Engineering topics

McCool, Alex

Publications and source records attributed to McCool, Alex.

At least 37 records · Page 2

NASA NTRS2001

Use of System Safety Risk Assessments for the Space Shuttle Reusable Solid Rocket Motor (RSRM)

This paper discusses the System Safety approach used to assess risk for the Space Shuttle Reusable Solid Rocket Motor (RSRM). Previous to the first RSRM flight in the fall of 1988, all systems were analyzed extensively to assure that hazards were identified, assessed and that the baseline risk was understood and appropriately communicated. Since the original RSRM baseline was established, Thiokol and NASA have implemented a number of initiatives that have further improved the RSRM. The robust design, completion of rigorous testing and flight success of the RSRM has resulted in a wise reluctance to make changes. One of the primary assessments required to accompany the documentation of each proposed change and aid in the decision making process is a risk assessment. Documentation supporting proposed changes, including the risk assessments from System Safety, are reviewed and assessed by Thiokol and NASA technical management. After thorough consideration, approved changes are implemented adding improvements to and reducing risk of the Space Shuttle RSRM.

Greenhalgh, Phillip O.↗

NASA NTRS2001

Space Shuttle Reusable Solid Rocket Motor Program Overview and Lessons Learned

An overview of the Space Shuttle Reusable Solid Rocket Motor (RSRM) program is provided with a summary of lessons learned since the first test firing in 1977. Fifteen different lessons learned are discussed that fundamentally changed the motor's design, processing, and RSRM program risk management systems. The evolution of the rocket motor design is presented including the baseline or High Performance Solid Rocket Motor (HPM), the Filament Wound Case (FWC), the RSRM, and the proposed Five-Segment Booster (FSB).

Graves, Stan R.↗

NASA NTRS2001

Environmentally Compatible Vapor-Phase Corrosion Inhibitor for Space Shuttle Hardware

USA-SRB Element is responsible for the assembly and refurbishment of the non-motor components of the SRB as part of Space Shuttle. Thrust Vector Control (TVC) frames structurally support components of the TVC system located in the aft skirt of the SRB. TVC frames are exposed to the seacoast environment after refurbishment and, also, to seawater immersion after splashdown, and during tow-back to CCAFS-Hangar AF refurbishment facilities. During refurbishment operations it was found that numerous TVC frames were experiencing internal corrosion and coating failures, both from salt air and seawater intrusions. Inspectors using borescopes would visually examine the internal cavities of the complicated aluminum alloy welded tubular structure. It was very difficult for inspectors to examine cavity corners and tubing intersections and particularly, to determine the extent of the corrosion and coating anomalies. Physical access to TVC frame internal cavities for corrosion removal and coating repair was virtually impossible, and an improved method using a Liquid (water based) Vapor-phase Corrosion Inhibitor (LVCI) for preventing initiation of new corrosion, and mitigating and/or stopping existing corrosion growth was recommended in lieu of hazardous paint solvents and high VOC/solvent based corrosion inhibitors. In addition, the borescopic inspection method used to detect corrosion, and/or coating anomalies had severe limitations because of part geometry, and an improved non-destructive inspection (NDI) method using Neutron Radiography (N-Ray) was also recommended.

Novak, Howard L.↗

NASA NTRS2001

Space Shuttle Main Engine (SSME) Evolution

The SSME when developed in the 1970's was a technological leap in space launch propulsion system design. The engine has safely supported the space shuttle for the last two decades and will be required for at least another decade to support human space flight to the international space station. This paper discusses the continued improvements and maturing of the system to its current state and future considerations for its critical role in the nations space program. Discussed are the initiatives of the late 1980's, which lead to three major upgrades through the 1990's. The current capabilities of the propulsion system are defined in the areas of highest programmatic importance: ascent risk, in-flight abort thrust, reusability, and operability. Future initiatives for improved shuttle safety, the paramount priority of the Space Shuttle program are discussed.

