10/22/2009
NCAM Receives NASA Achievement Award
Project on the High-Speed Machining Center Produces 100% Accuracy

	Photo #1
	Photo #2
	Photo #3
	Photo #4

On September 17, 2009, NASA’s Marshall Space Flight Center (MSFC) Materials and Processes Laboratory presented a special Group Achievement Award to an NCAM-led team for exemplary performance in support of the Constellation program’s Ares I Upper Stage Common Bulkhead.The presentation was made at Michoud by Wendell Colberg, Deputy Manager, Materials and Processes Laboratory, Engineering Directorate, NASA MSFC.

Photo #1 - With the HSMC1 in the background, Wendell Colberg (center), Deputy Manager, Materials and Processes Laboratory, Engineering Directorate (NASA MSFC) presented NASA Group Achievement Award Certificates to, L to R: Mark Lotz (NCAM Engineering Manager and Project Manager); Terry Coleman, Jonathan Swift, David Quigley (Lockheed Martin); Bruce Brailsford (NCAM Executive Director), Dr. Greg Dobson, John Alt, Steve Attaya, Lisa Johnson (NCAM).

The objective of the Project was the development and testing of manufacturing processes that will be utilized in fabrication of the Ares I Upper Stage Common Bulkhead. NCAM managed the Michoud phases of the project, including subcontracting with Lockheed Martin for additional technical support and working closely with the MSFC Upper Stage Common Bulkhead (CB) Team during planning and execution.
 
During April, 2009, the CB Team spent several days onsite at MAF where machining and a verification test was performed on a CB Demonstration Article using NCAM’s High-speed Machining Center (HSMC). The UNO-NCAM team was instrumental in supporting the logistics of receiving the Demonstration Article at MAF, scheduling of the HSMC, coordinating oven support, photography and video support, providing miscellaneous supplies, and return shipping to MSFC following completion of scheduled tasks.

Photo #2 - John Alt (NCAM) and Terry Coleman (Lockheed Martin) inspect the Demonstration Article after it is offloaded at MAF in April. In the background, Dr. Russell Trahan, Dean of the UNO College of Engineering, visits the project worksite.

The HSMC1 was used to accurately machine the core material to a specified curvature to facilitate bonding of the upper dome panel to the core. Photo #3 - HSMC1 cuts the core material.

After machining, a Verifilm test was done to verify the accuracy of the machining and the fit of the core material to the upper dome panel. Photo #4 - Members of the MSFC CB team apply Verifilm to the core.

The imprint of the core on the cured Verifilm confirmed that the machined core material was in 100% contact with the upper dome panel.