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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2008

Evaluation of the Effect of Silicone Contamination on Various Bond Systems and the Feasibility of Removing the Contamination

Silicone is a contaminant that can cause catastrophic failure of a bond system depending on the materials and processes used to fabricate the bond system, Unfortunately, more and more materials are fabricated using silicone. The purpose of this testing was to evaluate which bond systems are sensitive to silicone contamination and whether or not a cleaning process could be utilized to remove the silicone to bring the bond system performance back to baseline. Due to the extensive nature of the testing attempts will be made to generalize the understanding within classes of substrates, bond systems, and surface preparation and cleaning methods. This study was done by contaminating various meta! (steel, inconel, and aluminum), phenolic (carbon cloth phenolic and glass cloth phenolic), and rubber (natural rubber, asbestos-silicone dioxide filled natural butyldiene rubber, silica-filled ethylene propylenediene monomer, and carbon-filled ethylene propylenediene monomer) substrates which were then bonded using various adhesives and coatings (epoxy-based adhesives, paints, ablative compounds, and Chemlok adhesives) to determine the effect silicone contamination has on a given bond system's performance. The test configurations depended on the bond system being evaluated. The study also evaluated the feasibility of removing the silicone contamination by cleaning the contaminated substrate prior to bonding. The cleaning processes also varied depending on bond system.

Stanley, Stephanie D.↗
NASA NTRS2008

Evaluation of the Effect of Silicone Contamination on Various Bond Systems and the Feasibility of Removing the Contamination

Silicone is a contaminant that can cause catastrophic failure of a bond system depending on the materials and processes used to fabricate the bond system. Unfortunately, more and more materials are fabricated using silicone. The purpose of this testing was to evaluate which bond systems are sensitive to silicone contamination and whether or not a cleaning process could be utilized to remove the silicone to bring the bond system performance back to baseline. Due to the extensive nature of the testing, attempts will be made to generalize the understanding within classes of substrates, bond systems, and surface preparation and cleaning methods. This study was done by contaminating various metal (steel, Inconel, and aluminum), phenolic (carbon-cloth phenolic [CCP] and glass-cloth phenolic [GCP]), and rubber (natural rubber, asbestos-silicone dioxide filled natural butyldiene rubber [ASNBR]; silica-filled ethylene propylenediene monomer [SFEPDM], and carbon-filled ethylene propylenediene monomer [CFEPDM]) substrates which were then bonded using various adhesives and coatings (epoxy-based adhesives, paints, ablative compounds, and Chemlok adhesives) to determine the effect silicone contamination has on a given bond system's performance. The test configurations depended on the bond system being evaluated. The study also evaluated the feasibility of removing the silicone contamination by cleaning the contaminated substrate prior to bonding. The cleaning processes also varied depending on bond system.

Stanley, Stephanie D.↗
NASA NTRS1980

Shuttle subscale ablative nozzle tests

Recent subscale nozzle tests have identified new and promising carbon phenolic nozzle ablatives which utilize staple rayon, PAN, and pitch based carbon cloth. A 4-inch throat diameter submerged test nozzle designed for the 48-inch Jet Propulsion Laboratory char motor was used to evaluate five different designs incorporating 20 candidate ablatives. Test results indicate that several pitch and PAN-based carbon phenolic ablatives can provide erosion and char performance equivalent or superior to the present continuous rayon-based SRM ablative.

Powers, L. B.↗
NASA NTRS2003

NASA Tech Briefs, July 2003

Topics covered include: Real-Time, High-Frequency QRS Electrocardiograph; Software for Improved Extraction of Data From Tape Storage; Radio System for Locating Emergency Workers; Software for Displaying High-Frequency Test Data; Capacitor-Chain Successive-Approximation ADC; Simpler Alternative to an Optimum FQPSK-B Viterbi Receiver; Multilayer Patch Antenna Surrounded by a Metallic Wall; Software To Secure Distributed Propulsion Simulations; Explicit Pore Pressure Material Model in Carbon-Cloth Phenolic; Meshed-Pumpkin Super-Pressure Balloon Design; Corrosion Inhibitors as Penetrant Dyes for Radiography; Transparent Metal-Salt-Filled Polymeric Radiation Shields; Lightweight Energy Absorbers for Blast Containers; Brush-Wheel Samplers for Planetary Exploration; Dry Process for Making Polyimide/ Carbon-and-Boron-Fiber Tape; Relatively Inexpensive Rapid Prototyping of Small Parts; Magnetic Field Would Reduce Electron Backstreaming in Ion Thrusters; Alternative Electrochemical Systems for Ozonation of Water; Interferometer for Measuring Displacement to Within 20 pm; UV-Enhanced IR Raman System for Identifying Biohazards; Prognostics Methodology for Complex Systems; Algorithms for Haptic Rendering of 3D Objects; Modeling and Control of Aerothermoelastic Effects; Processing Digital Imagery to Enhance Perceptions of Realism; Analysis of Designs of Space Laboratories; Shields for Enhanced Protection Against High-Speed Debris; Study of Dislocation-Ordered In(x)Ga(1-x)As/GaAs Quantum Dots; and Tilt-Sensitivity Analysis for Space Telescopes.

