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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Comparisons of NDT Methods to Inspect Cork and Cork filled Epoxy Bands

Sheet cork and cork filled epoxy provide external insulation for the Reusable Solid Rocket Motor (RSRM) on the Nation's Space Transportation System (STS). Interest in the reliability of the external insulation bonds has increased since the Columbia incident. A non-destructive test (NDT) method that will provide the best inspection for these bonds has been under evaluation. Electronic Shearography has been selected as the primary NDT method for inspection of these bond lines in the RSRM production flow. ATK Launch Systems Group has purchased an electronic shearography system that includes a vacuum chamber that is used for evaluation of test parts and custom vacuum windows for inspection of full-scale motors. Although the electronic shearography technology has been selected as the primary method for inspection of the external bonds, other technologies that exist continue to be investigated. The NASA/Marshall Space Flight Center (MSFC) NDT department has inspected several samples for comparison with electronic shearography with various inspections systems in their laboratory. The systems that were evaluated are X-ray backscatter, terahertz imaging, and microwave imaging. The samples tested have some programmed flaws as well as some flaws that occurred naturally during the sample making process. These samples provide sufficient flaw variation for the evaluation of the different inspection systems. This paper will describe and compare the basic functionality, test method and test results including dissection for each inspection technology.

Lingbloom, Mike↗
NASA NTRSDate not supplied

Thermal Protection System P50 Cork Char Response Characterization to Ascent Flight Shear and Heating Environments

NASA’s Space Launch System (SLS) experienced deflagration of the acreage of the Core Stage base heat shield during the Green Run hot-fire test campaigns and Artemis I flight. The burning products from the base heat shield during Green Run hot-fire test operation led to concerns in aerothermal environments and thermal protection system (TPS) performance prior to Artemis I flight. Updated design thermal environments accounting for cork combustion were developed using Green Run measurements and assessed prior to Artemis I, resulting in increased TPS thickness for the base heat shield. This work documents a highly controlled ground test within the NASA Marshall Space Flight Center’s Propulsion Test Branch Hot Gas Facility (HGF) and investigates the P50 cork TPS response due to sensitivity changes in radiative heat rates and surface shear stress. Prior to testing at the HGF, most of the P50 cork panels had a thick layer of char due to the cork combustion process replicated in a thermal vacuum chamber. SLS ascent shear stress and heating rate profile were simulated within the HGF by running the combustion-driven wind tunnel at off-nominal conditions and Mach numbers below 1. This test data provided insight into aerothermal measurements from Artemis I flight as well as informing updated base heating design environments for Artemis II. An in-depth understanding of the TPS P50 cork char response and observations is presented for launch vehicle flight ascent environments.

aerothermodynamics↗
NASA NTRS2006

Laser Shearography Inspection of TPS (Thermal Protection System) Cork on RSRM (Reusable Solid Rocket Motors)

Laser Shearography is a viable inspection method for detection of de-bonds and voids within the external TPS (thermal protection system) on to the Space Shuttle RSRM (reusable solid rocket motors). Cork samples with thicknesses up to 1 inch were tested at the LTI (Laser Technology Incorporated) laboratory using vacuum-applied stress in a vacuum chamber. The testing proved that the technology could detect cork to steel un-bonds using vacuum stress techniques in the laboratory environment. The next logical step was to inspect the TPS on a RSRM. Although detailed post flight inspection has confirmed that ATK Thiokol's cork bonding technique provides a reliable cork to case bond, due to the Space Shuttle Columbia incident there is a great interest in verifying bond-lines on the external TPS. This interest provided and opportunity to inspect a RSRM motor with Laser Shearography. This paper will describe the laboratory testing and RSRM testing that has been performed to date. Descriptions of the test equipment setup and techniques for data collection and detailed results will be given. The data from the test show that Laser Shearography is an effective technology and readily adaptable to inspect a RSRM.

Lingbloom, Mike↗
NASA NTRS1965

Cork is used to make tooling patterns and molds

Sheet and waste cork are cemented together to provide a tooling pattern or mold. The cork form withstands moderately high temperatures under vacuum or pressure with minimum expansion, shrinkage, or distortion.

Hoffman, F. J.↗
NASA NTRS1977

Moldable cork ablation material

A successful thermal ablative material was manufactured. Moldable cork sheets were tested for density, tensile strength, tensile elongation, thermal conductivity, compression set, and specific heat. A moldable cork sheet, therefore, was established as a realistic product.

