.18

44

4

30

(1)

(1)

130

54

36

1.8

46

0.10

13

8

05

(2) .

130

320

220

P5S Carbon'

Round
Wirc
Round
Wire
Round
Wire
Round
Wire

2.0

55.

0.13

22

1

32

0.0043

0.012

130

87

44

. 1.7.
.

50

0.11

16

15

47

0.00008

(1)

,130

81

30

3.2 .

50

0.18

18

2

16

0.0014

(2)

5
130

4.9

50

28

1

55

0.0011

0.000008

130

3
33
590
25

15
33
170
100

130
95

270
,200"

130

'

,

.

Rzhr~nxs

44

Xone

'

'

(2)

.

.

Heavy transfer film. high torque, wear
. and leakage
I-Iigh leakage. seal lift off

150
4200
%I 1300
35
22

.

High wear

30

Very high rotating ring wear, early
seal failure

.

.

.

Very high wear pnd high,torque

C!:romc on
440C
'
Aluminum
OsiJc LA-2
C!:romiurn 3
Carbide
LC-:c
. S!iicon
Carbide

2 Flat
Spring

Chrome on
440C

Round
Wire

Chrome on
440C

Round
Wire

300

Sort material, low mechanical strength,
very high leakage

Inherent
In Design

20

High seal torque, restart impossible

I

3

Floating Carbon Face Type Seal
&gt;IYlOii
Chrome on
1'
I
44OC

4

Spring
Load'
Lbs.

440C
P2003
Carbon
P5S
Carbon

1:.

7

Damper
Spring
5 ~ e

Total
Face
Press.
psi

P5S Carbon Chrome on
RECU
Tungsten
Carbidc

,

lnheren t
In Design

.

3.7
3.6

55 ..

. .. .

50

-

.

0.18

. 0.16,
0.18

31

'

21

'

2
I6

50
40

0.0005
0.0003

(2)
'.

0.000003

5

330

.

.

260
60

Damper spring ma!$tnctioned
Good wear and leakage
Selective wear caused conical projcctions and high \wear and high leakage
Selective wcnr caused conical projections and high wear and high leakage
.
'

300

'
,

10
2

Very high wear, erratic and high leakage (rough surfaces)
Low mechanical s:rength, dimensional
instability. high leakage and wear

High torque a: operating pressure
Unit started at lowcr pressure
High torque and high leakage

2

Leakage was not significantly better
than present design
Leakage was 5 sci~nfor first four hours,
then increased to 20 scim

2

Low wear, low and repeatable Icakagc

�I~~ATERIALS
TESTED

.

'

TO~rlioi~iiizc
scal distortion and conscilocnt Icaliagc, it
is clesirablc to use ~natcrialsl~nvitlg,as ncarly as possil)lc,
similar espinsion charactcristics an6 masirnuin hcat .
concluctivity.
Listccl in Table 3 arc thcrmal expansion, conclactivity,
and Iiarclncss for scvcral scal matcrials. Other properti'es
sucll as film laying cl~aractcristics,friction and wcai-ing
qualitics, must bc dctcnnincd by actual test.
Various combinations of carbon facc and mating ring
matcrials wcrc tested as summarized in Tablc 4. Initial
tests nrcre performcd ising a seal with an intcgral carbon
'nose wit11 a G39 carbon fact nlatcrial operating versus
scveral cliflcrent mating ri~lg~natcrials.Carbon film transfer onto thc mating ring was hcavy and lcakagc, wcar,
and torque were gcncrally high ancl not acceptable.
A 1'2003 grapliitc matcrial with a clieinical salt imprconation
opcrati~igvcrsus scvcral mating ring material~
9
geilerally rcsultccl in high leakagc. Also, it was clisco\lcred
in the coursc of thc program that tliis ~natcrialwas hydroscopic and, tlicrcforc, not suitablc for cryogenic use.
Moisture attractecl to it rcsultcd in frcczing
- bctwcen tlic
seals and matigg rings \vithin the pump.
Next, a P5N casbon graphite facc material with a
chclnical salt impregnation was operatcd against a P5N
mating ring. This resulted in high friction, torquc, wear
and Icakagc, ancl confirmccl similar rcsults obtainccl with
othcr carbon vcrsus casbon combinations in this pump
unit. The 1'5N nose piccc was also tested versus flarnc
platcd mating rings of aluminum oxiclc ancl chromium
carbide. Carbon nose n7car and scal leakage \\we high.
This zppcarccl to bc due to sclcctive wcar of thc flamc
platetl materials resulting in sharp conical surface projcctions that abraiclecl thc carbon nosc matcrial. Thc P5N
was also opcratcd against a silicon cahidc mating ring.
\17ear and lcakagc wcre high and sealing \!?as erratic.
In an attempt to rcducc seal friction, two non-casbon
scal facc matcrials ~ \ ~ e tcstecl.
rc
One was a lligli tcrnpcratilrc material consisting largely of tungstcn disclcr~icle
solicl lubricant ancl the othcr was silvcr-tcflon composition. Both rcsullecl in higli. wcar ancl leakage. The tungsten disclc~liclematerial had Ihc undcsirablc property of
bccoming soft, dimensionally unstablc and wearing excessivcly after bcing cxposcd to liquid osygcn. Thc silverteflon material, duc to the fibrous nature of thc embcdclccl tenon particles, \\?asdiificult to polis11 to. the higli
dcgrcc of surface finish ncccnary for good scaling.'i\n
'attempt to run-in thc niatcrial did not improve its scaling characteristics.

