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An advanced lightweight insulation system suitable for use in long duration, low pressure planetary orbiter-type motor applications was developed. Experiments included the screening of various filler and binder materials with optimization studies combining the best of each. Small scale test motor data were used to judge the degree of success.
A reserach project to develop space stable thermal control coatings for large surfaces is discussed. Four major tasks are considered: (1) pigment development, (2) binder development, (3) environmental effects evaluations, and (4) general coatings investigations.
The mullite fiber based hardened compacted fibers (HCF) type of reusable surface insulation was further developed for use in the Space Shuttle Program. Two hundred fifty formulations of fiber mixtures, fillers, binders, and organic processing aids were made using mullite fibers as the basic ingredient. Most of the work was accomplished on 15-lb/cu ft material. It was established that higher density materials are stronger with strength values as high as 250 lb/sq in. in tension. New measurement techniques and equipment were developed for accurate determination of strength and strain to failure. Room temperature to 2300 F stress-strain relationships were made. The room temperature tensile modulus of elasticity is 61,700 lb/sq in. and the strain at failure is 0.165 percent, typically, when measured longitudinally parallel to the long axes of the fibers. Thermal insulating effectiveness was increased 20 percent by reducing the diameter of some of the fibers in the material. Improvements were made in density uniformity and strength uniformity in a block of HCF by mixing improvements and by the use of organic additives. Specifications were established on the materials and processes used in making the insulation.
Ply-tear webbing is essentially two plain webbings that are bound together by a portion of the warps and that can be torn apart and do work by breaking the binders. Nylon webbing were woven to range in tear force from 1 to 10 kilonewtons. This force is substantially independent of speed, which was as high as 100 m/sec in some cases. A specific energy absorption of 90 J/g was achieved in the dry state. However, lower rated webbings that absorb approximately 40 J/g are recommended for use in practice where it is acceptable.
Carbon-graphite seal ring bodies for operation at air temperatures to 1300 F(704 C) were manufactured from three select formulations. Mechanical and thermal properties, porosities, and oxidation rates were measured. The results have shown that: (1) Major property improvements anticipated from the screening studies were not realized because of processing problems associated with the scale-up in material size and probable deterioration of a phenolic resin binder; (2) the mechanical properties of a phenolic resin-bonded, carbon-graphite material can be improved by applying high pressure during carbonization; and (3) the textile form of graphite fiber used as the minor filler component in a carbon-graphite material can beneficially affect mechanical properties.
The basic insulation improvement study concentrated upon evaluating variables which could result in significant near-term gains in mechanical behavior and insulation effectiveness of the baseline system. The approaches undertaken included: evaluation of small diameter fibers, optimization of binder: slurry characteristics, evaluation of techniques for controlling fiber orientation, optimization of firing cycle, and the evaluation of methods for improving insulation efficiency. A detailed discussion of these basic insulation improvement studies is presented.
The manufacturing techniques, basic materials used, and equipment required to produce monolayer boron-aluminum composites are described. Tentative materials and process specifications are included. Improvements in bonding and filament spacing obtained through use of brazing powder in the fugitive binder are discussed.
The continuing efforts in upscaling to produce larger diameter Al/B tubes are described. While the basic methodology remains unchanged, the larger volume of acrylic binder material and its removal by dissolution in toluene had to be performed by dynamic scrubbing. Similarly, the boron and MCF continuous length requirements increased when a 6 foot long by 7 inches wide mat was needed. These modifications and associated problems are described fully with schematics. Also included are seven experiments conducted to prepare larger tubes. The thermal profile, drawing speeds, and furnace positions in the draw bench bay are presented along with metallographic evidence of composite cross sections.
Systematic development and evaluation of ceramic fiber Mullite are summarized: (1) Major reductions in thermal protection system weight have been achieved by reducing the density and thermal conductivity of the insulation by 20 and 25 percent; (2) already adequate structural margins-of-safety have been greatly enhanced by increasing the tensile strength and strain-to-failure capabilities of the insulation by factors of 3 and 2; (3) cost effectiveness has been increased through the achievement of a high degree of uniformity and reproducibility of properties and through process simplification and binder modifications; and (4) maximization of multimission capability at surface temperatures of 1644 K has been achieved through firing cycle adjustments and the development of a material with high dimensional stability.
Intumescent coating compositions have been prepared using the ammonium salt of 4-nitroaniline-2-sulfonic acid and a copolymer of polysulfide-epoxy resin as the binder, into which have been dispersed various fillers. The fillers used in the study were low density microballoons for density control and fibers for controlled intumescence on contoured substrates. The filler effect on the thermal-physical efficiency of coatings has been measured. The coating utilizing short length silica fibers has been shown to have superior mechanical, environmental, and thermal properties. The coating applied to the exterior of loaded weapons has increased the time-to-detonation from three minutes for the unprotected weapon to 10-13 minutes.
