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This viewgraph presentation provides information on the testing of a new foam for thermal protection of the Space Shuttle External Tank. The testing was conducted on an F-15 fighter aircraft.
Tension, biaxial, and creep tests of 5Al-2.5Sn titanium alloy and computerized design for fiberglass-epoxy overwrapped titanium pressure vessel
Analysis, design, fabrication, and test activities were conducted to develop additional technology needed for application of filament-wound fiberglass struts to cryogenic flight tankage. It was conclusively verified that monocoque cylinder or ogive struts are optimum or near-optimum for the range of lengths and loads studied, that a higher strength-to-weight ratio can be achieved for fiberglass struts than for any metallic struts, and that integrally-wrapped metallic end fittings can be used to achieve axial load transfer without reliance on bond strength or mechanical fasteners.
Numerous studies and ground tests have shown that broad area cooling (also known as distributed cooling) can reduce or eliminate cryogenic propellant boil-off and enable long duration storage in space. Various combinations of cryocoolers, circulators, heat exchangers and other hardware could be used to build the system. In this study, several configurations of broad area cooling systems were compared by weighing hardware combinations, input power requirements, component availability, and Technical Readiness Level (TRL). The preferred system has a high TRL and can be scaled up to provide cooling capacities on the order of 150W at 90K
The most recent approach to the Space Infrared Telescope Facility (SIRTF) uses a new design concept in which the telescope is launched warm and subsequently cooled to operating temperture on orbit. At launch the cryostat is at 2 K and the telescope is at room temperature. Cooldown of the telescope will be accomplished initially through radiation to space. Final cooldown to the 5.5 K operating temperature is done with helium vapor. Initially the helium flow on orbit will be 10 to 20 times larger than required for steady-state operation. The vent line and the liquid-vapor phase separator (porous plug) therefore must accomodate a large dynamic operational range. For ground testing of IR instruments, the required temperature is 1.5 K. The helium tank temperature for both ground testing and space operations thus needs to be 1.4 K. We will present a discussion of the requirements, a conceptual design, and initial laboratory test results with candidate porous plugs and associated instrumentation. A discussion of possible connections to the design of Gravity Probe-B cryostat will also be presented.
The most recent approach to the Space Infrared Telescope Facility (SIRTF) uses a new design concept in which the telescope is launched warm and subsequently cooled to operating temperature on orbit. At launch, the cryostat is at 2 K and the telescope is at room temperature. Cooldown of the telescope will be accomplished initially through radiation to space. Final cooldown to the 5.5 K operating temperature is done with helium vapor. Initially, the helium flow on orbit will be 20 to 30 times larger than required for steady-state operation. The vent line and the liquid/vapor phase separator (porous plug) therefore must accommodate a large dynamic operational range.For ground testing of IR instruments, the required temperature is 1.5 K. The helium tank temperature for both ground testing and space operations thus needs to be at 1.4 K. We present a discussion of the requirements, a conceptual design, and initial laboratory test results with candidate porous plugs and associated instrumentation. A discussion of possible connections to the design of the Gravity Probe-B cryostat will be presented also.
The 049 orbiter and launch configurations were tested in a trisonic wind tunnel to obtain preliminary loads information on the orbiter alone, orbiter in presence of the H/O tank and orbiter in the full launch configuration. The orbiter consisted of the baseline 049 double-delta wing, twin vertical stabilizers, seven degrees of dihedral and included abort rockets. The orbiter was mounted at minus 1.50 degree of incidence (fuselage centerline relative to H/O tank centerline) in the launch configuration. The solid rocket motors were mounted at a radial location of 21 degrees from the horizontal centerline of the H/O tank. The test was conducted over a Mach number range of 0.6 to 4.96. Nominal angle of attack and angle of sideslip ranges of minus 6 to plus 6 degrees were tested. In addition, the orbiter alone was tested over an angle of attack range of minus 6 to plus 26 degrees.
