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The cost data for solid propellant rocket engines for use with the space shuttle are presented. The data are based on the selected 156 inch parallel and series burn configurations. Summary cost data are provided for the production of the 120 inch and 260 inch configurations. Graphs depicting parametric cost estimating relationships are included.
The program planning acquisition functions for the development of the solid propellant rocket engine for the space shuttle booster is presented. The subjects discussed are: (1) program management, (2) contracts administration, (3) systems engineering, (4) configuration management, and (5) maintenance engineering. The plans for manufacturing, testing, and operations support are included.
The application of laser holographic interferometric techniques for nondestructive inspection of material structures commonly used in aerospace works is investigated. Two types of structures, composite plate and solid fuel rocket engine motor casing, were examined. In conducting the experiments, both CW HeNe gas lasers and Q-switched ruby lasers were used as light sources for holographic recording setups. Different stressing schemes were investigated as to their effectiveness in generating maximum deformation at regions of structural weakness such as flaws and disbonds. Experimental results on stressing schemes such as thermal stressing, pressurized stressing, transducer excitation, and mechanical impact are presented and evaluated.
Emission into the atmosphere of aerospace vehicle exhaust effluents and by-products is considered by using atmospheric diffusion models to calculate downwind concentrations and dosages from various engine and solid rocket booster (SRB) exhaust by-products. A major effort is being made to gather detailed data on the chemical reactions that take place between the exhaust effluents and the atmosphere. Basic diffusion estimation formulas consider normal exhaust releases, abnormal releases, leaks, and inadvertent spills. Cloud rise formulas for use in source identification are included and meteorological inputs covered.
A program to identify surplus solid rocket propellant engines which would be available for a program of functional integrity testing was conducted. The engines are classified as: (1) upper stage and apogee engines, (2) sounding rocket and launch vehicle engines, and (3) jato, sled, and tactical engines. Nearly all the engines were available because their age exceeds the warranted shelf life. The preference for testing included tests at nominal flight conditions, at design limits, and to establish margin limits. The principal failure modes of interest were case bond separation and grain bore cracking. Data concerning the identification and characteristics of each engine are tabulated. Methods for conducting the tests are described.
A research project to develop a computer program for the preliminary design and performance analysis of solid propellant rocket engines is discussed. The following capabilities are included as computer program options: (1) treatment of wagon wheel cross sectional propellant configurations alone or in combination with circular perforated grains, (2) calculation of ignition transients with the igniter treated as a small rocket engine, (3) representation of spherical circular perforated grain ends as an alternative to the conical end surface approximation used in the original program, and (4) graphical presentation of program results using a digital plotter.
The use of the difference in chamber pressure between solid rocket booster engines as a controlling signal to the flight control system during booster thrust tailoff was examined. In addition, the control capability of the Generalized Attitude Control System (GACS) was compared to that of the baseline. Results indicate that the difference in chamber pressure signal provided essentially no improvement. However, the GACS is considerably better than the baseline in controlling during tailoff disturbances.
Chemical reactions expected to occur among the constituents of solid-fuel rocket engine effluents in the hot region behind a Mach disk are analyzed theoretically. With the use of a rocket plume model that assumes the flow to be separated in the base region, and a chemical reaction scheme that includes evaporation of alumina and the associated reactions of 17 gas species, the reformation of the effluent is calculated. It is shown that AlClO and AlOH are produced in exchange for a corresponding reduction in the amounts of HCl and Al2O3. For the case of the space shuttle booster engines, up to 2% of the original mass of the rocket fuel can possibly be converted to these two new species and deposited in the atmosphere between the altitudes of 10 and 40 km. No adverse effects on the atmospheric environment are anticipated with the addition of these two new species.
