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NASA NTRS2013

Development of the International Space Station Fine Water Mist Portable Fire Extinguisher

The National Aeronautics and Space Administration (NASA) is developing a Fine Water Mist (FWM) Portable Fire Extinguisher (PFE) for use on the International Space Station (ISS). The ISS presently uses two different types of fire extinguishers: a water foam extinguisher in the Russian Segments, and a carbon dioxide extinguisher in the United States Orbital Segments, which include Columbus and Kibo pressurized elements. Currently, there are operational and compatibility concerns with the emergency breathing equipment and the carbon dioxide extinguisher. ISS emergency response breathing equipment does not filter carbon dioxide; therefore, crew members are required to have an oxygen supply present during a fire event since the carbon dioxide PFE creates an unsafe breathing environment. The ISS program recommended a nontoxic fire extinguisher to mitigate this operational risk. The FWM PFE can extinguish a fire without creating a hazardous breathing environment for crewmembers. This paper will discuss the unique functional and performance requirements that have been levied on the FWM PFE, identify unique microgravity design considerations for liquid and gas systems, and discuss the NASA ISS specific fire standards that were developed to establish an acceptable portable fire extinguisher s performance.

Rodriquez, Branelle↗
NASA NTRS2006

Characterization of Space Shuttle Thermal Protection System (TPS) Materials for Return-to-Flight following the Shuttle Columbia Accident Investigation

During the Space Shuttle Columbia Accident Investigation, it was determined that a large chunk of polyurethane insulating foam (= 1.67 lbs) on the External Tank (ET) came loose during Columbia's ascent on 2-1-03. The foam piece struck some of the protective Reinforced Carbon-Carbon (RCC) panels on the leading edge of Columbia's left wing in the mid-wing area. This impact damaged Columbia to the extent that upon re-entry to Earth, superheGed air approaching 3,000 F caused the vehicle to break up, killing all seven astronauts on board. A paper after the Columbia Accident Investigation highlighted thermal analysis testing performed on External Tank TPS materials (1). These materials included BX-250 (now BX-265) rigid polyurethane foam and SLA-561 Super Lightweight Ablator (highly-filled silicone rubber). The large chunk of foam from Columbia originated fiom the left bipod ramp of the ET. The foam in this ramp area was hand-sprayed over the SLA material and various fittings, allowed to dry, and manually shaved into a ramp shape. In Return-to-Flight (RTF) efforts following Columbia, the decision was made to remove the foam in the bipod ramp areas. During RTF efforts, further thermal analysis testing was performed on BX-265 foam by DSC and DMA. Flat panels of foam about 2-in. thick were sprayed on ET tank material (aluminum alloys). The DSC testing showed that foam material very close to the metal substrate cured more slowly than bulk foam material. All of the foam used on the ET is considered fully cured about 21 days after it is sprayed. The RTF culminated in the successful launch of Space Shuttle Discovery on 7-26-05. Although the flight was a success, there was another serious incident of foam loss fiom the ET during Shuttle ascent. This time, a rather large chunk of BX-265 foam (= 0.9 lbs) came loose from the liquid hydrogen (LH2) PAL ramp, although the foam did not strike the Shuttle Orbiter containing the crew. DMA testing was performed on foam samples taken fiom a simulated PAL ramp panel. It was found that the smooth rind on the foam facing the cable tray did significantly affect the properties of foam at the PAL ramp surface. The smooth rind increased the storage modulus E' of the foam as much as 20- 40% over a temperature range of -145 to 95 C. Because of foam loss fiom the PAL ramp, future Shuttle flights were grounded indefinitely to allow further testing to better understand foam properties. The decision was also made to remove foam from the LH2 PAL, ramp. Other RTF efforts prior to the launch of Discovery included

Wingard, Doug↗
NASA NTRS2004

Analysis of Stainless Steel Sandwich Panels with a Metal Foam Care for Lightweight Fan Blade Design

