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NASA NTRS1985

Design and Fabrication of the NASA Decoupler Pylon for the F-16 Aircraft, Addendum 2

The decoupler pylons which were originally designed and assembled with bushings in the pivot joints were retrofitted with roller bearings. This retrofit, the supporting analyses and the fixture tests of the modified pylons are reported in this document. The loads and stress analysis was directed toward the redesigned parts which were the pylon links and pins. The loads and stress analysis indicates that the pylons with the bearing installation have reduced capacity with respect to the bushing design. Fixture tests of the redesigned pylons were conducted in the GD/FW facility. Breakout friction tests and vibration tests were conducted. The tests show that the joint friction is approximately one-half the level with bearings as compared with the bushing installation. The vibration test data was used to tune the pylon mathematical simulation and this revised pylon simulation was used to recompute airplane modes of vibration. These computed modes of vibration were used in complete airplane symmetric and antisymmetric flutter and aeroservoelastic analyses.

Clayton, J. D.↗

NASA NTRS1987

Designing transonic wind-tunnel test sections for flow diagnostics and laser velocimeter applications

The design, fabrication, and validation of the Basic Aerodynamic Facility (BARF), developed for the direct comparison of three-dimensional laser velocimetry (LV) and hot-wire techniques at transonic speeds, are discussed. To accommodate the installation of the three-dimensional orthogonal LV system in the BARF, the transonic slots were redesigned to house windows, and the test section mounting was redesigned to facilitate LV transversing. Two-dimensional and three-dimensional code validation tests of the LV test section showed uniform mean flow through the test section to sonic speeds, and fluctuating pressure measurements at subsonic speeds which are consistent with facilities with good flow quality.

Jones, G. S.↗

NASA NTRS1988

Circumferential flow analysis at the aft field joint of the Space Shuttle solid rocket motor

Flow analyses have been performed to determine the nature of the three-dimensional flow field in the vicinity of the aft-most field joint of the Space Shuttle Redesigned Solid Rocket Motor (RSRM). Specific objectives included the quantification of the circumferential pressure and velocity gradients at the joint location which might be caused by the non-uniform erosion of the rubber inhibitor which protrudes from the wall into the flow field. Three-dimensional Navier-Stokes equations have been solved in conjunction with the conservation equation for the turbulence energy and the dissipation rate. The numerical predictions have been compared with the measurements from a 7.5 percent scale cold flow model of the redesigned solid rocket motor.

Majumdar, Alok K.↗

NASA NTRS1989

Field joint environmental protection system vibration/pressurization qualification

The procedures used and results obtained from vibration testing the redesigned solid rocket motor (RSRM) field joint environmental protection system (FJEPS), hereafter referred to as the joint protection system (JPS) are documented. The major purposes were to certify that the flight-designed JPS will withstand the dynamic environmental conditions of the redesigned solid rocket booster, and to certify that the cartridge check valve (vent valve) will relieve pressure build-up under the JPS during the initial 120 sec of flight. Also, an evaluation of the extruded cork insulation bonding was performed after the vibration testing.

Cook, M.↗

NASA NTRS1989

Thermal re-design of the Galileo spacecraft for a Venus-earth-earth-gravity assist (VEEGA) trajectory

The cancellation of the Centaur upper stage program in the aftermath of the Challenger tragedy forced a redesign of the flight trajectory of the Galileo spacecraft to Jupiter, i.e., from a direct trajectory to the Venus-earth-earth-gravity-assist (VEEGA) trajectory on the lower energy two-stage inertial upper stage (IUS), with the result that the spacecraft would be exposed to more than twofold increase in peak solar irradiance. This paper describes the general system-level thermal redesign effort for the Galileo spacecraft, from the start of feasibility studies to its final implementation. Results indicate that the addition of sunshades and the generous utilization of second-surface aluminized Kapton surface material for reflecting high percentages of incident solar irradiation would 'harden' the spacecraft's existing thermal protection system adequately, provided that sun-pointing at the relatively higher solar irradiance levels could be maintained. The final miximum flight temperature predictions for the spacecraft's subsystem thermal designs are given.

