X-15 OPERATIONS FLIGHT REPORT



FLIGHT NO: 1-64-107 DATE OF REPORT: 7/18/66

PILOT: Major W. Knight DATE OF FLIGHT: 7/12/66

CARRIER AIRCRAFT: B-52 #003 LAUNCH LAKE: Mud Lake

ENGINE SERIAL: 10+ APU #1 16AN APU #2 20AN

PURPOSE OF FLIGHT: 1. Pilot Checkout (100% S&C)
 

2. IFDS Electrical Power Survey

3. Stickkicker (800 psi service)

4. Windowshade

I. Discussion of Previous Operations

A. See Section III, A. II. Aircraft Configuration Changes A. Instrumentation and experiment changes were made as follows:

1. APU turbine speed indication was incorporated on the PDM display in the monitor room utilizing a signal from the alternator excitor field voltage. The circuit is designed to protect against malfunction induced by the data pickoff.

2. The three phases and neutral ground leads from both alternators were instrumented for measurement of current for inflight duty cycle.

3. The wing-pod experiment configuration for the original 200K-flight plan included:
 

a. Micrometeorite

b. Nortronics Skybrightness

c. Pace transducer in the RH pod nose-cone

d. The Autonetics IR Scanner was initially installed in the RH pod tail-cone; however, C.G. considerations prior to flight resulted in disqualification of the experiment since the 28% to 40% wing tip chord pod C.G. limit could not be attained with any ballast combination. The RH tail-cone with ballast was installed in place of the Autonetics IR Scanner.

4. Revision of the flight plan from 200K with J. B. McKay as pilot to 130K with Major Knight as pilot, resulted in removal of both experiments in the LH wing-pod, the RH pod configuration remaining undamaged.

5. The MIT Phase II Apollo Scanner was installed for the original 200K flight and removed for the 130K flight (replaced with the regular light-weight tail-cone).

6. The 130K flight was made with a revised tape parameter configuration including readout of the Autonetics D9A computer three phase and D.C. voltages and computer dump signals to evaluate the computer dump occurring with power voltage transients. Some fifteen C.E.U. dump signals were monitored on the oscillograph.

7. Modifications were made to the Autonetics computer dump circuits to improve the consistency of computer memory turn on after voltage transient dumps. These changes were accomplished in the FRC inertial laboratory.
 

B. Aircraft changes included the following:
  1. Engine S/N 103 was replaced by S/N 107.

2. B. F. Goodrich, 12 ply tires, serviced to 295 psig were installed for flight. Aluminum wheel assemblies are used for these tires.

III. Preflight Events A. The aircraft was recovered from Lake Delamar after the emergency landing without incident. Recovery took place over the period of 5/7/66 through 5/9/66.

B. The main and nose gear assemblies and aircraft mounting structure were visually and dimensionally inspected after the emergency landing involving the lake overrun. Except for dirt in moving parts and normal wear, no damage was noted which could be attributed to the landing. The following parts were replaced:

 
Part Name Remarks

1. MLG bellcrank pivot-pin Normal wear

2. MLG bellcranks Galling of bearing shoulders experienced on previous operations

3. MLG down snubbers Dirt on actuator shaft

4. Nose-gear trunnion bearing Trunnion fitting undersize LH side (ground O.D. to provide
.0005 pinch)

5. Nose-gear down snubber Frozen bearing

6. Nose-gear assembly Dirt and seal wear due to trucking

7. Selected rivets in the MLG Original installation faulty bellcrank pivot support box
structure

8. MLG skid bungees Dirt
 

C. The canopy was returned to NAA, LAX, for repair of the damage sustained by the impact with the lake after jettisoning during the emergency landing. Repair consisted of straightening of the forward LH skirt corner, a scab patch on the RH skirt, and a replacement section of the RH seal longeron in the area of the GSAP camera mount. Repair was accomplished in the period of 5/10/66 through 5/25/66. The canopy fit was good after repair with some improvement in canopy opening loads, indicating physical distortion was not caused by jettison impact.

D. The RH engine-bay blowout panel was replaced after normal blowout occurred with the bay pressurization caused by the engine fuel scroll-case failure.

E. The NH3 tank vent-valve was replaced because of failure to relieve at the proper pressure.

F. Both APU controllers were replaced to accomplish the 360-day inspection and test.

G. The engine lube oil accumulator was replaced in engine s/w 107 because of suspected bladder leakage. A bench check did not reveal a leak.

H. The pitch-yaw RAS valve was replaced for leakage. A valve from stock was incorrectly wired. The valve mounting holes had been misalined, and slotting of the mounting holes was required to allow installation.

I. A satisfactory engine run was accomplished with engine S/N 107 on 5/31/66. A pump scroll-case fire was experienced on the first pump run. APU, BCS operations were also satisfactorily accomplished.

J. The Autonetics IR Scanner service with LHe was demonstrated, requiring approximately (1) hour. A 12 lb. 3 oz. lead ballast was added to the RH nose-cone to establish the required 40% wing tip chord C.G. limit based on the advertised Autonetics Scanner C.G. located (1) inch forward of the mounting flange, and an experiment weight of 51 pounds. See item II, A 3 d.