Source record↗
NASA NTRS2000

NARC Rayon Replacement Program for the Space Shuttle Reusable Solid Rocket Motor Nozzle: Screening Summary

Thiokol Corporation and NASA MSFC are jointly developing a replacement for North American Rayon Corporation (NARC) Aerospace Grade Rayon (1650/720 continuous filament), the precursor for the Carbon Cloth Phenolic (CCP) ablatives used in the Space Shuttle Reusable Solid Rocket Motor (RSRM) Nozzles. NARC discontinued production of Aerospace Grade Rayon in September 1997. NASA maintains a stockpile of NARC Rayon to support RSRM production through the summer of 2005. The program plan for selection and qualification of a replacement for NARC rayon was approved in August 1998. Screening activities began in February 1999. The intent of this paper is to provide a summary of the data generated during the screening phase of the NARC Rayon Replacement Program. Twelve cellulose based fibers (rayon and lyocell) were evaluated. These fibers were supplied by three independent vendors. Many of these fibers were carbonized by two independent carbonizers. Each candidate was tested according to standard acceptance test methods at each step of the manufacturing process. Additional testing was performed with the candidate CCPS, including hot fire tests, Process studies and mechanical and thermal characterization. Six of the twelve fiber candidates tested were dropped at the conclusion of Phase 1. The reasons for the elimination of these candidates included; difficulties in processing the material in the whitegoods, carbon and CCP forms; poor composite mechanical performance; and future availability concerns. The remaining six fibers demonstrated enough promise to merit continued evaluation and optimization of the CCP fabrication process. Note: Certain CCP data falls under the restrictions of US export laws, (ITAR, etc.) and will not be included in this paper.

Cook, R. V.↗
NASA NTRS1979

Unconventional nozzle tradeoff study

Plug cluster engine design, performance, weight, envelope, operational characteristics, development cost, and payload capability, were evaluated and comparisons were made with other space tug engine candidates using oxygen/hydrogen propellants. Parametric performance data were generated for existing developed or high technology thrust chambers clustered around a plug nozzle of very large diameter. The uncertainties in the performance prediction of plug cluster engines with large gaps between the modules (thrust chambers) were evaluated. The major uncertainty involves, the aerodynamics of the flow from discrete nozzles, and the lack of this flow to achieve the pressure ratio corresponding to the defined area ratio for a plug cluster. This uncertainty was reduced through a cluster design that consists of a plug contour that is formed from the cluster of high area ratio bell nozzles that have been scarfed. Light-weight, high area ratio, bell nozzles were achieved through the use of AGCarb (carbon-carbon cloth) nozzle extensions.

Obrien, C. J.↗
NASA NTRS1979

Space Shuttle solid rocket booster

Details of the design, operation, testing and recovery procedures of the reusable solid rocket boosters (SRB) are given. Using a composite PBAN propellant, they will provide the primary thrust (six million pounds maximum at 20 s after ignition) within a 3 g acceleration constraint, as well as thrust vector control for the Space Shuttle. The drogues were tested to a load of 305,000 pounds, and the main parachutes to 205,000. Insulation in the solid rocket motor (SRM) will be provided by asbestos-silica dioxide filled acrylonitrile butadiene rubber ('asbestos filled NBR') except in high erosion areas (principally in the aft dome), where a carbon-filled ethylene propylene diene monomer-neopreme rubber will be utilized. Furthermore, twenty uses for the SRM nozzle will be allowed by its ablative materials, which are principally carbon cloth and silica cloth phenolics.

Hardy, G. B.↗
NASA NTRS1980

Current and projected use of carbon composites in United States aircraft

Carbon composite materials are finding limited use in both civil and military aircraft structures to exploit their weight saving potential for improved performance or fuel efficiency. Since these needs are growing, and a manufacturing cost savings potential is also recognized, wider use of composites in the near future may be expected. Carbon composites generally involve fiber volume fractions in excess of 60 percent in a variety of orthotropic sandwich or solid laminates. Bidirectional woven carbon cloth, common in recently designed structure, may provide higher, more uniform laminate conductivities than tape.

