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Material was specifically developed for manufacture of insulating tiles, but it can be molded into other shapes as required. Basic raw materials are high-purity silica fiber, fumed-silica powder, and reagent-grade starch. Only purest materials are used, and care must be taken to avoid contamination during processing.
The experimental determination of purge bag materials properties, development of purge bag manufacturing techniques, experimental evaluation of a subscale purge bag under simulated operating conditions and the experimental evaluation of the purge pin concept for MLI purging are discussed. The basic purge bag material, epoxy fiberglass bounded by skins of FEP Teflon, showed no significant permeability to helium flow under normal operating conditions. Purge bag small scale manufacturing tests were conducted to develop tooling and fabrication techniques for use in full scale bag manufacture. A purge bag material layup technique was developed whereby the two plys of epoxy fiberglass enclosed between skins of FEP Teflon are vacuum bag cured in an oven in a single operation. The material is cured on a tool with the shape of a purge bag half. Plastic tooling was selected for use in bag fabrication. A model purge bag 0.6 m in diameter was fabricated and subjected to a series of structural and environmental tests simulating various flight type environments. Pressure cycling tests at high (450 K) and low (200 K) temperature as well as acoustic loading tests were performed. The purge bag concept proved to be structurally sound and was used for the full scale bag detailed design model.
A data dump is presented containing space shuttle orbiter maneuvering engine performance, weight, envelope, and interface pressure requirements for candidate propellant combinations (NTO/MMH, NTO50-50, LOX/MMH, LOX/50-50, LOX/N2H4, LOX/C3H8, and LOX/RP-1) and cooling concepts (regenerative and dump/film). These data are presented parametrically for the thrust, chamber pressure, nozzle expansion ratio, and engine mixture ratio ranges of interest. Also included is information describing sensitivity to system changes; reliability, maintainability and safety; development programs and associated critical technology areas; engine cost comparisons during development and operation; and ecological effects.
PPO form was tested for mechanical strength, for the effects of 100 thermal cycles from 450 K (359 F) to 21 K (-423 F) and for gas flow resistance characteristics. PPO foam panels were investigated for density variations, methods for joining panels were studied and panel joint thermal test specimens were fabricated. The range of foam panel thickness under investigation was extended to include 7 mm (0.3 in) and 70 mm (2.8 in) panels which also were tested for thermal performance.
A systems analysis of the expendable second stage/reusable booster system is presented. The subjects discussed are: (1) mission/system requirements, (2) spacecraft performance, (3) trajectories, (4) aerodynamics, (5) stability and control, (6) loads, (7) heating, and (8) acoustic environment.
The results of a conceptual study of the resource requirements for a single-stage earth-orbital vehicle are presented. All aspects of program costs for the design, manufacture, test, transportation, launch, and facility modifications were considered. The following program costs are discussed: configuration definition, cost groundrules and assumptions, program requirements, work breakdown structure, cost estimation methods, and cost analysis. High cost areas are identified.
During radiant testing of mullite panels, temperatures in the insulation and support structure exceeded those predicted on the basis of guarded hot plate thermal conductivity tests. Similar results were obtained during arc tunnel tests of mullite specimens. The differences between effective conductivity and guarded hot plate values suggested that radiant transfer through the mullite was occurring. To study the radiant transport, measurements were made of the infrared transmission through various insulating materials and fibers of interest to the shuttle program, using black body sources over the range of 780 to 2000 K. Experimental data were analyzed and scattering coefficients were derived for a variety of materials, fiber diameters, and source temperature.
Arc tunnel tests on convective heating in surface insulation plate joints and gaps show that excessively wide gaps experience significant convective heating and may result in bondline overheating. A contoured joint affords more heat protection than a butt joint.
Thermal and mechanical property evaluations of three candidate RSI materials are presented. The techniques used to characterize material response during plasma arc exposures are described.
Test results show that sea salt contamination and thermal cycles cause significant changes in the morphology of surface insulation coatings with increased melting. Sea salt contamination and thermal cycles do not have a significant effect on emittance of mullite and silica composite coatings at high temperatures (1300 K). At the lower temperatures there is apparently some effect on emittance but the evidence is inconclusive because of the absence of multiple tests.
Changes in coating morphology of mullite, silica, and ceramic mullite fiber at two heating rates are described followed by a discussion of the changes in surface chemistry that occur during convective heating tests. Subsequently, the surface chemistry changes observed are compared to similar data obtained from radiantly heated coatings and the significance of the difference between the results is discussed. Finally, the changes in chemistry of the coatings in cross section before and after convectively heated cyclic testing are discussed and the significance of surface chemistry changes are described. Results indicate that the thermal conductivity of mullite surface insulation is higher than that of silica insulation, based on thermal response data. Acoustic excitation of cracked silica tiles does not lead to catastrophic failure such as spallation or tile loss. Cracks in mullite material after thermal exposure lead to fracturing of the coating and surface insulation material after acoustic excitation.
Space environment effects on space shuttle thermal protection system design
An extensive development and testing program on adhesive systems shows that: (1) A closed cell silicone rubber sponge bonded to substrates with thin bond lines of glass filled adhesive exhibits density and modulus values approximately one third that of solid silicone adhesives; (2) utilization of glass or phenolic microballoons as fillers in silicone adhesives reduces density but increases moduli of the vulcanized materials; (3) the silicone elastomer based adhesives appear to be complex systems rather than homogeneous, isotropic materials. Tensile, shear, and compression properties plotted versus temperature verify this conjecture; and (4) constant strain-stress relaxation tests on glass-filled adhesive show that stress relaxation is most pronounced near the glass transition temperature.
Three methods of attaching surface insulation tiles to shuttle primary structure have been proposed: direct bond, mechanical attachment, and subpanels with standoffs. The direct bond approach is lightweight but is difficult to refurbish and inspect. The subpanel approach is heavier but allows for easy refurbishment since subpanels are easily removed and replaced. The mechanical attachment approach allows easy refurbishment and inspection and is lightweight when an efficient insulator is used between surface insulation tiles and primary structure.
This paper presents the results of a preliminary study to establish electrical power requirements, investigate candidate power sources, and select a representative power generation concept for the NASA Space Shuttle booster stage. Design guidelines and system performance requirements are established. Candidate power sources and combinations thereof are defined and weight estimates made. The selected power source concept utilizes secondary silver-zinc batteries, engine-driven alternators with constant speed drive, and an airbreathing gas turbine. The need for cost optimization, within safety, reliability, and performance constraints, is emphasized as being the most important criteria in design of the final system.
The total infrared scattering and absorption cross sections of both flexible and rigidized high temperature fibrous insulations have been measured. The methods for accomplishing these measurements are described. Infrared reflection and transmission spectra were obtained to study the dependence of the total cross sections on the spectral characteristics of the transported radiation. These results are applied to steady-state effective thermal conductivity measurements via a four-flux model of radiative heat transfer to separate the radiative component and to calculate the effective thermal conductivity under transient heating conditions. Data for both silica and mullite fibers are presented.
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