'

. An h.lYl0K ciubon fucc piccc with an antilnony atldilive \\.as tested \rcrsus I~nrdcnccl(Ilc 55) 440c stainlcss
slccl. This material producccl a vcry I~cnvytralisfcr filn~
on tlic mating ring. l'llc carl&gt;on fcicc \\.as polislicd. IZcSulL:~utlediagc.wils low but scal friction torclt~c\ifas exccssivcly high.
Tests wcrc also. conducted \\lit11 a I'5N carbon scal
face opcrating vcrsus ~natingrings of harcl clirolnc platc
on bcryllii~mcoppcr and also versus tungstcn carbide witli
a nickcl binclcr. In both cascs thc mating rings ancl
carbon faccs werc vcry liglltly scorccl across tllc arcas of
contact. A vcry light carbon transfcr film was prcscnt on
the mating rings. Lcakagc.and \ircar resl~ltswcrc approsimately thc salnc as obtainccl will1 P5N vcrsus harcl chromc
on 440c stainlcss stecl.
?lie bcst and most consistc~ltrcsults wcrc obtainccl with
a P5N carbon face opcraling versus a mating ring of
hard chrome platc on annealed 440c stainlcss stccl. ljrear,
leakagc, and friction torque wcrc within acceptable limits
and werc repeatable. This material co~nl&gt;iilation
has bccn
qualified ancl is presently being med in'a liq~iicloxygen
punlp on a space veliicle.
CONCLUSIONS

From the work clcscril~cdhcrein tlic followi~lgcon
clusions nrere reached:
1. The best seal co~nbilialionconsistccl of a P5N ear-

bon face opcrating vcrsus a rotating ring of Ilarcl
chronic platc 011 annealcc1440c stainless steel with a
hydra~ilicoverbalailce of 55%, a face pressure of 10
psi ancl a spring load of 2.5 lbs.
2. The over-all pcrformaucc of the floating carbon facc
typc scal was superior to tlie intcgral facc type
seal.
3. The floating carbon facc seal \rw..found to have thc
following advantagcs:
a. Scal facc distortion cluc to the differential contraction bctwecn the carbon face ancl thc stainless stccl Lcllo\\~send platc was eliminated.
b. Aclcquatc axial ancl torsional. .vil&gt;ration damping
- was achicvcd by friction between the car1)on
.
facc and the seal stationary keys with no conse.
qucnt incrcasc in bcllows spring rate.
c. Rcfinisliing and rcplacclncnt of tllc scal ca'rbon
facc coulcl be donc without removal of the scal
from
thc pump housing.
.
d. Thc Iappccl bcllo~\~s
encl plate dicl not rcqriirc
rcfinisliing during the life of tllc unit. .
'

.

