Engineering topics

Dunlap, Patrick H., Jr.

Publications and source records attributed to Dunlap, Patrick H., Jr..

At least 55 records · Page 3

NASA NTRS2003

Advanced Control Surface Seal Development at NASA GRC for Future Space Launch Vehicles

NASA s Glenn Research Center (GRC) is developing advanced control surface seal technologies for future space launch vehicles as part of the Next Generation Launch Technology project (NGLT). New resilient seal designs are currently being fabricated and high temperature seal preloading devices are being developed as a means of improving seal resiliency. GRC has designed several new test rigs to simulate the temperatures, pressures, and scrubbing conditions that seals would have to endure during service. A hot compression test rig and hot scrub test rig have been developed to perform tests at temperatures up to 3000 F. Another new test rig allows simultaneous seal flow and scrub tests at room temperature to evaluate changes in seal performance with scrubbing. These test rigs will be used to evaluate the new seal designs. The group is also performing tests on advanced TPS seal concepts for Boeing using these new test facilities.

Dunlap, Patrick H., Jr.↗

NASA NTRS2002

Advanced Control Surface Seal Development at NASA GRC for 3rd Generation RLV

NASA's Glenn Research Center (GRC) is developing advanced control surface seal technologies for the 3rd Generation RLV program. GRC has designed several new test rigs to simulate the temperatures, pressures, and scrubbing conditions that seals would have to endure during service. A hot compression test rig and hot scrub test rig are being developed to perform tests at temperatures up to 3000 F. Another new test rig allows simultaneous seal flow and scrub tests at room temperature to evaluate changes in seal performance with scrubbing. High temperature ceramic preloading devices are being developed and evaluated as ways to improve seal resiliency.

Dunlap, Patrick H., Jr.↗

NASA NTRS2002

Overview of NASA Glenn Seal Program

NASA Glenn hosted the Seals/Secondary Air System Workshop on October 30-31, 2001. Each year NASA and our industry and university partners share their respective seal technology developments. We use these workshops as a technical forum to exchange recent advancements and "lessons-learned" in advancing seal technology and solving problems of common interest. As in the past we are publishing two volumes. Volume I will be publicly available and individual papers will be made available on-line through the web page address listed at the end of this chapter. Volume II will be restricted under International Traffic and Arms Regulations (I.T.A.R.) and/or Export Administration Regulations (E.A.R.).

Steinetz, Bruce M.↗

NASA NTRS2002

Third Generation RLV Structural Seal Development Programs at NASA GRC

NASA GRC's work on high temperature structural seal development began in the late 1980's and early 1990's under the NASP (National Aero-Space Plane) project. Bruce Steinetz led the in-house propulsion system seal development program and oversaw industry efforts for propulsion system and airframe seal development for this vehicle. a propulsion system seal location in the NASP engine is shown. The seals were located along the edge of a movable panel in the engine to seal the gap between the panel and adjacent engine sidewalls. More recently, we worked with Rocketdyne on high temperature seals for the linear aerospike engine ramps. In applications such as the former X-33 program, multiple aerospike engine modules would be installed side by side on the vehicle. Seals are required in between adjacent engine modules along the edges and base of the engines. The seals have to withstand the extreme temperatures produced byt he thrusters at the top of the ramps while accommodating large deflections between adjacent ramps. We came up with several promising seal concepts for this application and shared them with Rocketdyne.

Dunlap, Patrick H., Jr.↗

NASA NTRS2002

Development and Capabilities of Unique Structural Seal Test Rigs

High temperature structural seals are necessary in many aerospace and aeronautical applications to minimize any detrimental effects originating from undesired leakage. The NASA Glenn Research Center has been and continues to be a pioneer in the development and evaluation of these types of seals. The current focus for the development of structural seals is for the 3rd Generation Reusable Launch Vehicle (RLV), which is scheduled to replace the current space shuttle system around 2025. Specific areas of development under this program include seals for propulsion systems (such as the hypersonic air-breathing ISTAR engine concept based upon Rocket Based Combined Cycle technology) and control surface seals for spacecraft including the autonomous rescue X-38 Crew Return Vehicle and the X-37 Space Maneuver Vehicle.

