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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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At least 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
NASA NTRS1994

The Determination of Forces and Moments on a Gimballed SRM Nozzle Using a Cold Flow Model

The Solid Rocket Motor Air Flow Facility (SAF) at NASA Marshall Space Flight Center was used to characterize the flow in the critical aft end and nozzle of a solid propellant rocket motor (SRM) as part of the design phase of development. The SAF is a high pressure, blowdown facility which supplies a controlled flow of air to a subscale model of the internal port and nozzle of a SRM to enable measurement and evaluation of the flow field and surface pressure distributions. The ASRM Aft Section/Nozzle Model is an 8 percent scale model of the 19 second burn time aft port geometry and nozzle of the Advanced Solid Rocket Motor, the now canceled new generation space Shuttle Booster. It has the capability to simulate fixed nozzle gimbal angles of 0, 4, and 8 degrees. The model was tested at full scale motor Reynolds Numbers with extensive surface pressure instrumentation to enable detailed mapping of the surface pressure distributions over the nozzle interior surface, the exterior surface of the nozzle nose and the surface of the simulated propellant grain in the aft motor port. A mathematical analysis and associated numerical procedure were developed to integrate the measured surface pressure distributions to determine the lateral and axial forces on the moveable section of the nozzle, the effective model thrust and the effective aerodynamic thrust vector (as opposed to the geometric nozzle gimbal angle). The nozzle lateral and axial aerodynamic loads and moments about the pivot point are required for design purposes and require complex, three dimensional flow analyses. The alignment of the thrust vector with the nozzle geometric centerline is also a design requirement requiring three dimensional analyses which were supported by this experimental program. The model was tested with all three gimbal angles at three pressure levels to determine Reynolds number effects and reproducibility. This program was successful in demonstrating that a measured surface pressure distribution could be integrated to determine the lateral and axial loads, moments and thrust vector alignment for the scaled model of a large space booster nozzle. Numerical results were provided which are scaleable to the full scale rocket motor and can be used as benchmark data for 3-D CFD analyses.

Whitesides, R. Harold↗
NASA NTRS2011

Measuring Fluctuating Pressure Levels and Vibration Response in a Jet Plume

The characterization of loads due to solid rocket motor plume impingement allows for moreaccurate analyses of components subjected to such an environment. Typically, test verification of predicted loads due to these conditions is widely overlooked or unsuccessful. ATA Engineering, Inc., performed testing during a solid rocket motor firing to obtain acceleration and pressure responses in the hydrodynamic field surrounding the jet plume. The test environment necessitated a robust design to facilitate measurements being made in close proximity to the jet plume. This paper presents the process of designing a test fixture and an instrumentation package that could withstand the solid rocket plume environment and protect the required instrumentation.

Osterholt, Douglas J.↗
NASA NTRS1992

ASRM case insulation design and development

This paper describes the achievements made on the Advanced Solid Rocket Motor (ASRM) case insulation design and development program. The ASRM case insulation system described herein protects the metal case and joints from direct radiation and hot gas impingement. Critical failure of solid rocket systems is often traceable to failure of the insulation design. The wide ranging accomplishments included the development of a nonasbestos insulation material for ASRM that replaced the existing Redesigned Solid Rocket Motor (RSRM) asbestos-filled nitrile butadiene rubber (NBR) along with a performance gain of 300 pounds, and improved reliability of all the insulation joint designs, i.e., segmented case joint, case-to-nozzle and case-to-igniter joint. The insulation process development program included the internal stripwinding process. This process advancement allowed Aerojet to match to exceed the capability of other propulsion companies.

Bell, Matthew S.↗
NASA NTRS1975

Space shuttle SRM plume expansion sensitivity analysis

The exhaust plumes of the space shuttle solid rocket motors can have a significant effect on the base pressure and base drag of the shuttle vehicle. A parametric analysis was conducted to assess the sensitivity of the initial plume expansion angle of analytical solid rocket motor flow fields to various analytical input parameters and operating conditions. The results of the analysis are presented and conclusions reached regarding the sensitivity of the initial plume expansion angle to each parameter investigated. Operating conditions parametrically varied were chamber pressure, nozzle inlet angle, nozzle throat radius of curvature ratio and propellant particle loading. Empirical particle parameters investigated were mean size, local drag coefficient and local heat transfer coefficient. Sensitivity of the initial plume expansion angle to gas thermochemistry model and local drag coefficient model assumptions were determined.