K. The aircraft was mated to B-52 #003 at 0330 hours on 6/2/66.

L. Flight l-A-105 was accomplished on 6/2/66 with John B. McKay as pilot. No service problems were experienced; however, takeoff was delayed to 1100 hours by C-130 problems. The IFDS computer would not reset for an extended period after the electrical power transfer from B-52 precision source to APU power. As a result the rate-of-climb indicator was lost. The aircraft systems were sequenced through the engine igniter idle phase. The IFDS recovered eventually and performed well on the return to Edwards.

M. Troubleshooting of the IFDS power-transfer problem resulted in replacement of the internal-external power-transfer relay which showed signs of contact arcing. The IFDS display switch was also changed because of voltage transients which occurred with switch operation resulting in IFDS computer malfunction. The system was preflighted satisfactorily and accepted for flight.

N. The aircraft servicing was completed through liquid-oxygen on 6/7/66 before the flight was canceled for Delamar weather. No service was accomplished on 6/8/66 because of EAFB weather.

O. Questions arose concerning the actual C.G. position for the RH wing pod containing the Autonetics IR Scanner. The experiment was removed for measurement because of uncertainty expressed by Autonetics personnel who specified the C.G. position at 1" aft of the mounting flange. The C.G. measured at 3.5 inches forward of the flange, and it became impossible to maintain the 96.5 lb gross limit for the pod with the 28% to 40% wing tip chord position range.

P. Weather caused flight cancellation on 6/9/66.

Q. Flight l-A-106 was completed on 6/10/66 with John B. McKay as pilot. Servicing was accomplished without incident. A 10 minute turn was accomplished at 15 minutes to launch to allow additional time for C-130 positioning. The IFDS computer malfunction after power transfer would not reset for 2.5 minutes. Inflight tests were conducted after system recovery which included transfer of IFDS electrical power to the B-52 precision inverters and a re-transfer to X-15 bus (then powered by B-52 alternators) with duplicate results. Immediately after flight, an APU run with IFDS operating failed to produce a malfunction. The No. 2 APU electrical load was increased by supplying both busses during the test, which showed that alternator capacity was adequate.

R. The aircraft was demated for extensive IFDS tests. The IFDS computer F-3 was returned to the laboratory for functional tests. Preliminary analysis indicated IFDS conditions:
 

a. X-15 alternator power was adequate.

b. The computer dump occurred 4 seconds after power transfer action (the computer memory power transfer occurs with operation of a 4 second time-delay relay).

c. Analog outputs were oscillating at 3 to 4 CPS with a corresponding 0.6 amp three-phase power oscillation when the computer malfunction could not be reset.

d. Adding and subtracting AC loads by operation of other No. 2 electrical bus systems including MIT, SAS, and instrumentation did not produce transients affecting IFDS during ground checks.
 

All manner of tests were accomplished in the laboratory and aircraft which failed to define to exact cause for the inflight electrical power transfer problem. A complete wiring continuity check, physical inspection and relay operation, were made during the period of 6/14/66 through 6/20/66. Many cases of poor workmanship, burned relay contacts, etc., were found but which did not relate to the power transfer action.

S. The "Generator Out" lights exhibited an intermittent dimming action which were traced to high-resistance contacts in a protective panel unit.

T. Aircraft preflights were initiated on 6/21/66. The RAS and manual pitch-yaw valves were replaced because of leakage.

U. A Goodrich Tire Company representative inspected the 50-odd new 12-ply nose-gear tires recently delivered to X-15 stock to evaluate the weather checking of the sidewall rubber. Apparently, exposure after inflation results in severe weather checking. Use of the tires was not affected; however, the condition will result in premature rejection of the tires.

V. The No. 2 APU tank was replaced because of leakage in the Vicone bladder.

W. The flight plan was changed from the 200K altitude flight with J. B. McKay to a 130K altitude flight with Major W. Knight on 6/24/66.

X. APU runs were accomplished on 6/27/66. SAS, ASAS, preflight effort was increased because of the necessity to loan X-15-2 a SAS servo module, replacement of the yaw SAS servo because of leakage, and return of the ASAS case previously loaned to X-15-2.

Y. The aircraft was mated to B-52 #003 on 7/8/66. After cancellation due to weather, the No. 1 APU pressure switch was replaced because of H202 leakage into the APU propellant system by and overload during jettison procedures.

Z. Engine preflight functionals were again accomplished on 7/11/66.
 

IV. Flight Events A. A revised checklist incorporating an early APU start and IFDS power transfer was accomplished to allow evaluation of any IFDS malfunction occurring with the power transfer. Normal IFDS operation was obtained throughout the flight.

B. The aircraft was landed short of the two-mile mark; however, the lake surface was hard and the conditions of landing were normal. Touchdown was accomplished with a 5° sideslip, 6 feet per second rate of descent, with 20° of speed brake. The pilot made roll inputs to correct direction with a resultant aft fuselage displacement relative to the nose-gear track.

During the nose-gear preflight for the next flight, the nose gear was found to be bent. Comments are included in the Flight Report 1-65-108.
 
 

Approved by: Prepared by:

Perry V. Row Ronald S. Waite

X-15 Senior Project Engineer X-15 Project Engineer