Worlund, Len A.↗

NASA NTRS2001

MNASA as a Test for Carbon Fiber Thermal Barrier Development

A carbon fiber rope thermal barrier is being evaluated as a replacement for the conventional room temperature vulcanizing (RTV) thermal barrier that is currently used to protect o-rings in Reusable Solid Rocket Motor (RSRM) nozzle joints. Performance requirements include its ability to cool any incoming, hot propellant gases that fill and pressurize the nozzle joints, filter slag and particulates, and to perform adequately in various joint assembly conditions as well as dynamic flight motion. Modified National Aeronautics and Space Administration (MNASA) motors, with their inherent and unique ability to replicate select RSRM internal environment features, were an integral step in the development path leading to full scale RSRM static test demonstration of the carbon fiber rope (CFR) joint concept. These 1/4 scale RSRM motors serve to bridge the gap between the other classes of subscale test motors (extremely small and moderate duration, or small scale and short duration) and the critical asset RSRM static test motors. A series of MNASA tests have been used to demonstrate carbon fiber rope performance and have provided rationale for implementation into a full-scale static motor and flight qualification.

Bauer, Paul↗

NASA NTRS2001

Surface Analysis Evaluation of Handwipe Cleaning for the Space Shuttle RSRM

In this paper we discuss the role of surface-sensitive spectroscopy (electron spectroscopy for chemical analysis, or ESCA) in the selection of solvents to replace 1,1,1-trichloroethane in handwipe cleaning of bonding surfaces on NASA's Space Shuttle Reusable Solid Rocket Motor (RSRM). Removal of common process soils from a wide variety of metallic and polymeric substrates was characterized. The cleaning efficiency was usually more dependent on the type of substrate being cleaned and the specific process soil than on the solvent used. A few substrates that are microscopically rough or porous proved to be difficult to clean with any cleaner, and some soils were very tenacious and difficult to remove from any substrate below detection limits. Overall, the work showed that a wide variety of solvents will perform at least as well as 1,1,1-trichloroethane.

Lesley, Michael W.↗

NASA NTRS2001

ODC-Free Solvent Implementation for Phenolics Cleaning

During phenolic liner manufacture, resin-impregnated (pre-preg) bias tape of silica, glass, or carbon cloth is tape-wrapped, cured, machined, and then wiped with 1,1,1 tri-chloroethane (TCA) to remove contaminants that may have been introduced during machining and handling. Following the TCA wipe, the machined surface is given a resin wet-coat and over-wrapped with more prepreg and cured. A TCA replacement solvent for these wiping operations must effectively remove both surface contaminants, and sub-surface oils and greases while not compromising the integrity of this interface. Selection of a TCA replacement solvent for phenolic over-wrap interface cleaning began with sub-scale compatibility tests with cured phenolics. Additional compatibility tests included assessment of solvent retention in machined phenolic surfaces. Results from these tests showed that, while the candidate solvent did not degrade the cured phenolics, it was retained in higher concentrations than TCA in phenolic surfaces. This effect was most pronounced with glass and silica cloth phenolics with steep ply angles relative to the wiped surfaces.

Wurth, Laura↗

NASA NTRS2001

Automated Inspection of the RSRM Case O-Ring Seal Surface

An automated inspection system has been developed to inspect the o-ring sealing surfaces on the Space Shuttle reusable solid rocket motor (RSRM) case segment joints. A laser digitizing system is used to create a three dimensional map of the o-ring sealing surfaces. This data is analyzed for any irregularities, which are noted for further inspection and disposition. This paper describes both the hardware and the software used to gather data as well as the methods developed to analyze the data. The RSRM is assembled from four casting segments. Each of the field joints between these segments is sealed with three o-rings. These o-rings are critical for the proper operation of the motor. After launch the booster segments are recovered and reused. As part of the refurbishment process the o-ring sealing surfaces are inspected for any irregularities. The system developed uses a combination of commercial and customized hardware and software. The system uses two computer systems in a real time environment to control a laser, an XYZ precision table, and case rotation and position information. The system is capable of inspecting both the tang end and the clevis end of the RSRM field joint. The o-ring grooves and flat sealing surfaces are inspected.