The quest for cheap, low density and high performance materials in the design of aircraft and rotorcraft engine fan and propeller blades poses immense challenges to the materials and structural design engineers. Traditionally, these components have been fabricated using expensive materials such as light weight titanium alloys, polymeric composite materials and carbon-carbon composites. The present study investigates the use of P sandwich foam fan blade made up of solid face sheets and a metal foam core. The face sheets and the metal foam core material were an aerospace grade precipitation hardened 17-4 PH stainless steel with high strength and high toughness. The stiffness of the sandwich structure is increased by separating the two face sheets by a foam core. The resulting structure possesses a high stiffness while being lighter than a similar solid construction. Since the face sheets carry the applied bending loads, the sandwich architecture is a viable engineering concept. The material properties of 17-4 PH metal foam are reviewed briefly to describe the characteristics of the sandwich structure for a fan blade application. A vibration analysis for natural frequencies and P detailed stress analysis on the 17-4 PH sandwich foam blade design for different combinations of skin thickness and core volume %re presented with a comparison to a solid titanium blade.

Min, James B.↗
NASA NTRS2009

Improved Fabrication of Ceramic Matrix Composite/Foam Core Integrated Structures

The use of hybridized carbon/silicon carbide (C/SiC) fabric to reinforce ceramic matrix composite face sheets and the integration of such face sheets with a foam core creates a sandwich structure capable of withstanding high-heatflux environments (150 W/cm2) in which the core provides a temperature drop of 1,000 C between the surface and the back face without cracking or delamination of the structure. The composite face sheet exhibits a bilinear response, which results from the SiC matrix not being cracked on fabrication. In addition, the structure exhibits damage tolerance under impact with projectiles, showing no penetration to the back face sheet. These attributes make the composite ideal for leading edge structures and control surfaces in aerospace vehicles, as well as for acreage thermal protection systems and in high-temperature, lightweight stiffened structures. By tailoring the coefficient of thermal expansion (CTE) of a carbon fiber containing ceramic matrix composite (CMC) face sheet to match that of a ceramic foam core, the face sheet and the core can be integrally fabricated without any delamination. Carbon and SiC are woven together in the reinforcing fabric. Integral densification of the CMC and the foam core is accomplished with chemical vapor deposition, eliminating the need for bond-line adhesive. This means there is no need to separately fabricate the core and the face sheet, or to bond the two elements together, risking edge delamination during use. Fibers of two or more types are woven together on a loom. The carbon and ceramic fibers are pulled into the same pick location during the weaving process. Tow spacing may be varied to accommodate the increased volume of the combined fiber tows while maintaining a target fiber volume fraction in the composite. Foam pore size, strut thickness, and ratio of face sheet to core thickness can be used to tailor thermal and mechanical properties. The anticipated CTE for the hybridized composite is managed by the choice of constituents, varying fiber tow sizes and constituent part ratios. This structural concept provides high strength and stiffness at low density 1.06 g/cm3 in panels tested. Varieties of face sheet constructions are possible, including variations in fiber type and weave geometry. The integrated structures possible with this composite could eliminate the need for non-load-bearing thermal protection systems on top of a structural component. The back sheet can readily be integrated to substructures through the incorporation of ribs. This would eliminate weight and cost for aerospace missions.

Hurwitz, Frances I.↗
NASA NTRS2009

Inert Welding/Brazing Gas Filters and Dryers

The use of hybridized carbon/silicon carbide (C/SiC) fabric to reinforce ceramic matrix composite face sheets and the integration of such face sheets with a foam core creates a sandwich structure capable of withstanding high-heat-flux environments (150 W/sq cm) in which the core provides a temperature drop of 1,000 C between the surface and the back face without cracking or delamination of the structure. The composite face sheet exhibits a bilinear response, which results from the SiC matrix not being cracked on fabrication. In addition, the structure exhibits damage tolerance under impact with projectiles, showing no penetration to the back face sheet. These attributes make the composite ideal for leading-edge structures and control surfaces in aerospace vehicles, as well as for acreage thermal protection systems and in high-temperature, lightweight stiffened structures. By tailoring the coefficient of thermal expansion (CTE) of a carbon fiber containing ceramic matrix composite (CMC) face sheet to match that of a ceramic foam core, the face sheet and the core can be integrally fabricated without any delamination. Carbon and SiC are woven together in the reinforcing fabric. Integral densification of the CMC and the foam core is accomplished with chemical vapor deposition, eliminating the need for bond-line adhesive. This means there is no need to separately fabricate the core and the face sheet, or to bond the two elements together, risking edge delamination during use. Fibers of two or more types are woven together on a loom. The carbon and ceramic fibers are pulled into the same "pick" location during the weaving process. Tow spacing may be varied to accommodate the increased volume of the combined fiber tows while maintaining a target fiber volume fraction in the composite. Foam pore size, strut thickness, and ratio of face sheet to core thickness can be used to tailor thermal and mechanical properties. The anticipated CTE for the hybridized composite is managed by the choice of constituents, varying fiber tow sizes and constituent part ratios. This structural concept provides high strength and stiffness at low density 1.06 g/cu cm in panels tested. Varieties of face sheet constructions are possible, including variations in fiber type and weave geometry. The integrated structures possible with this composite could eliminate the need for non-load-bearing thermal protection systems on top of a structural component. The back sheet can readily be integrated to substructures through the incorporation of ribs. This would eliminate weight and cost for aerospace missions.

