Surface step induced gap heating in the Shuttle Thermal Protection System
Previously cited in issue 5, p. 606, Accession no. A83-16533
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Previously cited in issue 5, p. 606, Accession no. A83-16533
Previously cited in issue 19, p. 2029, Accession no. A82-30079
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Six space shuttle reusable surface insulation tiles were tested in the NASA Lewis Research Center's electron bombardment test facility. The 30-cm-square specimens were assembled by using the same materials and techniques used to apply the tiles to the space shuttle and were composed to 15-cm- and 20-cm-square tiles and pieces on 0.6-cm-thick aluminum substrates. There were two specimens of each of three thicknesses. One specimen of each thickness had gaps of less than 0.1 cm between tiles, and the other had gaps of approximately 0.15 cm. The specimens were exposed to monoenergetic electron beams (2 to 25 keV) with nominal fluxes of 0.1 and 1 nA/sq. cm. Tests were conducted with both grounded and floating substrates. The data presented include charging rates, equilibrium potentials, and substrate currents. There is evidence that discharging occurred.
Concluding tests for the thermogravimetric and FTIR analyses of DC 1200 silane primers are discussed as well as methods for HPLC and GC analyses and for determining titanium and silicon by atomic absorption spectroscopy. Tables summarizes results obtained for residue, ash, titanium, silicone, Si/Ti ratio, OH-absorption, the lap-shear test, and the GC headspace for alcohols.
Fourier transform infrared spectroscopy is currently the best technique for observing hydrolytic changes in DC 1200 silane the primers caused by moisture in the atmosphere. To further prove that FTIR can be used as a criterion test for acceptance of silane primer lots, intensities of the FTIR OH- band are being compared with primer adhesive bond strength using a mechanical test suggested by NASA. Results of tests for shear strength and Oh-absorption are tabulated and compared with FTIR absorption intensities in the OH-region.
Results of lap shear tests of various silane primers are presented in graphs and tables. The OH-absorption of these primers (FTIR area values) are correlated with the lap shear tests of coated panels.
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The detection of excited oxygen and ozone molecules formed by surface catalyzed oxygen atom recombination and reaction was investigated by laser induced fluorescence (LIF), molecular beam mass spectrometric (MBMS), and field ionization (FI) techniques. The experiment used partially dissociated oxygen flows from a microwave discharge at pressures in the range from 60 to 400 Pa or from an inductively coupled RF discharge at atmospheric pressure. The catalyst materials investigated were nickel and the reaction cured glass coating used for Space Shuttle reusable surface insulation tiles. Nonradiative loss processes for the laser excited states makes LIF detection of O2 difficult such that formation of excited oxygen molecules could not be detected in the flow from the microwave discharge or in the gaseous products of atom loss on nickel. MBMS experiments showed that ozone was a product of heterogeneous O atom loss on nickel and tile surfaces at low temperatures and that ozone is lost on these materials at elevated temperatures. FI was separately investigated as a method by which excited oxygen molecules may be conveniently detected. Partial O2 dissociation decreases the current produced by FI of the gas.
Surfaces of interest to space vehicle heat shield design were struck by a 2 W argon ion laser line while subjected to supersonic arc jet flow conditions. Emission spectra were taken at 90 deg to the angle of laser incidence on the test object. Results showed possible weak Raman shifts which could not be directly tied to any particular parameter such as surface temperature or gas composition. The investigation must be considered exploratory in terms of findings. Many undesirable effects were found and corrected as the project progressed. For instance, initial spectra settings led to ghosts which were eliminated by closing the intermediate of filter slit of the Spex from 8 to 3 mm. Further, under certain conditions, plasma lines from the laser were observed. Several materials were also investigated at room temperature for Raman shifts. Results showed Raman shifts for RCC and TEOS coated materials. The HRSI materials showed only weak Raman shifts, however, substantial efforts were made in studying these materials. Baseline materials showed the technique to be sound. The original goal was to find a Raman shift for the High-temperature Reusable Surface Insulation (HRSI) Reaction Cured borosilicate Glass (RCG) coated material and tie the amplitude of this peak to Arc jet conditions. Weak Raman shifts may be present, however, time limitations prevented confirmation.
It is the teams view that there is a general lack of awareness of orbiter tile susceptibility to damage by debris - the same applies to the care and critical nature of the shuttle elements and operations process so necessary to minimizing damaging debris - it is essential that all involved employees, both government and contractor, understand that minuscule loose objects or materials coming off the elements will most likely cause some tile damage at the speed encountered during ascent. It is recommended that descriptive material, photos, video tape, debris samples and other appropriate matter be assembled and provided to the proper organizations for dissemination to their employees - it should emphasize that the tiles perform outstanding in their debris-free design environment; but, are extremely sensitive to small particle damage.
Concluded remarks are: (1) advanced carbon-carbon (ACC) substrate fabrication technology in good shape; (2) ACC coating improvements satisfactory but additional work needed; (3) non-destructive test techniques to monitor hardware during operational life needed; and (4) cost reduction approaches a high priority.
The topics addressed are history of reusable external insulation (RSI), and examples of shuttle RSI development challenges, which includes: (1) manufacturing of raw materials, such as fibers, coating components; (2) design of tile planform size, strain isolation, and gap heating; (3) insulation, such as bonding, bond verification, tolerances, and quality control; and (4) operation, such as durability, and water proofing.
A method of producing a three dimensional angle interlock ceramic fiber which is stable to high aeroacoustic noise of about 170 decibels and to high temperatures of about 2500 F is disclosed. The method uses multiple separate strands of a ceramic fiber or ceramic tow suitable for weaving having multiple warp fibers and multiple fill fibers woven with a modified fly-shuttle loom or rapier shuttleless loom which has nip rolls, a modified fabric advancement mechanism and at least eight harnesses in connection with a Dobby pattern chain utilizing sufficient heddles for each warp fiber and a reed which accommodates at least 168 ends per inch. The method produces a multilayered top fabric, rib fabric and single-layered bottom fabric.
The evolution and pursuit of the reflecting heat-shield concept has resulted in a refined and sophisticated high-performance material: ultra-pure, slip-cast, fused silica (SCFS). Silica is "tailored" to the intense planetary entry environments through a combination of its good ablative qualities and outstanding reflective properties in the correct spectral region. Extensive development of SCFS has produced a series of candidate materials which are experimentally evaluated and compared in a simulated entry environment. The detailed response of silica to combined heating is discussed, and the relative merits of SCFS and carbon phenolic are indicated.
The purpose of the X-38 program is to greatly reduce the costs and schedule for the development of Crew Return Vehicles (CRV's) and Crew Transfer Vehicles (CTV's) through the use of the rapid development methodology associated with an X-project (Ground Testing, Atmospheric Testing and Space Flight Testing).
Contents include the following: Motivation. Current light weight insulation. Advantages of preceramic-polymer-derived ceramic foams. Rigid insulation materials. Tailor foam microstructures. Experimental approach. Results: sacrificial materials, sacrificial fillers. Comparison of foam microstructures. Density of ceramic foams. Phase evolution and properties: oxidation behavior. mechanical properties, aerothermal performance. Impact damage of microcellular foams. Conclusions.