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Hand-held tool measures small gaps between tiles rapidly and accurately, even when gap is tapered or indented below surface. Tool indicates gap dimensions on calibrated disk. Measurements are accurate within plus or minus 0.003 inch. Tool was developed for determining gap between tiles on Space Shuttle, but may be of use in other applications requiring precise setting of gaps between tiles or other structures.
Two tests of undensified Space Shuttle thermal protection tiles under combined static and dynamic loads were conducted. The tiles had a density of approximately 144 Kg/cum (LI900 tiles) and were mounted on a strain isolation pad which was 0.41 cm (.160 inch) thick. A combined static and dynamic mission stress histogram representative of the W-3 area of the wing of the orbiter vehicle was applied. The stress histogram was provided by the space shuttle project. Results presented include: tabulation of measured peak and root-mean-square (RMS) accelerations in both compression and tension; peak SIP stress in compression and tension, peak and RMS amplitude response ratios; lateral to vertical response ratios; response time histories; peak stress distributions (histograms), and SIP extension measured both with and without static tension at various mission times.
Excessively large gaps between tiles on Space Shuttle eliminated without time-consuming and costly procedure of removing and replacing tiles. Ceramic tile silver is bonded in gap. Bonded silver prevents airframe under gap from getting too hot during reentry and presents aerodynamically smooth exterior surface.
Tile Failure Probability Model (TFPM) program originally developed to quantitatively assess risk of tile loss of thermal-protection tile from Space Shuttle Orbiter. TFPM is fairly specific to orbiter, but basic technique is applied in other structural design situations where anticipated loads and material strength have significantly variable probability distributions.
This paper demonstrates the use of an engineering data management system to facilitate the extensive stress analyses of the Space Shuttle Orbiter thermal protection system. Descriptions are given of the approach and methods used (1) to gather, organize, and store the data, (2) to query data interactively, (3) to generate graphic displays of the data, and (4) to access, transform, and prepare the data for input to a stress analysis program. The relational information management system was found to be well suited to the tile analysis problem because information related to many separate tiles could be accessed individually from a data base having a natural organization from an engineering viewpoint. The flexible user features of the system facilitated changes in data content and organization which occurred during the development and refinement of the tile analysis procedure. Additionally, the query language supported retrieval of data to satisfy a variety of user-specified conditions.
A large variety of tests were made to determine the strength, fatigue and thermal characteristics of the thermal-protection system of the Shuttle orbiter. The present paper describes first-launch-critical tests which were conducted in the Langley 8-Foot Transonic Pressure Tunnel (8'TPT) which simulated the time histories of Shuttle ascent loads on tile arrays bonded to structures which accurately duplicated those of the Shuttle. The time varying free-stream conditions were provided by controlling the deflection angle history of diffuser spoiler flaps in an automated way. Time histories of the critical-load parameters imposed on the tile arrays in the tunnel are compared in the paper to those expected in flight. In addition, the effect of repeated load pulses on the smoothness of the surface and condition of the tiles is discussed briefly.
This paper presents the Shuttle tile ascent environments and outlines the procedures used to convert these environments into tile loads. Testing which was performed to quantify or verify the loads is also discussed, along with the load combination rationale. The discussion of the ascent environment is limited to the transonic/supersonic portion of the mission since mechanical design loads occur during this time, and to specific regions of the vehicle, in particular those regions in which undensified critical (black) tiles are located.
This paper will discuss the Shuttle tile ascent environments and outline the procedures used to convert these environments into tile loads. Testing which was performed to quantify or verify the loads will also be discussed, along with the load combination rationale which was used. The discussion of the ascent environment will be limited to the transonic/supersonic portion of the mission since mechanical design loads occur during this time, and to specific regions of the vehicle, in particular those regions in which undensified critical (black) tiles are located. The induced environments can be broken down into three categories. The first of these are aerodynamic environments. These, in turn, are broken down into two categories-- (I) quasi-steady, which includes spatial surface pressure gradients, pressure differentials due to vent lag, and skin friction, and (2) the unsteady aerodynamics (aero-buffet). The second induced environment is defined as the vibration of the skin-stringer aluminum panels (hereafter referred to as the substrate) due to the acoustic environment. The third environment is defined as a quasi-steady substrate deflection, which results from in-plane and out-of-plane substrate loads.
