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Research and development of fiber glass filament wound engine case design for 260 inch diameter class solid propellant rocket engines
A simple analysis of igniter design is described which is sufficiently general to be applicable to any 'basket'-type housing containing one or more charges. The gas equation of state is used in conjunction with the experimentally determined propellant burning-rate law to predict the pressure-time histories in the igniter housing and the rocket motor. Typical numerical results are presented for three cases which represent three experimental conditions tested in a project on low-smoke motors where the requirements on the exhaust were sufficiently stringent to preclude condensible matter from the igniter. Pressure was measured continuously in time at two locations in the igniter housing and at the head end of the motor case. The agreement between theoretical and experimental results is felt to be encouraging considering the complexity of the problem and the many simplifications in the analysis.
This report documents the completion of the Revolutionary Vertical Lift Technology Project Annual Performance Indicator 24-3.2.4.1: “Apply and document reliability prediction for high reliability motor concept.” Two modeling tools were completed for calculation of reliability of fault-tolerant (FT) motors, and key FT operations of a modular FT motor were demonstrated experimentally. The two models are complementary tools for the stakeholder and user community. Both models employ Markov chain theory. The first model is a time-homogeneous Markov chain model, and the second is a time-inhomogeneous Markov-Weibull model. This report’s main sections are as follows: 1.0 Introduction, 2.0 Theory, 3.0 Motor Reliability Models, 4.0 Validation of FT Operation by Hardware Demonstration, and 5.0 Concluding Remarks. Novel contributions to the field include development of a modular FT motor concept for electrified vertical takeoff and landing (eVTOL) application, solution methods to solve the reliability calculations, development of figures of merit, and the introduction of “linked chains” to formulate a building-block approach for time-inhomogeneous Markov-Weibull modeling of motor reliability. Example case studies have been completed, and results are provided and discussed herein. A four-module FT motor concept was developed to a preliminary-design level of detail. This eVTOL FT motor concept was designed for galvanic, magnetic, and thermal isolation of stator winding faults. The reliability of the concept motor was calculated using a time-inhomogeneous Markov chain model. Employing average failure rate as a metric, 570 times greater reliability was achieved as compared to a baseline motor without fault tolerance. A demonstrator motor was built and tested. The testing demonstrated the key features of FT operation and validated the essential premises of the FT motor concepts presented herein. The experiments included successful demonstration of the feasibility of the following four key FT features: (1) terminal open-circuit operation, (2) thermal isolation after fault, (3) terminal short-circuit operation, and (4) internal short-circuit operation. These works indicate that FT modular motor drives offer promise for addressing the daunting reliability gap that electric aircraft propulsor drives are facing relative to the best conventional motor drive technology that is available today.
Thrust-terminating system conceived to reduce thrust of solid-propellant rocket motor in controlled manner such that thrust loads not increased or decreased beyond predictable levels. Concept involves explosively cutting opposing venting pairs in case of rocket motor above nozzles to initiate venting of chamber and reduction of thrust. Vents sized and numbered to control amount and rate of reduction in thrust.
