Newman, John | Search NASA

NASA NTRS2013

Unibody Composite Pressurized Structure

An integrated, generic unibody composite pressurized structure (UCPS) combined with a positive expulsion device (PED), consisting of an elastomeric bladder for monopropellant hydrazine, has been quasi-standardized for spacecraft use. The combination functions as an all-composite, non-metallic, propellant tank with bladder. The integrated UCPS combines several previous innovations - specifically, the linerless, all-composite cryogenic tank technology; all-composite boss; resin formulation; and integrated stringer system. The innovation combines the UCPS with an integrated propellant management device (PMD), the PED or bladder, to create an entirely unique system for in-space use. The UCPS is a pressure vessel that incorporates skirts, stringers, and other structures so that it is both an in-space hydrazine tank, and also a structural support system for a spacecraft in a single, all-composite unit. This innovation builds on the progress in the development of a previous SBIR (Small Business Innovation Research) Phase I with Glenn Research Center and an SBIR III with Johnson Space Center that included the fabrication of two 42-in. (≈107-cm) diameter all-composite cryogenic (LOX and liquid methane) UCPS test tanks for a lunar lander. This Phase II provides hydra zine compatibility testing of the elastomeric bladder, a see-through PED to validate the expulsion process and model, and a complete UCPS-based PED with stringers and skirts that will be used to conduct initial qualification and expulsion tests. This extends the UCPS technology to include hydrazine-based, in-space pro - pulsion applications and can also be used for electric propulsion. This innovation creates a system that, in comparison to the traditional approach, is lower in weight, cost, volume, and production time; is stronger; and is capable of much higher pressures. It also has fewer failure modes, and is applicable to both chemical and electric propulsion systems.

Rufer, Markus↗

NASA NTRS2006

Laser Shearography Inspection of TPS (Thermal Protection System) Cork on RSRM (Reusable Solid Rocket Motors)

Laser Shearography is a viable inspection method for detection of de-bonds and voids within the external TPS (thermal protection system) on to the Space Shuttle RSRM (reusable solid rocket motors). Cork samples with thicknesses up to 1 inch were tested at the LTI (Laser Technology Incorporated) laboratory using vacuum-applied stress in a vacuum chamber. The testing proved that the technology could detect cork to steel un-bonds using vacuum stress techniques in the laboratory environment. The next logical step was to inspect the TPS on a RSRM. Although detailed post flight inspection has confirmed that ATK Thiokol's cork bonding technique provides a reliable cork to case bond, due to the Space Shuttle Columbia incident there is a great interest in verifying bond-lines on the external TPS. This interest provided and opportunity to inspect a RSRM motor with Laser Shearography. This paper will describe the laboratory testing and RSRM testing that has been performed to date. Descriptions of the test equipment setup and techniques for data collection and detailed results will be given. The data from the test show that Laser Shearography is an effective technology and readily adaptable to inspect a RSRM.

Lingbloom, Mike↗