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At least 181 records · Page 10

Test methodology for evaluation of fireworthy aircraft seat cushions

Aircraft seat materials were evaluated in terms of their thermal performance. The materials were evaluated using (a) thermogravimetric analysis, (b) differential scanning calorimetry, (c) a modified NBS smoke chamber to determine the rate of mass loss and (d) the NASA T-3 apparatus to determine the thermal efficiency. In this paper, the modified NBS smoke chamber will be described in detail since it provided the most conclusive results. The NBS smoke chamber was modified to measure the weight loss of materials when exposed to a radiant heat source over the range of 2.5 to 7.5 W/cm sq. This chamber has been utilized to evaluate the thermal performance of various heat blocking layers utilized to protect the polyurethane cushioning foam used in aircraft seats. Various kinds of heat blocking layers were evaluated by monitoring the weight loss of miniature seat cushions when exposed to the radiant heat. The effectiveness of aluminized heat blocking systems was demonstrated when compared to conventional heat blocking layers such as neoprene. All heat blocking systems showed good fire protection capabilities when compared to the state-of-the-art, i.e., wool-nylon over polyurethane foam.

Kourtides, D. A.↗

Aircraft surface coatings

Liquid, spray on elastomeric polyurethanes are selected and investigated as best candidates for aircraft external protective coatings. Flight tests are conducted to measure drag effects of these coatings compared to paints and a bare metal surface. The durability of two elastometric polyurethanes are assessed in airline flight service evaluations. Laboratory tests are performed to determine corrosion protection properties, compatibility with aircraft thermal anti-icing systems, the effect of coating thickness on erosion durability, and the erosion characteristics of composite leading edges-bare and coated. A cost and benefits assessment is made to determine the economic value of various coating configurations to the airlines.

Source record↗

Electrostatic Spraying With Conductive Liquids

Thin, uniform polymer coatings applied in water base normally impossible to charge. Electrostatic sprayer modified so applies coatings suspended or dissolved in electrically conductive liquids. Nozzle and gun constructed of nonconductive molded plastic. Liquid passageway made long enough electrical leakage through it low. Coaxial hose for liquid built of polytetrafluoroethylene tube, insulating sleeve, and polyurethane jacket. Sprayer provided with insulated seal at gun-to-hose connection, nonconductive airhose, pressure tank electrically isolated from ground, and special nozzle electrode. Supply of atomizing air reduced so particle momentum controlled by electrostatic field more effectively. Developed to apply water-base polyurethane coating to woven, shaped polyester fabric. Coating provides pressure seal for fabric, which is part of spacesuit. Also useful for applying waterproof, decorative, or protective coatings to fabrics for use on Earth.

Kosmo, Joseph J.↗

Foam formation in low gravity

An apparatus that produced the first polyurethane foam in low gravity has been described. The chemicals were mixed together in an apparatus designed for operation in low gravity. Mixing was by means of stirring the chemicals with an electric motor and propeller in a mixing chamber. The apparatus was flown on Consort 1, the first low-gravity materials payload launched by a commercial rocket launch team. The sounding rocket flight produced over 7 min of low gravity during which a polyurethane spheroidal foam of approximately 2300 cu cm was formed. Photographs of the formation of the foam during the flight show the development of the spheroidal form. This begins as a small sphere and grows to approximately a 17-cm-diam spheroid. The apparatus will be flown again on subsequent low-gravity flights.

Wessling, Francis C.↗

Lightweight, fire-retardant, crashworthy aircraft seat cushioning

A two page discussion of non-aerospace seating applications and the design of NASA's safety seat cushioning (SSC) is presented. The SSC was designed for both safety and comfort in order to replace polyurethane cushioning which is flammable and produces lethal fumes upon combustion. The SSC is composed of advanced fabric reinforced composites and is lightweight, fire-retardent, and crashworthy. The seat design consists of central elliptical tubular spring supports made of fire-resistant and fatigue-durable composites surrounded by a fire-blocking sheath. The cushioning is made crashworthy by incorporating energy-absorbing, viscoelastic layers between the nested, elliptical-hoop springs. The design is intended to provide comfortable seating that meets aircraft-loading requirements without using the conventional polyurethane materials. The designs of an aircraft seat and structural components of the SSC are also presented.