ODell, Keith P.↗

NASA NTRS2001

ODC-Free Solvent Implementation Issues for Vulcanized Rubber and Bond Systems

Thiokol Propulsion has worked extensively to replace 1,1,1-trichloroethane (TCA) with ozone depleting chemicals (ODC)-free solvents for use in the manufacture of the Reusable Solid Rocket Motor (RSRM) for the Space Shuttle Program. As Thiokol has transitioned from sub-scale to full-scale testing and implementation of these new solvents, issues have been discovered which have required special attention. The original intent of Thiokol's solvent replacement strategy was to replace TCA with a single drop-in solvent for all equivalent applications. We have learned that a single candidate does not exist for replacing TCA. Solvent incompatibility with process materials has caused us to seek for niche solvents and/or processing changes that provide an ODC-free solution for special applications. This paper addresses some of the solvent incompatibilities, which have lead to processes changes and possible niche solvent usage. These incompatibilities were discovered during full-scale testing of ODC-free solvents and relate to vulcanized rubber and bond systems in the RSRM. Specifically, the following items are presented: (1) Cure effects of d-limonene based solvents on Silica Filled Ethylene Propylene Diene Monomer (SF-EPDM) rubber. During full-scale test operations, Thiokol discovered that d-limonene (terpene) based solvents inhibit the cure of EPDM rubber. Subsequent testing showed the same issue with Nitrile Butadiene Rubber (NBR). Also discussed are efforts to minimize uncured rubber exposure to solvents; and (2) Cured bond system sensitivity to ODC-free solvents. During full scale testing it was discovered that a natural rubber to steel vulcanized bond could degrade after prolonged exposure to ODC-free solvents. Follow on testing showed that low vapor pressure and residence time seemed to be most likely cause for failure.

Hodgson, James R.↗

NASA NTRS2001

Reducing Bolt Preload Variation with Angle-of-Twist Bolt Loading

Critical high-pressure sealing joints on the Space Shuttle reusable solid rocket motor require precise control of bolt preload to ensure proper joint function. As the reusable solid rocket motor experiences rapid internal pressurization, correct bolt preloads maintain the sealing capability and structural integrity of the hardware. The angle-of-twist process provides the right combination of preload accuracy, reliability, process control, and assembly-friendly design. It improves significantly over previous methods. The sophisticated angle-of-twist process controls have yielded answers to all discrepancies encountered while the simplicity of the root process has assured joint preload reliability.

Thompson, Bryce↗

NASA NTRS2001

Achieving Space Shuttle ATO Using the Five-Segment Booster (FSB)

As part of the continuing effort to identify approaches to improve the safety and reliability of the Space Shuttle system, a Five-Segment Booster (FSB) design was conceptualized as a replacement for the current Space Shuttle boosters. The FSB offers a simple, unique approach to improve astronaut safety and increase performance margin. To determine the feasibility of the FSB, a Phase A study effort was sponsored by NASA and directed by the Marshall Space Flight Center. This study was initiated in March of 1999 and completed in December of 2000. The basic objective of this study was to assess the feasibility of the FSB design concept and also estimate the cost and scope of a full-scale development program for the FSB. In order to ensure an effective and thorough evaluation of the FSB concept, four team members were put on contract to support various areas of importance in assessing the overall feasibility of the design approach.