Smith, S. D.↗
NASA NTRS1983

Development of space shuttle ignition overpressure environment and correlation with flight data

The Space Transportation (STS) launch vehicles are more complex than other launch vehicles. A comprehensive analysis of the lift-off event is required so that the responses of the vehicle and payloads can be predicted. The transient overpressure induced by ignition of the solid rocket motors (SRM's) is one of the critical design factors assessed for lift-off. The STS-1 ignition overpressure design environment was developed from 6.4-percent scale-model tests in which the Tomahawk solid rocket motors were used to simulate the start-up process of the SRM's. The overpressures measured during STS-1 lift-off were much more severe than predicted. The reasons for this anomaly are discussed in this paper. The 6.4-percent scale model was redesigned and used as a tool to develop an effective ignition overpressure suppression system for STS-2 and subsequent flights. Also presented are advancements in subscale-model simulation and theoretical understanding of this transient overpressure phenomenon that led to the successful development of the fix.

Lai, S.↗
NASA NTRS2004

Subscale Testing of Nozzle Ablative Materials in a Supersonic Particle Impingement Environment

Recent efforts to evaluate materials to replace the current NARC rayon used in the nozzle ablative of the NASA's Reusable Solid Rocket Motor (SRM), several tests were developed to look at the performance of supersonic particle impact region of the aft exit cone. It was seen in early testing that some potential candidates did not perform as well as the current NARC based material and so the 24 inch Solid Rocket Motor (SRTM) exit cone design was extended and contoured to induce particle impingement in the aft end. The SRTM testing provided a larger testbed to evaluate the results seen in the Solid Fuel Supersonic Blast Tube. Testing was performed in each test bed on two variants of the final two candidate materials. The materials were a standard prewoven Lyocell, a postwoven Lyocell, an Enka rayon, and Enka rayon processed at a higher carbonization temperature. This paper presents the results of the four materials in the SSBT and the SRTM tests as compared against the NARC baseline. Erosion, char, and plylift results are discussed in detail.

Howse, S.↗
NASA NTRS2001

Thermal Characterization of Epoxy Adhesive by Hotfire Testing

This paper describes subscale solid-rocket motor hot-fire testing of epoxy adhesives in flame surface bondlines to evaluate heat-affected depth, char depth and ablation rate. Hot-fire testing is part of an adhesive down-selection program on the Space Shuttle Solid Rocket Motor Nozzle to provide additional confidence in the down-selected adhesives. The current nozzle structural adhesive bond system is being replaced due to obsolescence. Prior to hot-fire testing, adhesives were tested for chemical, physical and mechanical properties, which resulted in the selection of two potential replacement adhesives, Resin Technology Group's TIGA 321 and 3M's EC2615XLW. Hot-fire testing consisted of four forty-pound charge (FPC) motors fabricated in configurations that would allow side-by-side comparison testing of the candidate replacement adhesives with the current RSRM adhesives. Results of the FPC motor testing show that: 1) the phenolic char depths on radial bondlines is approximately the same and vary depending on the position in the blast tube regardless of which adhesive was used, 2) the replacement candidate adhesive char depths are equivalent to the char depths of the current adhesives, 3) the heat-affected depths of the candidate and current adhesives are equivalent, and 4) the ablation rates for both replacement adhesives were equivalent to the current adhesives.

Spomer, Ken A.↗
NASA NTRS1991

The full-scale process and design changes for elimination of insulation edge separations and voids in tang flap area

Qualification of the full-scale process and design changes for elimination of redesigned solid rocket motor tang nitrile butadiene rubber insulation edge separations and voids was performed from 24 March to 3 December 1990. The objectives of this test were: to qualify design and process changes on flight hardware using a tie ply between the redesigned solid rocket motor steel case and the nitrile butadiene rubber insulation over the tang capture features; to qualify the use of methyl ethyl ketone in the tang flap region to reduce voids; and to determine if holes in the separator film reduce voids in the tang flap region. The tie ply is intended to aid insulation flow during the insulation cure process, and thus reduce or eliminate edge unbonds. Methyl ethyl ketone is intended to reduce voids in the tang flap area by providing better tacking characteristics. The perforated film was intended to provide possible vertical breathe paths to reduce voids in the tang area. Tang tie ply testing consisted of 270 deg of the tang circumference using a new layup method and 90 deg of the tang circumference using the current layup methods. Tie ply process success was defined as a reduction of insulation unbonds. Lack of any insulation edge unbonds on the tang area where the new process was used, and the presence of 17 unbonds with the current process, proves the test to be a success. Successful completion of this test has qualified the new processes.

