Abstract
An extensive development and qualification testing program was undertaken to obtain design information on cross-rolled sheet beryllium for the Agena D spacecraft. Curved Be panels were used as structural skins and doors for a weight reduction redesign. Two major problem areas were curved panel buckling allowables and panel edge attachment allowables. The present paper reports the studies and tests conducted to develop edge attachment allowables for the Be panels. Various rivets, bolts, and screws were tested using simple lap joints. Several methods of locally increasing the panel edges to reduce high bearing stresses were also investigated. Based on these tests, the final attachment design used No. 10 titanium screws in combination with integral edge thickening of the panels produced by selective chemical milling. In addition, exploratory testing of adhesive bonded and brazed joints was conducted, and such joints proved to be satisfactory for certain applications. The use of Be sheet now available, with better and more consistent properties, permits its increased utilization in light weight aerospace structures.
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