Reeve, R.↗

NASA NTRS1989

Thermal design of the Galileo bus and Retro Propulsion Module

The Galileo spacecraft (S/C) consists of an Orbiter and Probe which have instruments to investigate the chemical composition and physical state of Jupiter's atmosphere, the Jovian satellites and the structure and physical dynamics of the Jovian magnetosphere. Galileo was at the Kennedy Space Center (KSC) preparing for a May 1986 launch at the time of the Challenger accident. The delay and an incraease in mission time has decreased the Radioisotope Thermoelectric Generator power output significantly. A change to the Inertial Upper Stage from the more powerful Centaur G-Prime has resulted in a trajectory that requires gravity assists once by Venus and twice by earth. The resulting peak solar intensity of this roundabout trajectory is more than twice the previous design value for the direct trajectory. Galileo was returned to the Jet Propulsion Laboratory (JPL) from KSC in February 1987 to begin the rework of the S/C thermal design. Verification of the thermal redesign was completed in the JPL 25' space simulator in August and November of 1988. This paper summarizes the thermal design and redesign of the Bus and Retro Propulsion Model.

Avila, A.↗

NASA NTRS1988

Transient Pressure Test Article test program

The Transient Pressure Test Article test program being conducted at NASA-Marshall is described. The main goal of the TPTA test program is to provide data to verify the sealing capability of the redesigned SRM field joints, the nozzle-to-case joint, and the igniter joint. The TPTA test program can be used to demonstrate the assembly/disassembly and reusability of the redesigned joints along with the adequacy of assembly/disassembly tooling, procedures, and inspections.

Vibbart, Charles M.↗

NASA NTRS1989

Flight motor set 360L001 (STS-26R). Volume 5: Nozzle component

A review of the performance and post-flight condition of the STS-26 Redesigned Solid Rocket Motor (RSRM) nozzles is presented. The nozzle assemblies, flown on the Space Shuttle Discovery on 29 September 1988, were tested to demonstrate flex bearing system reusability. The evaluation indicated no condition that would adversely affect the reusability of the flex bearing system. Inspection showed that the flex bearings did not leak, were not damaged by water impact, had the expected erosion profiles, and that the remaining ablative liner thicknesses met the performance margin of safety. Applicable Discrepancy Reports and Process Departures, the Nozzle Component Program Team performance evaluation, and the Redesign Program Review Board assessment are included.

George, Russell J.↗

NASA NTRS1989

Transient Pressure Test Article Test Program

The Transient Pressure Test Article (TPTA) test program is being conducted at a new test facility located in the East Test Area at the National Aeronautics and Space Administration's (NASA's) Marshall Space Flight Center (MSFC) in Huntsville, Alabama. This facility, along with the special test equipment (STE) required for facility support, was constructed specifically to test and verify the sealing capability of the Redesigned Solid Rocket Motor (RSRM) field, igniter, and nozzle joints. The test article consists of full scale RSRM hardware loaded with inert propellant and assembled in a short stack configuration. The TPTA is pressurized by igniting a propellant cartridge capable of inducing a pressure rise rate which stimulates the ignition transient that occurs during launch. Dynamic loads are applied during the pressure cycle to simulate external tank attach (ETA) strut loads present on the ETA ring. Sealing ability of the redesigned joints is evaluated under joint movement conditions produced by these combined loads since joint sealing ability depends on seal resilience velocity being greater than gap opening velocity. Also, maximum flight dynamic loads are applied to the test article which is either pressurized to 600 psia using gaseous nitrogen (GN2) or applied to the test article as the pressure decays inside the test article on the down cycle after the ignition transient cycle. This new test facility is examined with respect to its capabilities. In addition, both the topic of test effectiveness versus space vehicle flight performance and new aerospace test techniques, as well as a comparison between the old SRM design and the RSRM are presented.