Danforth, Richard A.↗
NASA NTRS1990

Flight motor set 360L001 (STS-26R). Volume 1: System overview, revision A

The NASA space shuttle flight STS-26R, launched at 11:37.00.009 am, EDT on 29 Sep. 1988, used the redesigned solid rocket motors (RSRM) 360L001A and 360L001B. Evaluation of the ground environment instrumentation (GEI) data recorded prior to flight showed no launch commit criteria violations; that the field joint heater and aft skirt thermal conditioning systems performed adequately; and that the GEI data showed good agreement with thermal model predictions. Evaluation of the developmental flight instrumentation (DFI) revealed excellent agreement with both the predicted and required ballistic specifications. All parameters were well within the GEI specification requirements including propellant burn rates, specific impulse values, and thrust imbalance. Recorded strain values also indicated satisfactory radial growth and stress levels, as well as verification of adequate safety factors. Postflight inspection of the insulation, seals, case, and nozzles showed overall excellent performance. Some thermal DFI protective cork was missing, and inoperative field joint vent valves on the thermal protection cork allowed water entry into the field joints upon splashdown. Evaluation of these anomalies, as well as complete evaluation of all Redesigned Solid Rocket Motor components, is contained.

Garecht, Diane M.↗
NASA NTRS1994

Environmentally sound manufacturing

The NASA/Thiokol/industry team has developed and started implementation of an environmentally sound manufacturing plan for the continued production of solid rocket motors. They have worked with other industry representatives and the U.S. Environmental Protection Agency to prepare a comprehensive plan to eliminate all ozone depleting chemicals from manufacturing processes and to reduce the use of other hazardous materials used to produce the space shuttle reusable solid rocket motors. The team used a classical approach for problem solving combined with a creative synthesis of new approaches to attack this problem. As our ability to gather data on the state of the Earth's environmental health increases, environmentally sound manufacturing must become an integral part of the business decision making process.

Caddy, Larry A.↗
NASA NTRS1990

Qualification of the RSRM case membrane case-to-insulation bondline inspection using the Thiokol Corporation ultrasonic RSRM bondline inspection system

Qualification testing of Combustion Engineering's AMDATA Intraspect/98 Data Acquisition and Imaging System that applies to the redesigned solid rocket motor (RSRM) case membrane case-to-insulation bondline inspection was performed. Testing was performed at M-67, the Thiokol Corp. RSRM Assembly Facility. The purpose of the inspection was to verify the integrity of the case membrane case-to-insulation bondline. The case membrane scanner was calibrated on the redesigned solid rocket motor case segment calibration standard, which had an intentional 1.0 by 1.0 in. case-to-insulation unbond. The case membrane scanner was then used to scan a 20 by 20 in. membrane area of the case segment. Calibration of the scanner was then rechecked on the calibration standard to ensure that the calibration settings did not change during the case membrane scan. This procedure was successfully performed five times to qualify the unbond detection capability of the case membrane scanner.

Cook, M.↗
NASA NTRS2011

Ares I-X Test Flight Reference Trajectory Development

Ares I-X was the first test flight of NASA's Constellation Program's Ares I crew launch vehicle. Ares I is a two stage to orbit launch vehicle that provides crew access to low Earth orbit for NASA's future manned exploration missions. The Ares I first stage consists of a Shuttle solid rocket motor (SRM) modified to include an additional propellant segment and a liquid propellant upper stage with an Apollo J2X engine modified to increase its thrust capability. The modified propulsion systems were not available for the first test flight, thus the test had to be conducted with an existing Shuttle 4 segment reusable solid rocket motor (RSRM) and an inert Upper Stage. The test flight's primary objective was to demonstrate controllability of an Ares I vehicle during first stage boost and the ability to perform a successful separation. In order to demonstrate controllability, the Ares I-X ascent control algorithms had to maintain stable flight throughout a flight environment equivalent to Ares I. The goal of the test flight reference trajectory development was to design a boost trajectory using the existing RSRM that results in a flight environment equivalent to Ares I. A trajectory similarity metric was defined as the integrated difference between the Ares I and Ares I-X Mach versus dynamic pressure relationships. Optimization analyses were performed that minimized the metric by adjusting the inert upper stage weight and the ascent steering profile. The sensitivity of the optimal upper stage weight and steering profile to launch month was also investigated. A response surface approach was used to verify the optimization results. The analyses successfully defined monthly ascent trajectories that matched the Ares I reference trajectory dynamic pressure versus Mach number relationship to within 10% through Mach 3.5. The upper stage weight required to achieve the match was found to be feasible and varied less than 5% throughout the year. The paper will discuss the flight test requirements, provide Ares I-X vehicle background, discuss the optimization analyses used to meet the requirements, present analysis results, and compare the reference trajectory to the reconstructed flight trajectory.