DeMange, Jeffrey J.↗

NASA NTRS2002

Analyses of Control Surface Seal Tested in the Ames Arc Jet Tunnel (Panel Test Facility)

The contents include: 1) Rope Seal; 2) Improvements to porous medial simulation in CFD-ACE+; 3) Porous media heat transfer validation case-stead-state and transient flat plate; 4) Simulation of GRC cold flow seal test fixture; 5) Simulation of calibration plate in the Panel Test Facility (PTF); and 6) Simulation of rope seal test in the PTF. This paper is in viewgraph form.

Reich, Alton J.↗

NASA NTRS2002

Rocket Motor Joint Construction Including Thermal Barrier

A thermal barrier for extremely high temperature applications consists of a carbon fiber core and one or more layers of braided carbon fibers surrounding the core. The thermal barrier is preferably a large diameter ring, having a relatively small cross-section. The thermal barrier is particularly suited for use as part of a joint structure in solid rocket motor casings to protect low temperature elements such as the primary and secondary elastomeric O-ring seals therein from high temperature gases of the rocket motor. The thermal barrier exhibits adequate porosity to allow pressure to reach the radially outward disposed O-ring seals allowing them to seat and perform the primary sealing function. The thermal barrier is disposed in a cavity or groove in the casing joint, between the hot propulsion gases interior of the rocket motor and primary and secondary O-ring seals. The characteristics of the thermal barrier may be enhanced in different applications by the inclusion of certain compounds in the casing joint, by the inclusion of RTV sealant or similar materials at the site of the thermal barrier, and/or by the incorporation of a metal core or plurality of metal braids within the carbon braid in the thermal barrier structure.

Steinetz, Bruce M.↗

NASA NTRS2002

Investigations of Control Surface Seals for Re-entry Vehicles

Re-entry vehicles generally require control surfaces (e.g., rudders, body flaps) to steer them during flight. Control surface seals are installed along hinge lines and where control surface edges move close to the vehicle body. These seals must operate at high temperatures and limit heat transfer to underlying structures to prevent them from overheating and causing possible loss of vehicle structural integrity. This paper presents results for thermal analyses and mechanical testing conducted on the baseline rudder/fin seal design for the X-38 re-entry vehicle. Exposure of the seals in a compressed state at the predicted peak seal temperature of 1900 F resulted in loss of seal resiliency. The vertical Inconel rudder/fin rub surface was re-designed to account for this loss of resiliency. Room temperature compression tests revealed that seal unit loads and contact pressures were below limits set to protect Shuttle thermal tiles on the horizontal sealing surface. The seals survived an ambient temperature 1000 cycle scrub test over sanded Shuttle tiles and were able to disengage and re-engage the tile edges during testing. Arc jet tests confirmed the need for seals in the rudder/fin gap location because a single seal caused a large temperature drop (delta T = 1710 F) in the gap.

