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NASA NTRSDate not supplied

Coolant Leak from ISS External Active Thermal Control System (EATCS) – An Examination of Most Probable

The Port (P1) and Starboard (S1) External Active Thermal Control Systems (EATCS) are single phase, mechanically pumped ammonia loops that operate independently to cool majority of the hardware and payloads onboard the International Space Station (ISS). A slow ammonia leak was detected using pressure and quantity telemetry five years after the P1 EATCS was activated. The leak gradually accelerated to a rate that locating and isolating the leak became imperative to maintain cooling capability. Partial pressure measurements from the Robotic External Leak Locator (RELL) scan surveys narrowed the search to the supply and return jumpers connecting one of three radiators to the system. Subsequently, the ISS crew performed high definition video surveys during an Extravehicular Activity (EVA), or spacewalk, and ammonia flakes were observed projecting from the jumpers. Thus, the ground teams were confident that the culprit of the ammonia leak were the jumpers. The ammonia leak stopped after ground teams remotely isolated and vented those jumpers and associated radiator. Both jumpers were removed and returned to the ground, and a root cause investigation was conducted. A calibrated leak test determined the bulk of the ammonia leaked through a pair of seals in a Quick Disconnect (QD), or connector, on one end of the return jumper. The return jumper QD was dissected, visually inspected, chemically tested and evaluated. The results indicated the most probable cause of the accelerating ammonia leak was due to defective seals, plating delamination underneath the seals, and on-orbit thermal cycles exacerbating the delamination. Both jumpers were refurbished, relaunched to the ISS, and scheduled to be reinstalled during an EVA in 2022. It appeared the issue was unique, but recently the S1 EATCS is showing signs of an accelerating ammonia leak, and RELL scans narrowed the source to a similar pair of radiator jumpers.

Thermal Control↗
NASA NTRSDate not supplied

Coolant Leak from ISS External Active Thermal Control System (EATCS) – An Examination of Most Probable

The Port (P1) and Starboard (S1) External Active Thermal Control Systems (EATCS) are single phase, mechanically pumped ammonia loops that operate independently to cool majority of the hardware and payloads onboard the International Space Station (ISS). A slow ammonia leak was detected using pressure and quantity telemetry five years after the P1 EATCS was activated. The leak gradually accelerated to a rate that locating and isolating the leak became imperative to maintain cooling capability. Partial pressure measurements from the Robotic External Leak Locator (RELL) scan surveys narrowed the search to the supply and return jumpers connecting one of three radiators to the system. Subsequently, the ISS crew performed high-definition video surveys during an Extravehicular Activity (EVA), or spacewalk, and ammonia flakes were observed projecting from the jumpers. Thus, the ground teams were confident that the culprit of the ammonia leak were the jumpers. The ammonia leak stopped after ground teams remotely isolated and vented those jumpers and associated radiator. Both jumpers were removed and returned to the ground, and a root cause investigation was conducted. A calibrated leak test determined the bulk of the ammonia leaked through a pair of seals in a Quick Disconnect (QD), or connector, on one end of the return jumper. The return jumper QD was dissected, visually inspected, chemically tested and evaluated. The results indicated the most probable cause of the accelerating ammonia leak was due to defective seals, plating delamination underneath the seals, and on-orbit thermal cycles exacerbating the delamination. Both jumpers were refurbished, relaunched to the ISS, and scheduled to be reinstalled during an EVA in 2022. It appeared the issue was unique, but recently the S1 EATCS is showing signs of an accelerating ammonia leak, and RELL scans narrowed the source to a similar pair of radiator jumpers.

Darnell Cowan↗
NASA NTRS2001

Delta L: An Apparatus for Measuring Macromolecule Crystal Growth Rates in Microgravity