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&lt;p&gt;Perhaps the Saturn V’s greatest claim to fame is the Apollo Program, specifically Apollo 11. Several manned and unmanned missions that tested the rocket preceded the Apollo 11 launch. Apollo 11 was the United States’ ultimate victory in the space race with the Soviet Union; the spacecraft successfully landed on the moon, and its crew members were the first men in history to set foot on Earth’s rocky satellite.&lt;/p&gt;
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                <text>A number of considerations are necessary in instrumentation programming, many of which are either not applicable or applicable to a lesser degree in other types of programming. This paper discusses these problems in general terms and illustrates how they have been dealt with specifically. The latter is done by describing the programming and operation of a data reduction system.</text>
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&lt;p&gt;Perhaps the Saturn V’s greatest claim to fame is the Apollo Program, specifically Apollo 11. Several manned and unmanned missions that tested the rocket preceded the Apollo 11 launch. Apollo 11 was the United States’ ultimate victory in the space race with the Soviet Union; the spacecraft successfully landed on the moon, and its crew members were the first men in history to set foot on Earth’s rocky satellite.&lt;/p&gt;
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            </elementTextContainer>
          </element>
          <element elementId="41">
            <name>Description</name>
            <description>An account of the resource</description>
            <elementTextContainer>
              <elementText elementTextId="45989">
                <text>This document contains the transcript from the Apollo 7 mission. This transcript contains the communication from the first seven days of the ten day mission.</text>
              </elementText>
            </elementTextContainer>
          </element>
          <element elementId="39">
            <name>Creator</name>
            <description>An entity primarily responsible for making the resource</description>
            <elementTextContainer>
              <elementText elementTextId="45990">
                <text>Apollo News Center.</text>
              </elementText>
            </elementTextContainer>
          </element>
          <element elementId="40">
            <name>Date</name>
            <description>A point or period of time associated with an event in the lifecycle of the resource</description>
            <elementTextContainer>
              <elementText elementTextId="45991">
                <text>1968-10-11</text>
              </elementText>
            </elementTextContainer>
          </element>
          <element elementId="49">
            <name>Subject</name>
            <description>The topic of the resource</description>
            <elementTextContainer>
              <elementText elementTextId="45992">
                <text>Apollo 7 flight</text>
              </elementText>
              <elementText elementTextId="45993">
                <text> Manned space flight</text>
              </elementText>
              <elementText elementTextId="45994">
                <text>Project Apollo (U.S.)</text>
              </elementText>
              <elementText elementTextId="45995">
                <text>Saturn Project (U.S.)</text>
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          </element>
          <element elementId="48">
            <name>Source</name>
            <description>A related resource from which the described resource is derived</description>
            <elementTextContainer>
              <elementText elementTextId="45997">
                <text>Saturn V Collection</text>
              </elementText>
              <elementText elementTextId="45998">
                <text>Box 28, Folder 35</text>
              </elementText>
              <elementText elementTextId="206406">
                <text>University of Alabama in Huntsville Archives, Special Collections, and Digital Initiatives, Huntsville, Alabama</text>
              </elementText>
            </elementTextContainer>
          </element>
          <element elementId="44">
            <name>Language</name>
            <description>A language of the resource</description>
            <elementTextContainer>
              <elementText elementTextId="45999">
                <text>en</text>
              </elementText>
            </elementTextContainer>
          </element>
          <element elementId="47">
            <name>Rights</name>
            <description>Information about rights held in and over the resource</description>
            <elementTextContainer>
              <elementText elementTextId="46000">
                <text>This material may be protected under U. S. Copyright Law (Title 17, U.S. Code) which governs the making of photocopies or reproductions of copyrighted materials. You may use the digitized material for private study, scholarship, or research. Though the University of Alabama in Huntsville Archives and Special Collections has physical ownership of the material in its collections, in some cases we may not own the copyright to the material. It is the patron's obligation to determine and satisfy copyright restrictions when publishing or otherwise distributing materials found in our collections.</text>
              </elementText>
            </elementTextContainer>
          </element>
          <element elementId="46">
            <name>Relation</name>
            <description>A related resource</description>
            <elementTextContainer>
              <elementText elementTextId="46001">
                <text>spc_stnv_000075_000118</text>
              </elementText>
            </elementTextContainer>
          </element>
          <element elementId="71">
            <name>Is Referenced By</name>
            <description>A related resource that references, cites, or otherwise points to the described resource.</description>
            <elementTextContainer>
              <elementText elementTextId="46002">
                <text>http://libarchstor.uah.edu:8081/repositories/2/archival_objects/17976</text>
              </elementText>
            </elementTextContainer>
          </element>
          <element elementId="82">
            <name>Temporal Coverage</name>
            <description>Temporal characteristics of the resource.</description>
            <elementTextContainer>
              <elementText elementTextId="90094">
                <text>1960-1969</text>
              </elementText>
            </elementTextContainer>
          </element>
          <element elementId="51">
            <name>Type</name>
            <description>The nature or genre of the resource</description>
            <elementTextContainer>
              <elementText elementTextId="90095">
                <text>Transcripts</text>
              </elementText>
              <elementText elementTextId="90096">
                <text>Text</text>
              </elementText>
            </elementTextContainer>
          </element>
        </elementContainer>
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