**AMS-02 Weekly Activity Report, December 2, 2006**

Upcoming Events:

-   AMS Integration Meeting at CERN January 25 -- 26, 2006

-   AMS General Technical Interchange Meeting (TIM) at CERN January 30
    -- February 3, 2006.

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-   AMS-02 Phase II Safety Review -- Date TBD (Schedule under review) --
    JSC

    Upcoming Tests:

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-   Interface Plate Static Test -- Date TBD -- Location TBD

-   Lower Joint Static Test -- Date TBD -- Location TBD

-   STA Sine Sweep Test -- August 2006 -- INFN, Terni, Italy

-   STA Acoustic Test -- October 2006 -- ESTEC, Noordwijk, Netherlands

-   Full Assembly Modal & Static Tests -- January 2007 -- IABG, Munich,
    Germany

**AMS-02 Design**

-   EVA Foldable Remotely Operated Electrical Umbilical (ROEU) Bracket
    model design primarily is complete. Detail and Assembly Drawings are
    in work. The usual tolerance work and drawing review is in order.
    The space qualified Pip Pin specification has been identified and
    price and availability information is forth coming once we are
    satisfied with the detail design.

-   The two thermal blanket bracket drawings are completed but not
    uploaded.

-   The Thermal blanket assembly drawing for the VC Outer Cylinder and
    Inner Conical Flange is at 95 percent complete.

-   The Inner Conical Flange thermal blanket template has been changed
    to include shielding material from the tracker.

-   Primary Support Stand (PSS) top level drawing is currently in check.

-   USS-02 build-up drawing, decals drawing, Upper USS-02 drawing, and
    Lower USS-02 drawing are checked and ready to be uploaded into EDRS.

-   USS-02 Keel Assembly drawing is uploaded into EDRS and waiting to be
    signed and released.

-   Thirty five (35) PSS drawings were released from EDRS.

-   The drawings for the VC Shipping Fixture modifications have been
    submitted to checking.

**AMS-02 Flight and GSE Manufacturing:**

-   The Sill Joints are being held up at the vendor due to nickel
    plating problems. The final machining operations peeled up some of
    the plating out of the Trunnion hole. It was determined by
    engineering that the original plating thickness was too thin. A DR
    was generated and approved to fix the problem by removing the
    remaining plating, enlarging the hole, re-plating and final
    machining the bore (if necessary). This may affect schedule. We will
    not know the extent until time estimates are received back from the
    vendor performing the work (Metalex).

-   Riveting of the Lower USS-02 Center Body Assembly is complete.

** **

-   Assembly of the PSS is to commence Monday 12/5/05.

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-   The USS-02 Keel has been assembled on the assembly fixture. It is
    currently being aligned with the rest of the hardware.

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-   The Primary Support Stand subcomponents are being finalized for
    assembly.

**GSE & STE**

-   An analyst is currently working on the Primary Support Stand (PSS)
    medium level configuration stress analysis.  Analyst received the
    set of nonlinear runs from the Loads group and the analyst ran
    NASPOST.  The NASPOST raw data was then processed using MathCAD. 
    MathCAD files were created for both Air Transportation and Truck
    Transportation scenarios.   The beams that compose the PSS were all
    analyzed and preliminary results were reviewed by the analyst and
    the lead engineer.  Analyst will now analyze the fasteners in the
    PSS.

-   Checking redlines for the X-Y sine sweep transition frame drawings
    were incorporated.

-   The top level assembly drawing for the assembly of the mass
    simulator into the Vacuum Case Test Fixture (VCTF) has been
    completed and submitted to checking. In addition, the drawings have
    been supplied to stress for analysis.

**Vacuum Case**

-   The UT inspection of the Vacuum Case closeout welds has been
    completed. The final report is in work and will determine which
    areas need to be repaired. Repairs and inspection are expected to
    take 1-2 days.

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-   DRs for the STA Vacuum Case are being worked.

-   The drawings for the VC Shipping Fixture modifications have been
    submitted to checking.

**Modal & Static Tests**

-   Work is progressing on generating STEP and IGES models of the AMS-02
    Payload for delivery to IABG. The STEP model has been successfully
    created but the IGES model conversion process is currently crashing
    due to the limitation of the PC. The conversion process is being
    resubmitted with a lower resolution on parts to see if the PC can
    handle the translation. In addition, the model is being submitted to
    a server for translation by the Unigraphics system administrator.
    Problems are still being encountered with the translation and it
    will be allowed to run over the weekend to determine if the
    conversion will work.

**Avionics**

-   Continued efforts in resolving Uninterruptible Power Supply (UPS)
    cable integration issues so that manufacture of the UPS can begin.

-   Continued efforts in resolving CDD thermal test issues so that
    manufacture of the CDD test article can begin.

-   Continued efforts to publish Revision B to the Uninterruptible Power
    Supply (UPS) State of Work.

-   Resolved bonding and grounding requirements definition for the
    AMS-02 MLI specification, and provided revised text with these
    changes to EC.  The AMS-02 MLI blankets must be compliant with ISS
    requirements found in SSP-30245 and with SSP requirements, as
    documented in NASA/TP-1999-209263.  The revised text was reviewed
    with the local Boeing co-chairman of the ISS Electromagnetic Effects
    Panel (EMEP), and who concurred with the wording.

-   Began reviewing the drawings for the flight article integration
    cables.  Following drawing review, PRs will be placed to procure
    materials for flight cable assembly.

-   Inspected the Flight Remotely Operated Electrical Umbilical (ROEU)
    Payload Disconnect Assembly (PDA), and several discrepant items were
    found.  These were identified to SSP, USA and Boeing engineers and
    QA, who will submit rectifying instructions via E-mail.  The AMS-02
    team will be responsible for implementing these steps.

-   Successfully resolved an issue with fault path bonding (Class H
    bond) via riveted joints on the Lower USS.  This issue was
    identified when it was determined that EM can only perform Class 1A
    (not Class 3) touch-up chem-film alodining.  The concern was that
    the Class 1A alodine would have greater electrical resistance that
    the Class 3 alodine, and that the resistance values might exceed the
    requirement for Class H bond.  A milli-ohm meter was used to measure
    the resistance across several Lower USS riveted joints, and these
    values are several orders of magnitude lower, or better, than the
    requirement.  Additionally, the approach to effecting fault path
    bonding over riveted joints was reviewed with the local Boeing
    co-chairman of the ISS Electromagnetic Effects Panel (EMEP), and who
    concurred with the design.

**Experiment Mentoring (ECAL)**

-   Meetings were held with NASA ES representatives twice this week to
    discuss ECAL bolt analysis issues.  The ECAL bolts were reanalyzed
    to show compliance with NSTS 08307 requirements.  Negative margins
    of safety for the gapping of the bolts attaching the Bracket to Side
    Panel interface was discussed at length.  Actions were given to
    prove that gapping would not cause a shift in the fundamental
    frequency of the ECAL assembly and show that the gapping would not
    result in any fatigue problems in the bolts themselves.  The
    additional analysis was completed and the results were presented to
    NASA ES representatives.  The ES representatives were satisfied with
    the analysis results and agree that we have satisfactorily proven
    that joint separation for the ECAL is not an issue.  These analysis
    results will be documented and issued as a separate report to be
    sent to both the ECAL developers and NASA.  Replacement bolts for
    the ECAL will be ordered this coming week.