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Twelve samples of cellular polymers were evaluated in the course of developing test methods for toxic materials characterization. Six samples were flexible polyurethane foams, three were rigid polyurethane foams, two were high density rigid foams, and one was a modified polyimide foam. Some effects of formulation variables are discussed.
One sample each of commercial polyurethane and polychloroprene flexible foams were evaluated using the USF/NASA toxicity screening test method. Air flow rates of 0, 0.16, 16, and 48 ml/sec were used to determine the effect of air flow on relative toxicity. Time to first sign of incapacitation and time to death were substantially reduced with both polyurethane and polychloroprene flexible foams by the introduction of 16 to 48 ml/sec air flow. The relative toxicity rankings of these materials were not altered by changes in air flow. Under these test conditions, the polyurethane foam consistently appeared more toxic than the polychloroprene foam. Samples of six different colors from the same fabric were evaluated separately, using the USF/NASA toxicity screening test method, to determine the effect of fabric dye, if any. The material was an upholstery fabric, consisting of 46 percent cotton, 33 percent wool, and 21 percent nylon. There appeared to be no significant effect of fabric dye on relative toxicity, for this material under these test conditions.
Analyses of the Apollo-Soyuz science demonstrations on chemical foams and liquid spreading are presented. The chemical foams demonstation showed that aqueous foams and gas/liquid dispersions are more stable in low-g than on the ground. Unique chemical reactions in low-g foams and gas/liquid dispersions are therefore possible. Further ground tests on the formaldehyde clock reaction led to the rather surprising conclusions that surfaces can exert a nucleation effect and that long-range surface influences on chemical reaction rates are apparently operative.
Recent developments in polyimide chemistry show promise for producing materials with very low flammability and a wide range of mechanical properties. Polyimide foams can be synthesized to provide fire safety without detectable formation of smoke or toxic byproducts below 204 C (400 F), thus avoiding an environment which is lethal to human habitation. This work has been and is currently being performed under development programs, the objective of which is to provide cost effective processes for producing thermally stable, polyimide flexible resilient foams, thermal-acoustical insulating materials, rigid low density foam panels, and high strength foam structures. The chemical and physical properties demonstrated by these materials represent a technological advancement in the art of thermally stable polyimide polymers which are expected to insure fire protection of structures and components used in air transportation and space exploration. Data compiled to date on thermal, physical and functional properties of these materials are presented.
The thermal response characteristics of fabric and fabric-foam assemblies are described. The various aspects of the ignition behavior of contemporary aircraft passenger seat upholstery fabric materials relative to fabric materials made from thermally stable polymers are evaluated. The role of the polymeric foam backing on the thermal response of the fabric-foam assembly is also ascertained. The optimum utilization of improved fire-resistant fabric and foam materials in the construction of aircraft passenger seats is suggested.
Polyurethane foam provides effective mask in electroplating of copper or nickel. Thin layer of Turco maskant painted on area to be masked: Layer ensures polyurethane foam removed easily after served its purpose. Component A, isocyanate, and component B, polyol, mixed together and brushed or sprayed on mask area. Mixture reacts, yielding polyurethane foam. Foam prevents deposition of nickel or copper on covered area. New method saves time, increases productivity and uses less material than older procedures.
229-page report describes work done to determine burning characteristics of present and proposed seat-cushion materials and types of construction. Tested cushions classified in four groups: standard cushion construction, standard cushion construction with protective covering enveloping urethane-foam core, standard cushion construction with protective covering enveloping non-fire-retarded urethane-foam core, and standard cushion construction with urethane-foam core replaced by advanced fire-resistant foam. Report includes still photographs and presents quantitative data from each test in graphs and tables.
Critical technology experiments have been performed on thermal energy storage modules in support of the Brayton Advanced Heat Receiver program. The modules are wedge-shaped canisters designed to minimize the mechanical stresses that occur during the phase change of the lithium fluoride phase change material. Nickel foam inserts were used in some of the canisters to provide thermal conductivity enhancement and to distribute the void volume. Two canisters, one with a nickel foam insert, and one without, were thermally cycled in various orientations in a fluidized bed furnace. The only measurable impact of the nickel foam was seen when the back and short sides of the canister were insulated to simulate operation in the advanced receiver design. In tests with insulation, the furnace to back side delta T was larger in the canister with the nickel foam insert, probably due to the radiant absorptivity of the nickel. However, the differences in the temperature profiles of the two canisters were small, and in many cases the profiles matched fairly well. Computed Tomography (CT) was successfully used to nondestructively demarcate void locations in the canisters. Finally, canister dimensional stability, which was measured throughout the thermal cycling test program with an inspection fixture was satisfactory with a maximum change of 0.635 mm (0.025 in.).