Strongly diffracting high quality macromolecule crystals of suitable volume are keenly sought for X-ray diffraction analysis so that high-resolution molecular structure data can be obtained. Such data is of tremendous value to medical research, agriculture and commercial biotechnology. In previous studies by many investigators microgravity has been reported in some instances to improve biological macromolecule X-ray crystal quality while little or no improvement was observed in other cases. A better understanding of processes effecting crystal quality improvement in microgravity will therefore be of great benefit in optimizing crystallization success in microgravity. In ground based research with the protein lysozyme we have previously shown that a population of crystals grown under the same solution conditions, exhibit a variation in X-ray diffraction properties (Judge et al., 1999). We have also observed that under the same solution conditions, individual crystals will grow at slightly different growth rates. This phenomenon is called growth rate dispersion. For small molecule materials growth rate dispersion has been directly related to crystal quality (Cunningham et al., 1991; Ristic et al., 1991). We therefore postulate that microgravity may act to improve crystal quality by reducing growth rate dispersion. If this is the case then as different, Materials exhibit different degrees of growth rate dispersion on the ground then growth rate dispersion could be used to screen which materials may benefit the most from microgravity crystallization. In order to assess this theory the Delta L hardware is being developed so that macromolecule crystal growth rates can be measured in microgravity. Crystal growth rate is defined as the change or delta in crystal size (defined as a characteristic length, L) over time; hence the name of the hardware. Delta L will consist of an optics, a fluids, and a data acquisition sub-assemblies. The optics assembly will consist of a video microscope camera mounted on three axis computer controlled translation stages. The fluids assembly consists of macromolecule and precipitant reservoirs, a temperature controlled growth cell and waste container, The data acquisition is achieved by using a frame-gabber, with images being stored on a hard drive. In operation, macromolecule and precipitant solution will be injected into the temperature controlled growth cell. As macromolecule crystals grow, the video microscope camera controlled by the translation stages, will be used to locate and record images of individual crystals, returning to the same crystals at specific time intervals. The images will be stored on the hard drive and used to calculate the crystal growth rate. To prevent vibrations interfering in the crystal growth rate measurements (Snell et al., 1997) Delta L will be used in connection with the Glovebox Integrated Microgravity Isolation Technology (g-LIMIT) inside the Microgravity Science Glovebox (MSG), onboard the International Space Station (ISS).

Judge, Russell A.↗
NASA NTRS1986

Peristaltic Pump With a Stable Output

Proposed design for peristaltic pump decreases flow-rate change that results from loss of elasticity. Instead of tubing, new pump uses special flexible liner as pumping channel. Liner molded as single piece of flexible plastic with helical internal channels. Three rollers move around inner wall of liner, compressing channels and forcing liquid before constrictions. As rollers move on, channels open elastically, drawing in liquid from inlet port and making it available when rollers return.

Chandler, J. A.↗
NASA NTRS1999

Calcium Kinetics During Space Flight

Bone loss is one of the most detrimental effects of space flight, threatening to limit the duration of human space missions. The ability to understand and counteract this loss will be critical for crew health and safety during and after extended-duration missions. The hypotheses to be tested in this project are that space flight alters calcium homeostasis and bone mineral metabolism, and that calcium homeostasis and bone mineral metabolism will return to baseline within days to weeks of return to Earth. These hypotheses will be evidenced by elevated rates of bone mineral resorption and decreased bone mineral deposition, decreased absorption of dietary calcium, altered calcitropic endocrine profiles, elevated excretion of calcium in urine and feces, and elevated excretion of markers of bone resorption. The second hypothesis will be evidenced by return of indices of calcium homeostasis and bone metabolism to preflight levels within days to weeks of return to Earth. Studies will be conducted on International Space Station astronauts before, during, and after extended-duration flights. Measurements of calcium kinetics, bone mass, and endocrine/biochemical markers of bone and calcium homeostasis will be conducted. Kinetic studies utilizing dual isotope tracer kinetic studies and mathematical modeling techniques will allow for determination of bone calcium deposition, bone calcium resorption, dietary calcium absorption and calcium excretion (both urinary and endogenous fecal excretion). These studies will build upon preliminary work conducted on the Russian Mir space station. The results from this project will be critical for clarifying how microgravity affects bone and calcium homeostasis, and will provide an important control point for assessment of countermeasure efficacy. These results are expected to aid in developing countermeasures for bone loss, both for space crews and for individuals on Earth who have metabolic bone diseases.