Haslim, Leonard A.↗

Organic contamination of LDEF

A brown stain of varying thickness was present on most of the exterior surface of the retrieved Long Duration Exposure Facility (LDEF). Tape lifts of Earth-end LDEF surfaces taken showed that the surface particle cleanliness immediately after retrieval was very good, but faint footprints of the tape strips on the tested surfaces indicated a very faint film was removed by the tape. Solvent wipes of these surfaces showed that the stain was not amenable to standard organic solvent removal. Infrared spectra of optical windows from tray E5 show that the organic film is hydrocarbon in composition, but is not similar to the oil that seeped from tray C12. Very dark and heavy deposits of the stain is present at openings and vents to the interior of LDEF. Heavy brown and blue-green deposits are present in the interior of LDEF where sunlight penetrated through cracks and vent openings. The exterior of LDEF had significant areas painted with a white polyurethane paint for thermal control, and almost all of the interior was painted with a black polyurethane paint. Brown staining is consistent with outgassing of hydrocarbons from these paints by rapid solar UV induced polymerization of the outgassed hydrocarbons when they hit sunlight exposed areas.

Harvey, Gale A.↗

Organic contamination of LDEF

A brown stain of varying thickness was present on most of the exterior surface of the retrieved Long Duration Exposure Facility (LDEF). Tape lifts of Earth-end LDEF surfaces taken in Feb. 1990 showed that the surface particle cleanliness immediately after retrieval was very good, but faint footprints of the tape strips on the tested surfaces indicated a very faint film was removed by the tape. Solvent wipes of these surfaces showed that the stain was not amenable to standard organic solvent removal. Infrared spectra of optical windows from tray E5 and scrapings indicate that the film is primarily of organic composition, but is not similar to the oil that seeped from tray C12. Very dark and heavy deposits of the stain are present at openings and vents to the interior of the LDEF. Heavy brown and blue-green deposits are present in the interior of LDEF where sunlight penetrated through cracks and vent openings. Photographs of the deintegrated LDEF graphically show the stain distribution. The exterior of the LDEF had significant areas painted with a white polyurethane paint for thermal control, and almost all of the interior was painted with a black polyurethane paint for thermal control. The brown staining of the LDEF is consistent with long-term outgassing of hydrocarbons from these paints followed by rapid solar-ultraviolet-induced polymerization of the outgassed hydrocarbons when the outgassed molecules stuck to surfaces exposed to sunlight.

Harvey, Gale A.↗

Positron lifetime spectroscopy for investigation of thin polymer coatings

In the aerospace industry, applications for polymer coatings are increasing. They are now used for thermal control on aerospace structures and for protective insulating layers on optical and microelectronic components. However, the effectiveness of polymer coatings depends strongly on their microstructure and adhesion to the substrates. Currently, no technique exists to adequately monitor the quality of these coatings. We have adapted positron lifetime spectroscopy to investigate the quality of thin coatings. Results of measurements on thin (25-micron) polyurethane coatings on aluminum and steel substrates have been compared with measurements on thicker (0.2-cm) self-standing polyurethane discs. In all cases, we find positron lifetime groups centered around 560 psec, which corresponds to the presence of 0.9-A(exp 3) free-volume cells. However, the number of these free-volume cells in thin coatings is larger than in thick discs. This suggests that some of these cells may be located in the interfacial regions between the coatings and the substrates. These results and their structural implications are discussed in this report.

Singh, Jag J.↗

Experimental Observations of the Effect of Gravity Changes on Smoldering Combustion

The effects of gravity changes on the natural convection smolder characteristics of flexible polyurethane foam were determined in order to provide information on the potential onset of a smolder-initiated fire in a space-based facility. Experiments were conducted in an aircraft following parabolic trajectories providing up to 25 seconds of low gravity. Temperature histories of polyurethane foam were measured at several locations along the fuel sample interior. Results are presented and discussed for both upward and downward smoldering. Results indicate that gravity significantly effects the competition between supply of oxidizer to, and the transfer of heat to and from the reaction zone. This competition determines the characteristics of the smolder reaction. Within the reaction zone the reduction in oxygen supply in low gravity is dominant and the reaction weakens. Away from the reaction zone the reduction in convective cooling at low gravity tends to increase the material temperature. The opposite was observed at high gravity.