Goudy, Jerry↗
NASA NTRS1970

Lightweight, self-evacuated insulation panels

Multilayer insulation of prefabricated panels is developed for cryogenic storage tanks. System utilizes panels of aluminized Mylar separated by sheets of low conductivity polyurethane foam. Panels are self-evacuated by cryopumping of gaseous carbon dioxide at time of use.

Dengler, R. P.↗
NASA NTRS1973

Polyimide foam for the thermal insulation and fire protection

The preparation of chemically resistant and flame retardant foams from polyfunctional aromatic carboxylic acid derivatives and organic polyisocyanates is outlined. It was found that polyimide foams of reproducible density above 1 lb./ft. and below 6 lbs./cu ft. can be obtained by employing in the reaction of least 2% by weight of siloxane-glycol copolymer as a surfactant which acts as a specific density control agent. Polyimide foams into which reinforcing fibers such as silicon dioxide and carbon fibers may be incorporated were also produced.

Rosser, R. W.↗
NASA NTRS1995

Long-term hygrothermal effects on damage tolerance of hybrid composite sandwich panels

A sandwich construction, composed of hybrid carbon-glass fiber-reinforced plastic skins and a syntactic foam core, was selected as the design concept for a wind tunnel compressor blade application, where high damage tolerance and durability are of major importance. Beam specimens were prepared from open-edge and encapsulated sandwich panels which had previously been immersed in water at different temperatures for periods of up to about two years in the extreme case. Moisture absorption and strength characteristics, as related to time of exposure to hygrothermal conditions, were evaluated for the sandwich specimens and their constituents (skins and foam). After different exposure periods, low-velocity impact damage was inflicted on most sandwich specimens and damage characteristics were related to impact energy. Eventually, the residual compressive strengths of the damaged (and undamaged) beams were determined flexurally. Test results show that exposure to hygrothermal conditions leads to significant strength reductions for foam specimens and open-edge sandwich panels, compared with reference specimens stored at room temperature. In the case of skin specimens and for beams prepared from encapsulated sanwich panels that had previously been exposed to hygrothermal conditions, moisture absorption was found to improve strength as related to the reference case. The beneficial effect of moisture on skin performance was, however, limited to moisture contents below 1% (at 50 C and lower temperatures). Above this moisture level and at higher temperatures, strength degradation of the skin seems to prevail.

Ishai, Ori↗
NASA NTRS2017

Development of Trace Contaminant Control Prototypes for the Primary Life Support System (PLSS)

Results are presented on the development of Trace Contaminant Control (TCC) Prototypes for use in Extravehicular Activities (EVAs), and more specifically in the Primary Life Support System (PLSS). The current TC-control technology involves the use of a packed bed of acid-impregnated granular charcoal, which is non-regenerable, and the carbon-based sorbent under development in this project can be regenerated by exposure to vacuum at room temperature. Data on sorption and desorption of ammonia and formaldehyde, which are major TCs of concern, as well as pressure-drop calculations were used to design and test 1/6-scale and full-scale trace contaminant control system (TCCS) prototypes. Carbon sorbents were fabricated in both the granular and foam-supported forms. Sorbent performance was tested for ammonia sorption and vacuum regeneration in 1/6-scale, and pressure-drop characteristics were measured at flow rates relevant to the PLSS application.