Smith, Scott M.↗
NASA NTRS2000

X-38 Vehicle 131R Free Flights 1 and 2

The X-38 program is using a modern flight control system (FCS) architecture originally developed by Honeywell called MACH. During last year's SAE G&C subcommittee meeting, we outlined the design, implementation and testing of MACH in X-38 Vehicles 132, 131R & 201. During this year's SAE meeting, I'll focus upon the first two free flights of V131R, describing what caused the roll-over in FF1 and how we fixed it for FF2. I only have 30 minutes, so it will be a quick summary including VHS video. X-38 is a NASA JSC/DFRC experimental flight test program developing a series of prototypes for an International Space Station (ISS) Crew Return Vehicle (CRV), often described as an ISS "lifeboat." X-38 Vehicle 132 Free Flight 3 was the first flight test of a modern FCS architecture called Multi-Application ControlH (MACH), developed by the Honeywell Technology Center in Minneapolis and Honeywell's Houston Engineering Center. MACH wraps classical Proportional+integral (P+I) outer attitude loops around modern dynamic inversion attitude rate loops. The presentation at last year's SAE Aerospace Meeting No. 85 focused upon the design and testing of the FCS algorithm and Vehicle 132 Free Flight 3. This presentation will summarize flight control and aerodynamics lessons learned during Free Flights 1 and 2 of Vehicle 131R, a subsonic test vehicle laying the groundwork for the orbital/entry test of Vehicle 201 in 2003.

Munday, Steve↗
NASA NTRS2000

X-38 Experimental Controls Laws

X-38 Experimental Control Laws X-38 is a NASA JSC/DFRC experimental flight test program developing a series of prototypes for an International Space Station (ISS) Crew Return Vehicle, often called an ISS "lifeboat." X- 38 Vehicle 132 Free Flight 3, currently scheduled for the end of this month, will be the first flight test of a modem FCS architecture called Multi-Application Control-Honeywell (MACH), originally developed by the Honeywell Technology Center. MACH wraps classical P&I outer attitude loops around a modem dynamic inversion attitude rate loop. The dynamic inversion process requires that the flight computer have an onboard aircraft model of expected vehicle dynamics based upon the aerodynamic database. Dynamic inversion is computationally intensive, so some timing modifications were made to implement MACH on the slower flight computers of the subsonic test vehicles. In addition to linear stability margin analyses and high fidelity 6-DOF simulation, hardware-in-the-loop testing is used to verify the implementation of MACH and its robustness to aerodynamic and environmental uncertainties and disturbances.

Munday, Steve↗
NASA NTRS2014

Effects of Long Duration Spaceflight on Venous and Arterial Compliance in Astronants

1. Project Overview Visual impairment and intracranial pressure (VIIP) is a spaceflight-associated medical condition affecting at least a third of American astronauts who have flown International Space Station (ISS) missions. VIIP is defined primarily by visual acuity deficits and anatomical changes to eye structures. In some astronauts, eye-related changes do not revert back to the preflight state upon return to Earth. Our team will study some of the possible causes for this syndrome. This will be achieved by reviewing previous astronaut data for factors that may predispose astronauts to higher rates of developing this syndrome or greater severity of symptoms. Additionally, we will conduct 3 separate experiments that will characterize vessels in the head and neck and measure the effects of the experimental conditions on ocular structures and function. 2. Technical Summary The primary objective of this study is to determine whether vascular compliance is altered by spaceflight and whether such adaptations are related to the incidence of the VIIP. In particular, we will measure ocular parameters and vascular compliance in vessels of the head and neck in astronauts who have no spaceflight experience (Ground), in astronauts before, during, and after spaceflight (Flight), and in bed rest subjects with conditions similar to spaceflight (Bed Rest). Additionally, we will analyze astronaut data from the Lifetime Surveillance of Astronaut Health (LSAH) archives to determine which factors might be predictive of the development of VIIP (Data Mining). The project will be conducted in four separate, but related parts. Hypothesis The central hypothesis of this proposal is that exposure to the spaceflight environment aboard the ISS may lead to development of the VIIP syndrome (increased intracranial pressure and impaired visual acuity) and that this may be related to alterations in venous and/or arterial compliance in the head and neck. Specific Aims 1. To determine whether noninvasive measures of venous and arterial compliance are altered by long-duration spaceflight exposure in ISS astronauts and whether these changes are related to the development of the VIIP syndrome. (Flight) 2. To determine whether previous spaceflight experience predispose astronauts to lower venous compliance and/or the development of the VIIP syndrome. (Ground + Flight) 3. To use a 14-day, 6deg head-down-tilt bed rest as a model of spaceflight, to evaluate the effect of aging on vascular compliance using a subject population similar to younger (25-35 yr) and older (45-55 yr) astronaut cohorts. (Bed Rest) 4. To determine what factors contribute to lower venous compliance and/or the development of the VIIP syndrome in astronauts. (Data Mining) 3. Earth Applications This research may inform the mechanisms that regulate blood/fluid flow in and out of the brain in the head and neck. This information may help with understanding of the mechanisms behind idiopathic intracranial hypertension. 4. Link to NASA Taskbook Entry Not Yet Available