An investigation was conducted in the Langley 20-foot free-spinning tunnel on a 1/20-scale model of an unswept-wing, twin-engine, observation airplane. The effects of control settings and movements on the erect spin and recovery characteristics for the normal loading and the most rearward center-of-gravity loading (external wing tanks full) were determined. Also, tests were made to determine the effect on the spin and recovery characteristics of a large radar store, of empty and full external wing tanks, and of an asymmetrical condition when one empty or one full external wing tank is carried. Spin-recovery parachute tests were also performed. The results of the tests indicate that erect spins obtained on the airplane for the normal loading should be satisfactorily terminated by rudder reversal to full against the spin, ailerons moved to with the spin, followed one-half turn later by forward movement of the stick to neutral. With the radar store, with wing tanks empty, or with an asymmetrical condition when one empty tank is on either wing, satisfactory recoveries can be obtained by using the same technique as for the normal loading. Recoveries for the model with a rearward center-of-gravity loading (external wing tanks full) or with a full tank on the wing inboard of the spin axis will be slow to unsatisfactory with rudder reversal to full against the spin followed by brisk forward stick movement. With a full tank on the wing outboard of the spin axis, the recoveries will be satisfactory. Spins in the landing configuration should be terminated by first retracting the flaps, slats, and landing gear, after which recovery should be attempted immediately by using the recovery technique recommended for the normal loading condition. Inverted spins can be satisfactorily terminated by rudder reversal to full against the spin followed by neutralization of the longitudinal and lateral controls. A 12.7-foot-diameter tail parachute with a towline length of 21.7 feet and a drag coefficient of 0.65 should be satisfactory for recoveries from erect and inverted demonstration spins when used simultaneously with movement of rudder to neutral.
Large transient pressure pulses, referred to as a helium hammer, which occurred in the transfer line of the main cryogenic tank during the development tests of the Infrared Astronomical Satellite, launched on January 25, 1983, are analyzed, and the measures taken to prevent a failure described. The modifications include an installation of a 2.3-liter surge tank upstream, and a back-up relief valve downstream, of a burst disk. The surge tank is designed to attenuate a 0.33-MPa pressure pulse at the inlet down to 0.092 MPa at the outlet. A mechanism of the pulse generation is suggested, which involves flashing and rapid recondensation of the small amount of liquid entering the warm section of a transition to room temperature.
On the composite cryotank technology development (CCTD) project, the Boeing Company built two cryotanks as a means of advancing technology and manufacturing readiness levels (TRL and MRL) and lowering the risk of fabricating full-scale fuel containment vessels.1 CCTD focused on upper stage extended duration applications where long term storage of propellants is required. The project involved the design, analysis, fabrication, and test of manufacturing demonstration units (MDU), a 2.4 m (precursor) and a 5.5 m composite cryotank. Key design features included one-piece wall construction to minimize overall weight (eliminating the need for a bellyband joint), 3-dimensionally (3D) reinforced y-joint material to alleviate stress concentrations at the tank to skirt interface and a purge-able fluted core skirt to carry high axial launch loads. The tanks were made with OoA curing pre-impregnated (prepreg) carbon/epoxy (C/E) slit-tape tow (STT) that contained thin micro-crack resistant plies in the tank wall center to impede permeation. The tanks were fabricated at Boeing's Seattle-based Advanced Development Center (ADC) using RAFP and multipiece break-down tooling. The tooling was designed and built by Janicki Industries (JI) at Sedro Woolley, Washington. Tank assemblage consisted of co-bonded dome covers, one-piece fluted core skirts and mechanical fastened cover/sump. Ultrasonic inspection was performed after every cure or bond and a structural health monitoring system (SHMS) was installed to identify potential impact damage events (in-process and/or during transportation). The tanks were low temperature tested at NASA's George C. Marshall Space Flight Center (MSFC) in Huntsville, Alabama. The testing, which consisted of a sequence of fill/drain pressure and thermal cycles using LH2, was successfully concluded in 2012 on the 2.4 m tank and in 2014 on the 5.5 m tank. Structural, thermal, and permeation performance data was obtained. 2 Critical design features and manufacturing advancements, which helped to validate 25% weight and 30% cost reduction projections, were matured. These advancements will help to guide future composite tank integration activities on next generation long duration aircraft and space launch vehicles. Because CCTD addressed innovative design features, heavy lift size scale-up, multipiece captured tooling, new generation automated material placement (AMP) equipment and OoA materials, this chapter should be of interest to educators, students and manufacturers of composite hardware and flight vehicles.
During the initial certification test of the forward structural attachment of the space shuttle orbiter to the external tank, pyrotechnic shock from actuation of the separation device resulted in structural failure of the thermal protection tiles surrounding the attachment. Because of the high shock associated with the separation bolt, the development of alternative low shock separation designs was initiated. Two concepts that incorporate a 5.08 centimeter frangible nut as the release device were developed and tested.