Torero, J. L.↗

Self-Calibrating, Variable-Flow Pumping System

Pumping system provides accurate, controlled flows of two chemical liquids mixed in spray head and react to form rigid or flexible polyurethane or polyisocyanurate foam. Compatible with currently used polyurethane-based coating materials and gas-bubble-forming agents (called "blowing agents" in industry) and expected to be compatible with materials that used in near future. Handles environmentally acceptable substitutes for chlorofluorocarbon foaming agents.

Walls, Joe T.↗

Lunar Lander project: A study on future manned missions to the Moon

This project is based on designing a small lunar probe which will conduct research relating to future manned missions to the moon. The basic design calls for two experiments to be run. The first of these experiments is an enclosed environment section which will be exposed to solar radiation while on the moon. The purpose of this experiment is to determine the effect of radiation on an enclosed environment and how different shielding materials can be used to moderate this effect. The eight compartments will have the following covering materials: glass, polarized glass, plexiglass, polyurethane, and boron impregnated versions of the polyurethane and plexiglass. The enclosed atmosphere will be sampled by a mass spectrometer to determine elemental breakdown of its primary constituents. This is needed so that an accurate atmospheric processing system can be designed for a manned mission. The second experiment is a seismic study of the moon. A small penetrating probe will be shot into the lunar surface and data will be collected onboard the lander by an electronic seismograph which will store the data in the data storage unit for retrieval and transmission once every twenty-three hours. The project is designed to last ten years with possible extended life for an additional nine years at which point power requirements prevent proper functioning of the various systems.

Source record↗

Experimental observations of the effect of gravity changes on smoldering combustion

An experimental study is conducted to determine the effect of gravity changes on the natural convection smolder characteristics of flexible polyurethane foam. Gravity, and consequently buoyancy, is expected to affect smoldering because it induces convective transport of mass and heat to and from the reaction zone. The overall objective of the work is to provide information about the potential onset of a smolder-initiated fire in a space-based facility. Experiments are conducted in an aircraft following parabolic trajectories that provide up to 25 s of low gravity (KC-135A) and up to 20 s (Learjet Model 25), with a pull-up and pull-out of approximately 2 g per parabola. Measurements are performed, during a series of parabolas, of the temperature histories of the polyurethane foam at several locations along the fuel sample interior, both for upward and downward propagation. The measurements show that gravity plays a significant role in the competition between the supply of oxidizer to, and the transfer of heat to and from, the reaction zone.

Torero, J. L.↗

Microgravity smoldering combustion on the USML-1 Space Shuttle mission

Preliminary results from an experimental study of the smolder characteristics of a porous combustible material (flexible polyurethane foam) in normal and microgravity are presented. The experiments, limited in fuel sample size and power available for ignition, show that the smolder process was primarily controlled by heat losses from the reaction to the surrounding environment In microgravity, the reduced heat losses due to the absence of natural convection result in only slightly higher temperatures in the quiescent microgravity test than in normal gravity, but a dramatically larger production of combustion products in all microgravity tests. Particularly significant is the proportionately larger amount of carbon monoxide and light organic compounds produced in microgravity, despite comparable temperatures and similar char patterns. This excessive production of fuel-rich combustion products may be a generic characteristic of smoldering polyurethane in microgravity, with an associated increase in the toxic hazard of smolder in spacecraft.

Stocker, Dennis P.↗

Development and Qualification of Alternate Blowing Agents for Space Shuttle External Tank Thermal Protection System