Platts, Steven↗
NASA NTRS1993

A local instability of tidally distorted accretion disks

Hydrodynamic accretion disks in binary star systems have local, three-dimensional, approximately incompressible instabilities whose growth rate is linearly proportional to the tidal field of the secondary star. The instability occurs throughout the disk but is most rapid in the outer parts. The free energy for the instability derives from the tidal distortion of the disk rather than its differential rotation. The instability will excite m-parallel 1 internal waves of the type discussed by Vishniac et al. (1992), and it should facilitate return of angular momentum from the disk to the secondary star. It is closely related to a recently discovered instability that has been suggested as a mechanism for transition to turbulence in terrestrial and laboratory flows, but whether it will lead to strong turbulence in disks is as yet unclear.

Goodman, Jeremy↗
NASA NTRS2006

NASA Crew and Cargo Launch Vehicle Development Approach Builds on Lessons from Past and Present Missions

The United States (US) Vision for Space Exploration, announced in January 2004, outlines the National Aeronautics and Space Administration's (NASA) strategic goals and objectives, including retiring the Space Shuttle and replacing it with new space transportation systems for missions to the Moon, Mars, and beyond. The Crew Exploration Vehicle (CEV) that the new human-rated Crew Launch Vehicle (CLV) lofts into space early next decade will initially ferry astronauts to the International Space Station (ISS) Toward the end of the next decade, a heavy-lift Cargo Launch Vehicle (CaLV) will deliver the Earth Departure Stage (EDS) carrying the Lunar Surface Access Module (LSAM) to low-Earth orbit (LEO), where it will rendezvous with the CEV launched on the CLV and return astronauts to the Moon for the first time in over 30 years. This paper outlines how NASA is building these new space transportation systems on a foundation of legacy technical and management knowledge, using extensive experience gained from past and ongoing launch vehicle programs to maximize its design and development approach, with the objective of reducing total life cycle costs through operational efficiencies such as hardware commonality. For example, the CLV in-line configuration is composed of a 5-segment Reusable Solid Rocket Booster (RSRB), which is an upgrade of the current Space Shuttle 4- segment RSRB, and a new upper stage powered by the liquid oxygen/liquid hydrogen (LOX/LH2) J-2X engine, which is an evolution of the J-2 engine that powered the Apollo Program s Saturn V second and third stages in the 1960s and 1970s. The CaLV configuration consists of a propulsion system composed of two 5-segment RSRBs and a 33- foot core stage that will provide the LOX/LED needed for five commercially available RS-68 main engines. The J-2X also will power the EDS. The Exploration Launch Projects, managed by the Exploration Launch Office located at NASA's Marshall Space Flight Center, is leading the design, development, testing, and operations planning for these new space transportation systems. Utilizing a foundation of heritage hardware and management lessons learned mitigates both technical and programmatic risk. Project engineers and managers work closely with the Space Shuttle Program to transition hardware, infrastructure, and workforce assets to the new launch systems, leveraging a wealth of knowledge from Shuffle operations. In addition, NASA and its industry partners have tapped into valuable Apollo databases and are applying corporate wisdom conveyed firsthand by Apollo-era veterans of America s original Moon missions. Learning from its successes and failures, NASA employs rigorous systems engineering and systems management processes and principles in a disciplined, integrated fashion to further improve the probability of mission success.

Dumbacher, Daniel L.↗
NASA NTRS1992

Results of an International Space Crew Debrief

In order to identify potential multi-cultural and multinational problems for future International Space Station Freedom crew, a crew debrief questionnaire was developed for U.S. astronauts who flew on shuttle missions with one or more crew members from other countries. Methods: From 1981-90, a total of 20 U.S. astronauts flew on international space missions. Debriefs were mailed to all 20 with instructions not to identify themselves or their specific mission. The debrief focused primarily on preflight training and post flight incidents of misunderstanding, miscommunication, and interpersonal friction among crewmembers. Astronauts were also asked to rate the impact of the incident to the mission (low, medium, high). Results: Ten astronauts responded, but only nine responses were able to be scored, for a return rate of 45 percent. 42 incidents were reported, 9 in the preflight period, 26 inflight, and 7 in the postflight period. Most of the incidents were rated at a low or medium impact, but 5 of the inflight incidents were rated at a 'high' mission impact. A number of causes for the problems were listed, and are discussed. Conclusions: The debrief respondents provide useful and timely recommendations on preflight training which might help facilitate the integration of multinational crews and prevent multi-cultural or multinational factors from interfering with mission operations.

