Qualification Thermal CycleTest Aqualification thermal cycletestwasperformed todemonstrate theabilityofthefinealignment assemblies toperform intheISSspaceenvironment, meeting allthermal andmechanical performance requirements 1°.Thiscomponent leveltestcorrelated tosystem levelperformance inthatthetemperatures usedfortestwerepredicted fromsystem level(truss)thermal analysis. Thecomponent testpartlyverifies abilityoftheP6primary andcontingency nutstocomply withthepredicted system bornemisalignments relative toZ1finealignment features. Thetestalsoevaluated bearing rotation andraceslidingat temperature extremes. Withregardtonutrotation/sliding performance, results ofthisambient pressure testcorrelate wellwith results ofanearlierHuman Thermal Vacuum (HTV)test11.IntheHTVtest,amisalignment testwas performed attemperature extremes, simulating bothoveralltrussthermal-structural deflections andlocal mechanism thermal-structural deflections (clearance changes duetodifferential coefficients ofthermal expansion between mechanism moving elements). Functional testing atseveral pointsofthistestwas successful, including confirmation thattheprimary boltdidnotloosenasaresultofthermal cycling, and visualinspection revealed nochange occurred. Thetestalsoverified thatthefinealignment features, bolts,launchrestraint cap,etc.havesufficient clearance toengage/disengage attemperature extremes. Qualification Misaliqnment Test Aqualification misalignment testwasperformed toverifythattheZ1andP6finealignment interfaces engage andcanbeboltedtogether whenthereisanangular misalignment between thetwostructures, whenthereisalateraloffsetbetween theZ1andP6assemblies, andwhenthereisagapbetween theZ1 shearcylinder andthefaceofthesleeveintheP6ball/receptacle 12. Thiscomponent leveltestcorrelated tosystem levelperformance inthatthethermal-structural deflections thatthemechanism's degrees offreedom aredesigned toaccommodate, arethetrussdeflections. These trussdeflections areduetooverallZ1toP6trusstemperature differences, notlocaltemperatures ofthe mechanisms themselves. Testgapsandmisalignments simulate thosethatmayoccurbetween theP6 andZ1duetoworstcasesystem levelon-orbit thermal effects andmanufacturing tolerances. This component testalsocorrelated tosystem levelperformance inthatthetestfixturesimulated theP6truss backup structure stiffness. TheP6finiteelement modelwasusedtocalculate required fixturestiffness. Fixture stiffness wastestverified priortouseinthemisalignment test.Agraphical viewofthe misalignment testsetupisshowninFigure17. Inthequalification misalignment test,performed atroomtemperature, onlysimulated overall truss thermal-structural deflections wereaddressed. However, intheHTVtest,themisalignment testwas performed attemperature extremes, simulating bothoveralltrussthermal-structural deflections, andlocal mechanism thermal-structural deflections (clearance changes duetodifferential coefficients ofthermal expansion between mechanism moving elements). Therefore resultsofboththequalification andHTV misalignment testsprovided confidence thatthemechanism wouldperform asrequired inthespace environment. Qualification StaticLoadsTest Thequalification staticloadstestwasperformed toverifythefunctionality ofthetestarticles afterthe application of1.0timesthedesignlimiton-orbit loads_3.Anadditional objective wastomeasure theforce required toslidetheP6assembly underapplied limitloads.Thestrength ofthetestarticlewasverified for 1.5timesthedesignlimiton-orbit loads.Thiscomponent leveltestcorrelated tosystem levelperformance inthatthestructural testloadvalueswerederived fromsystem-level analyses. Theseloadsinclude onorbitmechanical loads,thermal loads,andmisalignment loadsduetomanufacturing tolerances. Test casesincluded configurations withonlytheprimary boltengaged, andcaseswithonlythecontingency bolt engaged. Aftertheapplication oflimitloads,nodamage wasfoundandtheunitspassed themechanical functional tests.Nofailureoccurred afterapplication ofultimate loads. Loadversusdeflection datawas recorded foreachloadcaseandwasusedtodetermine jointstiffnesses. Qualification Contact Dynamics Test Aspecial contact dynamics testwasperformed tovalidate themathematical modelofthetruss attachment's finealignment features, comprising theball-nut andshearcylinder atonetrusscornerTM.This model,together withtheSRMSandCLAmodels madeupthesystem levelmodel,orfullsimulation asit 205