Vibbart, Charles M.↗

NASA NTRS1990

Technical Evaluation Motor no. 5 (TEM-5)

Technical Evaluation Motor No. 5 (TEM-5) was static test fired at the Thiokol Corporation Static Test Bay T-97. TEM-5 was a full scale, full duration static test fire of a high performance motor (HPM) configuration solid rocket motor (SRM). The primary purpose of TEM static tests is to recover SRM case and nozzle hardware for use in the redesigned solid rocket motor (RSRM) flight program. Inspection and instrumentation data indicate that the TEM-5 static test firing was successful. The ambient temperature during the test was 41 F and the propellant mean bulk temperature (PMBT) was 72 F. Ballistics performance values were within the specified requirements. The overall performance of the TEM-5 components and test equipment was nominal. Dissembly inspection revealed that joint putty was in contact with the inner groove of the inner primary seal of the ignitor adapter-to-forward dome (inner) joint gasket; this condition had not occurred on any previous static test motor or flight RSRM. While no qualification issues were addressed on TEM-5, two significant component changes were evaluated. Those changes were a new vented assembly process for the case-to-nozzle joint and the installation of two redesigned field joint protection systems. Performance of the vented case-to-nozzle joint assembly was successful, and the assembly/performance differences between the two field joint protection system (FJPS) configurations were compared.

Cook, M.↗

NASA NTRS1990

Qualification of the RSRM case membrane case-to-insulation bondline inspection using the Thiokol Corporation ultrasonic RSRM bondline inspection system

Qualification testing of Combustion Engineering's AMDATA Intraspect/98 Data Acquisition and Imaging System that applies to the redesigned solid rocket motor (RSRM) case membrane case-to-insulation bondline inspection was performed. Testing was performed at M-67, the Thiokol Corp. RSRM Assembly Facility. The purpose of the inspection was to verify the integrity of the case membrane case-to-insulation bondline. The case membrane scanner was calibrated on the redesigned solid rocket motor case segment calibration standard, which had an intentional 1.0 by 1.0 in. case-to-insulation unbond. The case membrane scanner was then used to scan a 20 by 20 in. membrane area of the case segment. Calibration of the scanner was then rechecked on the calibration standard to ensure that the calibration settings did not change during the case membrane scan. This procedure was successfully performed five times to qualify the unbond detection capability of the case membrane scanner.

Cook, M.↗

NASA NTRS1989

QM-8 final performance evaluation report: SEALS, volume 4

The Space Shuttle Redesigned Solid Rocket Motor (RSRM) static test of Qualification Motor-8 (QM-8) was conducted. The QM-8 test article was the fifth full-scale, full-duration test, and the third qualification motor to incorporate the redesigned case field joint and nozzle-to-case joint. This was the second static test conducted in the T-97 test facility, which is equipped with actuators for inducing external side loads to a 360 degree external tank (ET) attach ring during test motor operation, and permits heating/cooling of an entire motor. The QM-8 motor was cooled to a temperature which ensured that the maximum propellant mean bulk temperature (PMBT) of 40 F was achieved at firing. All test results are not included, but rather, the performance of the metal case, field joints, and nozzle-to-case joint is addressed. The involvement is studied of the Structural Applications and Structural Design Groups with the QM-8 test which includes: assembly procedures of the field and nozzle-to-case joints, joint leak check results, structural test results, and post-test inspection evaluations.