Stiffness version of finite element method used for numerical analysis of small elementary regions of solid propellant grains
The complex space shuttle design was comprised of four components: the external tank, two solid rocket boosters (SRB), and the orbiter vehicle. Six orbiters were used during the life of the program. In order of introduction into the fleet, they were: Enterprise (a test vehicle), Columbia, Challenger, Discovery, Atlantis and Endeavour. The space shuttle had the unique ability to launch into orbit, perform on-orbit tasks, return to earth and land on a runway. It was an orbiting laboratory, International Space Station crew delivery and supply replenisher, satellite launcher and payload delivery vehicle, all in one. Except for the external tank, all components of the space shuttle were designed to be reusable for many flights. ATK s reusable solid rocket motors (RSRM) were designed to be flown, recovered, and the metal components reused 20 times. Following each space shuttle launch, the SRBs would parachute into the ocean and be recovered by the Liberty Star and Freedom Star recovery ships. The recovered boosters would then be received at the Cape Canaveral Air Force Station Hangar AF facility for disassembly and engineering post-flight evaluation. At Hangar AF, the RSRM field joints were demated and the segments prepared to be returned to Utah by railcar. The segments were then shipped to ATK s facilities in Clearfield for additional evaluation prior to washout, disassembly and refurbishment. Later the refurbished metal components would be transported to ATK s Promontory facilities to begin a new cycle. ATK s RSRMs were manufactured in Promontory, Utah. During the Space Shuttle Program, ATK supported NASA s Marshall Space Flight Center whose responsibility was for all propulsion elements on the program, including the main engines and solid rocket motors. On launch day for the space shuttle, ATK s Launch Site Operations employees at Kennedy Space Center (KSC) provided lead engineering support for ground operations and NASA s chief engineer. It was ATK s responsibility to have a representative in Firing Room 2 at KSC in case of potential motor problems. However, the last time ATK was responsible for a space shuttle launch slip was 1989. During launch, engineers were also stationed in Promontory on teleconference with counterparts at KSC in the event their support was required.
A numerical study has been made of the low density plume flow from a small thruster motor. For the case studied, the addition of a thin plume shield with a diameter 1.67 times the nozzle exit diameter was found to lead to a reduction in the backflow by several orders of magnitude. Calculations were also made for the three-dimensional flow produced by a pair of motors, in order to determine the increase in the backflow due to the interaction of the plumes. The calculations were made with the direct simulation Monte Carlo (DSMC) method, and one of the purposes of the work was to test a new and faster set of algorithms for this method.
The performance of the 360L007, Seventh Flight, redesigned Solid Rocket Motors (RSRM) is assessed with respect to case hardware and joint sealing issues as seen from post-flight assessment of the case and seals. Potential anomalies are classified and summarized. The post-flight assessment of both motors showed the case segments to be in good condition. Field joint fretting indications on this flight set ranged from none on one joint through light (less than 0.003 inch deep) on most of the joints to locally medium (greater than 0.003, less than 0.005 inch deep) on two joints. No new fretting was found in old fretting locations. All fretting was mapped from the inner clevis leg. The capture feature fretting was not mapped due to the difficulty of measuring the fretting in the capture feature region, but it is assumed that the capture feature had similar damage as the inner clevis leg. Post-flight assessment of both motors showed the seal components to be in good condition.
Various types of twin strap-on boosters were evaluated by applying them to a core vehicle. The core vehicle has a clipped delta wing and a simple circular body, and is equipped with five Space Shuttle main engines. The only propellants in the core vehicle are liquid oxygen and liquid hydrogen. The strap-on boosters investigated include the current Shuttle solid rocket motors with steel cases and advanced solids with graphite composite filament-wound cases. Also, two types of liquid-oxygen/hydrocarbon boosters were investigated - one pair without crossfeed to the core vehicle and one with. The payloads obtained were tabulated for various assumptions, such as power levels on the core vehicle engines, number of engines, and maximum allowable flight dynamic pressures. The payload for the core vehicle with two filament-wound Shuttle solid rocket strap-on boosters was 83,000 lb and the payload for two liquid strap-ons with crossfeed was 84,000 lb. The core vehicle with Shuttle solid rocket strap-on boosters is regarded as a near term technology system.
Dynamic, flexible ceramic seals developed for use at high temperatures in high-performance, variable-geometry, hypersonic airplane engines. Stacked ceramic wafers pressed against stationary sidewall by pressure in one or more metal bellows. Seals also used in hypersonic engines, two-dimensional convergent/divergent and vectored-thrust exhaust nozzles, airframes of reentry vehicles, casings of rocket motors furnaces, and other applications.