Dunlap, Patrick H., Jr.↗

NASA NTRS2002

Rudder/Fin Seals Investigated for the X-38 Re-Entry Vehicle

NASA is developing the X-38 vehicle that will demonstrate the technologies required for a potential crew return vehicle for the International Space Station. This vehicle would serve both as an ambulance for medical emergencies and as an evacuation vehicle for the space station. Control surfaces on the X-38 (body flaps and rudder/fin assemblies) require high temperature seals to limit hot gas ingestion and the transfer of heat to underlying low temperature structures. Working with the NASA Johnson Space Center, the Seals Team at the NASA Glenn Research Center completed a series of tests to further characterize baseline seal designs for the rudder/fin interfaces of the X-38. The structures of the rudder/fin assembly and its associated seals are shown in the the preceding illustration. Tests performed at Glenn indicated that exposure of the seals in a compressed state at simulated seal re-entry temperatures resulted in a large permanent set and loss of seal resiliency. This could be of concern because the seals are required to maintain contact with the sealing surfaces while the vehicle goes through the maximum re-entry heating cycle to prevent hot gases from leaking past the seals and damaging interior low-temperature structures. To simulate conditions in which the seals may become unloaded during use, such as when they take on a large permanent set, Glenn researchers performed room temperature flow and compression tests to determine seal flow rates, resiliency, and unit loads under minimal loads. Flow rates through an unloaded (i.e., 0-percent compression) double seal arrangement were twice those of a double seal compressed to the 20-percent design compression level. These flow rates are being used in thermal analyses to predict the effect of flow through the seals on over-all seal temperatures. Compression test results showed that seal unit loads and contact pressures were below the limits that Johnson had set as goals for the seals. In the rudder/fin seal location, the seals are in contact with shuttle thermal tiles and are moved across the tiles as the rudder is rotated during re-entry. Low seal unit loads and contact pressures are required to limit the loads on these tiles and minimize any damage that the seals could cause. A series of tests were performed on these seals in NASA Ames Research Center's arc jet facility. The arc jet facility approximates relevant thermal environments that a seal or other structure would be subjected to during extreme heating conditions such as those experienced during space vehicle re-entry. Eleven tests were completed, including one test in which no seal was installed in the gap to examine the flow of heat down into the gap. The seal was compressed between stationary insulation tiles and a movable elevon that was rotated during the test to deflect the arc jet exhaust into the seal gap. Peak seal temperatures as high as 2000 F were reached during the 5-min tests. Results of these tests indicate satisfactory performance of the seal for single-use (e.g., X-38) applications. The results of these tests were shared with the NASA Johnson Space Center and are being used to validate aerothermostructural analysis codes that predict seal temperatures under these conditions. The tests performed at Glenn have provided valuable information to Johnson about the performance of the seals that they are considering using in the rudder/fin location of the X-38 vehicle. Glenn and Johnson are currently defining what additional work needs to be done to develop the final rudder/fin seal design for the X-38 vehicle.

Dunlap, Patrick H., Jr.↗

NASA NTRS2002

Thermal Barrier/Seal for Extreme Temperature Applications

Large solid rocket motors, as found on the Space Shuttle, are fabricated in segments for manufacturing considerations, bolted together, and sealed using conventional Viton O-ring seals. Similarly the nine large solid rocket motor nozzles are assembled from several different segments, bolted together, and sealed at six joint locations using conventional O-ring seals. The 5500 F combustion gases are generally kept a safe distance away from the seals by thick layers of phenolic or rubber insulation. Joint-fill compounds, including RTV (room temperature vulcanized compound) and polysulfide filler, are used to fill the joints in the insulation to prevent a direct flow-path to the O-rings. Normally these two stages of protection are enough to prevent a direct flow-path of the 900-psi hot gases from reaching the temperature-sensitive O-ring seals. However, in the current design 1 out of 15 Space Shuttle solid rocket motors experience hot gas effects on the Joint 6 wiper (sacrificial) O-rings. Also worrisome is the fact that joints have experienced heat effects on materials between the RTV and the O-rings, and in two cases O-rings have experienced heat effects. These conditions lead to extensive reviews of the post-flight conditions as part of the effort to monitor flight safety. We have developed a braided carbon fiber thermal barrier to replace the joint fill compounds in the Space Shuttle solid rocket motor nozzles to reduce the incoming 5500 F combustion gas temperature and permit only cool (approximately 100 F) gas to reach the temperature-sensitive O-ring seals. Implementation of this thermal barrier provides more robust, consistent operation with shorter turn around times between Shuttle launches.