Leonard, R.↗
NASA NTRS1983

Rubber-toughened polyfunctional epoxies - Brominated vs nonbrominated formulated for graphite composites

A new, commercially available, trifunctional epoxy resin (tris-(hydroxyphenyl)-methane triglycidyl ether) was modified with synthetic rubber to increase the impact resistance of epoxy/graphite composites. These composites were reinforced with commercially available satin-weave carbon cloth using two formulations of epoxies (brominated and nonbrominated) containing various amounts of carboxy-terminated butadience acrylonitrile (CTBN) rubber that had been prereacted with epoxy resin. The impact resistance was determined by measuring the interlaminar shear strength of the composites after impact. The mechanical properties, such as flexural strength and modulus at room temperature and at 93 C, were also determined. Measurements were taken of the flammability and glass transition temperature (Tg); and a thermal-gravimetric analysis was made.

Nir, Z.↗
NASA NTRS1983

Development of new and improved polymer matrix resin systems, phase 1

Vinystilbazole (vinylstryrylpyridine) and vinylpolystyrulpyridine were prepared for the purpose of modifying bismaleimide composite resins. Cure studies of resins systems were investigated by differential scanning calorimetry. The vinylstyrylpyridine-modified bismaleimide composite resins were found to have lower cure and gel temperatures, and shorter cure times than the corresponding unmodified composite resins. The resin systems were reinforced with commercially avialable satin-weave carbon cloth. Prepregs were fabricated by solvent or hot melt techniques. Thermal stability, flammability, moisture absorption, and mechanical properties of the composites (such as flexural strength, modulus, tensile and short beam shear strength) were determined. Composite laminates showed substantial improvements in both processability and mechanical properties compared to he bismaleimide control systems. The vinylstyrylpyridine modified bismaleimide resins can be used as advanced matrix resins for graphite secondary structures where ease of processing, fireworthiness, and high temperature stability are required for aerospace applications.

Hsu, M. S.↗
NASA NTRS1984

Vinylstyrylpyridine-modified bismaleimide composite resins

Vinylstilbazole (vinylstyrylpyridine) and vinylpolystyrylpyridine was prepared for the purpose of modifying bismaleimide composite resins. Cure studies of resin systems were investigated by differential scanning calorimetry. The vinylstyrylpyridine-modified bismaleimide composite resins were found to have lower cure and gel temperatures, and shorter cure times than the corresponding unmodified composite resins. The resin systems were reinforced with commercially available satin-weave carbon cloth fabricated by hot melt (or solvent) techniques. Thermal stability, flammability, moisture absorption, and mechanical properties of the composites (such as flexural strength, modulus, tensile and short beam shear strength) were determined. Composite laminates showed substantial improvements in both processability and mechanical properties compared to the bismaleimide control systems.

Hsu, M.-T. S.↗
NASA NTRS1986

Fire-Resistant Belt Panel for Airplane Windows

Window-belt panel for airplanes fire resistant and generates little smoke when exposed to flames. Panel incorporates fire-shield layer adding minimal weight but delays or prevents fire from burning through. Structural core of panel is Nomex or equivalent polyamide paper honeycomb. Fire shield, made of fluororubber sheet, incorporated in multiple-ply facing bonded to core. Outer layers of multiple-ply facing and back face of panel consist of biwoven carbon-cloth impregnated with phenolic resin.

Trabold, E. L.↗
NASA NTRS1986

Pocketing mechanics of SRM nozzle liner

A systems approach was adopted to study the pocketing phenomena on a solid rocket nozzle liner. The classical thermoelastic analysis was used to identify marginally strained regions on the composite liner erosion surface and at a depth coincident with the peak value of the across ply coefficient of thermal expansion. A failure criterion was introduced which included a thermal term and permitted failure assessment over the charred liner. The method was verified by satisfactory application to a reported related experiment. Liner pocketing mechanism was attributed to very localized material degradation caused during manufacturing process either by reduction of fiber strength and/or by concentration of resin volume fraction. Pocketing scenario over the degraged material was constructed with supporting formulation to predict size of fissures with respect to degraded material size and location in the liner and with burn time. Sensitivities of liner material parameters were determined to influence test programs designed to update mechanical data base of carbon cloth phenolic over the char temperature range.

Verderaime, V. S.↗
NASA NTRS1989

Qualification Motor no. 8 (QM-8), volume 1

All inspection and instrumentation data indicate that the QM-8 static test firing conducted 20 January 1989 was successful. Ambient temperature at T-0 was 28 F. With two flights successfully accomplished, this final test in the redesigned solid rocket motor (RSRM) program certified that the design meets motor performance requirements under extreme cold conditions. This test was a prerequisite to the third flight. The entire test article was cold conditioned at 20 to 25 F for approximately 31 days to assure a maximum propellant mean bulk temperature (PMBT) of 40 F, making it the lowest PMBT in the history of the program. This extreme condition also presented the opportunity to certify critical components at low temperatures. Certification of field joint and igniter heaters, adhesive bondline integrity, flex bearing performance, flight instrumentation performance, RSRM seal performance, and LSC and nozzle plug performance was accomplished. Prior to motor ignition, the field joints were maintained between 75 to 130 F, the igniter-to-case joint was maintained between 75 to 123 F, and the case-to-nozzle joint was maintained between 75 to 120 F. QM-8 was tested with induced side loads to simulate the strut loads experienced during ignition and maximum aerodynamic loading conditions. The ability of the safe and arm device to change position from safe-to-arm and arm-to-safe was certified. Ballistics performance was certified at the lower limits. Values were within specification requirements. Nozzle performance was nominal with typical erosion. The use of Fiberite carbon-cloth phenolic was certified. The water deluge system, CO2 quench, and other test equipment performed as planned during all required test operations.