The Aerospace industry has a long history of using low density polyurethane and polyurethane-modified isocyanurate foam systems as lightweight, low cost, easily processed cryogenic Thermal Protection Systems (TPS) for ascent vehicles. The Thermal Protection System of the Space Shuttle External Tank (ET) is required so that quality liquid cryogenic propellant can be supplied to the Orbiter main engines and to protect the metal structure of the tanks from becoming too hot from aerodynamic heating, hence preventing premature break-up of the tank. These foams are all blown with CFC-1 I blowing agent which has been identified by the Environmental Protection Agency (EPA) as an ozone depleting substance. CFCs will not be manufactured after 1995, Consequently, alternate blowing agent substances must be identified and implemented to assure continued ET manufacture and delivery. This paper describes the various testing performed to select and qualify HCFC-1 41 b as a near term drop-in replacement for CFC-11. Although originally intended to be a one for one substitution in the formulation, several technical issues were identified regarding material performance and processability which required both formulation changes and special processing considerations to overcome. In order to evaluate these material changes, each material was subjected to various tests to qualify them to meet the various loads imposed on them during long term storage, pre-launch operations, launch, separation and re-entry. Each material was tested for structural, thermal, aeroshear, and stress/strain loads for the various flight environments each encounters. Details of the development and qualification program and the resolution of specific problems are discussed in this paper.

Williams, Charles W.↗

Microgravity Smoldering Combustion on the USML-1 Space Shuttle Mission

Preliminary results from an experimental study of the smolder characteristics of a porous combustible material (flexible polyurethane foam) in normal and microgravity are presented. The experiments, limited in fuel sample size and power available for ignition, show that the smolder process was primarily controlled by heat losses from the reaction to the surrounding environment. In microgravity, the reduced heat losses due to the absence of natural convection result in only slightly higher temperatures in the quiescent microgravity test than in normal gravity but a dramatically larger production of combustion products in all microgravity tests. Particularly significant is the proportionately larger amount of carbon monoxide and light organic compounds produced in microgravity, despite comparable temperatures and similar char patterns. This excessive production of fuel-rich combustion products may be a generic characteristic of smoldering polyurethane in microgravity, with an associated increase in the toxic hazard of smolder in spacecraft.

Stocker, Dennis P.↗

Smoldering News From STS-77 Endeavour

The Microgravity Smoldering Combustion (MSC) experiment lifted off aboard the Space Shuttle Endeavour for its second flight in May 1996, as part of the STS-77 mission. This experiment is part of a series of studies focused on the smolder characteristics of porous combustible materials in a microgravity environment. Smoldering is a nonflaming form of combustion that takes place in the interior of combustible materials. Common examples of smoldering are nonflaming embers, charcoal briquettes, and cigarettes. The objective of this study is to provide a better understanding of the controlling mechanisms of smoldering in microgravity and normal Earth gravity (1g). As with other forms of combustion, gravity affects the availability of air and transport of heat, and therefore, the rate of combustion. The results of the microgravity experiments will be compared with identical ones carried out in 1g. In addition, they will be used to verify present theories of smolder combustion and will provide new insights into the process of smoldering combustion, enhancing our fundamental understanding of this frequently encountered combustion process and guiding improvements in fire safety practices. Two smoldering combustion tests with polyurethane foam were successfully accomplished during the STS-77 mission. The tests investigated smoldering combustion in a quiescent (no-flow) enriched oxygen environment, and in an air environment with a 2-mm/sec airflow through the fuel sample. The primary data from the tests are the ignition characteristics, spread rate, smolder reaction temperature, and products of combustion (solid and gas). On both the first mission on STS-69 and the second mission on STS-77, a smolder front propagated the length of the forced-flow samples, with the spread rate between the corresponding upward and downward 1g smolder rates. Neither of the quiescent cases propagated combustion (the first case was due in part to a problem with the experiment electronics). These results show a dramatic difference from the normal gravity results, where smolder propagation is very rapid and complete for both of these conditions. The experiment was conceived by Prof. A. Carlos Fernandez-Pello at the University of California-Berkeley. The MSC hardware was designed and built at the NASA Lewis Research Center by a team of civil servants and contractors from NYMA, Inc., and Aerospace Design & Fabrication, Inc. (ADF). The hardware consists of two sealed aluminum combustion chambers (each being a half a cylinder). The chambers hold the MSC test section, data acquisition electronics, power distribution electronics, and instrumentation. The hardware is fitted into a 5-ft(sup 3) Get-Away-Special (GAS) canister that is mounted in the shuttle cargo bay. The test section consists of a quartz cylinder that contains the polyurethane foam sample and an igniter. This igniter, which is an electrically heated wire sandwiched between two porous ceramic disks, is mounted in contact with the end of the foam sample. An array of 12 thermocouples placed axially and radially along the foam sample provide temperature histories, which are used to determine the rate of smolder propagation, and the characteristics of the reaction.