Steinetz, Bruce M.↗

NASA NTRS2001

Rudder/Fin Seal Investigations for the X-38 Re-Entry Vehicle

NASA is currently developing the X-38 vehicle that will be used to demonstrate the technologies required for a crew return vehicle (CRV) for the International Space Station (ISS). The CRV will serve both as an ambulance for medical emergencies and as an evacuation vehicle for the Space Station. Control surfaces on the X-38 (body flaps and rudders/fins) require high temperature seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent over-temperature of these structures and possible loss of the vehicle. NASA's Johnson Space Center (JSC) and Glenn Research Center (GRC) are working together to develop and evaluate seals for the rudder/fin control surfaces. The specific objectives of this study are to measure seal flow rates, resiliency, and unit loads in as-received and temperature-exposed conditions and compare the measured results to property goals where applicable. Areas for future work would then be identified.

Dunlap, Patrick H., Jr.↗

NASA NTRS2001

Further Investigations of Control Surface Seals for the X-38 Re-Entry Vehicle

NASA is currently developing the X-38 vehicle that will be used to demonstrate the technologies required for a potential crew return vehicle (CRV) for the International Space Station. This vehicle would serve both as an ambulance for medical emergencies and as an evacuation vehicle for the Space Station. Control surfaces on the X-38 (body flaps and rudder/fin assemblies) require high temperature seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent over-temperature of these structures and possible loss of the vehicle. NASAs Johnson Space Center (JSC) and Glenn Research Center (GRC) are working together to develop and evaluate seals for these control surfaces. This paper presents results for compression. flow, scrub, and arc jet tests conducted on the baseline X-38 rudder/fin seal design. Room temperature seal compression tests were performed at low compression levels to determine load versus linear compression, preload. contact area, stiffness. and resiliency characteristics under low load conditions. For all compression levels that were tested, unit loads and contact pressures for the seals were below the 5 lb/in. and 10 psi limits required to limit the loads on the adjoining Shuttle thermal tiles that the seals will contact. Flow rates through an unloaded (i.e. 0% compression) double arrangement were twice those of a double seal compressed to the 20% design compression level. The seals survived an ambient temperature 1000 cycle scrub test over relatively rough Shuttle tile surfaces. The seals were able to disengage and re-engage the edges of the rub surface tiles while being scrubbed over them. Arc jet tests were performed to experimentally determine anticipated seal temperatures for representative flow boundary conditions (pressures and temperatures) under simulated vehicle re-entry conditions. Installation of a single seat in the gap of the test fixture caused a large temperature drop (1710 F) across the seal location as compared to an open gap condition (140 F) confirming the need for seals in the rudder/fin gap location. The seal acted as an effective thermal barrier limiting heat convection through the seal gap and minimizing temperature increases downstream of the seal during maximum heating conditions.

Dunlap, Patrick H., Jr.↗

NASA NTRS2000

Rudder/Fin Seal Investigations for the X-38 Re-Entry Vehicle

NASA is currently developing the X-38 vehicle that will be used to demonstrate the technologies required for a crew return vehicle (CRV) for the International Space Station. The X-38 control surfaces require high temperature seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent over-temperature of these structures and possible loss of the vehicle. This paper presents results for thermal analyses and flow and compression tests conducted on as-received and thermally exposed seals for the rudder/fin location of the X-38. A thermal analysis of the rudder/fin dual seal assembly based on representative heating rates on the windward surface of the rudder/fin area predicted a peak seal temperature of 1900 F. The temperature-exposed seals were heated in a compressed state at 1900 F corresponding to the predicted peak temperature. Room temperature compression tests were performed to determine load versus linear compression, preload, contact area, stiffness, and resiliency characteristics for the as-received and temperature-exposed seals. Temperature exposure resulted in permanent set and loss of resiliency in these seals. Unit loads and contact pressures for the seals were below the five pounds/inch and ten psi limits set to limit the loads on the Shuttle thermal tiles that the seals seal against in the rudder/fin location. Measured seal flow rates for a double seal were about 4.5 times higher than the preliminary seal flow goal. The seal designs examined in this study are expected to be able to endure the high temperatures that they will be exposed to for a single-use life. Tests performed herein combined with future analyses, arc jet tests, and scrubbing tests will be used to select the final seal design for this application.