Wojtowicz, Marek↗
NASA NTRS2004

The Influence of Mesh Density on the Impact Response of a Shuttle Leading-Edge Panel Finite Element Simulation

A study was performed to examine the influence of varying mesh density on an LS-DYNA simulation of a rectangular-shaped foam projectile impacting the space shuttle leading edge Panel 6. The shuttle leading-edge panels are fabricated of reinforced carbon-carbon (RCC) material. During the study, nine cases were executed with all possible combinations of coarse, baseline, and fine meshes of the foam and panel. For each simulation, the same material properties and impact conditions were specified and only the mesh density was varied. In the baseline model, the shell elements representing the RCC panel are approximately 0.2-in. on edge, whereas the foam elements are about 0.5-in. on edge. The element nominal edge-length for the baseline panel was halved to create a fine panel (0.1-in. edge length) mesh and doubled to create a coarse panel (0.4-in. edge length) mesh. In addition, the element nominal edge-length of the baseline foam projectile was halved (0.25-in. edge length) to create a fine foam mesh and doubled (1.0- in. edge length) to create a coarse foam mesh. The initial impact velocity of the foam was 775 ft/s. The simulations were executed in LS-DYNA version 960 for 6 ms of simulation time. Contour plots of resultant panel displacement and effective stress in the foam were compared at five discrete time intervals. Also, time-history responses of internal and kinetic energy of the panel, kinetic and hourglass energy of the foam, and resultant contact force were plotted to determine the influence of mesh density. As a final comparison, the model with a fine panel and fine foam mesh was executed with slightly different material properties for the RCC. For this model, the average degraded properties of the RCC were replaced with the maximum degraded properties. Similar comparisons of panel and foam responses were made for the average and maximum degraded models.

Jackson, Karen E.↗
NASA NTRS2006

A Mesh Refinement Study on the Impact Response of a Shuttle Leading-Edge Panel Finite Element Simulation

A study was performed to examine the influence of varying mesh density on an LS-DYNA simulation of a rectangular-shaped foam projectile impacting the space shuttle leading edge Panel 6. The shuttle leading-edge panels are fabricated of reinforced carbon-carbon (RCC) material. During the study, nine cases were executed with all possible combinations of coarse, baseline, and fine meshes of the foam and panel. For each simulation, the same material properties and impact conditions were specified and only the mesh density was varied. In the baseline model, the shell elements representing the RCC panel are approximately 0.2-in. on edge, whereas the foam elements are about 0.5-in. on edge. The element nominal edge-length for the baseline panel was halved to create a fine panel (0.1-in. edge length) mesh and doubled to create a coarse panel (0.4-in. edge length) mesh. In addition, the element nominal edge-length of the baseline foam projectile was halved (0.25-in. edge length) to create a fine foam mesh and doubled (1.0-in. edge length) to create a coarse foam mesh. The initial impact velocity of the foam was 775 ft/s. The simulations were executed in LS-DYNA for 6 ms of simulation time. Contour plots of resultant panel displacement and effective stress in the foam were compared at four discrete time intervals. Also, time-history responses of internal and kinetic energy of the panel, kinetic and hourglass energy of the foam, and resultant contact force were plotted to determine the influence of mesh density.

Fasanella, Edwin L.↗
NASA NTRS2008

Refractory Ceramic Foams for Novel Applications

Workers at NASA Ames Research center are endeavoring to develop durable, oxidation-resistant, foam thermal protection systems (TPSs) that would be suitable for covering large exterior spacecraft surfaces, would have low to moderate densities, and would have temperature capabilities comparable to those of carbon-based TPSs [reusable at 3,000 F (.1,650 C)] with application of suitable coatings. These foams may also be useful for repairing TPSs while in orbit. Moreover, on Earth as well as in outer space, these foams might be useful as catalyst supports and filters. Preceramic polymers are obvious candidates for use in making the foams in question. The use of these polymers offers advantages over processing routes followed in making conventional ceramics. Among the advantages are the ability to plastically form parts, the ability to form pyrolized ceramic materials at lower temperatures, and the ability to form high-purity microstructures having properties that can be tailored to satisfy requirements. Heretofore, preceramic polymers have been used mostly in the production of such low-dimensional products as fibers because the loss of volatiles during pyrolysis of the polymers leads to porosity and large shrinkage (in excess of 30 percent). In addition, efforts to form bulk structures from preceramic polymers have resulted in severe cracking during pyrolysis. However, because the foams in question would consist of networks of thin struts (in contradistinction to nonporous dense solids), these foams are ideal candidates for processing along a preceramic-polymer route.

