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Simple method saves time, money, and material. In new method cable remains in place while new insulation is applied to damaged portion. Method results in new terminations with safety factor equal to that of any portion of cable.
An ultrasonic inspection specification which incorporates existing industry practices for straight beam modes with a new approach to the angle beam reference standard was developed. The method employs a commercially available letter "I" die stamp to impress a controlled shape ultrasonic reflector using common hand tools. The specification is designed to produce very stringent inspections and is primarily intended for utilization in the grading of material used in high load-low safety factor applications, such as cryogenic wind tunnel models and support hardware.
The design of prospective NASA space station components which inherently possess the means for structural growth without compromising initial system characteristics is considered. In structural design terms, space station growth can be achieved by increasing design safety factors, introducing dynamic isolators to prevent loads from reaching the initial components, or preplanning the refurbishment of the original structure with stronger elements. Design tradeoffs will be based on the definition of on-orbit loads, including docking and maneuvering, whose derived load spectra will allow the estimation of fatigue life. Improvements must be made in structural materials selection in order to reduce contamination, slow degradation, and extend the life of coatings. To minimize on-orbit maintenance, long service life lubrication systems with advanced sealing devices must be developed.
The technical and economic feasibility of using electromagnetically launched EML payloads propelled from the Earth's surface to LEO, GEO, lunar orbit, or to interplanetary space was assessed. Analyses of the designs of rail accelerators and coaxial magnetic accelerators show that each is capable of launching to space payloads of 800 KG or more. A hybrid launcher in which EML is used for the first 2 KM/sec followed by chemical rocket stages was also tested. A cost estimates study shows that one to two EML launches per day are needed to break even, compared to a four-stage rocket. Development models are discussed for: (1) Earth orbital missions; (2) lunar base supply mission; (3) solar system escape mission; (4) Earth escape missions; (5) suborbital missions; (6) electromagnetic boost missions; and (7) space-based missions. Safety factors, environmental impacts, and EML systems analysis are discussed. Alternate systems examined include electrothermal thrustors, an EML rocket gun; an EML theta gun, and Soviet electromagnetic accelerators.
Ground rules and assumptions; operations; orbit considerations/dynamics; tether system design and dynamics; functional requirements; hardware concepts; and safety factors are examined for five scenarios: tethered effected separation of an Earth bound shuttle from the space station; tether effected orbit boost of a spacecraft (AXAF) into its operational orbit from the shuttle; an operational science/technology platform tether deployed from space station; a tether mediated rendezvous involving an OMV tether deployed from space station to rendezvous with an aerobraked OTV returning to geosynchronous orbit from a payload delivery mission; and an electrodynamic tether used in a dual motor/generator mode to serve as the primary energy storage facility for space station.
The potential servicing requirements of the Space Station and associated free-flying platforms are identified and analyzed; the selected servicing tasks encompass orbital maneuver vehicle refueling, reaction-control subsystem thruster module replacement, and body-mounted radiator changeout. Attention is presently given to the commonality of all servicing activities, the definition of servicing interfaces, and the roles played by automation and robotics. The servicing concepts for each representative servicing task were selected on the basis of a weighed combination of seven factors: safety, productivity, relative cost, mission effectiveness, design flexibility and simplicity, and development status.
The objective of this project was to provide the technology of high frequency, high power transmission lines to the 100 kW power range at 20 kHz frequency. In addition to the necessary design studies, a 150 m long, 600 V, 60 A transmission line was built, tested and delivered for full vacuum tests. The configuration analysis on five alternative configurations resulted in the final selection of the three parallel Litz straps configuration, which gave a virtually concentric design in the electromagnetic sense. Low inductance, low EMI and flexibility in handling are the key features of this configuration. The final design was made after a parametric study to minimize the losses, weight and inductance. The construction of the cable was completed with no major difficulties. The R,L,C parameters measured on the cable agreed well with the calculated values. The corona tests on insulation samples showed a safety factor of 3.