Following the tragedy of the Space Shuttle Columbia on February 1, 2003, a major effort commenced to develop a better understanding of debris impacts and their effect on the Space Shuttle subsystems. An initiative to develop and validate physics-based computer models to predict damage from such impacts was a fundamental component of this effort. To develop the models it was necessary to physically characterize Reinforced Carbon-Carbon (RCC) and various debris materials which could potentially shed on ascent and impact the Orbiter RCC leading edges. The validated models enabled the launch system community to use the impact analysis software LS DYNA to predict damage by potential and actual impact events on the Orbiter leading edge and nose cap thermal protection systems. Validation of the material models was done through a three-level approach: fundamental tests to obtain independent static and dynamic material model properties of materials of interest, sub-component impact tests to provide highly controlled impact test data for the correlation and validation of the models, and full-scale impact tests to establish the final level of confidence for the analysis methodology. This paper discusses the second level subcomponent test program in detail and its application to the LS DYNA model validation process. The level two testing consisted of over one hundred impact tests in the NASA Glenn Research Center Ballistic Impact Lab on 6 by 6 in. and 6 by 12 in. flat plates of RCC and evaluated three types of debris projectiles: BX 265 External Tank foam, ice, and PDL 1034 External Tank foam. These impact tests helped determine the level of damage generated in the RCC flat plates by each projectile. The information obtained from this testing validated the LS DYNA damage prediction models and provided a certain level of confidence to begin performing analysis for full-size RCC test articles for returning NASA to flight with STS 114 and beyond.
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Propellant densification has been identified as a critical technology in the development of single-stage-to-orbit reusable launch vehicles. Technology to create supercooled high-density liquid oxygen (LO2) and liquid hydrogen (LH2) is a key means to lowering launch vehicle costs. The densification of cryogenic propellants through subcooling allows 8 to 10 percent more propellant mass to be stored in a given unit volume, thereby improving the launch vehicle's overall performance. This allows for higher propellant mass fractions than would be possible with conventional normal boiling point cryogenic propellants, considering the normal boiling point of LO2 and LH2.
Richard Gilbech, External Tank "Tiger Team" Lead, begins this space shuttle news conference with detailing the two major objectives of the team. The objectives include: 1) Finding the root cause of the foam loss on STS-114; and 2) Near and long term improvements for the external tank. Wayne Hale, Space Shuttle Program Manager, presents a chart to explain the external tank foam loss during STS-114. He gives a possible launch date for STS-121 after there has been a repair to the foam on the External Tank. He further discusses the changes that need to be made to the surrounding areas of the plant in New Orleans, due to Hurricane Katrina. Bill Gerstemaier, NASA Associate Administrator for Space Operations, elaborates on the testing of the external tank foam loss. The discussion ends with questions from the news media about a fix for the foam, replacement of the tiles, foam loss avoidance, the root cause of foam loss and a possible date for a new external tank to be shipped to NASA Kennedy Space Center.
Crystalline silicotitanate (CST) ion exchanger is planned to be used to remove cesium (137Cs) from the aqueous phases of Hanford tank wastes in preparation for vitrification at the Waste Treatment and Immobilization Plant (WTP) Pretreatment Facility. Column scale up testing was conducted to evaluate performance of Cs exchange onto the CST. Batch contact testing was conducted to assess exchange kinetics of Cs exchange at four different CST PSDs. Column testing was conducted at three column sizes, small (2.5% full height), medium (12% full height), and full height, to assess Cs load performance behavior. Testing at the small scale was compared to actual Hanford tank waste testing to verify the validity of simulant tests to accurately represent full height column performance. A change in CST particle size was essential in scaling the small column dynamics up to full scale. Based on these results, a determination of intraparticle and film diffusion impacts on overall mass transfer coefficients will allow future modeling of the breakthrough performance at a range of process conditions.
The model tested was a 0.0091 scale representation of the ogive nose section of the External Tank with nose cap and lightning rod and protuberances. Pressure distribution around the nose cap was determined. Pressure data were also obtained along the ogive nose. Data were obtained over an angle of attack range of + or -5 degrees and over a Mach number range of .6 to 4.96. The Reynolds number per unit length (ft.) ranged from 4.1 million to 4.96 million. There were 22 pressure ports in a single row. Circumferential positions of 0, 22.5, 45, 67.5 and 90 degrees were simulated by rotating the model. The LO2 feed line and LO2 recirculation line were simulated. The effects of the nose spike were investigated over a range of Mach numbers. The data will be useful for venting analyses. Photographs showing flow visualization of the test configuration are given.
Pressure and heat transfer tests were conducted simulating flight conditions which the space shuttle external tank will experience prior to break-up. The tests were conducted in the Calspan 48-inch Hypersonic Shock Tunnel and simulated entry conditions for nominal, abort-once-around (AOA), and return to launch site (RTLS) launch occurrences. Surface pressure and heat-transfer-rate distributions were obtained with and without various protuberences (or exterior hardware) on the model at Mach numbers from 15.2 to 17.7 at angles of attack from -15 deg to -180 deg and at several roll angles. The tests were conducted over a Reynolds number range from 1300 to 58,000, based on model length.