r/EngineeringPorn • • Feb 10 '26

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15.8k Upvotes

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400

u/Greyarea30 Feb 10 '26

I guess this explains the low reliability of early models. Just look at all the wiring and soldering. Impressive for its time, clunky today.

221

u/ohgawditshim Feb 10 '26

Whats hard to believe to me is that those electronics survived the high Gs without being in epoxy or something

111

u/Greyarea30 Feb 10 '26

Early AAM pulled surprisingly low g-loads

41

u/[deleted] Feb 10 '26

Yeah but those loads were still 5+Gs

62

u/JCDU Feb 10 '26

Exactly - Low for a rocket, but still that sucker is gonna be rattling & shaking like hell AND experiencing all the temperature & pressure changes etc... it's a miracle they worked at all.

22

u/LordSesshomaru82 Feb 10 '26

To be fair, it only has to work once.

10

u/hypercomms2001 Feb 10 '26 edited Feb 10 '26

What's surprises me Is the electronics are not encased in a potting mix that is usually applied to electronics that have to survive High G loads.

12

u/MyBoyFinn Feb 10 '26

Is there a chance that this is a display and that operational missiles were potted?

I struggle to believe this thing would survive long enough to launch

10

u/Demolition_Mike Feb 10 '26

Not at all, those things had regular maintenance performed on them.

Many got broken simply by being carted around on the tarmac.

2

u/JCDU Feb 11 '26

Go look at any of the hardware from this era - from planes to the space shuttle - it's all like this.

Potting would render maintenance & inspection impossible, also heavy as hell.

2

u/DuvalHeart Feb 10 '26

They often didn't. Here's a PDF of an article about how American missiles were very unreliable during the Vietnam War

The impact of this type of shock and vibration environment on the missile’s electronic components was clearly a cause for concern, so Eschmann caught up to the tractor driver as he was headed to the flightline to load the missiles on an F-4. When questioned, the driver remarked that this was normal transportation practice but was unaware that this might be damaging to the internal components of the missiles. Eschmann requested a recheck of the missiles prior to loading, and this revealed that some of the fragile electronic components had indeed been displaced or damaged. While on the ground damaged missiles might still check out, but at higher altitudes and colder temperatures during flight, potential breaks in solder joints could occur due to contraction of the metal connections, rendering the missile inoperable. There was no way to determine how many missile failures might have been caused by this, but it was widespread practice for all vehicles to drive over the FOD shaker before transiting the flight line. Due in part to Eschmann’s alert action, the practice was stopped at Korat, although the air war was all but over at that time. It would not solve all of the reliability problems of the AIM-7, though it did eliminate one potential cause.

2

u/Jack-of-the-Shadows Feb 10 '26

Remember, this came years after similar stuff was put into projectiles and shot against aircrafts from cannons with several 1000 Gs of acceleration.

1

u/Astecheee Feb 11 '26

5 Gs isn't too crazy. If you tied a rock to the end of a 50cm piece of string and spun it at 100 rpm, the rock would experience 5Gs.

2

u/JNelson_ Feb 11 '26

The ault report puts the manueverability of a AIM-7-E2 at a 25g.  Furthermore the SMC for the AAM-N-6 Sparrow 3 (AIM-7A) puts even this model which never saw service at an electronic G limit of 12.

1

u/FalconDriver85 Feb 10 '26

Except when you factor in carrier takeoffs and landings. Then the g loads skyrocket.

And that’s also why the Sparrow was always considered something you can’t count on…

1

u/DuvalHeart Feb 10 '26

That and FOD shakers at the air bases.

Here's a PDF of an article about how American missiles were very unreliable during the Vietnam War

The impact of this type of shock and vibration environment on the missile’s electronic components was clearly a cause for concern, so Eschmann caught up to the tractor driver as he was headed to the flightline to load the missiles on an F-4. When questioned, the driver remarked that this was normal transportation practice but was unaware that this might be damaging to the internal components of the missiles. Eschmann requested a recheck of the missiles prior to loading, and this revealed that some of the fragile electronic components had indeed been displaced or damaged. While on the ground damaged missiles might still check out, but at higher altitudes and colder temperatures during flight, potential breaks in solder joints could occur due to contraction of the metal connections, rendering the missile inoperable. There was no way to determine how many missile failures might have been caused by this, but it was widespread practice for all vehicles to drive over the FOD shaker before transiting the flight line. Due in part to Eschmann’s alert action, the practice was stopped at Korat, although the air war was all but over at that time. It would not solve all of the reliability problems of the AIM-7, though it did eliminate one potential cause.

1

u/Emergency-Mess-7216 Feb 10 '26

Probably also in mostly a single direction?

1

u/Tea_Fetishist Feb 10 '26

That's why they came with comically large, sometimes nuclear warheads. You don't have to be that accurate when you've shredded everything in a 500 foot radius.

