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Flexseal assemblies, TVC actuators, hydraulic supply system, TVC electronic control unit, flight instrumentation system, ordnance system electronics, and hydrotest of SRM case segments are discussed, applied to typical component recertification test procedures.
Additional technical data have been prepared to supplement the data supplied in the SRM shuttle booster final report. These data cover performance characteristics utilizing motor efficiencies of 0.960 and 0.947 with nozzle divergence half angles of 15 deg and 20 deg, respectively; PBAN propellant characteristics; parametric data to extend baseline designs to varying states of SRM's; summary of SRM mass properties; and SRM exhaust plume profiles.
The design and performance of a motor developed for the first stage of the NASA SCOUT-D and E launch vehicles are discussed. The motor delivers a 30% higher total impulse and a 35 to 45% higher payload mass capability than its predecessor, the Algol IIB. The motor is 45 in. in diameter, has a length-to-diameter ratio of 8:1 and delivers an average 100,000-lb thrust for an action time of 72 sec. The motor design features a very high volumetrically loaded internal-burning charge of 17% aluminized polybutadiene propellant, a plasma-welded and heat-treated steel alloy case, and an all-ablative plastic nose liner enclosed in a steel shell. The only significant development problem was the grain design tailoring to account for erosive burning effects which occurred in the high-subsonic-Mach-number port. The tests performed on the motor are described.
Results are presented of firing a Nike rocket against a backstop for the purpose of obtaining pressure fluctuations in the rocket case and determining their relationship to structural vibrations of the case. Special care was required to obtain these pressure fluctuations because of the much higher static pressure generated in the rocket. Very small pressure fluctuations within the rocket case can cause significant vibration levels. A previously observed high frequency was shown to decrease with time before completely disappearing at about 1 second of burning time. The vibration of the case itself is probably related to the longitudinal structural modes at frequencies below 500 Hz and is dependent on local structural conditions at frequencies above this value.
The control authority approach is discussed as a major problem of the parallel burn soil shuttle configuration due to the many resulting system impacts regardless of the approach. The major trade studies and their results, which led to the recommendation of an SRB TVC control authority approach are presented.
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Preliminary analysis showed that the doubly curved triangular shell elements were too stiff for these shell structures. The doubly curved quadrilateral shell elements were found to give much improved results. A total of six load cases were analyzed in this study. The load cases were either those resulting from a static test using reaction straps to simulate the drop conditions or under assumed hydrodynamic conditions resulting from a drop test. The latter hydrodynamic conditions were obtained through an emperical fit of available data. Results obtained from a linear analysis were found to be consistent with results obtained elsewhere with NASTRAN and BOSOR. The nonlinear analysis showed that the originally assumed loads would result in failure of the shell structures. The nonlinear analysis also showed that it was useful to apply internal pressure as a stabilizing influence on collapse. A final analysis with an updated estimate of load conditions resulted in linear behavior up to full load.
The steps in the nozzle design process are examined. The nozzle designer's role in defining design requirements and constraints is included along with discussions of each of the three basic phases of the nozzle design process itself: (1) aerodynamic design, in which the gas-contacting surfaces are configured to produce the required performance within the envelope limits; (2) thermal design, in which termal liners and thermal insulators are selected and configured to maintain the surfaces as closely as practical against effects of erosion and to limit the structure temperature to acceptable levels; and (3) structural design, in which materials are selected and configured to support the thermal components and to sustain the predicted loads. Analytical techniques that are used to establish thermal and structural design integrity and to predict nozzle performance are discussed along with methods for nozzle quality assurance. Emphasis is placed on nozzle design and materials for modern high-temperature aluminized propellants. Recurring nozzle design problems of graphite cracking and ejection, differential erosion at material interfaces, lack of sufficient proven nondestructive testing (NDT) techniques, the uncertainty of adhesive bonding, and inadequate definition of material properties, particularly at high temperatures are considered.
This study focuses on establishing the sensitivity of predictions of NO production to uncertainties in altitude, reaction rate coefficients, turbulent mixing rates, and Mach disk size and location. The results show that relatively large variations in parameters related to these phenomena had surprisingly little effect on predicted NO production.