Source record↗
NASA NTRS1980

Cork-resin ablative insulation for complex surfaces and method for applying the same

A method of applying cork-resin ablative insulation material to complex curved surfaces is disclosed. The material is prepared by mixing finely divided cork with a B-stage curable thermosetting resin, forming the resulting mixture into a block, B-stage curing the resin-containing block, and slicing the block into sheets. The B-stage cured sheet is shaped to conform to the surface being insulated, and further curing is then performed. Curing of the resins only to B-stage before shaping enables application of sheet material to complex curved surfaces and avoids limitations and disadvantages presented in handling of fully cured sheet material.

Walker, H. M.↗
NASA NTRSDate not supplied

Thermal Protection System P50 Cork Environments and Response due to Radiative Heating

Space Launch System (SLS) experienced deflagration of the acreage of the Core Stage base heat shield during the Green Run hot-fire test campaigns and Artemis I flight. The burning products from the base heat shield during Green Run hot-fire test operation led to concerns in aerothermal environments and thermal protection system (TPS) performance prior to Artemis I flight. This work documents a highly controlled ground test within the NASA Marshall Space Flight Center’s Nonmetallic Materials Branch thermal vacuum chamber (TVC) and investigates the P50 cork heat transfer environments and thermal protection system (TPS) response due to sensitivity changes in radiative heat rates, ambient pressure, air entrainment mass flow rates, test gas and TPS sample types. An SLS ascent ambient pressure profile was also simulated within the TVC facility. This test data enabled the efforts toward the Artemis I SLS post-flight reconstruction and initial assessment of flight TPS performance. A ground test program was developed to gain an in-depth understanding of the cork combustion dynamics and TPS response due to the SLS launch vehicle flight ascent environments.

thermal protection system↗
NASA NTRS1977

Molding cork sheets to complex shapes

Partially cured cork sheet is easily formed to complex shapes and then final-cured. Temperature and pressure levels required for process depend upon resin system used and final density and strength desired. Sheet can be bonded to surface during final cure, or can be first-formed in mold and bonded to surface in separate step.

Sharpe, M. H.↗
NASA NTRS1980

Verification of the SRB motor case pin retainer band tips

The pin retainer band is a 1-1/4 in. wide by about 1/32 in. thick steel band that is stretched over the pins circumferentially at the joints of the solid rocket booster (SRB) motor case segments. Its purpose is to hold the retaining pins in place during flight. Since the band is thin and is mounted stretched, or under tension, over the pins which are greased in place, it is necessary to protect it thermally. Three typical areas of the band location on the SRB motor case joints were chosen for verifying the cork thermal prection system (TPS) performance on the band: the joint in front of the attach ring, at the aft skirt joint in front of the kick ring and in an unperturbed area at the forward segments of the SRB motor cases. The kick ring area pin retainer band cork TPS passed the test requirements in the region where there are no phenolic splice caps. In the splice cap areas where the band TPS is closed out around the splice with K5NA, additional amounts of K5NA material is required to adequately protect the steel band. TPS requirements were easily met in the one location where the ends of the steel band are joined together after installation and tensioning. The attack ring area pin retainer band TPS did not quite pass the heat load requirements with the .375 in. thick cork TPS as used for the kick ring area band. It is recommended that the cork thickness here be increased to .50 in. The unperturbed area band TPS presented no problems.

Karu, Z. S.↗
NASA NTRS1982

Results of tests of MTA-2 TPS on the SRB hold-down bolt blast container

The four solid rocket booster (SRB) hold-down posts are fastened to the mobile launch platform (MLP) with four large nuts. At liftoff the nuts are split with explosive changes to release the SRB/Shuttle. A blast container is placed over the nuts to protect the vehicle from flying debris. The blast container is a reusable part and has to be protected from aerodynamic heating during flight. The thermal protection system (TPS) used to protect these blast containers is cork. Fitting the flat cork sheet to this hemispherical shaped blast container is both time consuming and expensive. Another problem is removing the charred cork and epoxy glue from the blast containers. Replacements of this cork with another TPS material such as MTA-2 was examined. Heating rates along the centerline of the forward facing areas of the blast container were determined. The feasibility of using 1/2 in. MTA-2 on the SRB blast containers for protection from ascent, plume impingement and reentry heating is demonstrated.

Dean, W. G.↗
NASA NTRS1982

Results of tests of K5NA and a revised formulation of EPDM/cork patch material in MSFC Hot Gas Facility

During prelaunch procedures at Kennedy Space Center some of the EPDM Thermal Protection System material was damaged on the Solid Rocket Booster stiffener stubs. The preferred solution was to patch the damaged areas with a cork-filled epoxy patching compound. Before this was done, however, it was requested that this patching technique be checked out by testing it in the MSFC Hot Gas Facility. Two tests were run in the HFG in 1980. The results showed the patch material to be adequate. Since that time, the formulation of the cork-filled epoxy material has been changed. It became necessary to retest this concept to be sure that the new material is as good as or better than the original material. In addition to the revised formulation material, tests were also made using K5NA as the patch material. The objectives of the tests reported herein were to: (1) compare the thermal performance of the original and the new cork-filled epoxy formulations, and (2) compare the K5NA closeout material to these epoxy materials. Material specifications are also discussed.