Critical technology experiments have been performed on thermal energy storage modules in support of the NASA Advanced Solar Dynamic Brayton Heat Receiver Program. The modules, wedge-shaped canisters containing lithium fluoride (LiF), were designed to minimize the mechanical stresses that occur during the phase change of the LiF. Nickel foam inserts were placed in two of the test canisters to provide thermal conductivity enhancement and to distribute the void volume throughout the canister. A procedure was developed for reducing the nickel oxides on the nickel foam to enhance the wicking ability of the foam. The canisters were filled with LiF and closure-welded at the NASA Lewis Research Center. Two canisters, one with a nickel foam insert, the other without an insert, were thermally cycled in various orientations in a fluidized bed furnace. Computer-aided tomography was successfully used to nondestructively determine void locations in the canisters. Finally, canister dimensional stability was measured after thermal cycling with an inspection fixture.
Concentration of isocyanurate in polyurethane foam measured. Quantitative analysis important because concentration of isocyanurate affects chemical and physical properties of foam, and correlations between concentration and properties used to optimize foam formulations. Use of potassium ferricyanide as internal standard extended to other infrared spectral analyses of solids in which quantitative results required. Eliminates need to know thickness of sample. Synthesis of triphenylisocyanurate extended to production of pure compounds from substituted phenylisocyanates added to test foam formulations to determine improvements in thermal properties with pure or substituted triphenylisocyanurate.
The Space Shuttle is connected to the mobile launch platform (MLP) by four aft skirt hold down studs on each solid rocket booster (SRB). Prior to lift-off, the frangible nuts inside the aft skirt blast containers are severed into two nut halves by two pyrotechnic booster cartridges. This action releases the Space Shuttle and allows the hold down studs to eject through the aft skirt bore and then down into the MLP. USBI has been tasked to upgrade the blast container for two specific reasons: (1) To eliminate lead for environmental concerns, and (2) To reduce the chance of nut recontact with the holddown stud. Nut recontact with the stud has been identified as a likely contributor to stud hang-ups. This upgrade will replace the lead liner with a unique open cell aluminum foam material, that has commercial and military uses. The aluminum foam used as an energy absorber is a proven design in many other aerospace/defense applications. Additional benefits of using the open cell, energy absorbent aluminum foam in place of the solid lead liner are: (A) Lead handling/exposure and possible contamination, along with hazardous waste disposal, will be eliminated; (B) Approximately 200 lbs. weight savings will be contributed to each Space Shuttle flight by using aluminum foam instead of lead; (C) The new aluminum liner is designed to catch all shrapnel from frangible nuts, thus virtually eliminating chance of debris exiting the HDP and causing potential damage to the vehicle; and (D) Using the lighter aluminum liner instead of lead, allows for easier assembly and disassembly of blast container elements, which also improves safety, operator handling, and the efficiency of operations.
Thiokol Propulsion encountered a situation where gas path can form in the Filler material in joints between the phenolic in the Space Shuttle Reusable Solid Rocket Motor nozzle. An investigation determined that the method for injecting the filler material into the joint created a pressurized pocket of air that forced its way to the surface while the filler was curing. The path that the air took remained open some situations leaving a path for hot gas to get deep into the joint. The condition that created the gas path has been corrected by modifications to the manufacturing process, but a design solution that would reduce processing time is being pursued. A strip of open cell installed deep into the joint, can serve as a barrier to the Filler material. Testing indicates that the foam eliminates the pressure pocket, and does not prevent detection of leakage of the o-ring seals during leak test. Open cell foam does not have thermal resistance capability and mechanical structure, which would be required in the event of a gas path. A replacement to open cell foam is now being considered. Braided carbon fiber rope has the permeability characteristics of foam and it has thermal resistance characteristics as well. Braided carbon fiber rope (BCFR) has been tested in simulated joints in subscale rocket motor. Results of the testing indicate that braided carbon fiber rope can significantly reduce gas temperature by as much es 3000 F in a nozzle joint configuration. BCFR can be installed as a barrier to stop the joint filler material or it can used as the thermal barrier alone.