This paper describes the power and command system architecture of the X-57 Maxwell flight demonstrator aircraft. The X-57 is an experimental aircraft designed to demonstrate radically improved aircraft efficiency with a 3.5 times aero-propulsive efficiency gain at a "high-speed cruise" flight condition for comparable general aviation aircraft. These gains are enabled by integrating the design of a new, optimized wing and a new electric propulsion system. As a result, the X-57 vehicle takes advantage of the new capabilities afforded by electric motors as primary propulsors. Integrating new technologies into critical systems in experimental aircraft poses unique challenges that require careful design considerations across the entire vehicle system, such as qualification of new propulsors (motors, in the case of the X-57 aircraft), compatibility of existing systems with a new electric power distribution bus, and instrumentation and monitoring of newly qualified propulsion system devices.
The performance of the 360L009, Ninth Flight, Redesigned Solid Rocket Motors (RSRM) is assessed in respect to case hardware and joint sealing issues as seen from post-fire assessment of the case and seals. In addition, all of the potential anomalies have been classified and summarized. The post-fire assessment of both motors showed the case segments to be in good condition. Field joint fretting of this flight set ranged from light on most of the joints to locally heavy on three of the joints. The LH aft field joint is the most heavily fretted joint to date; this joint had previously fretted areas from STS-27. No new fretting was found in old fretting locations. However, new frets were found at the edges of repaired areas on both the LH center and aft field joints. All fretting was mapped from the inner clevis leg. The capture feature fretting was not mapped due to the difficulty of measuring the fretting in the capture feature region. It is assumed that the capture feature had damage similar to that on the inner clevis leg.
Efforts to achieve a 100 mile urban range, to reduce petroleum usage 40% to 70%, and to commercialize battery technology are discussed with emphasis on an all plastic body, four passenger car that is flywheel assisted and battery powered, and on an all metal body, four passenger car with front wheel drive and front motor. For the near term case, a parallel hybrid in which the electric motor and the internal combustion engine may directly power the drive wheels, is preferred to a series design. A five passenger car in which the electric motor and the gasoline engine both feed into the same transmission is discussed. Upgraded demonstration vehicles were tested using advanced lead acid, nickel zinc, nickel iron, and zinc chloride batteries to determine maximum acceleration, constant speed, and battery behavior. The near term batteries demonstrated significant improvement relative to current lead acid batteries. The increase in range was due to improved energy density, and ampere hour capacity, with relatively 1 small weight and volume differences.
NASA's all-electric X-57 airplane will utilize 14 electric motors, of which 12 are exclusively for lift augmentation during takeoff and landing. This report covers the design and development process taken to create an open reference model representative of the 12 lift augmenting motors. A combined worst case scenario was used as the design point, which represents the simultaneously occurring worst case aspects of thermal, static stress, electromagnetic, and rotor dynamic conditions. This work also highlights the tightly coupled nature of aerospace electric motor design, requiring constant iteration between all disciplines involved. Further adding to the uniqueness is the cooling method, which is limited to nacelle skin forced convection cooling only, no internal air flow is permitted. The stator outer diameter limit of 156.45 mm greatly impacts the degree of coupling between the electromagnetic design with the thermal analysis. The permanent magnet synchronous motor developed here operates between 385 V and 538 V, at a peak current of 50 A. Detailed electromagnetic, thermal, static load, and rotordynamic analysis was completed for this electric motor; all of which are required for a full design. The rotordynamic analysis took into consideration the motor housing which is designed specifically for this motor. The final electric motor has a mass of 2.34 kg, produces 24.1 Nm of torque with a specific power of 5.56 kW/kg, and has an efficiency of 96.61% at the combined worst case design point.