Koudelka, John M.↗

Material Issues in Space Shuttle Composite Overwrapped Pressure Vessels

Composite Overwrapped Pressure Vessels (COPV) store gases used in four subsystems for NASA's Space Shuttle Fleet. While there are 24 COPV on each Orbiter ranging in size from 19-40", stress rupture failure of a pressurized Orbiter COPV on the ground or in flight is a catastrophic hazard and would likely lead to significant damage/loss of vehicle and/or life and is categorized as a Crit 1 failure. These vessels were manufactured during the late 1970's and into the early 1980's using Titanium liners, Kevlar 49 fiber, epoxy matrix resin, and polyurethane coating. The COPVs are pressurized periodically to 3-5ksi and therefore experience significant strain in the composite overwrap. Similar composite vessels were developed in a variety of DOE Programs (primarily at Lawrence Livermore National Laboratories or LLNL), as well as for NASA Space Shuttle Fleet Leader COPV program. The NASA Engineering Safety Center (NESC) formed an Independent Technical Assessment (ITA) team whose primary focus was to investigate whether or not enough composite life remained in the Shuttle COPV in order to provide a strategic rationale for continued COPV use aboard the Space Shuttle Fleet with the existing 25-year-old vessels. Several material science issues were examined and will be discussed in this presentation including morphological changes to Kevlar 49 fiber under stress, manufacturing changes in Kevlar 49 and their effect on morphology and tensile strength, epoxy resin strain, composite creep, degradation of polyurethane coatings, and Titanium yield characteristics.

Sutter, James K.↗

Characterization of Space Shuttle Thermal Protection System (TPS) Materials for Return-to-Flight following the Shuttle Columbia Accident Investigation

During the Space Shuttle Columbia Accident Investigation, it was determined that a large chunk of polyurethane insulating foam (= 1.67 lbs) on the External Tank (ET) came loose during Columbia's ascent on 2-1-03. The foam piece struck some of the protective Reinforced Carbon-Carbon (RCC) panels on the leading edge of Columbia's left wing in the mid-wing area. This impact damaged Columbia to the extent that upon re-entry to Earth, superheGed air approaching 3,000 F caused the vehicle to break up, killing all seven astronauts on board. A paper after the Columbia Accident Investigation highlighted thermal analysis testing performed on External Tank TPS materials (1). These materials included BX-250 (now BX-265) rigid polyurethane foam and SLA-561 Super Lightweight Ablator (highly-filled silicone rubber). The large chunk of foam from Columbia originated fiom the left bipod ramp of the ET. The foam in this ramp area was hand-sprayed over the SLA material and various fittings, allowed to dry, and manually shaved into a ramp shape. In Return-to-Flight (RTF) efforts following Columbia, the decision was made to remove the foam in the bipod ramp areas. During RTF efforts, further thermal analysis testing was performed on BX-265 foam by DSC and DMA. Flat panels of foam about 2-in. thick were sprayed on ET tank material (aluminum alloys). The DSC testing showed that foam material very close to the metal substrate cured more slowly than bulk foam material. All of the foam used on the ET is considered fully cured about 21 days after it is sprayed. The RTF culminated in the successful launch of Space Shuttle Discovery on 7-26-05. Although the flight was a success, there was another serious incident of foam loss fiom the ET during Shuttle ascent. This time, a rather large chunk of BX-265 foam (= 0.9 lbs) came loose from the liquid hydrogen (LH2) PAL ramp, although the foam did not strike the Shuttle Orbiter containing the crew. DMA testing was performed on foam samples taken fiom a simulated PAL ramp panel. It was found that the smooth rind on the foam facing the cable tray did significantly affect the properties of foam at the PAL ramp surface. The smooth rind increased the storage modulus E' of the foam as much as 20- 40% over a temperature range of -145 to 95 C. Because of foam loss fiom the PAL ramp, future Shuttle flights were grounded indefinitely to allow further testing to better understand foam properties. The decision was also made to remove foam from the LH2 PAL, ramp. Other RTF efforts prior to the launch of Discovery included

Wingard, Doug↗