Santy, P. A.↗
NASA NTRS2000

Mir Contamination Observations and Implications to the International Space Station

A series of external contamination measurements were made on the Russian Mir Space Station. The Mir external contamination observations summarized in this paper were essential in assessing the system level impact of Russian Segment induced contamination on the International Space Station (ISS). Mir contamination observations include results from a series of flight experiments: CNES Comes-Aragatz, retrieved NASA camera bracket, Euro-Mir '95 ICA, retrieved NASA Trek blanket, Russian Astra-II, Mir Solar Array Return Experiment (SARE), etc. Results from these experiments were studied in detail to characterize Mir induced contamination. In conjunction with Mir contamination observations, Russian materials samples were tested for condensable outgassing rates in the U.S. These test results were essential in the characterization of Mir contamination sources. Once Mir contamination sources were identified and characterized, activities to assess the implications to ISS were implemented. As a result, modifications in Russian materials selection and/or usage were implemented to control contamination and mitigate risk to ISS.

Soares, Carlos↗
NASA NTRS1983

A FMCW Radar Ranging Device for the Teleoperator Maneuvering System

A frequency-modulated continuous wave radar system is under development in the Communications Systems Branch of the Information and Electronic Systems Laboratory at Marshall Space Flight Center. The radar unit is being designed for use on the teleoperator maneuvering system. Its function is to provide millimeter-level accuracy in range and range rate measurements out to a range of thirty meters. This will facilitate soft docking with accuracy. This report is an updating of previous developments reported on this system. An innovation in the system is the utilization of a standard reference signal generated by shunting a portion of the radar energy into a shorted coaxial delay line. The regular radar target return signal is constantly compared with the reference signal to provide internal error compensation. Within a five meter range, a limit imposed by present laboratory dimensions, the radar system exhibits reliable accuracy with range error less than 0.2%.

Mcdonald, M. W.↗
NASA NTRS1999

Stardust: The Adventure has Begun

The NASA Discovery STARDUST Mission was launched in February, 1999 to fly through the coma of P/Wild 2 in January, 2004 and return captured cometary and interplanetary dust particles to earth in January, 2006 for detailed analyses by the international science community. The STARDUST spacecraft is carrying a dust collector employing JPL Aerogel for collecting interstellar dust during interplanetary cruise and cometary dust during Wild 2 flyby. Additional instrumentation include the MPI fur Extraterrestrische Physik Cometary and Interplanetary Dust Analyzer, the University of Chicago Dust Flux Monitor and the JPL Imaging Camera. Doppler tracking of the spacecraft and high rate attitude orientation and body-fixed rate data from engineering subsystems will also provide science information. The presentation will describe the mission, scientific objectives and current state of the spacecraft in detail.

Duxbury, Thomas C.↗
NASA NTRS2016

Exploring Cognition Using Software Defined Radios for NASA Missions

NASA missions typically operate using a communication infrastructure that requires significant schedule planning with limited flexibility when the needs of the mission change. Parameters such as modulation, coding scheme, frequency, and data rate are fixed for the life of the mission. This is due to antiquated hardware and software for both the space and ground assets and a very complex set of mission profiles. Automated techniques in place by commercial telecommunication companies are being explored by NASA to determine their usability by NASA to reduce cost and increase science return. Adding cognition the ability to learn from past decisions and adjust behavior is also being investigated. Software Defined Radios are an ideal way to implement cognitive concepts. Cognition can be considered in many different aspects of the communication system. Radio functions, such as frequency, modulation, data rate, coding and filters can be adjusted based on measurements of signal degradation. Data delivery mechanisms and route changes based on past successes and failures can be made to more efficiently deliver the data to the end user. Automated antenna pointing can be added to improve gain, coverage, or adjust the target. Scheduling improvements and automation to reduce the dependence on humans provide more flexible capabilities. The Cognitive Communications project, funded by the Space Communication and Navigation Program, is exploring these concepts and using the SCaN Testbed on board the International Space Station to implement them as they evolve. The SCaN Testbed contains three Software Defined Radios and a flight computer. These four computing platforms, along with a tracking antenna system and the supporting ground infrastructure, will be used to implement various concepts in a system similar to those used by missions. Multiple universities and SBIR companies are supporting this investigation. This paper will describe the cognitive system ideas under consideration and the plan for implementing them on platforms, including the SCaN Testbed. Discussions in the paper will include how these concepts might be used to reduce cost and improve the science return for NASA missions.

