X-15 OPERATIONS FLIGHT REPORT



FLIGHT NO: 1-48-75 DATE OF REPORT: 5/25/64

PILOT: Capt. Joe Engle DATE OF FLIGHT: 5/19/64

CARRIER AIRCRAFT: B-52 #003 LAUNCH LAKE: Delamar

PURPOSE OF FLIGHT: 1. Phase II Optical Degradation Experiment, and

2. Altitude Buildup for Pilot

I. Discussion of Previous Operations

A. The flight control pitch system oscillations encountered during recent flights were corrected by component replacements. Four LH actuator changes were made before an acceptable unit was qualified for flight. Two inherent characteristics of the horizontal hydraulic actuator contributed to the difficulties: (l) actuator creeping or inconsistent positioning is associated with synchronization adjustments of the dual hydraulic system metering valves on the test bench, and (2) hydraulic damming is determined by metering valve spool to sleeve overlap and diametral clearances which can cause high breakout forces of the metering valve. A comparison of bench tests to aircraft environment was made and indicated high metering valve restoring force of approximately 30# on the bench compared to 0.5 pound in the aircraft. Synchronization adjustments on the bench will be made to best capabilities in lieu of maintenance specification gross requirements. A bench check of damming will also be included in the revised qualification tests. The revised bench tests are expected to define the actuator characteristics and minimize actuator rejections after installation in the aircraft. The LH horizontal hydraulic actuator used on flight 1-47-74 was evaluated on the simulator, and high metering valve breakout forces were encountered.

B. The angle of attack indicator bias-error of 3-4° noted on the previous flight was traced to a loose adjustment screw in the alpha differential syncro which is between the ball nose alpha syncro transmitter and the cockpit indicator. A revised adjustment locking scheme has been initiated to prevent inadvertent adjustment changes.

II. Aircraft Configuration Changes A. An optical horizon indicator was installed to provide a visual pitch attitude indication. The unit was supported by a bracket attached to the cockpit panel. III. Instrumentation Configuration Changes A. The six position manual IMC system switch was installed to provide the pilot KS-25 control for the altitude profile. IV. Preflight Events A. The nose gear door was removed, and a complete inspection made of the cockpit forward bulkhead including heatshield. Abnormal signs of overheat were not found to explain the smoke in the cockpit observed in the previous flight.

B. A SAS frequency response test was conducted as part of the inflight pitch oscillation investigation. A SAS preflight was also accomplished without note of SAS performance degradation.

C. The LH hydraulic actuator used on the previous flight was placed on the X-15 simulator for evaluation. A series of actuator changes was made because of surface drift, high metering valve breakout force (damming), and leakage. An acceptable actuator was finally obtained from X-15-2.

D. Improved response of the pitch trim system was obtained by replacement of the pitch trim feel bungee and load limiting bungee to eliminate system free play. The breakout force of the feel bungee was increased to .5# to improve the horizontal hydraulic actuator metering valve centering force.

E. The canopy was sent to NAA at LAX to replace the RH inner windshield. The bracket attached to the inner windshield retainer for the split vision mirror altitude reference was not reinstalled. Pin holes were found in the canopy seal during testing, and a seal replacement was accomplished.

F. Successful APU, BCS, RAS operations were accomplished on May 7, 1964. Engine S/N 109 was qualified for flight without an engine ground run.

G. The combination of a pessimistic weather forecast and conflicts with the Air Force Armed Forces Day flight demonstration resulted in reschedule of the flight from 5/14/64 to 5/19/64.

H. During final flight control system checkouts the pitch trim electric actuator failed with an intermittent clutch, causing a trim hunting action. A replacement unit from stock failed to operate after 4 bench test cycles. An acceptable trim electric actuator was obtained from X-15-2.

I. The aircraft was placed on static display for Armed Forces Day activities.

J. An installed recharge cycle was accomplished on the ships emergency battery to correct a low voltage encountered during load check. The load voltage was raised from 22 volts to 24 volts after recharge.

V. Flight Events A. The experiment power switch (MODE SWITCH) was not placed on until the outbound inflight test sequence (the request for "SWITCH ON" was not made after the inertial system was called in specs). The normal procedure requires power on in advance of test operation to allow for mount stability. Operation of the green light was obtained with pilot operation of the mode and test switches at the time of the outbound test. Apparently, the pilot placed the mode switch to OFF position at the conclusion of the test, where it would be normal procedure to set the mode switch in "AUTO" on the ground, remaining on throughout the flight. Based on data analysis, the power was not on the mount and KS-25 until approximately 50 seconds after burnout when the pilot noted the absence of a green light and cycled the mode switch on. The mount normally requires 3 minutes to erect, and due to the aircraft altitude during the erection cycle, mount stability was not obtained during the flight. In other respects the KS-25 system operation appeared normal.

B. Engine pump oscillations were noted in igniter idle prior to launch. Engine governing was on the metering valve fixed slot. Engine shutdown would occur automatically if oscillation exceeded the fuel high pressure manifold pressure setting, therefore the condition was accepted. The manifold and igniter chamber pressures steadied out after chamber light as expected. Restart after launch, if it would have been required, would utilize the automatic start sequence and the effect of pump oscillations during the rapid igniter idle transient would be minimized.
 
 

Approved by: (W. Albrecht - for) Prepared by:

Perry V. Row Ronald S. Waite

X-15 Senior Project Engineer X-15 Project Engineer