New directions in materials research dictated by stringent future requirements
Materials research for thermal reactors, jet engines, space shuttles, and space nuclear power systems
Manson, S. S.↗
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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An analysis of the booster plume impingement environment during the space shuttle nominal staging maneuver
An experimental study of the plume impingement heating on the space shuttle booster afterbody resulting from the space shuttle orbiter engine plumes was conducted. The 1/100-scale model tests consisted of one and two orbiter engine firings on a flat plate, a flat plate with a fin, and a cylinder model. The plume impingement heating rates on these surfaces were measured using thin film heat transfer gages. Results indicate the engine simulation is a reasonable approximation to the two engine configuration, but more tests are needed to verify the plume model of the main engine configuration. For impingment, results show models experienced laminar boundary layer convective heating. Therefore, tests at higher Reynolds numbers are needed to determine impingment heating.
Wojciechowski, C. J.↗
Study of aerodynamic surface control of space shuttle boost and reentry, volume 1
The optimization technique is described which was used in the study for applying modern optimal control technology to the design of shuttle booster engine reaction control systems and aerodynamic control systems. Complete formulations are presented for both the ascent and reentry portions of the study. These formulations include derivations of the 6D perturbation equations of motion and the process followed in the control and blending law selections. A total hybrid software concept applied to the study is described in detail. Conclusions and recommendations based on the results of the study are included.
Chang, C. J.↗
Active-standby servovalue/actuator development
A redundant, fail/operate fail/fixed servoactuator was constructed and tested along with electronic models of a servovalve. It was found that a torque motor switch is satisfactory for the space shuttle main engine hydraulic actuation system, and that this system provides an effective failure monitoring technique.
Masm, R. K.↗
Operating manual for coaxial injection combustion model
An operating manual for the coaxial injection combustion model (CICM) is presented as the final report for an eleven month effort designed to provide improvement, to verify, and to document the comprehensive computer program for analyzing the performance of thrust chamber operation with gas/liquid coaxial jet injection. The effort culminated in delivery of an operation FORTRAN IV computer program and associated documentation pertaining to the combustion conditions in the space shuttle main engine. The computer program is structured for compatibility with the standardized Joint Army-Navy-NASA-Air Force (JANNAF) performance evaluation procedure. Use of the CICM in conjunction with the JANNAF procedure allows the analysis of engine systems using coaxial gas/liquid injection.
Sutton, R. D.↗
Space shuttle SRM interim contract, part 2
The characteristics of the solid rocket propellant for use with the space shuttle rocket engine are discussed. Design ramifications have created different web thicknesses and motor operating pressures which have necessitated small changes in the required propellant burning rate at 1,000 psia. However, the SRM burning rate remains well within the range demonstrated in the Poseidon and Minuteman first stage motors. Any change in propellant burning rate can be accomplished readily by a slight modification in the oxidizer particle size distribution. The ballistic and mechanical properties of the propellant remain unchanged from the baseline (Configuration 0).
Source record↗
SSME/side loads analysis for flight configuration, revision A
This document describes the dynamic loads analysis accomplished for the Space Shuttle Main Engine (SSME) considering the side load excitation associated with transient flow separation on the engine bell during ground ignition. The results contained herein pertain only to the flight configuration. A Monte Carlo procedure was employed to select the input variables describing the side load excitation and the loads were statistically combined. This revision includes an active thrust vector control system representation and updated orbiter thrust structure stiffness characteristics. No future revisions are planned but may be necessary as system definition and input parameters change.
Holland, W.↗
Error protection capability of space shuttle data bus designs
Error protection assurance in the reliability of digital data communications is discussed. The need for error protection on the space shuttle data bus system has been recognized and specified as a hardware requirement. The error protection techniques of particular concern are those designed into the Shuttle Main Engine Interface (MEI) and the Orbiter Multiplex Interface Adapter (MIA). The techniques and circuit design details proposed for these hardware are analyzed in this report to determine their error protection capability. The capability is calculated in terms of the probability of an undetected word error. Calculated results are reported for a noise environment that ranges from the nominal noise level stated in the hardware specifications to burst levels which may occur in extreme or anomalous conditions.
