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Perform integration according to the Piston Integration Procedures above.
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Run wires from outside to inside the blast chamber. Make sure that the wires are shorted on the outside of the blast chamber. On the inside, unshort the e-match leads and connect it to the wires.
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Place the piston in the vacuum chamber (firebolt-fitting assembly pointing down).
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Clamp the piston between two bricks.
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Put the lid on the chamber and turn on the vacuum pump until pressure level reaches 0 psi.
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Only after exiting the chamber and closing the door, perform a countdown and connect the outside wires to a voltage source (battery).
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In the event of a misfire, disconnect the battery and wait at least 60 seconds before allowing anyone to enter the chamber/approach the test article.
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After firing, wait at least 60 seconds before entering the blast chamber.
- One plug was insufficiently filled with epoxy and leaked during the hydrostatic test at around 900 psi, that plug was not used
- The other three plugs passed hydrostatic testing
- When assembling the capsule with black powder, it was discovered that the current iteration did not fully contain the black powder and some granules leaked past the washer/burst disc.
- Reasons:
- Plugs were not fully screwed in due to epoxy on the threads and could not apply pressure to the washers
- Washers were loose in the capsules, allowing black powder to get past when shaken (could be due to above, could be separate, or both)
- Potential fixes:
- Be more careful when applying epoxy to the plugs to avoid gunking up the threads
- Make washers thicker to reduce the distance that the plugs have to be screwed in
- Use sealant substance between the washers and the reducing adapter (RTV gasket maker)
- For test, wrapped some teflon tape around the washers until they were friction fit into the reducing adapters, this created a sufficient seal to contain the black powder. This is not the preferred solution, however, and an easier to integrate solution is desired
- Reasons:
- The three plugs that passed hydrostatic testing were fired successfully
- Those plugs deployed the new 1" pistons fully and without incident