transmitters receivers↗
NASA NTRS1996

Some Sources of Contaminants in the Shuttle Bay Measured with Temperature-Controlled Quartz Crystal Microbalances (TQCM)

The sources of molecular deposits on a Temperature-Controlled Quartz Crystal Microbalance (TQCM) attached to the shuttle bay wall at some distance from the payload and pointing out of the bay have been investigated. Explored as possible sources are: (1) the outgassing of the shuttle tiles treated with the water proofing di-methyl-ethoxy-silane (DMES) compound, scattered back by the ambient molecules into the bay; (2) The ambient scattered return flux of the outgassing, from the RTV 560 silicone which is used as the adhesive for the tiles; (3) the ambient scattered return flux of the payload outgassing; (4) the return C, flux from outgassing source originating near, below, or adjacent to the package containing the TQCM; and (5) the self-scattering of venting plumes and outgassing above the monitor package depositing on the TQCM. In all of these sources, the magnitudes of the outgassing, of the leakage rates, and venting had to be estimated in the absence of data. The resulting analyses which can be useful for similar investigations, indicates that the outgassin- from the tiles, the RTV, the payloads, or the shuttle may not have been the sources of the deposit (about 1 micro g/cm(sup 2) during a the period from bay door opening and payload release from the bay). It appears more probable that the origin is the self- and/or ambient-scattered return fluxes originating near, below, or internal to the monitor package.

Scialdone, John J.↗
NASA NTRS2000

Rudder/Fin Seal Investigations for the X-38 Re-Entry Vehicle

NASA is currently developing the X-38 vehicle that will be used to demonstrate the technologies required for a crew return vehicle (CRV) for the International Space Station. The X-38 control surfaces require high temperature seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent over-temperature of these structures and possible loss of the vehicle. This paper presents results for thermal analyses and flow and compression tests conducted on as-received and thermally exposed seals for the rudder/fin location of the X-38. A thermal analysis of the rudder/fin dual seal assembly based on representative heating rates on the windward surface of the rudder/fin area predicted a peak seal temperature of 1900 F. The temperature-exposed seals were heated in a compressed state at 1900 F corresponding to the predicted peak temperature. Room temperature compression tests were performed to determine load versus linear compression, preload, contact area, stiffness, and resiliency characteristics for the as-received and temperature-exposed seals. Temperature exposure resulted in permanent set and loss of resiliency in these seals. Unit loads and contact pressures for the seals were below the 5 lb/in. and 10 psi limits set to limit the loads on the Shuttle thermal tiles that the seals seal against in the rudder/fin location. Measured seal flow rates for a double seal were about 4.5 times higher than the preliminary seal flow goal. The seal designs examined in this study are expected to be able to endure the high temperatures that they will be exposed to for a single-use life. Tests performed herein combined with future analyses, arc jet tests, and scrubbing tests will be used to select the final seal design for this application.

Dunlap, Patrick H., Jr.↗
NASA NTRS2000

Rudder/Fin Seal Investigations for the X-38 Re-Entry Vehicle

NASA is currently developing the X-38 vehicle that will be used to demonstrate the technologies required for a crew return vehicle (CRV) for the International Space Station. The X-38 control surfaces require high temperature seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent over-temperature of these structures and possible loss of the vehicle. This paper presents results for thermal analyses and flow and compression tests conducted on as-received and thermally exposed seals for the rudder/fin location of the X-38. A thermal analysis of the rudder/fin dual seal assembly based on representative heating rates on the windward surface of the rudder/fin area predicted a peak seal temperature of 1900 F. The temperature-exposed seals were heated in a compressed state at 1900 F corresponding to the predicted peak temperature. Room temperature compression tests were performed to determine load versus linear compression, preload, contact area, stiffness, and resiliency characteristics for the as-received and temperature-exposed seals. Temperature exposure resulted in permanent set and loss of resiliency in these seals. Unit loads and contact pressures for the seals were below the five pounds/inch and ten psi limits set to limit the loads on the Shuttle thermal tiles that the seals seal against in the rudder/fin location. Measured seal flow rates for a double seal were about 4.5 times higher than the preliminary seal flow goal. The seal designs examined in this study are expected to be able to endure the high temperatures that they will be exposed to for a single-use life. Tests performed herein combined with future analyses, arc jet tests, and scrubbing tests will be used to select the final seal design for this application.

Dunlap, Patrick H., Jr.↗