The NASA space shuttle flight STS-26R, launched at 11:37.00.009 a.m. EDT on 29 Sep. 1988, used the redesigned solid rocket motors (RSRM) 360LOO1A and 360LOO1B. Evaluation of the ground environment instrumentation (GEI) data recorded prior to flight showed: (1) no launch commit criteria violations, (2) that the field joint heater and aft skirt thermal conditioning systems performed adequately, and (3) that the GEI data showed good agreement with thermal model predictions. Evaluation of the developmental flight instrumentation (DFI) revealed excellent agreement with both the predicted and required ballistic specifications. All parameters were well within the CEI specification requirements including propellant burn rates, specific impulse values, and thrust imbalance. Recorded strain values also indicated satisfactory radial growth and stress levels, as well as verification of adequate safety factors. Postflight inspection of the insulation, seals, case, and nozzles showed overall excellent performance. Some thermal DFI protective cork was missing, and inoperative field joint vent valves on the thermal protection cork allowed water entry into the field joints upon splashdown. Evaluation of these anomalies, as well as complete evaluation of all RSRM components, is presented.
When welded structures depend on properties beyond the elastic limit to qualify their ultimate safety factor, and weld-parent materials abruptly change at the interface, then stress discontinuity is inevitable. The stress concentration is mildly sensitive to material relative strain hardening and acutely sensitive to applied stress fields. Peak stresses occur on the weld surface, at the interface, and dissipate within a 0.01-inch band. When the stress is intense, the weld will always fracture at the interface. The analysis incorporates a classical mechanics model to more sharply define stress spikes within the bandwidth, and suggests a relative material index and Poisson's ratio related to strain hardening. Implications are discussed which are applicable to industries of high performance structures.
The postfire condition of the external and internal insulation for STS-26 is documented and the thermal safety factors of the RSRM-1A and RSRM-1B internal insulation are evaluated. The Insulation Component Program Team assessment of the observation is discussed.
The insulation component of the Redesigned Solid Rocket Motor (RSRM) is discussed. The results of all visual evaluations and a thermal safety factor analysis are given. The data contained here supersedes the interim release and the insulation data presented in the Clearfield 10 day report. The objective is to document the postflight condition of the internal and external insulation of nozzle to case joints, the case field joints, the igniter to case joints, and the acreage insulation which made up RSRM-4A and RSRM-4B.
The redesigned solid rocket motor (RSRM) flight set 360L003 was launched on March 13, 1989 as part of NASA space shuttle mission STS-29R. As was the case with flight sets 360L001 and 360L002 (STS-26R and STS-27R), both motors (360L003A and 360L003B) performed in an excellent manner. Evaluation of the ground environment instrumentation measurements verified thermal model analysis data and showed agreement with predicted environmental effects. The right-hand aft field joint primary heater failed during the countdown; the secondary heater was activated and performed as designed. All other field joint heaters and aft skirt thermal conditioning systems had no anomalies. Shuttle thermal imager infrared readings compared favorably with measured ground environment instrumentation data. No thermal launch commit criteria violations occurred at any time. Evaluation of the development flight instrumentation showed exceptional propulsion performance. All ballistic parameters closely matched the predicted values and were well within the required specification levels. Girth and biaxial strain gage measurements compared closely with corresponding gages on previous flight motors, static tests, and with preflight predictions. Adequate safety factors were verified. (Some ignition transient spiking was noted in a few girth gages; the spiking was determined not to be representative of actual case behavior, but an instrumentation phenomena.) The accelerometers again measured high vibration amplitude levels during the ignition transient and the reentry Max Q phases. Postflight inspection showed that all combustion gas was contained by the insulation in the field and case-to-nozzle joints. No anomalous insulation erosion patterns were found, and the seals that did directly contain motor pressure showed no heat effects, erosion, or blowby. All anomalies identified were a result of splashdown damage, with the exception of fretting in the case field joint interference (nonsealing) surfaces and a prelaunch field joint heater failure. The disposition of all anomalies and the complete results are reported.
Flight 5 aft segments with nozzles were exposed to -17 F temperatures while awaiting shipment to KSC in February, 1989. No records were found which show that any previous nozzles were exposed to air temperatures as low as those seen by the Flight 5 nozzles. Thermal analysis shows that the temperature of the fixed housing, and forward and aft exit cone components dropped as low as -10 F. Structural analysis of the nozzles at these low temperatures show the forward and aft exit cone adhesive bonds to have a positive margin of safety, based on a 2.0 safety factor. These analyses show the normal and shear stresses in the fixed housing bond as low values. However, the hoop and meridinal stresses were predicted to be in the 4000 psi range; the failure stress allowable of EA913NA adhesive at -7 F. If the bonds did break in directions perpendicular to the surfaces, called bond crazing, no normal bond strength would be lost. Testing was conducted in two phases, showing that no degradation to the adhesive bonds occurred while the Flight 5 nozzles were subjected to subzero temperatures. The results of these tests are documented. Phase 1 testing cooled a full-scale RSRM insulated fixed housing to -13 F, with extensive bondline inspections. Phase 2 testing cooled the witness panel adhesive tensile buttions to -13 F, with failure strengths recorded before, during, and after the cooldown.
