4. TEST PROGRAM 



It is the intention of this section to describe the pre-deploy- 

 ment testing performed and summarize the results obtained. 

 The nature of the test program has been dictated by the schedule 

 and funding environment. As a result we have emphasized dem- 

 onstrations of component adequacy. Little testing has been done 

 with the objective of developing improved components. 



4. 1 Structural Testing 



Structural testing consisted of: 



a. sample testing to determine yield and rupture 



b. proof testing of critical in-line components 



c. radiographic and other inspections of shackles, 

 couplings, terminations, and other fittings 



Experience has demonstrated the need for proof testing all 

 critical components since quality control procedures are rarely 

 known to be adequate. This is not to say that proof testing is a 

 satisfactory substitute for quality control. It is the only means 

 at our disposal to minimize the probability of a structural fail- 

 ure during installation and during the first few weeks of operation. 

 It will be seen that all tensioned components of the telescope were 

 proof loaded except wire rope couplings, head frame. Station 1 

 bridle, sensor stations, and anchors. These components (except 

 anchors) require only radiographic and dye-penetrant inspection 

 since they are inherently structurally reliable and much over- 

 strengthed. 



4. 1, 1 Testing of Wire Rope Shots 



Table 4-1 outlines the tensile yield and ultimate strength tests 

 performed on sample wire rope shots, including swaged termin- 

 ations. 



The swaged stainless steel terminations on the B-3540 wire 

 rope slipped off because standard terminations and swaging dies 

 for 9/32" wire rope were mistakenly used (the B-3540 wire rope 

 diameter is . 016" less than 9/32"). Both the first and second 

 orders (October 1967 and June 1968) exhibited this error. In 

 each case the problem was fixed under schedule duress by re- 

 swaging the terminations using special dies. The correct pro- 

 cedure is to use terminations specially bored for the . 265" 

 rope diameter. Re-swaging introduced a small curvature to 

 the terminations and cold- worked the material more than 

 desired. As a result the life expectancy of the terminations 

 and wire rope may have been reduced. Fig. 4-1 contains photo- 

 graphs of a failed termination pulled off during testing at NOB, 

 Bermuda. 



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