Dunlap, Patrick H., Jr.↗

NASA NTRS2000

Development of Thermal Barriers For Solid Rocket Motor Nozzle Joints

Joints in the Space Shuttle solid rocket motors are sealed by O-rings to contain combustion gases inside the rocket that reach pressures of up to 900 psi and temperatures of up to 5500 F. To provide protection for the O-rings, the motors are insulated with either phenolic or rubber insulation. Gaps in the joints leading up to the O-rings are filled with polysulfide joint-fill compounds as an additional level of protection. The current RSRM nozzle-to-case joint design incorporating primary, secondary, and wiper O-rings experiences gas paths through the joint-fill compound to the innermost wiper O-ring in about one out of every seven motors. Although this does not pose a safety hazard to the motor, it is an undesirable condition that NASA and rocket manufacturer Thiokol want to eliminate. Each nozzle-to-case joint gas path results in extensive reviews and evaluation before flights can be resumed. Thiokol and NASA Marshall are currently working to improve the nozzle-to-case joint design by implementing a more reliable J-leg design that has been used successfully in the field and igniter joint. They are also planning to incorporate the NASA Glenn braided carbon fiber thermal barrier into the joint. The thermal barrier would act as an additional level of protection for the O-rings and allow the elimination of the joint-fill compound from the joint.

Steinetz, Bruce M.↗

NASA NTRS2000

Rudder/Fin Seal Investigations for the X-38 Re-Entry Vehicle

NASA is currently developing the X-38 vehicle that will be used to demonstrate the technologies required for a crew return vehicle (CRV) for the International Space Station. The X-38 control surfaces require high temperature seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent over-temperature of these structures and possible loss of the vehicle. This paper presents results for thermal analyses and flow and compression tests conducted on as-received and thermally exposed seals for the rudder/fin location of the X-38. A thermal analysis of the rudder/fin dual seal assembly based on representative heating rates on the windward surface of the rudder/fin area predicted a peak seal temperature of 1900 F. The temperature-exposed seals were heated in a compressed state at 1900 F corresponding to the predicted peak temperature. Room temperature compression tests were performed to determine load versus linear compression, preload, contact area, stiffness, and resiliency characteristics for the as-received and temperature-exposed seals. Temperature exposure resulted in permanent set and loss of resiliency in these seals. Unit loads and contact pressures for the seals were below the 5 lb/in. and 10 psi limits set to limit the loads on the Shuttle thermal tiles that the seals seal against in the rudder/fin location. Measured seal flow rates for a double seal were about 4.5 times higher than the preliminary seal flow goal. The seal designs examined in this study are expected to be able to endure the high temperatures that they will be exposed to for a single-use life. Tests performed herein combined with future analyses, arc jet tests, and scrubbing tests will be used to select the final seal design for this application.

Dunlap, Patrick H., Jr.↗

NASA NTRS2000

Thermal Barriers Developed for Solid Rocket Motor Nozzle Joints

Space shuttle solid rocket motor case assembly joints are sealed with conventional O-ring seals that are shielded from 5500 F combustion gases by thick layers of insulation and by special joint-fill compounds that fill assembly splitlines in the insulation. On a number of occasions, NASA has observed hot gas penetration through defects in the joint-fill compound of several of the rocket nozzle assembly joints. In the current nozzle-to-case joint, NASA has observed penetration of hot combustion gases through the joint-fill compound to the inboard wiper O-ring in one out of seven motors. Although this condition does not threaten motor safety, evidence of hot gas penetration to the wiper O-ring results in extensive reviews before resuming flight. The solid rocket motor manufacturer (Thiokol) approached the NASA Glenn Research Center at Lewis Field about the possibility of applying Glenn's braided fiber preform seal as a thermal barrier to protect the O-ring seals. Glenn and Thiokol are working to improve the nozzle-to-case joint design by implementing a more reliable J-leg design and by using a braided carbon fiber thermal barrier that would resist any hot gases that the J-leg does not block.