The NASA space shuttle flight STS-26R, launched at 11:37.00.009 am, EDT on 29 Sep. 1988, used the redesigned solid rocket motors (RSRM) 360L001A and 360L001B. Evaluation of the ground environment instrumentation (GEI) data recorded prior to flight showed no launch commit criteria violations; that the field joint heater and aft skirt thermal conditioning systems performed adequately; and that the GEI data showed good agreement with thermal model predictions. Evaluation of the developmental flight instrumentation (DFI) revealed excellent agreement with both the predicted and required ballistic specifications. All parameters were well within the GEI specification requirements including propellant burn rates, specific impulse values, and thrust imbalance. Recorded strain values also indicated satisfactory radial growth and stress levels, as well as verification of adequate safety factors. Postflight inspection of the insulation, seals, case, and nozzles showed overall excellent performance. Some thermal DFI protective cork was missing, and inoperative field joint vent valves on the thermal protection cork allowed water entry into the field joints upon splashdown. Evaluation of these anomalies, as well as complete evaluation of all Redesigned Solid Rocket Motor components, is contained.
Ultimate safety factors of high performance structures depend on stress behavior beyond the elastic limit, a region not too well understood. An analytical modeling approach was developed to gain fundamental insights into inelastic responses of simple structural elements. Nonlinear material properties were expressed in engineering stresses and strains variables and combined with strength of material stress and strain equations similar to numerical piece-wise linear method. Integrations are continuous which allows for more detailed solutions. Included with interesting results are the classical combined axial tension and bending load model and the strain gauge conversion to stress beyond the elastic limit. Material discontinuity stress factors in butt-welds were derived. This is a working-type document with analytical methods and results applicable to all industries of high reliability structures.
Volume 3 of this postfire report deals with the insulation component of the RSRM. The report is released twice for each flight set. The interim release contract date is on or before 60 days after the last field joint or nozzle to case joint is disassembled at KSC and contain the results of the KSC visual evaluation. The data contained in Volume 3 interim release supersedes the insulation data presented in the KSC 10 day report. The final release contract data is on or before 60 days after the last factory joint is disassembled at the Clearfield H-7 facility and contains the results of all visual evaluations and a thermal safety factor analysis. The data contained in the Volume 3 final release supersedes the interim release and the insulation data presented in the Clearfield 10 day report.
Space transfer vehicles and other power and propulsion systems require long-life turbopumps. Rolling element bearings used in current turbopumps do not have sufficient life for these applications. Process fluid foil bearings have established long life, with exceptional reliability, over a wide range of temperatures and fluids in many high-speed turbomachinery applications. However, liquid hydrogen turbopumps require high-load capacity bearings. An experimental study was conducted to measure foil journal bearing load capacity in liquid hydrogen, using a bearing designed specifically for cryogenic hydrogen turbopump applications. Additional performance parameters such as power loss, stability, cooling flow requirements, and bearing life were measured. These tests showed a load capacity safety factor of approximately 10 for liquid hydrogen turbopump applictions. These tests also demonstrated good rotor stability, low power loss and cooling flow, and long life.
The initial advanced communication technology satellite (ACTS) mobile terminal (AMT) demonstrations will involve two-way communications between the high-bit-rate link evaluation terminal (HBR-LET), which is a fixed terminal (FT), and a van-housed mobile terminal (MT). The HBR-LET has the capability of adjusting its transmitted uplink power over an approximately 10-dB range to compensate for forward uplink rain attenuation. However, because of size and weight limitations, the MT cannot use power control as a rain compensation technique. Consequently, the AMT rain compensation algorithm (RCA) is based on a formula for varying the transmitted data rate in either direction to maintain link performance within acceptable limits. The objective of the AMT RCA is to ensure reliable operation in both the forward and return directions despite the possibility of uplink or downlink fading due to rain events in the vicinity of the FT or MT. In particular, the RCA must maintain at least a 3-dB link margin at the highest possible transmission rate (AMT can operate at 9.6, 4.8, or 2.4 kb/s) permitted by the prevailing channel conditions. The 3-dB minimum link margin is a system design safety factor to accommodate conceivable implementation losses.