{"id":6466,"date":"2016-09-08T07:00:09","date_gmt":"2016-09-08T14:00:09","guid":{"rendered":"https:\/\/blogschapman.wpenginepowered.com\/scst\/2016\/09\/08\/one-chapman-college-graduate-and-the-apollo-space-program\/"},"modified":"2016-09-08T07:00:09","modified_gmt":"2016-09-08T14:00:09","slug":"one-chapman-college-graduate-and-the-apollo-space-program","status":"publish","type":"post","link":"https:\/\/blogs.chapman.edu\/scst\/2016\/09\/08\/one-chapman-college-graduate-and-the-apollo-space-program\/","title":{"rendered":"One Chapman College Graduate and the Apollo Space Program"},"content":{"rendered":"
\"Alumnus
Alumnus Cal (Collins” Roe ’62<\/figcaption><\/figure>\n

Cal (Collins) Roe grew up in Burbank, CA,\u00a0where he graduated high school and\u00a0studied engineering at a local community\u00a0college. Following his then-girlfriend\u2019s\u00a0example, Roe enrolled in chemistry\u00a0classes and then decided to join his girlfriend at Chapman College to study the\u00a0chemistry of plastic materials – a decision\u00a0that would set the pace of the rest of his\u00a0career. Pursuing plastics seemed\u00a0attractive as he was already working for\u00a0an epoxy resin distributor mixing industrial\u00a0chemicals and the late 1950\u2019s saw a boom\u00a0in the plastics industry. Once he graduated from Chapman College in 1962, Roe\u00a0landed a chemical analysis position with General Precision where he stayed for\u00a0the next three years.<\/p>\n

His time with General Precision would eventually transition into a career with the\u00a0Douglas Aircraft Company, a private contractor that was involved in the Apollo\u00a0missions that sent a manned spacecraft to the Moon and back again. The Apollo\u00a0program consisted of manned missions to the moon that occurred from\u00a01963-1972. In order to bring these first astronauts to space, NASA used the\u00a0Saturn V Rocket Series, which is where the SIVb that Roe helped on would come\u00a0into play. While working as a junior lab engineer, Roe met senior engineers for\u00a0the Apollo program who needed a \u201cspark plug\u201d to restart the Saturn IVb rocket\u00a0engine<\/a>. Roe made two versions using temperature resistant glass fiber reinforced\u00a0silicone plastic. His ingenuity impressed the engineers and very shortly after, they\u00a0offered Roe a position with the Apollo program in Huntington Beach, CA. There,\u00a0he would work on what would become the SiVb rocket \u2013 the third stage for the\u00a0Saturn V rocket and a major component for the Apollo program.<\/p>\n

The third stage SIVb utilized liquid hydrogen (at -423 F) fuel, and liquid oxygen\u00a0(at -297 F) as the oxidezer. Roe\u2019s challenge was to minimize the boil-off of\u00a0these cryogenic liquids while being structurally sound at these huge temperature\u00a0extremes. \u201cMy primary involvement was the manufacturing and the bonding of\u00a0polyurethane foam to the internal surfaces of the liquid hydrogen fuel tank,\u201d he\u00a0says. \u201cOur materials research had determined that polyurethane foam could be\u00a0One Chapman College Graduate and the Apollo Space Program\u00a0repeatedly chilled to liquid hydrogen temperature (-423 F), and back to ambient\u00a0temperature if glass threads were dispersed throughout the foam in all three\u00a0directions (north-south, east-west, up-down).\u201d After the glass thread weaving,\u00a0foam expansion around the threads, curing, and machining, a 3D foam tile\u00a0resulted. Thousands of 3D tile were bonded to the interior of the hydrogen tank\u00a0under very specific conditions of time, temperature, pressure, and humidity\u00a0conditions using an epoxy paste adhesive. To gain work-life of the epoxy, the\u00a0entire hydrogen tank assembly (22 Ft in diameter and 58 feet long) was located\u00a0in a barn sized building and first chilled to 35 to 40 degrees F during the 3D tile\u00a0bonding. Then when all the 3D tile were bonded, the epoxy adhesive was then\u00a0cured at 170 to 180 degrees F.<\/p>\n

