This color documentary film is about the 1974 DC-10 redesign for a four-segment articulated rudder out of graphite epoxy composite by the Douglas Aircraft Company (contract NAS1-12954) on behalf of the NASA Langley Research Center. The film opens with a view of the final product on a McDonnel Douglas DC-1o aircraft, which expands out to show the plane taxing on a runway before taking off (:08-1:08). An artist’s rendition of the seven initial design concepts is shown (1:09-1:57). The final ribs-stiffened skin design is shown as a prototype of graphite epoxy composites. Two scientists cover it using a thermal expansion molding technique. An artist’s rendition follows (1:58-2:50). A one-step manufacturing process is shown as thick silicone rubber is poured into a mold. Internal elements are molded together through a machine. A large form die is shown (2:51-4:09). Two scientists work on the rudder skin panels by cutting from uncured graphite epoxy tape (4:10-4:48). A scientist fabricates rudder component test articles using foam blocks and pushed into an oven to cure (4:49-5:20). Static testing of the spar is performed, which fails (5:21-6:00). The hinge fitting fastener is tested for fatigue strength (6:01-6:44). A residual static strength test is performed (6:45). Four full-scale prototype rudders are made (6:54-7:31). A rudder box component is subjected to vibration testing. Engineers wear headphones and turn switches (7:32-8:14). Static load tests are conducted on a second rudder. One test uses a whiffle tree loading fixture on the third rudder (8:15-9:04). Ground testing is performed on the fourth rudder for certification by the Federal Aviation Administration. An ultra-sonic inspection is shown. The scientist attaches the probes and the results are shown on cathode-ray screen displays (9:05-9:57). The graphite composite has a static test program run on it. A hydraulic actuator simulates air loads through a compression whiffle tree system (9:58-10:32). The final test duplicated an all well load (10:33-10:59). Thick silicone rubber is poured into the die molds (11:00-11:09). Men in lab coats work on various machines. The leading edge is attached using flex screws. The trailing edge is attached (11:10-12:00). A worker injects a cold set adhesive along the trailing edge, which is then tamped down and the edge attached. Rivets are added, shown up-close (12:01-12:34). The tip assembly is riveted to the upper closing rib of the rudder box (12:35-12:56). A worker wears headphones and performs the laboratory modal vibration survey tests in front of a stack of machines with dials. DC-10 push rods vibrate against the rudder as part of the test (12:57-13:58). The first rudder is listed into place and installed in April, 1976 on a DC-10 airliner and tested in flight (13:59-14:18). A second rudder is installed into place on a Western Airlines DC-10 and used in flight (14:19-14:53). A hand opens a notebook to show a sketch of the advanced composite rudder section for a commercial jetliner and the final product actually being assembled (14:55-15:45). A Western Airlines DC-10 flies by the camera (15:46-16:02).

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This film is part of the Periscope Film LLC archive, one of the largest historic military, transportation, and aviation stock footage collections in the USA. Entirely film backed, this material is available for licensing in 24p HD, 2k and 4k. For more information visit http://www.PeriscopeFilm.com