Steinetz, Bruce M.↗

NASA NTRS1999

Feasibility Assessment of Thermal Barriers for RSRM Nozzle Joint Locations

Solid rockets, including the Space Shuttle solid rocket motor, are generally manufactured in large segments which are then shipped to their final destination where they are assembled. These large segments are sealed with a system of primary and secondary 0-rings to contain combustion gases inside the rocket which are at pressures of up to 900 psi and temperatures of up to 5500 F. The seals are protected from hot combustion gases by thick layers of phenolic insulation and by joint-filling compounds between these layers. Recently, though, routine inspections of nozzle-to-case joints in the Shuttle solid rocket motors during disassembly revealed erosion of the primary O-rings. Jets of hot gas leaked through gaps in the joint-filling compound between the layers of insulation and impinged on the O-rings. This is not supposed to take place, so NASA and Thiokol, the manufacturer of the rockets, initiated an investigation and found that design improvements could be made in this joint. One such improvement would involve using NASA Lewis braided thermal barriers as another level of protection for the O-ring seals against the hot combustion gases.

Steinetz, Bruce M.↗

NASA NTRS1999

Development of Thermal Barriers for Solid Rocket Motor Nozzle Joints

The Space Shuttle solid rocket motor case assembly joints are sealed using conventional 0-ring seals. The 5500+F combustion gases are kept a safe distance away from the seals by thick layers of insulation. Special joint-fill compounds are used to fill the joints in the insulation to prevent a direct flowpath to the seals. On a number of occasions. NASA has observed in several of the rocket nozzle assembly joints hot gas penetration through defects in the joint- fill compound. The current nozzle-to-case joint design incorporates primary, secondary and wiper (inner-most) 0-rings and polysulfide joint-fill compound. In the current design, 1 out of 7 motors experience hot gas to the wiper 0-ring. Though the condition does not threaten motor safety, evidence of hot gas to the wiper 0-ring results in extensive reviews before resuming flight. NASA and solid rocket motor manufacturer Thiokol are working to improve the nozzle-to-case joint design by implementing a more reliable J-leg design and a thermal barrier, This paper presents burn-resistance, temperature drop, flow and resiliency test results for several types of NASA braided carbon-fiber thermal barriers. Burn tests were performed to determine the time to burn through each of the thermal barriers when exposed to the flame of an oxy-acetylene torch (5500 F), representative of the 5500 F solid rocket motor combustion temperatures. Thermal barriers braided out of carbon fibers endured the flame for over 6 minutes, three times longer than solid rocket motor burn time. Tests were performed on two thermal barrier braid architectures, denoted Carbon-3 and Carbon-6, to measure the temperature drop across and along the barrier in a compressed state when subjected to the flame of an oxyacetylene torch. Carbon-3 and Carbon-6 thermal barriers were excellent insulators causing temperature drops through their diameter of up to a 2800 and 2560 F. respectively. Gas temperature 1/4" downstream of the thermal barrier were within the downstream Viton 0-ring temperature limit of 600 F. Carbon-6 performed extremely well in subscale rocket "char" motor tests when subjected to hot gas at 3200 F for an 11 second rocket firing, simulating the maximum downstream joint cavity fill time. The thermal barrier reduced the incoming hot gas temperature by 2200 F in an intentionally oversized gap defect, spread the incoming jet flow, and blocked hot slag, thereby offering protection to the downstream 0-rings.

Steinetz, Bruce M.↗