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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 preliminary Contract End Item (CEI) specification presents the performance, design, and verification requirements for Morton Thiokol's Space Shuttle Block 2 Solid Rocket Motor (SRM).
Two and three dimensional internal flowfield solutions for critical points in the Space Shuttle solid rocket booster burn time were developed using the Lockheed Huntsville GIM/PAID Navier-Stokes solvers. These perfect gas, viscous solutions for the high performance motor characterize the flow in the aft segment and nozzle of the booster. Two dimensional axisymmetric solutions were developed at t = 20 and t = 85 sec motor burn times. The t = 85 sec solution indicates that the aft segment forward inhibitor stub produces vortices with are shed and convected downwards. A three dimensional 3.5 deg gimbaled nozzle flowfield solution was developed for the aft segment and nozzle at t = 9 sec motor burn time. This perfect gas, viscous analysis, provided a steady state solution for the core region and the flow through the nozzle, but indicated that unsteady flow exists in the region under the nozzle nose and near the flexible boot and nozzle/case joint. The flow in the nozzle/case joint region is characterized by low magnitude pressure waves which travel in the circumferential direction. From the two and three dimensional flowfield calculations presented it can be concluded that there is no evidence from these results that steady state gas dynamics is the primary mechanism resulting in the nozzle pocketing erosion experienced on SRM nozzles 8A or 17B. The steady state flowfield results indicate pocketing erosion is not directly initiated by a steady state gas dynamics phenomenon.
The following investigation reviews and evaluates the use of stress relaxation test data for the structural analysis of Solid Rocket Motor (SRM) propellants and other polymer materials used for liners, insulators, inhibitors, and seals. The stress relaxation data is examined and a new mathematical structural model is proposed. This model has potentially wide application to structural analysis of polymer materials and other materials generally characterized as being made of viscoelastic materials. A dynamic modulus is derived from the new model for stress relaxation modulus and is compared to the old viscoelastic model and experimental data.
Following the Pershing 2 incident in 1985 and the Peacekeeper ignition during core removal in 1987, it was found that propellant can be much more sensitive to Electrostatic Discharges (ESD) than ever before realized. As a result of the Peacekeeper motor near miss incident, a friction machine was designed and fabricated, and used to determine friction hazards during core removal. Friction testing with and electrical charge being applied across the friction plates resulted in propellant ignitions at low friction pressures and extremely low ESD levels. The objective of this test series was to determine the sensitivity of solid rocket propellant to combined friction pressure and electrostatic stimuli and to compare the sensitivity of the SRM propellant to Peacekeeper propellant. The tests are fully discussed, summarized and conclusions drawn.
The nozzle-to-case joint on the Shuttle SRM (as redesigned after the Challenger accident) features an adhesive sealant filling and bonding the joint, with a wiper O-ring to prevent the adhesive from reaching and disabling the closure O-ring. Flawless implementation of that joint design would ensure that hot, corrosive propellant combustion gases never reach the closure O-ring. However, understanding the flow field related to bonding defects is prudent. A comprehensive test program was conducted to quantify such flow fields and associated heating environments. A two-dimensional, full-scale model represented 65 inches of the nozzle joint, using unheated air as the test medium, in a blowdown mode. Geometry variations modeled RSRM assembly tolerances, and two types of bonding defects: pullaways and blowholes. A range of the magnitude of each type defect was tested. Also a range of operational parameters was tested, representative of the RSRM flow environment, including duplication of RSRM Mach and Reynolds numbers. Extensive instrumentation was provided to quantify pressures, heat rates, and velocities. The resulting data established that larger geometric defects cause larger pressure and larger heating, at the closure O-ring region. Velocity trends were not so straight-forward. Variations in assembly tolerances did not generally affect flow fields or heating. Operational parameters affected flow fields and heating as might be expected, increasing density or velocity increased heating. Complete details of this test effort are presented.
A contaminant is any material or substance which is potentially undesirable or which may adversely affect any part, component, or assembly. Contamination control of SRM hardware surfaces is a serious concern, for both Thiokol and NASA, with particular concern for contaminants which may adversely affect bonding surfaces. The purpose of this study is to develop laboratory analytical techniques which will make it possible to certify the cleanliness of any designated surface, with special focus on particulates (dust, dirt, lint, etc.), oils (hydrocarbons, silicones, plasticizers, etc.), and greases (HD-2, fluorocarbon grease, etc.). The hardware surfaces of concern will include D6AC steel, aluminum alloys, anodized aluminum alloys, glass/phenolic, carbon/phenolic, NBR/asbestos-silica, and EPDM rubber.
