Axisymmetric shell analysis of the Space Shuttle solid rocket booster field joint
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The feasibility of developing and producing a launch vehicle from an external tank (ET) and an engine module that mounts inline to the tankage at the aft end and contains six space transportation main engines (STME), was assessed. The primary mission of this launch vehicle would be to place a PLS (personnel launch vehicle) into a low earth orbit (LEO). The vehicle tankage and the assembly of the engine module, was evaluated to determine what, if any, manufacturing/production impacts would be incurred if this vehicle were built along side the current ET at Michoud Assembly Facility. It was determined that there would be no significant impacts to produce seven of these vehicles per year while concurrently producing 12 ETs per year. Preliminary estimates of both nonrecurring and recurring costs for this vehicle concept were made.
The topics are presented in viewgraph form and include the following: LRB study results summary -- Feb. 1989; LRB study results -- Jan. 1990; Shuttle configuration with booster options; LRB study results -- Sept. 1990; LRB statement of work tasks; ground rules and assumptions; study flow of design, manufacturing/production, and test program/certification; study products; study schedule; and candidate 1.5 stage engine arrangements.
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White Hypalon paint is brush-applied as a moisture barrier coating over cork surfaces on each of the two Space Shuttle SRBS. Fine cracks have been observed in the Hypalon coating three times historically on laboratory witness panels, but never on flight hardware. Recent samples of the cracked and standard ("good") Hypalon were removed from cork surfaces and were tested by Thermal Gravimetric Analysis (TGA), Thermomechanical (TMA) and Differential Scanning Calorimetry (DSC) thermal analysis techniques. The TGA data showed that at 700 C, where only paint pigment solids remain, the cracked material had about 9 weight percent more material remaining than the standard material, probably indicating incomplete mixing of the paint before it was brush-applied to produce the cracked material. Use of the TMA film tension method showed that the average static modulus vs. temperature was about 3 to 6 times higher for the cracked material than for the standard material, indicating a much higher stiffness for the cracked Hypalon. The TMA data also showed than an increased coating thickness for the cracked Hypalon was not a factor in the anomaly.
Mechanical property characterization was performed on AS4/3501-6 graphite/epoxy and SC350G syntactic foam for the SRB Composite Nose Cap Shuttle Upgrades Project. Lamina level properties for the graphite/epoxy were determined at room temperature, 240 F, 350 F, 480 F, 600 F, and 350 F after a cycle to 600 F. Graphite/epoxy samples were moisture conditioned prior to testing. The syntactic foam material was tested at room temperature, 350 F, and 480 F. A high-temperature test facility was developed at MSFC. Testing was performed with quartz lamp heaters and high resistance heater strips. The thermal history profile of the nose cap was simulated in order to test materials at various times during launch. A correlation study was performed with Southern Research Institute to confirm the test methodology and validity of test results. A-basis allowables were generated from the results of testing on three lots of material.
White Hypalon paint is brush-applied as a moisture barrier coating over cork surfaces on each of the two Space Shuttle SRBs. Fine cracks have been observed in the Hypalon coating three times historically on laboratory witness panels, but never on flight hardware. Samples of the cracked and standard ("good") Hypalon were removed from witness panel cork surfaces, and were tested in 1998 by Thermogravimetric Analysis (TGA), TMA and Differential Scanning Calorimetry (DSC) thermal analysis techniques. The TGA data showed that at 700C, where only paint pigment solids remain, the cracked material had about 9 weight percent more material remaining than the standard material, probably indicating incomplete mixing of the paint before it was brush-applied to produce the cracked material. Use of the TMA film/fiber technique showed that the average modulus (stiffness) vs. temperature was about 3 to 6 times higher for the cracked material than for the standard material. The TMA data also showed that an increase in coating thickness for the cracked Hypalon was not a factor in the anomaly.
The paper discusses the following: assess the impact of aging and usage on SRB Forward and Aft Integrated Electronic Assemblies (IEA's); d3etermine the relative position of the IEA's on their expected reliability curves; provide recommendations, with supporting rationale, for any upgrades necessary to maintain reliability and logistic supportability through the year 2020; if upgrades are recommended the team will define a roadmap for the design and implementation of the upgrade; assess the other reusable boxes on the SRB to determine if the screening tests between flights are adequate; and assess the other reusable boxes on the SRB to determine if they are wearing out.
The USA LLC Materials & Processes (M&P) Engineering Department had recommended the application and evaluation of Ion Vapor Deposition (IVD) aluminum to SRB Hardware for corrosion protection and elimination of hazardous materials and processes such as cadmium plating. IVD is an environmentally friendly process that has no volatile organic compounds (VOCs), or hazardous waste residues. It lends itself to use with hardware exposed to corrosive seacoast environments as found at Kennedy Space Center (KSC), and Cape Canaveral Air Force Station (CCAFS), Florida. Lifting apparatus initially coated with cadmium plating for corrosion protection; was stripped and successfully re-coated with IVD aluminum after the cadmium plating no longer protected the GSE from corrosion, Since then, and after completion of a significant test program, the first flight application of the IVD Aluminum process on the Drogue Parachute Ratchet Assembly is scheduled for 2002.
No abstract available
My name is Mike Prince and I was one of eleven Brevard County teachers selected by United Space Alliance, LLC (USA), to work at the Kennedy Space Center (KSQ along side USA & NASA engineers during the Summer of 2007. Attached is a summary of my experience.
The Space Shuttle Columbia Accident revealed a fundamental problem of the Space Shuttle Program regarding debris. Prior to the tragedy, the Space Shuttle requirement stated that no debris should be liberated that would jeopardize the flight crew and/or mission success. When the accident investigation determined that a large piece of foam debris was the primary cause of the loss of the shuttle and crew, it became apparent that the risk and scope of - damage that could be caused by certain types of debris, especially - ice and foam, were not fully understood. There was no clear understanding of the materials that could become debris, the path the debris might take during flight, the structures the debris might impact or the damage the impact might cause. In addition to supporting the primary NASA and USA goal of returning the Space Shuttle to flight by understanding the SRB debris environment and capability to withstand that environment, the SRB debris assessment project was divided into four primary tasks that were required to be completed to support the RTF goal. These tasks were (1) debris environment definition, (2) impact testing, (3) model correlation and (4) hardware evaluation. Additionally, the project aligned with USA's corporate goals of safety, customer satisfaction, professional development and fiscal accountability.
No abstract available
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