Dean, W. G.↗
NASA NTRS1982

SRB attach ring phenolic TPS fishtail seal evaluation tests

The SRB attach ring is thermally protected with layered phenolic cloth fairings that are fastened to the ring. The gap between the fairings and the motor case is closed off with a rubber seal of a fishtail cross sectional shape bonded to the phenolic. On both the STS-1 and STS-2 flights this gap was discovered to vary anywhere from an intended gap of 0.375 in. to an actual measured gap of 0.60 in. due to tolerances. Tests were conducted with and without a 0.25 in. thick cork shim placed under the seal with a 0.60 in. gap under the phenolic TPS to determine and compare the performance of the seal in the two different configurations. To alleviate the difficult and costly procedure of installing the cork shim under the seal, especially after phenolic TPS mounting on the attach ring, large fishtail seals of idential Elder gray silicon material and two different hardnesses were tested. A similar matrix of tests was conducted with this new large fishtail seal, and seals with both type hardnesses performed well regardless of whether or not the seal was bonded in the phenolic at the front of the seal groove. Similar results had been obtained with the original small fishtail seal which performed adequately with the 0.25 in. cork shim under it.

Karu, Z. S.↗
NASA NTRS1990

Evaluation of EA-934NA with 2.5 percent Cab-O-Sil

Currently, Hysol adhesive EA-934NA is used to bond the Field Joint Protection System on the Shuttle rocket motors at Kennedy Space Center. However, due to processing problems, an adhesive with a higher viscosity is needed to alleviate these difficulties. One possible solution is to add Cab-O-Sil to the current adhesive. The adhesive strength and bond strengths that can be obtained when 2.5 percent Cab-O-Sil is added to adhesive EA-934NA are examined and tested over a range of test temperatures from -20 to 300 F. Tensile adhesion button and lap shear specimens were bonded to D6AC steel and uniaxial tensile specimens (testing for strength, initial tangent modulus, elongation and Poisson's ratio) were prepared using Hysol adhesive EA-934NA with 2.5 percent Cab-O-Sil added. These specimens were tested at -20, 20, 75, 100, 125, 150, 200, 250, and 300 F, respectively. Additional tensile adhesion button specimens bonding Rust-Oleum primed and painted D6AC steel to itself and to cork using adhesive EA-934NA with 2.5 percent Cab-O-Sil added were tested at 20, 75, 125, 200, and 300 F, respectively. Results generally show decreasing strength values with increasing test temperatures. The bond strengths obtained using cork as a substrate were totally dependent on the cohesive strength of the cork.

Caldwell, Gordon A.↗
DOE OSTI2024

Experimental Study of Underground Heat Storage via Hydraulic Fractures

In this study, we present a laboratory setup to test the energy flow in the form of underground heat storage using hydraulic fractures, a so-called Fracture Thermal Energy Storage (FTES) system. In the experiment, de-ionized water is circulated under high pressure through steel tubing automatically heated to a target temperature. The fluid adjusts to the tubing temperature during its flow before entering a production well drilled into a 250 mm edge length block of Zimbabwe Gabbro. The warm fluid then circulates through a previously created hydraulic fracture at mid-height of the block to a production well drilled at the block periphery. External fracture appearances are sealed using an epoxy resin and the production well by a cork of polydimethylsiloxane. In this cork, tubing to an open outlet is glued. We demonstrated through the results of a preliminary heating experiment that we can transfer nearly all of the heat from the circulating fluid to the block. An efficient charging of the thermal battery is achieved. This first-order demonstration is currently under further improvement and serves as a knowledge basis for the upscaling of mid- to large-scale field implementation of FTES systems.

Möri, Andreas↗
NASA NTRS1980

A simple self-sealing plug

Inexpensive self-expanding plug makes convenient low-pressure seal. Simple elastomeric plug seals round ports and holes better than regular cork. Plug is inserted with plastic tool that squeezes it to diameter smaller than port opening. Once tool is removed, plug self-expands to its original shape, exerting stronger pressure to sealed surface than cork. Plug is less expensive to make than screw-on or cam-expanded seals.

Ruppe, E. P.↗
NASA NTRS1988

Flight motor set 360L001 (STS-26R), volume 1

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.

Ricks, Glen A.↗
NASA NTRS1990

Flight motor set 360L001 (STS-26R). Volume 1: System overview, revision A

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.

Garecht, Diane M.↗