Sauvageau, Donald R.↗

NASA NTRS2001

Kinetic Energy Corrections for Slip-Stick Behavior in Brittle Adhesives

Fracture mechanics is the study of the failure of a body that contains a flaw. In the energy balance approach to fracture mechanics, contributions from the external work and elastic strain energy are accounted for but rarely are corrections for the kinetic energy given. Under slip-stick conditions, part of the external work is expended as kinetic energy. The magnitude of this kinetic energy depends upon the shape of the crack. A specimen with a blunt crack will fail at a high load and the crack will catastrophically travel through the material until the kinetic energy is dissipated. Material with a sharp crack will fail at a lower load but will still be catastrophic in nature. A kinetic term is incorporated into the energy balance approach. This term accounts for the velocity of the crack after failure and how far the crack travels before arresting. This correction makes the shape of the initiation crack irrelevant. When applied to data generated by tapered double cantilever beam specimens under slip-stick conditions, the scatter in the measured critical strain energy release rate is significantly reduced.

Macon, David J.↗

NASA NTRS2001

Issues Related to Cleaning Complex Geometry Surfaces with ODC-Free Solvents

Implementing ozone depleting chemicals (ODC)-free solvents into full-scale reusable solid rocket motor cleaning operations has presented problems due to the low vapor pressures of the solvents. Because of slow evaporation, solvent retention is a problem on porous substrates or on surfaces with irregular geometry, such as threaded boltholes, leak check ports, and nozzle backfill joints. The new solvents are being evaluated to replace 1,1,1-trichloroethane, which readily evaporates from these surfaces. Selection of the solvents to be evaluated on full-scale hardware was made based on results of subscale tests performed with flat surface coupons, which did not manifest the problem. Test efforts have been undertaken to address concerns with the slow-evaporating solvents. These concerns include effects on materials due to long-term exposure to solvent, potential migration from bolthole threads to seal surfaces, and effects on bolt loading due to solvent retention in threads. Tests performed to date have verified that retained solvent does not affect materials or hardware performance. Process modifications have also been developed to assist drying, and these can be implemented if additional drying becomes necessary.

Bradford, Blake F.↗

NASA NTRS2001

Thermal Characterization of Epoxy Adhesive by Hotfire Testing

This paper describes subscale solid-rocket motor hot-fire testing of epoxy adhesives in flame surface bondlines to evaluate heat-affected depth, char depth and ablation rate. Hot-fire testing is part of an adhesive down-selection program on the Space Shuttle Solid Rocket Motor Nozzle to provide additional confidence in the down-selected adhesives. The current nozzle structural adhesive bond system is being replaced due to obsolescence. Prior to hot-fire testing, adhesives were tested for chemical, physical and mechanical properties, which resulted in the selection of two potential replacement adhesives, Resin Technology Group's TIGA 321 and 3M's EC2615XLW. Hot-fire testing consisted of four forty-pound charge (FPC) motors fabricated in configurations that would allow side-by-side comparison testing of the candidate replacement adhesives with the current RSRM adhesives. Results of the FPC motor testing show that: 1) the phenolic char depths on radial bondlines is approximately the same and vary depending on the position in the blast tube regardless of which adhesive was used, 2) the replacement candidate adhesive char depths are equivalent to the char depths of the current adhesives, 3) the heat-affected depths of the candidate and current adhesives are equivalent, and 4) the ablation rates for both replacement adhesives were equivalent to the current adhesives.

Spomer, Ken A.↗

NASA NTRS2001

Real-Time Inhibitor Recession Measurements in the Space Shuttle Reusable Solid Rocket Motors

Real-time char line recession measurements were made on propellant inhibitors of the Space Shuttle Reusable Solid Rocket Motor (RSRM). The RSRM FSM-8 static test motor propellant inhibitors (composed of a rubber insulation material) were successfully instrumented with eroding potentiometers and thermocouples. The data was used to establish inhibitor recession versus time relationships. Normally, pre-fire and post-fire insulation thickness measurements establish the thermal performance of an ablating insulation material. However, post-fire inhibitor decomposition and recession measurements are complicated by the fact that most of the inhibitor is back during motor operation. It is therefore a difficult task to evaluate the thermal protection offered by the inhibitor material. Real-time measurements would help this task. The instrumentation program for this static test motor marks the first time that real-time inhibitors. This report presents that data for the center and aft field joint forward facing inhibitors. The data was primarily used to measure char line recession of the forward face of the inhibitors which provides inhibitor thickness reduction versus time data. The data was also used to estimate the inhibitor height versus time relationship during motor operation.