(Previously cited in issue 19, p. 3285, Accession no. A81-40975)
The damage potentials to the space shuttle orbiter caused by the high velocity particles contained in the exhaust plume of an upper stage is discussed. In particular, the particle size distribution and composition, the velocity of the particles and the expected contribution from shuttle launched upper stages are addressed. Particle size estimates based on historical data are compapred with those derived from upper stage motor performance testing. The particle velocities as determined by the best available plume computational technique are presented. The shuttle is scheduled to launch approximately 135 upper-stages over its lifetime looking at the currently scheduled flights and averaging over a yearly basis yields the contribution of particulates from the uper-stages. On the average, 91,645 llbs of Al2O3 will be ejected on each launch. The analysis to determine how much of this 91,645 lbs will remain in orbit or the decay rate is yet to be accomplished.
Traditional composite lamination theory was used to compute the constitutive matrices using a potential range of lamina properties. Sensitivity of vibrational frequencies was examined for variations in constituent materials and geometric properties. The material component interactions examined were the lamina longitudinal and transverse Young's modulus, the lamina Poisson's ratio, and the shear modulus. Fiber and resin properties were related to the frequency response through lamina properties. Geometric properties examined are void ratio and helical wind angle. Capabilities and applications of the SPAR and NASTRAN computer codes are examined for laminated cylindrical shells.
Presented is an assessment of case growth for two D6AC steel SRM case segments with multiple flight use and a comparison of these two cases with two new cases. Dimensional changes in the sealing diameter areas were recorded for the used cases and after hydroproofing of the new cases.
The ice Nucleus activity of exhaust particles generated from combustion of Space Shuttle propellant in small rocket motors has been measured. The activity at -20 C was substantially lower than that of aerosols generated by unpressurized combustion of propellant samples in previous studies. The activity decays rapidly with time and is decreased further in the presence of moist air. These tests corroborate the low effectivity ice nucleus measurement results obtained in the exhaust ground cloud of the Space Shuttle. Such low ice nucleus activity implies that Space Shuttle induced inadvertent weather modification via an ice phase process is extremely unlikely.
This analysis extends the investigation presented at the 17th Joint Propulsion Conference in 1981 to include fifteen sets of Space Shuttle flight data. The previous report dealt only with static test data and the first flight pair. The objective is to compare the authors' previous theoretical analysis of thrust imbalance with actual Space Shuttle performance. The theoretical prediction method, which involves a Monte Carlo technique, is reviewed briefly as are salient features of the flight instrumentation system and the statistical analysis. A scheme for smoothing flight data is discussed. The effects of changes in design parameters are discussed with special emphasis on the filament wound motor case being developed to replace the steel case. Good agreement between the predictions and the flight data is demonstrated.
Erratic pockets of erosion have occurred on the inner perimeter of the 404 rocket nozzle ring during liftoff firing. It is thought that it may be caused by pockets of volatile matter entrapped during manufacture. A thermal post cure was suggested as a possible means of outgassing such pockets, if they in fact do exist. To confirm an outgassing during a post cure and to establish a working upper temperature limit, thermal gravimetric and differential calorimetric analyses were made on a number of samples from two 404 rings supplied by the manufacturer. Continuous weight loss was observed over the temperature range explored (750 F) indicating outgassing, and a strong exothermic reaction occurs beginning about 390 F. Thus, an upper post cure temperature of 350 F is recommended. To determine the possible effect of a post cure on physical properties, the following tests will be made on matched sets of cured and post cured material: x-radiography (internal structure), linear dimensions, weight, porosity, cross ply thermal expansion, drop and double notch shear strengths, and tensional strength in the ply direction.
Erosive burning has been predicted to be enhanced by factors that increase the level of turbulence close to the propellant surface, such a high cross flow velocity, low surface blowing rate, propellant surface roughness, and adverse pressure gradient. A study is reported which was carried out with the objective of measuring the effects of these parameters on the scaling to larger rocket motor sizes of the transition to, or threshold conditions for, erosive burning rate augmentation. The results are used to develop a scaling criterion for the threshold conditions for erosive burning.
The history of the analyses for the hydraulic force control systems of the T-97 test facility is presented. Two approaches that were investigated for softening the hydraulic systems for improved performance are presented. A valve modification and inclusion of a proportional-integral controller that finally stabilized the system are described. A simulated test case is shown and compared to actual test data from the QM-7 test. The simulated results are very close to the real results but indicate a slightly higher open-loop gain than for the real system.