Stackpoole, M.↗
NASA NTRS1984

Design of a composite wing extension for a general aviation aircraft

A composite wing extension was designed for a typical general aviation aircraft to improve lift curve slope, dihedral effect, and lift to drag ratio. Advanced composite materials were used in the design to evaluate their use as primary structural components in general aviation aircraft. Extensive wind tunnel tests were used to evaluate six extension shapes. The extension shape chosen as the best choice was 28 inches long with a total area of 17 square feet. Subsequent flight tests showed the wing extension's predicted aerodynamic improvements to be correct. The structural design of the wing extension consisted of a hybrid laminate carbon core with outer layers of Kevlar - layed up over a foam interior which acted as an internal support. The laminate skin of the wing extension was designed from strength requirements, and the foam core was included to prevent buckling. A joint lap was recommended to attach the wing extension to the main wing structure.

Adney, P. S.↗
NASA NTRS2005

Nondestructive Evaluation of Space Shuttle External Tank Foam

During launch of Shuttle Columbia, mission STS-107, a large piece of spray on foam insulation (SOFI) separated from the external tank left bipod ramp area impacting the shuttle orbiter left wing leading edge. "Analysis showed that this large piece of foam struck Columbia on the underside of the left wing after launch. Later, analysis showed that the larger piece struck Columbia on the underside of the left wing, around Reinforced Carbon-Carbon (RCC) panels 5 through 9, at 81.9 seconds after launch. Further photographic analysis revealed that the large foam piece was approximately 21 to 27 inches long and 12 to 18 inches wide and was moving at a relative velocity to the Shuttle stack of 625 to 840 feet per second (416 to 573 miles per hour) at the time of impact." This impact damaged the wing leading edge resulting in loss of orbiter thermal protection. The piece of errant foam was part of a bipod ramp which was designed to meet thermal and aerodynamic requirements in that region of the external tank (ET).

Thom, Robert L.↗
NASA NTRS2004

A Summary of the Space Shuttle Columbia Tragedy and the Use of LS Dyna in the Accident Investigation and Return to Flight Efforts

On February 1, 2003, the Space Shuttle Columbia broke apart during reentry resulting in loss of 7 crewmembers and craft. For the next several months an extensive investigation of the accident ensued involving a nationwide team of experts from NASA, industry, and academia, spanning dozens of technical disciplines. The Columbia Accident Investigation Board (CAIB), a group of experts assembled to conduct an investigation independent of NASA concluded in August, 2003 that the cause of the loss of Columbia and its crew was a breach in the left wing leading edge Reinforced Carbon-Carbon (RCC) thermal protection system initiated by the impact of thermal insulating foam that had separated from the orbiters external fuel tank 81 seconds into the missions launch. During reentry, this breach allowed superheated air to penetrate behind the leading edge and erode the aluminum structure of left wing which ultimately led to the breakup of the orbiter. In order to gain a better understanding the foam impact on the orbiters RCC wing leading edge, a multi-center team of NASA and Boeing impact experts was formed to characterize the foam and RCC materials for impact analysis using LS Dyna. Dyna predictions were validated with sub-component and full scale tests. LS Dyna proved to be a valuable asset in supporting both the Columbia Accident Investigation and NASA s return to flight efforts. This paper summarizes Columbia Accident and the nearly seven month long investigation that followed. The use of LS-DYNA in this effort is highlighted. Contributions to the investigation and return to flight efforts of the multicenter team consisting of members from NASA Glenn, NASA Langley, and Boeing Philadelphia are introduced and covered in detail in papers to follow in these proceedings.