A friction and wear life study was conducted on the use of a polyimide (PI) varnish as a binder for the solid lubricant, graphite fluoride (CF sub 1.1) sub n. Also studied were the lubricating properties of PI thin films with no solid lubricant additives. For comparison, similar experiments on PI-bonded MoS2 and burnished films of MoS2 or (CF sub 1.1) sub n were conducted. The best results were obtained with the PI-bonded (CF sub 1.1) sub n films. The polyimide thin films (with no solid lubricant additives) did not lubricate well at 25 C; however, when heated to 100 C, low friction and long wear lives were obtained.
The objective of this work was to better define the effects of propellant composition variables on the acceleration induced burning-rate augmentation of solid propellants. The rate augmentation of an aluminized propellant at a given acceleration level was found to be a nonlinear inverse function of the reference or static burning rate and not controlled by binder or catalyst type at a given reference rate. A nonaluminized and a low rate double-base propellant exhibited strong transient rate augmentation due to surface pitting resulting from the retention of hot particles on the propellant surface.
Two experimental techniques were developed. In the first, an electrochemical method was used with a single crystal ZnO electrode and with the material of interest dissolved in the electrolyte. In the other an electron spin resonance method was used so that measurements related to thermal control coatings could be made with the ZnO in the form of powder, either alone or in formulation of a binder. A simplified model regarding the relationship between the electron density and time is considered.
Review of the photometric work on eclipse reappearances of Io. New observations of eclipse reappearances of Io confirm the posteclipse brightness anomaly reported by Binder and Cruikshank (1964) but testify to its intermittent nature. A posteclipse anomaly of approximately 0.07 mag was observed on two occasions in 1972, while observations of Europa and Ganymede showed no brightness anomaly greater than 0.01 mag. The atmospheric condensation model for the anomaly on Io is reviewed in terms of the quantity of frost required to produce the effect and the corresponding amount of gas liberated to the atmosphere upon sublimation. The observational data and the results from a stellar occultation are in general accord with the theoretical predictions of the stability of heavy gases on Io, while both observational and theoretical criteria are satisfied by a tenuous atmosphere of a heavy gas such as methane or ammonia having a surface pressure of about 0.1 microbar.
The exhaust products of a solid rocket motor using as propellant 14% binder, 16% aluminum, and 70% (wt) ammonium perchlorate consist of hydrogen chloride, water, alumina, and other compounds. The equilibrium and some frozen compositions of the chemical species upon interaction with the atmosphere were computed. The conditions under which hydrogen chloride interacts with the water vapor in humid air to form an aerosol containing hydrochloric acid were computed for various weight ratios of air/exhaust products. These computations were also performed for the case of a combined SRM and hydrogen-oxygen rocket engine. Regimes of temperature and relative humidity where this aerosol is expected were identified. Within these regimes, the concentration of HCL in the aerosol and weight fraction of aerosol to gas phase were plotted. Hydrochloric acid aerosol formation was found to be particularly likely in cool humid weather.
Insulation systems composed of micrometer-sized fibers bonded together with small amounts of binder have been developed for aerospace applications. The materials have a very high volid content and low density and can be characterized as a rigidized network of fibers randomly oriented in three-dimensional space. Analytical models suitable for the evaluation of the mechanical behavior of rigidized fibrous materials have been developed. The models treat the material as a space frame structure and includes the effects of joint fixity and fiber curvature. The geometrical and material property variabilities are represented by a number of trusses oriented in five planes. Each truss may have different material and geometric properties. Techniques have been developed to describe the continuous material property and geometry functions as a series of descrete quantities that can be used to describe each of the trusses in the model. Parametric studies were performed to show the influence of material variables on the mechanical behavior of the material. Results of calculations show good agreement with measured properties.
Attempts made to develop processes capable of producing metal composites in structural shapes and sizes suitable for space applications are described. The processes must be continuous and promise to lower fabrication costs. Special attention was given to the aluminum boride (Al/b) composite system. Results show that despite adequate temperature control, the consolidation characteristics did not improve as expected. Inadequate binder removal was identified as the cause responsible. An Al/c (aluminum-graphite) composite was also examined.
A solid propellant composition of improved efficiency is described which includes an oxidizer containing ammonium perchlorate, and a powered metal fuel, preferably aluminum or beryllium, in the form of a composite. The metal fuel is contained in the crystalline lattice framework of the oxidizer, as well as within the oxidizer particles, and is disposed in the interstices between the oxidizer particles of the composition. The propellant composition is produced by a process comprising the crystallization of ammonium perchlorate in water, in the presence of finely divided aluminum or beryllium. A suitable binder is incorporated in the propellant composition to bind the individual particles of metal with the particles of oxidizer containing occluded metal.