Small destructive test panels were made with the same materials and under the\u00a0same conditions as the flight hardware to verify that the specific conditions of\u00a0time, temperature, pressure, and humidity were within specification tolerances.\u00a0The process would culminate when test coupons were cut from the test panel\u00a0and tested in liquid nitrogen (-320 F). Occasionally, something would go wrong,\u00a0leading Roe and the rest of the team to the conclusion that something in the\u00a0bonding process was faulty. \u201cWe had a few frantic weeks at one point as all the\u00a0coupons were failing when immersed in the liquid nitrogen. After reviewing all\u00a0the data, testing the actual foam in the tank, analyzing the epoxy adhesive etc.,\u00a0and we could not find anything wrong,\u201d he explains. \u201cWe were making plans to\u00a0remove all the 3D foam or possibly scrap several tanks. Finally, we found that the\u00a0chemical department had \u2018improved\u2019 the corrosion resistance of the anodic\u00a0coating. The new improved anodic would not withstand the liquid nitrogen. The\u00a0tank skins were anodized by the old method, and the coupons were anodized by\u00a0the new method. We had our test panels anodized by the old way and the\u00a0problem went away.\u201d<\/p>\n

When the Apollo project ended, Roe was involved with the Skylab project,<\/a> where\u00a0he and his colleagues converted the hydrogen fuel tank into living quarters in\u00a0space. At the time, NASA was concerned about losing the nearly 400,000\u00a0workers that had helped put a man on the moon and the Skylab was a way to\u00a0retain many of those employees. Scientifically this would lead to reopened\u00a0discussions on the integrity of 3D polyurethane foam and astronaut safety. The\u00a0polyurethane foam would burn almost explosively in the pure oxygen atmosphere\u00a0One Chapman College Graduate and the Apollo Space Program\u00a0being utilized and thus, a solution needed to be found and Roe\u2019s team was\u00a0involved. Testing indicated aluminum foil bonded to the internal foam surface\u00a0would extinguish the flame in pure oxygen. The greatest exasperation in this\u00a0project was to please the interior designers\u2019 tastes for a less offensive color for\u00a0the inner walls of Sky-Lab. Eventually they settled for a light yellow Teflon coating\u00a0that had recently been developed by DuPont for use for non-stick household\u00a0frying pans. The mock-up of Sky-Lab at the Smithsonian owes its pastel yellow\u00a0walls to the work of Cal Roe in 1969.<\/p>\n

\u201cMy job was to maintain the process specification. This is a document that\u00a0provides detailed instruction on how to do something, and what materials to use.\u00a0The NASA process requirements for the man-rated Apollo program were very\u00a0specific. When a number, like temperature, is specified then there has to be a\u00a0tolerance. There also must be test data at the tolerance limits to show that the\u00a0properties of the materials are the same. Thus, there is a lot of material testing to\u00a0support the process specification.<\/p>\n

During a weeks work I would daily visit the production area and talk with the\u00a0production personnel, where \u201cI spent many hours inside a Saturn iVb hydrogen\u00a0tank observing the workers to assure the actual production process being used\u00a0was in accordance with the specifications we developed in the laboratory.\u201d I\u2019d\u00a0review a new design drawing to assure the proper process specifications were\u00a0specified on design drawings, I\u2019d talk with NASA personnel to prove that a recent\u00a0coupon failure was not a concern, I\u2019d visit the laboratory to check on some\u00a0testing or watch some tests, and I\u2019d write a revision to the process specification.<\/p>\n

This is where I learned the importance of the written word, and I really improved\u00a0my writing skills over my college work.\u201d\u00a0The Skylab would eventually launch and orbit the earth from 1973 until 1979\u00a0when it would reenter the earth\u2019s atmosphere but shortly thereafter, Roe\u2019s work\u00a0with the space program decreased. \u201cI had no desire to get into supervision,\u00a0because I enjoyed the hands-on work with the hardware. People problems were\u00a0not for me. During my career I worked on many programs involving adhesive\u00a0bonding including launching the GPS satellites. I retired in 1995, and now live in\u00a0Oceanside CA with a lot of useless aerospace data fading from my 79 year old\u00a0memory.\u201d<\/p>\n","protected":false},"excerpt":{"rendered":"

Alumnus Cal (Collins) Roe \\’62<\/p>\n","protected":false},"author":1168,"featured_media":10320,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","ast-disable-related-posts":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"default","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"custom_author_name":"","chapman_pin_hero_slider":"","footnotes":""},"categories":[5],"tags":[8],"class_list":["post-6466","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-alumni","tag-chemistry"],"yoast_head":"\nSchmid College of Science and Technology | Chapman Blogs<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/blogs.chapman.edu\/scst\/2016\/09\/08\/one-chapman-college-graduate-and-the-apollo-space-program\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"One Chapman College Graduate and the Apollo Space Program - 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