The highlights of the many wind-tunnel tests conducted in the course of the Space Shuttle development program are presented with emphasis on instrumentation applications. The examples of tests discussed include airframe aerodynamics, aerodynamic heating, aerodynamic noise, tile dynamic response, and tile loads. Many of the tests were conducted with standard wind-tunnel instrumentation. Most of the more unusual instrumentation requirements were related to the thermal protection system, where some pressure-sensor concepts were adapted to measure airloads on tiles. These measurements provided the only quantitative data that could be used to confirm the airload analysis procedure. Limited applications of computers to experimental control, in conjunction with data taken during Shuttle tests, have resulted in substantial benefits in overall test efficiency.
Simple addition to ceramic insulating tiles provides backup properties that minimize transfer of heat through tiles when their surfaces become damaged. Addition of 3 percent by weight of 320- or 600-grit silicon carbide powder to ceramic during production results in impregnated tile material that resists overheating. Silicon carbide increases emittance and decreases transmittance of ceramic.
Waterproofing agent methyltrimethoxysilane applied to silica thermal insulation tiles in simple vapor-deposition process. Other waterproofing agents in same series include methylsiloxane and hexamethyldisilazane. Originally developed for insulating tiles for spacecraft, agents also find uses in roofing tiles, insulation for buildings or solar-energy systems, or solar reflectors.
Proportions of ingredients and sintering time/temperature schedule changed. Production process for lightweight, high-strength ceramic insulating tiles for Space Shuttle more than just scaled-up version of laboratory process for making small tiles. Boron in aluminum borosilicate fibers allows fusion at points where fibers contact each other during sintering, thereby greatly strengthening tiles structure.
Technique for applying ceramic coating to fibrous silica/alumina insulation tiles prevents cracks and substantially reduces firing time. To reduce thermal stresses in tile being coated, high-temperature, shorttime firing schedule implemented. Such schedule allows coating to mature while substrate remains at relatively low temperature, reducing stress differential between coating and substrate. Technique used to repair tiles with damaged coatings and possibly used in heat-treating objects made of materials having different thermal-expansion coefficients.
A user's guide for the computer program that calculates the steady-state aerodynamic loads on the Shuttle thermal-protection tiles is presented. The main element in the program is the MITAS-II, Martin Marietta Interactive Thermal Analysis System. The MITAS-II is used to calculate the mass flow in a nine-tile model designed to simulate conditions duing a Shuttle flight. The procedures used to execute the program using the MITAS-II software are described. A list of the necessry software and data files along with a brief description of their functions is given. The format of the data file containing the surface pressure data is specified. The interpolation techniques used to calculate the pressure profile over the tile matrix are briefly described. In addition, the output from a sample run is explained. The actual output and the procedure file used to execute the program at NASA Langley Research Center on a CDC CYBER-175 are provided in the appendices.
Late in the development of the Space Shuttle thermal protection system (TPS), a major problem was encountered with the attachment of the tiles to the spacecraft's exterior skin. To insure an adequate margin, each tile had to be proof tested. The risk of damaging a tile during proof test was quite high. For this reason, an acoustic emission system was developed and used in conjunction with the proof test to insure no significant damage occurred.
Improved lightweight insulating silica/aluminum borosilicate/silicon carbide tiles combine increased tensile strength with low thermal conductivity. Changes in composition substantially improve heat-insulating properties of silica-based refractory tile. Silicon carbide particles act as high-emissivity radiation scatterers in tile material.
Densification process increases impact resistance of lightweight, porous silica tile without appreciably raising weight. Colloidal suspension of silica used to increase density of small portion of tile to be strengthened. Process controls penetration of suspension laterally and vertically so densification limited to volume where needed. Insures weight increased only minimally. See also "Attaching Metal Fasteners to Silica Tiles" (MSC-20537).
The Shuttle Orbiter thermal protection system uses a Strain Isolation Pad (SIP) between the tile and the Orbiter. This paper presents experimental measurements of the pressure drop and associated flow rate through a sample of the SIP material. Included are data for a range of air densities representative of Shuttle ascent and re-entry trajectories. Also presented are new theoretical and correlative methods which predict the experimental data. These methods will help in predicting venting characteristics of tile assemblies during ascent, and hot gas leak under the tiles during descent. The predictive philosophy developed is useful in the study of fibrous and porous media fluid mechanics.