Melis, Matthew↗
NASA NTRS2007

The Columbia Accident Investigation and The NASA Glenn Ballistic Impact Laboratory Contributions Supporting NASA's Return to Flight

On February 1, 2003, the Space Shuttle Columbia broke apart during reentry, resulting in loss of the vehicle and its seven crewmembers. For the next several months, an extensive investigation of the accident ensued involving a nationwide team of experts from NASA, industry, and academia, spanning dozens of technical disciplines. The Columbia Accident Investigation Board (CAIB), a group of experts assembled to conduct an investigation independent of NASA, concluded in August, 2003 that the most likely cause of the loss of Columbia and its crew was a breach in the left wing leading edge Reinforced Carbon-Carbon (RCC) thermal protection system initiated by the impact of thermal insulating foam that had separated from the orbiters external fuel tank 81 seconds into the mission's launch. During reentry, this breach allowed superheated air to penetrate behind the leading edge and erode the aluminum structure of left wing, which ultimately led to the breakup of the orbiter. The findings of the CAIB were supported by ballistic impact tests, which simulated the physics of External Tank Foam impact on the RCC wing leading edge material. These tests ranged from fundamental material characterization tests to full-scale Orbiter Wing Leading Edge tests. Following the accident investigation, NASA spent the next 18 months focused on returning the shuttle safely to flight. In order to fully evaluate all potential impact threats from the many debris sources on the Space Shuttle during ascent, NASA instituted a significant impact testing program. The results from these tests led to the validation of high-fidelity computer models, capable of predicting actual or potential Shuttle impact events, were used in the certification of STS-114, NASA s Return to Flight Mission, as safe to fly. This presentation will provide a look into the inner workings of the Space Shuttle and a behind the scenes perspective on the impact analysis and testing done for the Columbia Accident Investigation and NASA's Return to Flight programs. In addition, highlights from recent Shuttle missions are presented.

Melis, Matthew E.↗
NASA NTRS2006

An Overview of Spray-On Foam Insulation Applications on the Space Shuttle's External Tank: Foam Applications and Foam Shedding Mechanisms

The Columbia Accident Investigation Board (CAIB) concluded that the cause of the tragic loss of the Space Shuttle Columbia and its crew was a breach in the thermal protection system on the leading edge of the left wing. The breach was initiated by a piece of insulating foam that separated from the left bipod ramp of the External Tank and struck the wing in the vicinity of the lower half of Reinforced Carbon-Carbon panel No. 8 at 81.9 seconds after launch. The CAIB conclusion has spawned numerous studies to identify the cause of and factors influencing foam shedding and foam debris liberation from the External Tank during ascent. The symposium on the Thermo-mechanics and Fracture of Space Shuttle External Tank Spray-On Foam Insulation is a collection of presentations that discuss the physics and mechanics of the ET SOFI with the objective of improving analytical and numerical methods for predicting foam thermo-mechanical and fracture behavior. This keynote presentation sets the stage for the presentations contained in this symposium by introducing the audience to the various types of SOFI applications on the Shuttle s External Tank and by discussing the various mechanisms that are believed to be the cause of foam shedding during the Shuttle s ascent to space

Sullivan, Roy M.↗
NASA NTRS1972

Improved oxidation-resistant carbon and graphite materials

A variety of silicon-carbide treated carbon and graphite products were prepared, and oxidation and strength properties determined. Carbon and graphite materials used in the preliminary study include fiber, tape, felt, foam, bulk, and laminar configurations. The silicon-carbide treatment used in preparing the oxidation resistant specimens employs either vacuum or ultrasonic impregnation of various silicone-silicon mixtures into the matrix material. The impregnation phase is followed by controlled thermal reaction at which time the silicon carbide is synthesized and takes the form of an integral protective boundary layer. Thickness of the layer ranges from a fraction of a mil to 10 mils, depending on the matrix material and processing parameters. Oxidation resistance of all the silicon-carbide-treated specimens investigated was found to be significantly improved. Mechanical strengths of the laminar composites were also found to be somewhat improved. At room temperature the specific strength of the silicon-carbide treated fibers and tapes was degraded to some extent; however, their relative strengths were significantly increased at elevated temperatures in oxidizing atmosphere.

Muir, H. M.↗