The general problem of the nonlinear growth and limiting amplitude of acoustic waves in a combustion chamber is treated in three parts: (1) the general conservation equations are expanded in two small parameters, and then combined to yield a nonlinear inhomogeneous wave equation, (2) the unsteady pressure and velocity fields are expressed as a synthesis of the normal modes of the chamber, but with unknown time-varying amplitudes, and (3) the system of nonlinear equations is treated by the method of averaging to produce a set of coupled nonlinear first order differential equations for the amplitudes and phases of the modes. This approximate analysis is applied to the investigation of the unstable motions in a solid propellant rocket engine and in a T burner.
Elements of the shuttle program that directly affect the mission success and crew safety were investigated. These elements included the shuttle orbiter, the main engine, the solid rocket boosters, avionic system, ground support equipment and the approach and landing operations. The thermal protection systems were studied in detail. Crew training and ground simulation test procedures were reviewed.
Data were obtained for a resonance tube having a vent at the center in the lateral boundary, an average flow being introduced at the ends. Experiments were done for both circular and slot vents, over ranges of both frequency and Mach number. It was demonstrated that a subsonic exhaust vent in the lateral boundary of a cold flow resonance tube provides a gain of acoustic energy for the fundamental mode within the resonance tube. The gain of acoustic energy increases approximately linearly with the Mach number, as predicted by the one-dimensional analysis. The one-dimensional result gives the values for the slope representing the variation of the attenuation coefficient of the exhaust vent with respect to the average Mach number of the flow within roughly 30% of those measured. It has been verified that the subsonic vent produces a gain proportional to the average Mach number, proportional to the frequency, and independent of the shape. The results may be applicable to the study of vibration phenomena in solid propellant rocket engines.
The National Space Transportation System is a national resources serving the government, Department of Defense and commercial needs of the USA and others. Four orbital flight tests were completed July 4, 1982, and the first Operational Flight (STS-5) which placed two commercial communications into orbit was conducted November 11, 1982. February 1983 marked the first flight of the newest orbiter, Challenger. Planned firsts in 1983 include: use of higher performance main engines and solid rocket boosters, around-the-clock crew operations, a night landing, extra-vehicular activity, a dedicated DOD mission, and the first flight of a woman crew member. By the end of 1983, five commercial payloads and two tracking and data relay satellites should be deployed and thirty-seven crew members should have made flights aboard the space shuttle.
Hydrogen propellant leakage poses significant operational problems in the rocket propulsion industry as well as for space exploratory applications. Vigorous efforts have been devoted to minimizing hydrogen leakage in assembly, test, and launch operations related to hydrogen propellant. The objective has been to reduce the operational cost of assembling and maintaining hydrogen delivery systems. Specifically, efforts have been made to develop a hydrogen leak detection system for point-contact measurement. Under the auspices of Lewis Research Center, the Electronics Design Center at Case Western Reserve University, Cleveland, Ohio, has undertaken the development of a point-contact hydrogen gas sensor with potential applications to the hydrogen propellant industry. We envision a sensor array consisting of numbers of discrete hydrogen sensors that can be located in potential leak sites. Silicon-based microfabrication and micromachining techniques are used in the fabrication of these sensor prototypes. Evaluations of the sensor are carried out in-house at Case Western Reserve University as well as at Lewis Research Center and GenCorp Aerojet, Sacramento, California. The hydrogen gas sensor is not only applicable in a hydrogen propulsion system, but also usable in many other civilian and industrial settings. This includes vehicles or facility use, or in the production of hydrogen gas. Dual space and commercial uses of these point-contacted hydrogen sensors are feasible and will directly meet the needs and objectives of NASA as well as various industrial segments.
In this volume, volume 4 (of five volumes), the discussion is focussed on the system models and related data references and has the following subsections: space shuttle main engine, integrated solid rocket booster, orbiter auxiliary power units/hydraulics, and electrical power system.
Four solid-propellant rocket engines of nominal 1000-pound-thrust were tested for starting characteristics at pressure altitudes ranging from 112,500 to 123,000 feet and at a temperature of -75 F. All engines ignited and operated successfully. Average chamber pressures ranged from 1060 to ll90 pounds per square inch absolute with action times from 1.51 to 1.64 seconds and ignition delays from 0.070 t o approximately 0.088 second. The chamber pressures and action times were near the specifications, but the ignition delay was almost twice the specified value of 0.040 second.