A goal of the GTX effort has been to demonstrate the feasibility of a single stage-to-orbit (SSTO) vehicle that delivers a small payload to low earth orbit. The small payload class was chosen in order to minimize the risk and cost of development of this revolutionary system. A preliminary design study by the GTX team has resulted in the current configuration that offers considerable promise for meeting the stated goal. The size and gross lift-off weight resulting from scaling the current design to closure however may be considered impractical for the small payload. In lieu of evolving the project' reference vehicle to a large-payload class, this paper offers the alternative of using solid-rocket motors in order to close the vehicle at a practical scale. This approach offers a near-term, quasi-reusable system that easily evolves to reusable SSTO following subsequent development and optimization. This paper presents an overview of the impact of the addition of SRM's to the GTX reference vehicle#s performance and trajectory. The overall methods of vehicle modeling and trajectory optimization will also be presented. A key element in the trajectory optimization is the use of the program OTIS 3.10 that provides rapid convergence and a great deal of flexibility to the user. This paper will also present the methods used to implement GTX requirements into OTIS modeling.
A goal of the GTX effort has been to demonstrate the feasibility of a single stage- to- orbit (SSTO) vehicle that delivers a small payload to low earth orbit. The small payload class was chosen in order to minimize the risk and cost of development of this revolutionary system. A preliminary design study by the GTX team has resulted in the current configuration that offers considerable promise for meeting the stated goal. The size and gross lift-off weight resulting from scaling the current design to closure however may be considered impractical for the small payload. In lieu of evolving the project's reference vehicle to a large-payload class, this paper offers the alternative of using solid-rocket motors in order to close the vehicle at a practical scale. This approach offers a near-term, quasi-reusable system that easily evolves to reusable SSTO following subsequent development and optimization. This paper presents an overview of the impact of the addition of SRM's to the GTX reference vehicle's performance and trajectory. The overall methods of vehicle modeling and trajectory optimization will also be presented. A key element in the trajectory optimization is the use of the program OTIS 3.10 that provides rapid convergence and a great deal of flexibility to the user. This paper will also present the methods used to implement GTX requirements into OTIS modeling.
Thermal conductivity data were obtained by the axial one-dimensional heat flow method for a cylindrical rod 3.6 mm in diameter and 23 cm long with an electric heater at one end and a temperature controlled sink at the other. Variability of this iron was studied by means of electrical residual resistivity ratio measurements on 63 specimens. This study showed that with a two-hour anneal at 1000 C one can obtain a thermal conductivity Standard Reference Material that has variability of less than 1% in thermal conductivity.
An analysis of the water entry loads imposed on the reusable solid propellant rocket engine of the space shuttle following parachute descent is presented. The cases discussed are vertical motion, horizontal motion, and motion after penetration. Mathematical models, diagrams, and charts are included to support the theoretical considerations.
Thermal conductivity and electrical resistivity measurements were conducted on two lots of an austenitic stainless steel. Electrical resistivity measurements were performed on the second lot, both before and after the material was hot-swaged and reannealed to a size 1/10 the original diameter. These measurements indicate that this steel can be swaged and reannealed without an appreciable change in thermal conductivity. Electrical resistivity measurements as well as direct thermal conductivity measurements on several specimens from both lots indicate a material variability in these lots of less than 1% in thermal conductivity.
Various space shuttle ascent configurations were tested in a trisonic wind tunnel to determine the aerodynamic characteristics. The ascent configuration consisted of a NASA/MSC 040 orbiter in combination with various HO centerline tank and booster geometries. The aerodynamic interference between components of the space shuttle and the effect on the orbiter aerodynamics was determined. The various aerodynamic configurations tested were: (1) centerline HO tanks T1 and T2, (2) centerline HO tank T3, and (3) centerline HO tank H4.
Variations of nozzle performance characteristics of the model nozzles used in the Space Shuttle IA12B, IA12C, IA36 power-on launch vehicle test series are shown by comparison between experimental and analytical data. The experimental data are nozzle wall pressure distributions and schlieren photographs of the exhaust plume shapes. The exhaust plume shapes were simulated experimentally with cold flow while the analytical data were generated using a method-of-characteristics solution. Exhaust plume boundaries, boundary shockwave locations and nozzle wall pressure measurements calculated analytically agree favorably with the experimental data from the IA12C and IA36 test series. For the IA12B test series condensation was suspected in the exhaust plumes at the higher pressure ratios required to simulate the prototype plume shapes. Nozzle calibration tests for the series were conducted at pressure ratios where condensation either did not occur or if present did not produce a noticeable effect on the plume shapes. However, at the pressure ratios required in the power-on launch vehicle tests condensation probably occurs and could significantly affect the exhaust plume shapes.