McWhorter, Bruce B.↗

NASA NTRS2001

Development of Flow and Heat Transfer Models for the Carbon Fiber Rope in Nozzle Joints of the Space Shuttle Reusable Solid Rocket Motor

Methodologies have been developed for modeling both gas dynamics and heat transfer inside the carbon fiber rope (CFR) for applications in the space shuttle reusable solid rocket motor joints. Specifically, the CFR is modeled using an equivalent rectangular duct with a cross-section area, friction factor and heat transfer coefficient such that this duct has the same amount of mass flow rate, pressure drop, and heat transfer rate as the CFR. An equation for the friction factor is derived based on the Darcy-Forschheimer law and the heat transfer coefficient is obtained from pipe flow correlations. The pressure, temperature and velocity of the gas inside the CFR are calculated using the one-dimensional Navier-Stokes equations. Various subscale tests, both cold flow and hot flow, have been carried out to validate and refine this CFR model. In particular, the following three types of testing were used: (1) cold flow in a RSRM nozzle-to-case joint geometry, (2) cold flow in a RSRM nozzle joint No. 2 geometry, and (3) hot flow in a RSRM nozzle joint environment simulator. The predicted pressure and temperature history are compared with experimental measurements. The effects of various input parameters for the model are discussed in detail.

Wang, Q.↗

NASA NTRS2001

Materials Compatibility Testing in RSRM ODC: Free Cleaner Selection

Government regulations have mandated production phase-outs of a number of solvents, including 1,1,1-trichloroethane, an ozone-depleting chemical (ODC). This solvent was used extensively in the production of the Reusable Solid Rocket Motors (RSRMs) for the Space Shuttle. Many tests have been performed to identify replacement cleaners. One major area of concern in the selection of a new cleaner has been compatibility. Some specific areas considered included cleaner compatibility with non-metallic surfaces, painted surfaces, support materials such as gloves and wipers as well as corrosive properties of the cleaners on the alloys used on these motors. The intent of this paper is to summarize the test logic, methodology, and results acquired from testing the many cleaner and material combinations.

Keen, Jill M.↗

NASA NTRS2001

Modeling the Gas Dynamics Environment in a Subscale Solid Rocket Test Motor

Subscale test motors are often used for the evaluation of solid rocket motor component materials such as internal insulation. These motors are useful for characterizing insulation performance behavior, screening insulation material candidates and obtaining material thermal and ablative property design data. One of the primary challenges associated with using subscale motors however, is the uncertainty involved when extrapolating the results to full-scale motor conditions. These uncertainties are related to differences in such phenomena as turbulent flow behavior and boundary layer development, propellant particle interactions with the wall, insulation off-gas mixing and thermochemical reactions with the bulk flow, radiation levels, material response to the local environment, and other anomalous flow conditions. In addition to the need for better understanding of physical mechanisms, there is also a need to better understand how to best simulate these phenomena using numerical modeling approaches such as computational fluid dynamics (CFD). To better understand and model interactions between major phenomena in a subscale test motor, a numerical study of the internal flow environment of a representative motor was performed. Simulation of the environment included not only gas dynamics, but two-phase flow modeling of entrained alumina particles like those found in an aluminized propellant, and offgassing from wall surfaces similar to an ablating insulation material. This work represents a starting point for establishing the internal environment of a subscale test motor using comprehensive modeling techniques, and lays the groundwork for improving the understanding of the applicability of subscale test data to full-scale motors. It was found that grid resolution, and inclusion of phenomena in addition to gas dynamics, such as two-phase and multi-component gas composition are all important factors that can effect the overall flow field predictions.

Eaton, Andrew M.↗