It is well known that under some operating conditions, rocket engines (using solid or liquid fuels) exhibit unstable modes of operation that can lead to engine malfunction and shutdown. The sources of these instabilities are diverse and are dependent on fuel, chamber geometry and various upstream sources such as pumps, valves and injection mechanism. It is believed that combustion-acoustic instabilities occur when the acoustic energy increase due to the unsteady heat release of the flame is greater than the losses of acoustic energy from the system [1, 2]. Giammar and Putnam [3] performed a comprehensive study of noise generated by gasfired industrial burners and made several key observations; flow noise was sometimes more intense than combustion roar, which tended to have a characteristic frequency spectrum. Turbulence was amplified by the flame. The noise power varied directly with combustion intensity and also with the product of pressure drop and heat release rate. Karchmer [4] correlated the noise emitted from a turbofan jet engine with that in the combustion chamber. This is important, since it quantified how much of the noise from an engine originates in the combustor. A physical interpretation of the interchange of energy between sound waves and unsteady heat release rates was given by Rayleigh [5] for inviscid, linear perturbations. Bloxidge et al [6] extended Rayleigh s criterion to describe the interaction of unsteady combustion with one-dimensional acoustic waves in a duct. Solutions to the mass, momentum and energy conservation equations in the pre- and post-flame zones were matched by making several assumptions about the combustion process. They concluded that changes in boundary conditions affect the energy balance of acoustic waves in the combustor. Abouseif et al [7] also solved the one-dimensional flow equations, but they used a onestep reaction to evaluate the unsteady heat release rate by relating it to temperature and velocity perturbations. Their analysis showed that oscillations arise from coupling between entropy waves produced at the flame and pressure waves originating from the nozzle. Yang and Culick [8] assumed a thin flame sheet, which is distorted by velocity and pressure oscillations. Conservation equations were expressed in integral form and solutions for the acoustic wave equations and complex frequencies were obtained. The imaginary part of the frequency indicated stability regions of the flame. Activation energy asymptotics together with a one-step reaction were used by McIntosh [9] to study the effects of acoustic forcing and feedback on unsteady, one-dimensional flames. He found that the flame stability was altered by the upstream acoustic feedback. Shyy et al [10] used a high-accuracy TVD scheme to simulate unsteady, one-dimensional longitudinal, combustion instabilities. However, numerical diffusion was not completely eliminated. Recently, Prasad [11] investigated numerically the interactions of pressure perturbations with premixed flames. He used complex chemistry to study responses of pressure perturbations in one-dimensional combustors. His results indicated that reflected and transmitted waves differed significantly from incident waves.
During his 28+ as a NASA employee, Mr. Duarte has had the privilege to work in several programs and projects (Space Shuttle Main Engine; Advanced Solid Rocket Booster; X-33; X-34; X-36; External Tank for the Space Shuttle; Space Shuttle missions and others) related to the NASA aerospace exploration program. At the VIII version of F-AIR COLOMBIA, the organizers want to have Colombian born aerospace professionals with experience in aerospace matters to contribute as panelists for this years theme, Benefits of Space Development for A Country. For more than 50 years NASA has lead the world in exploration through continuous advancement in science and innovative technologies. The results have been not only of a service to the nation but to humankind, as well. Those remarkable developments have resulted in positive impact in social and economic growth, enhancements in academics and educational horizons, creation of numerous investment opportunities for large corporations and small business, and a more comprehensive understanding of the universe. NASA has layout path for space exploration and has been of inspiration for scientist, academics and students. Benefits of NASA to the USA and Humanity, will provide a relevant contribution to the theme and objectives of this national event in Colombia.
Heat sterilizable solid propellant motor designs for interplanetary missions, considering case- bonded spherical, case-bonded cylindrical, free- standing, internal burning and free-standing end burning