The Space Shuttle is connected to the mobile launch platform (MLP) by four aft skirt hold down studs on each solid rocket booster (SRB). Prior to lift-off, the frangible nuts inside the aft skirt blast containers are severed into two nut halves by two pyrotechnic booster cartridges. This action releases the Space Shuttle and allows the hold down studs to eject through the aft skirt bore and then down into the MLP. USBI has been tasked to upgrade the blast container for two specific reasons: (1) To eliminate lead for environmental concerns, and (2) To reduce the chance of nut recontact with the holddown stud. Nut recontact with the stud has been identified as a likely contributor to stud hang-ups. This upgrade will replace the lead liner with a unique open cell aluminum foam material, that has commercial and military uses. The aluminum foam used as an energy absorber is a proven design in many other aerospace/defense applications. Additional benefits of using the open cell, energy absorbent aluminum foam in place of the solid lead liner are: (1) Lead handling / exposure and possible contamination, along with hazardous waste disposal, will be eliminated; (2) Approximately 200 lbs. weight savings will be contributed to each Space Shuttle flight by using aluminum foam instead of lead; (3) The new aluminum liner is designed to catch all shrapnel from frangible nuts, thus virtually eliminating chance of debris exiting the HDP and causing potential damage to the vehicle; (4) Using the lighter aluminum liner instead of lead, allows for easier assembly and disassembly of blast container elements, which also improves safety, operator handling, and the efficiency of operations.
This report documents the results of Task 14, "Structural Acoustic Prediction and Interior Noise Control Technology". The task was to evaluate the performance of tuned foam elements (termed Smart Foam) both analytically and experimentally. Results taken from a three-dimensional finite element model of an active, tuned foam element are presented. Measurements of sound absorption and sound transmission loss were taken using the model. These results agree well with published data. Experimental performance data were taken in Boeing's Interior Noise Test Facility where 12 smart foam elements were applied to a 757 sidewall. Several configurations were tested. Noise reductions of 5-10 dB were achieved over the 200-800 Hz bandwidth of the controller. Accelerometers mounted on the panel provided a good reference for the controller. Configurations with far-field error microphones outperformed near-field cases.
Boston Insulated Wire & Cable developed a new polyimide foam material, commercially known as Solimide, which resists ignition. It chars and decomposes when exposed to open flames. Used in the space shuttle, the material does not "outgas" until it begins to char making it safer than current materials with respect to toxic fumes. The polyimide can be made in two forms: a resilient foam and a rigid foam. Used in commercial transport interiors for such soft components as seat cushions to door, wall, floor, and ceiling panels. Material's flame resistance could lengthen from two minutes to five minutes, the time needed for passenger evacuation in a ground emergency. Could help reduce airline fuel consumption, since the foam is 50% lighter than current materials. Low-smoke cable assemblies used in rapid transit systems consists of an advanced wire and cable jacketing material with superior flame resistance and smoke retardation characteristics. Being supplied to mass transit systems in the U.S. and abroad.
The research described in this viewgraph presentation investigates the ascent of STS-107 and foam-debris impact, and contributes to understanding of the STS-107 accident using CFD tools. The goals of the research are to: 1) Quantify loads on foam bipod ramp during ascent; 2) Provide steady-state flow-fields to debris-transport simulations; 3) Simulate flight of foam debris using unsteady six-degree-of-freedom calculations; 4) Provide estimates of foam mass, velocity, and impact angle which correlate with video and film evidence.
During the launch of the Space Shuttle Columbia on January 16, 2003, foam originating from the external tank impacted the shuttle's left wing 81 seconds after lift-off. Then on February 1st, Space Shuttle Columbia broke-up during re-entry. In the weeks that followed, the Columbia Accident Investigation Board had formed various teams to investigate every aspect of the tragedy. One of these teams was the Impact Analysis Team, which was asked to investigate the foam impact on the wing leading edge. This paper will describe the approach and methodology used by the team to support the accident investigation, and more specifically the use of LS-DYNA for analyzing the foam impact event. Due to the success of the analytical predictions, the impact analysis team has also been asked to support Return to Flight activities. These activities will analyze a far broader range of impact events, but not with just foam and not only on the wing leading edge. The debris list has expanded and so have the possible impact locations. This paper will discuss the Return to Flight activities and the use of LS-DYNA to support them.
A technology review and assessment of modeling and analysis efforts underway in support of a safe return to flight of the thermal protection system (TPS) for the Space Shuttle external tank (ET) are summarized. This review and assessment effort focuses on the structural modeling and analysis practices employed for ET TPS foam design and analysis and on identifying analysis capabilities needed in the short-term and long-term. The current understanding of the relationship between complex flight environments and ET TPS foam failure modes are reviewed as they relate to modeling and analysis. A literature review on modeling and analysis of TPS foam material systems is also presented. Finally, a review of modeling and analysis tools employed in the Space Shuttle Program is presented for the ET TPS acreage and close-out foam regions. This review includes existing simplified engineering analysis tools are well as finite element analysis procedures.