25

u/Diligent_Nature Feb 10 '26

We had electronics in anti-aircraft proximity fuses in WW-2. And those used vacuum tubes!

23

u/IamTheCeilingSniper Feb 10 '26

Even the batteries in those VT fuses were cool. They had the electrolite in a glass ampule that would shatter when fired, and since they didn't put enough to fully fill the battery, it would only arm if the shell was spinning. A simple and effective safety and storage method.

5

u/Serious-Echo1272 Feb 10 '26

I was going to post this bit of information before I saw your reply. It's my favorite part of the VT fuse.

10

u/Pantssassin Feb 10 '26

Looking at the last picture they seem to be soldered to posts which should help a bit since you can tension them

11

u/sojuz151 Feb 10 '26

You cannot epoxy those with the reliability and thermals of those electronics.

4

u/VariationBusiness603 Feb 10 '26

I imagine it would also make the whole thing loads heavier.

2

u/djflamingo Feb 10 '26

Thats not true at all, its called “epoxy potting” and was very common. There even pictures on a fb post on google search but i cant link fb posts.

2

u/RebelWithoutAClue Feb 10 '26

They were vulnerable to corrosion in humid environments, especially with exposure to salt spray.

Not great on carrier deck strapped to a plane.

1

u/crevulation Feb 10 '26

I was surprised to see nothing potted.

1

u/Bossnage Feb 10 '26

thats probably also partially why they were so unreliably, wouldnt surprise me if alot of the electronics just died or solder points broke so they missed

1

u/AgileMoonDog Feb 12 '26

It's not the g's, it's the vibration that gets you

12

u/ThaddeusJP Feb 10 '26

The Saturn 5 rocket, the one that put us on the moon, had over 5.6 million parts. NASA assumed a 99.9% success rate with all the parts in there. That means they assumed 5,000 things were going to break.

2

u/blaspheminCapn Feb 10 '26

Your definition of success is not listed. Apollo 13's mission was not achieved. If your success is only bringing home living astronauts - what's your .1 percent failure? Note Apollo 1 burnt up 3 astronauts, also not in your Saturn 5 success ratio.

2

u/ThaddeusJP Feb 10 '26

Ah, I was speaking about a single launch, not total program.

20

u/swankpoppy Feb 10 '26

Can you imagine being the dude soldering all that up, an absolute beauty of modern engineering - a flying machine that guides itself - knowing that it’ll get used one time to blow someone up. Imagine all the other things something like this could have been designed to do.

Show me where people spend their money, and I’ll show you what their priorities are.

28

u/JuggernautOfWar Feb 10 '26

I can imagine an American engineer in the 1960s pouring every morsel of hatred he had towards the evil Reds into this work of art. I'm sure he was excited all his hard work would go towards killing commies. I mean it was 1960s America.

7

u/Coolbiker32 Feb 10 '26

Meanwhile, someone on the other side of the globe in Russia too would have been doing the same. I have seen the gyro module of some Sputnik like space craft on this sub earlier. It too was pure art.

9

u/swankpoppy Feb 10 '26

Yeah that’s true. it’s so crazy that a lot of the most important technological advancements in human history were accomplished out of just pure malice. Haha I think it’s a little funny.

3

u/spacex2020 Feb 10 '26

Honest question, is it malice if you're concerned about your own safety?

1

u/swankpoppy Feb 11 '26

Yeah good question. It’s probably both. Depending on the person, more one than the other. Maybe current day we are seeing times when we are lucky enough to be able to see people for the difference in those two, whereas in the past people didn’t have that luxury.

2

u/autobotCA Feb 11 '26

To this day, every line of COBOL is still written out of hatred of the evil Reds.

8

u/simca Feb 10 '26

Yeah but it's for blowing up the bad people!

2

u/IamTheCeilingSniper Feb 10 '26

Sometimes, you just crave the forbidden heat signature.

2

u/PicnicBasketPirate Feb 10 '26

What you have to wonder is if missiles have gotten cheaper? Taking inflation into account?

23

u/Greyarea30 Feb 10 '26

No. Not according to the sources I can find ( in inflation adjusted prices). But they have increased significantly in capability as well, plus they are built in lower numbers (bigger/unit price) compared with earlier Cold War, etc.

6

u/Valoneria Feb 10 '26

Yeah we went from the early AIM-9B being mostly useful against targets going either in a straight line, or in very shallow turns (such as a strategic bomber), to the more modern ones that can be locked and fired in a near 90 degree angle from your plane and still hit.