Garecht, D. M.↗
NASA NTRS1990

Flight motor set 360L002 (STS-27R). Volume 5: Nozzle component

A review of the performance and post-flight condition of the STS-27 Redesigned Solid Rocket Motor (RSRM) nozzles is presented. Thermal/Structural instrumentation data is reviewed, and applicable Discrepancy Reports (DRs) and Process Departures (PDs) are presented. The Nozzle Component Program Team (NCPT) performance evaluation and the Redesign Program Review Board (RPRB) assessment is included. The STS-27 nozzle assemblies were flown on the RSRM Second Flight (Space Shuttle Atlantis) on 2 December 1988. The nozzles were a partially submerged convergent and/or divergent movable design with an aft pivot point flexible bearing. The nozzle assemblies incorporated the following features: RSRM forward exit cone with snubber assembly, RSRM fixed housing, Structural backup Outer Boot Ring (OBR), RSRM cowl ring, RSRM nose inlet assembly, RSRM throat assembly, RSRM aft exit cone assembly with Linear-Shaped Charge (LSC), RTV backfill in Joints 1, 3, and 4, Use of EA913 NA adhesive in place of EA913 adhesive, Redesigned nozzle plug, and Carbon Cloth Phenolic (CCP) with 750 ppm sodium content. The CCP material usage for the STS-27 forward nozzle and aft exit cone assemblies is shown.

Meyer, S. A.↗
NASA NTRS1990

Flight motor set 36OH005 (STS-28R). Volume 5: (Nozzle component)

A review of the performance and post flight condition of the STS-28 redesigned solid rocket motor (RSRM) nozzles is presented in this document. Applicable discrepancy reports (DR's) and process departures (PD's) are presented in section 5.0. The nozzle component program team (NCPT) performance evaluation and the redesign program review board (RPRB) assessment is included in section 6.0. The STS-28 nozzle assemblies were flown on the RSRM fifth flight (Space Shuttle Columbia). The nozzles were a partially submerged convergent/divergent movable design with an aft pivot point flexible bearing. The nozzle assemblies incorporated the following features: (1) RSRM forward exit cone with snubber assembly; (2) RSRM fixed housing; (3) structural backup outer boot ring (OBR); (4) RSRM cowl ring; (5) RSRM nose inlet assembly; (6) RSRM throat assembly; (7) RSRM forward nose and aft inlet ring; (8) RSRM aft exit cone assembly with linear-shaped charge (LSC); (9) RTV backfill in joints 1, 3, and 4; (10) use of EA913 NA adhesive in place of EA913; (11) redesigned nozzle plug; and (12) carbon cloth phenolic (CCP) with 750 ppm sodium content. The RSRM fifth flight test objectives are as follows: (1) verify that flexible bearing seals operate within the specified temperature range; (2) verify that flexible bearing maintained a positive gas seal between its internal components; (3) inspect flexible bearing for damage due to water impact; (4) verify performance of the nozzle liner; (5) verify that nozzle parts are reusable; (6) verify through flight demonstration and a postflight inspection that the flexible bearing is reusable; (7) verify by inspection the remaining nozzle ablative thicknesses; and (8) verify the nozzle performance margins of safety.

Smith, Dan M., Jr.↗
NASA NTRS1992

Improved ablative materials for the ASRM nozzle

Rayon precursor carbon-cloth phenolic was developed more than 30 years ago and is used in most nozzles today including the Poseidon, Trident, Peacekeeper, Small ICBM, Space Shuttle, and numerous tactical and space systems. Specifications and manufacturing controls were placed on these materials and, once qualified, a no-change policy was instituted. The current material is acceptable; however, prepreg variability does not always accommodate the requirements of automation. The advanced solid rocket motor requires material with less variability for automated manufacturing. An advanced solid rocket motor materials team, composed of NASA, Thiokol, Aerojet, SRI, and Lockheed specialists, along with materials suppliers ICI Fiberite/Polycarbon, BP Chemicals/Hitco, and Amoco, embarked on a program to improve the current materials. The program consisted of heat treatment studies and standard and low-density material improvements evaluation. Improvements evaluated included fiber/fabric heat treatments, weave variations, resin application methods, process controls, and monitors.

Canfield, A.↗