Starr, Brett R.↗
NASA NTRS2005

Vehicle Assembly Building Fire Mishap Investigation Report. Volume I of V

On January 13, 2005, at approximately 1355, smoke was noticed on the 4th floor of D Tower in the Vehicle Assembly Building (VAB). Subsequently, a 911 call was made, a fire alarm pull station was activated, and the VAB was evacuated. The source of the smoke was determined to be a fire on the Low Bay M/N section roof near the Launch Control Center (LCC) Crossover. Due to the high visibility of the mishap, the KSC Center Director appointed a Mishap Investigation Board. Damage to government property was limited to the roof and a small number of ceiling tiles that were damaged by the fire fighters during the response. At the time of the mishap, there were hazardous commodities in the VAB including Solid Rocket Motors (SRMs) with open grain due to Solid Rocket Booster (SRB) igniter inspections. The Board agrees with the SGS Fire Services' theory that large amounts of smoke concentrated in the VAB D Tower and moved downward into the cable tunnel. The Board determined the proximate cause of this incident to be torching. HRI was installing a torch applied roof membrane which resulted in the ignition of combustible materials under the membrane near a wooden roof expansion joint. The torch applied roofing method is a universally accepted safe industry practice when applied to non-combustible surfaces. The combination of an open flame torch and combustible materiaLs presents an increased level of risk even with skilled applicators. The addition of high winds to this combination results in a risk the Board thinks can not be adequately mitigated. An appropriate risk assessment and analysis must be performed on the proposed roofing method to be used on high visibility facilities which represent unique national assets even when using common industry practices for repair and modification. The Board identified three root causes which contributed to or created the proximate cause and, if eliminated or modified, would have prevented the mishap: 1. Combustible materials in existing roof system 2. Wind speed and direction 3. Inadequate fire watch technique. Two contributing factors were identified which may have contributed to the occurrence but, if eliminated or modified, would not have prevented the occurrence: 1. HRI rushed to dry in and seal the roof on January 13 because heavy rain was predicted for the next day 2. No guidance on torching in windy conditions A total of 17 significant observations were noted during this investigation, which could lead to another mishap, or increase the severity of a mishap, but were not contributing factors in this mishap.

Kight, Ira↗
NASA NTRS2001

Vapor Grown Carbon Fiber/Phenolic Matrix Composites for Rocket Nozzles and Heat Shields

The ablation and mechanical and thermal properties of vapor grown carbon fiber (VGCF)/phenolic resin composites were evaluated to determine the potential of using this material in solid rocket motor nozzles. Composite specimens with varying VGCF loading (30%-50% wt) including one sample with ex-rayon carbon fiber plies were prepared and exposed to a plasma torch for 20 s with a heat flux of 16.5 MW/sq m at approximately 1650 C. Low erosion rates and little char formation were observed, confirming that these materials were promising for rocket motor nozzle materials. When fiber loadings increased, mechanical properties and ablative properties improved. The VGCF composites had low thermal conductivities (approximately 0.56 W/m-C) indicating they were good insulating materials. If a 65% fiber loading in VGCF composite can be achieved, then ablative properties are projected to be comparable to or better than the composite material currently used on the Space Shuttle Reusable Solid Rocket Motor (RSRM).

Patton, R. D.↗
NASA NTRS1997

Direct Measurement of Internal Flow Velocities in a Star-Slot Model

This paper presents the results of a cold flow experiment to make direct measurements of the velocity distribution in a model of a solid rocket motor star grain propellant slot. The experimental procedure utilizes a multi-component laser Doppler velocimeter (LDV) and an apparatus for seeding the flow with aluminum particles to determine the velocity components at various discrete locations within the star slot. The test article used in this investigation was a one-tenth scale, cold flow model based on the geometry of the Space Shuttle solid rocket motor head-end section. The results obtained for the direct measurements of velocity are compared to velocities calculated from measured pressure distributions to data obtained from oil smear experiments and flow visualization videos, and to heat transfer calorimeter data.

Foster, Winfred A., Jr.↗
NASA NTRS1995

Cleanliness evaluation of rough surfaces with diffuse IR reflectance

Contamination on bonding surfaces has been determined to be a primary cause for degraded bond strength in certain solid rocket motor bondlines. Hydrocarbon and silicone based organic contaminants that are airborne or directly introduced to a surface are a significant source of contamination. Diffuse infrared (IR) reflectance has historically been used as an effective technique for detection of organic contaminants, however, common laboratory methods involving the use of a Fourier transform IR spectrometer (FTIR) are impractical for inspecting the large bonding surface areas found on solid rocket motors. Optical methods involving the use of acousto-optic tunable filters and fixed bandpass optical filters are recommended for increased data acquisition speed. Testing and signal analysis methods are presented which provide for simultaneous measurement of contamination concentration and roughness level on rough metal surfaces contaminated with hydrocarbons.

Pearson, L. H.↗