This paper makes no attempt to comprehensively review erosive burning models or the data collected in pursuit of them; the interested reader could begin with Landsbaum for a historical summary. However, a discussion and comparison to recent work by McDonald and Rettenmaier and Heister will be included, along with data generated by Strand, et. al. Suffice it to say that the search for a way to predict erosive burning in any size motor with formulas cleanly applicable to a typical 1D ballistics analysis has been long thwarted. Some models were based on testing that failed to adequately simulate the solid rocket motor environment. In most cases, no real‐time burn rate measurement was available. Two popular models, even when calibrated to recent motor‐like real‐time burn rate data obtained by Furfaro, were shown by McMillin to be inadequate at modeling erosive burning in the Space Shuttle Reusable Solid Rocket Motor (RSRM), the Space Launch Systems' Five‐Segment RSRM (RSRMV), and the five‐segment Engineering Test Motor (ETM)‐3. Subsequently to the data cited from Strand and Furfaro, additional motors of the same kind as Furfaro's were tested with RSRMV propellant, utilizing 7 segments per motor and 3 throat sizes. By measuring propellant web thickness with ultrasonic gages, the burn rate was determined at cross‐flow Mach numbers up to Mach 0.8. Furthermore, because of the different throat sizes in otherwise identical motors, this provides a unique look at the effect of pressure and base burn rate on the erosive response. Figure 1 shows example of the data pertaining to the high Mach motor, where the port area is initially less than the throat area. The burn rate data was processed using a smoothing method developed to reduce the noise without too severely introducing end effects that limit the range of useful data. Then, an empirical ballistics scheme was used to estimate the flow condition based on the burn rate measurements and pressure measured between each segment.
A review of low cost large solid rocket motors developed at the Lewis Research Center is given. An estimate is made of the total cost reduction obtainable by incorporating this new technology package into the rocket motor design. The propellant, case material, insulation, nozzle ablatives, and thrust vector control are discussed. The effect of the new technology on motor cost is calculated for a typical expandable 260-in. booster application. Included in the cost analysis is the influence of motor performance variations due to specific impulse and weight changes. It is found for this application that motor costs may be reduced by up to 30% and that the economic attractiveness of future large solid rocket motors will be improved when the new technology is implemented.
Four booster separation motors (BSM) located at each end of every solid rocket booster (SRB) provide the needed side force to separate the boosters from the external tank at booster burnout. Four BSMs at the top of the SRB are located in a box pattern in the nose cone frustum. The four BSMs at the aft end of the SRB are arranged side-by-side on the SRB aft skirt. Aspects of BSM design and performance are considered, taking into account a motor design/performance summary, the case design, the insulation, the grain design, the nozzle/aft closure design, the ignition system, the propellant, and the motor assembly. Details of motor testing are also discussed, giving attention to development testing, qualification testing, and flight testing.
Since the beginning of the Space Shuttle Reusable Solid Rocket Motor (RSRM) program, nozzle-to-case joint polysulfide adhesive gas paths have occurred on several flight motors. These gas paths have allowed hot motor gases to reach the wiper O-ring. Even though these motors continue to fly safely with this condition, a desire was to reduce such occurrences. The RSRM currently uses a J-leg joint configuration on case field joints and igniter inner and outer joints. The J-leg joint configuration has been successfully demonstrated on numerous RSRM flight and static test motors, eliminating hot gas intrusion to the critical O-ring seals on these joints. Using the proven technology demonstrated on the case field joints and igniter joints, a nozzle-to-case joint J-leg design was developed for implementation on RSRM flight motors. This configuration provides an interference fit with nozzle fixed housing phenolics at assembly, with a series of pressurization gaps incorporated outboard of the joint mating surface to aid in joint pressurization and to eliminate any circumferential flow in this region. The joint insulation is bonded to the nozzle phenolics using the same pressure sensitive adhesive used in the case field joints and igniter joints. An enhancement to the nozzle-to-case joint J-leg configuration is the implementation of a carbon rope thermal barrier. The thermal barrier is located downstream of the joint bondline and is positioned within the joint in a manner where any hot gas intrusion into the joint passes through the thermal barrier, reducing gas temperatures to a level that would not affect O-rings downstream of the thermal barrier. This paper discusses the processes used in reaching a final nozzle-to-case joint J-leg design, provides structural and thermal results in support of the design, and identifies fabrication techniques and demonstrations used in arriving at the final configuration.