Nelsen, L. V.↗

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.↗

NASA NTRS1990

Long-term compression effects on elastomeric O-ring behavior

This paper discusses the results of testing performed on elastomeric seal materials that had been under compression for extended periods of time. Elastomeric seals used in the Space Shuttle redesigned solid rocket motors can experience compression times of up to six months. These seals must be capable of sealing internal motor pressure upon ignition. The tests described herein were performed in order to verify that the seals, which had experienced long-term compression could seal throughout motor operation. Testing was divided into two phases: (1) dynamic high pressure testing, and (2) resiliency testing. Dynamic testing was performed using specialized test fixtures that allowed simulation of the field joint movements during initial motor operation along with high pressure gas. Resiliency testing was performed using specialized test fixtures that also simulated field joint movements and also had the ability to measure the sealing force of the O-ring. Results from all testing indicated that the current elastomeric seals used in the redesigned solid rocket motors will seal during motor operations in the currently defined launch environments.

Clinton, R. G.↗

NASA NTRS1990

Assured Shuttle Availability Project

This paper discusses the development of the Assured Shuttle Availability Project (ASA). The ASA project has been created to provide a structure by which the Space Shuttle Program (SSP) may allocate resources to hardware redesign efforts required to extend effective Space Shuttle operational life through the year 2020. Specific ASA Project goals and evaluation criteria have been set, and redesign efforts have been evaluated using systems engineering methods.

Scott, John H.↗

NASA NTRS1991

Distributed-Computer System Optimizes SRB Joints

Initial calculations of redesign of joint on solid rocket booster (SRB) that failed during Space Shuttle tragedy showed redesign increased weight. Optimization techniques applied to determine whether weight could be reduced while keeping joint closed and limiting stresses. Analysis system developed by use of existing software coupling structural analysis with optimization computations. Software designed executable on network of computer workstations. Took advantage of parallelism offered by finite-difference technique of computing gradients to enable several workstations to contribute simultaneously to solution of problem. Key features, effective use of redundancies in hardware and flexible software, enabling optimization to proceed with minimal delay and decreased overall time to completion.

Rogers, James L., Jr.↗

NASA NTRS1990

Space shuttle development Motor No. 9 (DM-9), volume 1

The results obtained during the December 23, 1987 static firing of the DM-9 test article are presented. The DM-9 full-scale static test article employed redesigned solid rocket motor (RSRM) field joint capture feature hardware with J-seal insulation configuration, and nozzle-to-case joint radial bolt design with bonded insulation configuration. The nozzle incorporated RSRM components, including a thicker cowl with involuted outer boot ring. The nozzle employed redundant and verifiable seals in all five joints, and room temperature vulcanization backfill in three joints. With very few exceptions, the DM-9 test article was flight configuration. The test was conducted under extreme weather conditions: temperature of 25 F and wind at 15 to 20 mph. Ballistics performance values were within specification requirements. The RSRM field joint (J-seal) insulation configuration functioned as predicted with no indication of hot gases reaching the capture feature O-rings. There was a blowhole in the polysulfide adhesive in the nozzle-to-case joint, but no evidence of hot gases past the wiper O-ring. Nozzle design changes appeared to perform nominally, with the exception of the outer boot ring, which suffered partial structural breakup late in the test. Field joint heaters maintained the controlling resistance temperature device temperature within the specified requirements during heater operation. The thrust vector control system operated properly. The redesigned water deluge system, temperature conditioning equipment, and other test support equipment performed as planned.

Garecht, Diane M.↗

NASA NTRS1990

Potential reduction of en route noise from an advanced turboprop aircraft

When the en route noise of a representative aircraft powered by an eight-blade SR-7 propeller was previously calculated, the noise level was cited as a possible concern associated with the acceptance of advanced turboprop aircraft. Some potential methods for reducing the en route noise were then investigated and are reported. Source noise reductions from increasing the blade number and from operating at higher rotative speed to reach a local minimum noise point were investigated. Greater atmospheric attenuations for higher blade passing frequencies were also indicated. Potential en route noise reductions from these methods were calculated as 9.5 dB (6.5 dB(A)) for a 10-blade redesigned propeller and 15.5 dB (11 dB(A)) for a 12-blade redesigned propeller.

Dittmar, James H.↗