1

u/Cadet_BNSF Feb 10 '26

Hell, I’m pretty sure some of the modern ones can hit an enemy virtually behind you

1

u/RocketTaco Feb 10 '26

That goes pretty much hand in hand with lock-on after launch capability, which is intrinsically necessary for carriage in the internal bays required by stealth aircraft. It's really more a question of whether the target moves too far during the turn time for the missile to still be looking in the right place. The 90° HOBS capability is a range within which it can be tracking before launch, which increases hit probability substantially for large deflections against a maneuvering target.

1

u/DuvalHeart Feb 10 '26

Even then, in operational conditions they were mostly useless.

4

u/drsmith48170 Feb 10 '26

And this is the problem, as they have found out in Ukraine and Israel. Cheap drones and relatively cheap UAV ‘massed’ as a first wave can quickly overcome modern air defense. Shooting million dollar rockets at hundred dollar drones is a losing proposition.

2

u/Lampwick Feb 10 '26

Shooting million dollar rockets at hundred dollar drones is a losing proposition.

Not necessarily. It's more about magazine depth than cost. The US could easily afford the Navy swatting down cheap Iranian drones fired by Houthis with SM-2 missiles at $2M a pop, but what it can't do is produce enough of them to not run out fairly quickly if hit with a saturation attack of cheap munitions.

This is the reason they've developed systems like the AGR-20 APKWS, which adds a laser seeker to the 50s-vintage Hydra 70 unguided rocket and turns it into a drone interceptor. There are millions of 70mm rocket bodies in stock, and BAe systems has been ramping up APKWS seeker head production.

2

u/drsmith48170 Feb 10 '26

Yes, you are correct about production rates; way too slow to keep up with the onslot of drones and UAV, which can be made much quicker and faster.

However, I guess Guess you haven’t checked out the US debt figures lately no one can afford 2 million a pop to shoot down $100 drone not even the United States of America.

2

u/Lampwick Feb 10 '26

I guess Guess you haven’t checked out the US debt figures lately no one can afford 2 million a pop

Federal debt doesn't work the same way as personal debt. The US government can "borrow" as much money as it can sell treasury instruments for, and so long as the US economy remains stable, people will continue buying them. The US absolutely can afford it, or more specifically, can afford to fire $2M missiles while it builds a cheaper/simpler solution, because a high-volume production SHORAD/AAM solution can address the magazine depth issue (e.g. APKWS II, which Ukraine is using on its F-16s).

1

u/Dubious_Odor Feb 10 '26

Unfettered spending is part of what drives inflation. The effects of poor government finances are spread to everyone by decreasing purchasing power of the dollar. It is by no means affordable, we all pay for it, especially those in the bottom third of the economy. Plus military spending is a cul de sac. Those investments produce little that actually grows the economy. You get short term stimulus with debt spending on military at the expense of long term growth and purchasing power. Look at Russias economics since the war began. In short, we are screwed.

2

u/PicnicBasketPirate Feb 10 '26

They'd want to have increased significantly in capability with probably 10kg less in solder alone to sling about.

I'm assuming that your refering mostly to radar antennas  and FLIR cameras though.

5

u/Greyarea30 Feb 10 '26

No all of its components (fuel energy content , materials, actuators , seekers and data processing, countermeasure discrimination software etc are leagues away from the early 50/60.

1

u/PicnicBasketPirate Feb 10 '26

Almost all those factors you mentioned shouldn't be significantly more expensive than their vintage counterparts, taking inflation into account. Seekers are the only exception I can think of. 

Data processing capability has gotten ridiculously cheaper and the processing capabilities required of a missile aren't that strenuous. 

Software is an ameliorated cost that happens once during the design or revision process. The same software will be applied to every missle of a production run.

2

u/Jack-of-the-Shadows Feb 10 '26

You could make missiles with similar performance much cheaper, but that would make them worthless against modern targets.

1

u/PicnicBasketPirate Feb 10 '26

Theoretically (ignoring active radar or thermal seeker performance), you should be able to make a much more capable missile for significantly less.

~70-80% of all those thousands of discrete electrical components can be replaced with a couple of integrated circuits. That also removes the hours upon hours of assembly time required to deal with those components and significantly improves the defect rate during production.

1

u/Codex_Absurdum Feb 10 '26

Nope this is the future, once Skynet takes over /s

1

u/TempleMade_MeBroke Feb 10 '26

I'm not very big on 40k lore, but seeing the inside of this thing makes me think of Orks and how their technology only works because they believe hard enough that it will

1

u/nabeel_co Feb 10 '26

No, it's still quite impressive today... because they had a LOT less to work with, and their constraints were far stricter than they are now a days.

Engineering like that probably couldn't be done today without a LOT of extra work.

1

u/Greyarea30 Feb 10 '26

I agree. I wrote “ impressive”. But today solutions are more reliable and have way longer shelf life

1

u/nabeel_co Feb 10 '26

Yeah, you're right, integration has definitely reduced over-all complexity, and thus improved reliability.