Proch, G. E.↗
Validation testing of shallow notched round-bar screening test specimens
The capability of shallow-notched, round-bar, tensile specimens for screening critical environments as they affect the material fracture properties of the space shuttle main engine was tested and analyzed. Specimens containing a 0.050-inch-deep circumferential sharp notch were cyclically loaded in a 5000-psi hydrogen environment at temperatures of +70 and -15 F. Replication of test results and a marked change in cyclic life because of temperature variation demonstrated the validity of the specimen type to be utilized for screening tests.
Vroman, G. A.↗
High-Pressure Oxygen Test Evaluations
The relevance of impact sensitivity testing to the development of the space shuttle main engine is discussed in the light of the special requirements for the engine. The background and history of the evolution of liquid and gaseous oxygen testing techniques and philosophy is discussed also. The parameters critical to reliable testing are treated in considerable detail, and test apparatus and procedures are described and discussed. Materials threshold sensitivity determination procedures are considered and a decision logic diagram for sensitivity threshold determination was plotted. Finally, high-pressure materials sensitivity test data are given for selected metallic and nonmetallic materials.
Schwinghamer, R. J.↗
SSME-HAS dynamic load simulators
The space shuttle main engine propellant valve actuators (SSME) were designed to simulate the loads reflected into the SSME by the chamber coolant valve, the fuel preburner, and the oxidizer. The design, and functional description are included along with a list of the drawings. The load fixture control transform, friction torque, and flow calculations are reported.
Source record↗
Shuttle LOX loading transient study. Task 2 milestone report. National space and technology laboratories (NSTL) LOX loading facility analysis
Transient thermodynamic analyses were made of the LOX loading system proposed for the space shuttle main propulsion test article (MPTA). This system is made up of a LOX replenish system and a main LOX line which include the barge tank, the lines, pumps, and valves between the barge and the orbiter (ORB) ground service equipment (GSE) interface, the MPTA fill system, the space shuttle main engine (SSME) chilldown bleed system, and the GSE vent system. System analyses include predictions of system performance sensitivity to operating sequence and LOX flowrate, temperature, and quality at the ORB/GSE interface. The transient thermodynamic conditions at the SSME feed line entrance, ET entrance (tank bottom), and the SSME bleed/GSE vent TEE are also included. The analyses are based on continuous SSME bleed flow during GSE facility chilldown.
Glasgow, V. L.↗
Milestone report TCTP application to the SSME hydrogen system analysis
The Transient Cryogen Transfer Computer Program (TCTP) developed and verified for LOX systems by analyses of Skylab S-1B stage loading data from John F. Kennedy Space Center launches was extended to include hydrogen as the working fluid. The feasibility of incorporating TCTP into the space shuttle main engine dynamic model was studied. The program applications are documented.
Richards, J. S.↗
Task 3 Milestone Report, Kennedy Space Center (KSC) LOX Loading Facility Analyses
Transient thermodynamic analyses have been made for the Kennedy Space Center (KSC) LOX loading system proposed for the space shuttle. The primary objective of these analyses is to predict the sensitivity of system performance to operating procedures, flow rate, temperature, and quality at the orbiter (ORB)/ground service equipment (GSE) interface. A further objective is to establish required system chill-down times. These analyses also include the prediction of transient thermodynamic conditions for the facility vent line, shuttle main engine (SSME) feed line entrance, ORB/ET interface, and the ET entrance (tank bottom).
Glasgow, V. L.↗
SSME turbopump technology improvements via transient rotordynamic analysis
The rotordynamic behavior of the high pressure oxygen turbopump and high pressure fuel pump was analyzed for the Space Shuttle Main Engine. The identification of potential rotordynamic problem areas which might arise during operation of these units prior to their testing was accomplished. Alternative procedures for correcting potential rotordynamic problems should they occur were investigated. An adequate analytic and physical understanding of the turbopump rotordynamics was developed to improve the probability of a correct diagnosis of rotordynamic problems from test data. Transient rotordynamic models were developed for both turbopumps. The transient models model the hydrodynamic forces of the turbopump seals. A linear stability analysis was performed for the turbopump rotordynamics models, which included gyroscopic effects, seal forces, speed-dependent bearing characteristics, and internal rotor damping. Results are presented and discussed.
Childs, D. W.↗
An evaluation of dry film lubricants and substrate materials for use on SSME gimbal bearings
Failure of the spherical bearing shaft of the Space Shuttle Main Engine (SSME) gimbal bearing assembly was encountered during Design Verification Specification testing of the full scale engine. Investigation revealed that the failure was caused by a deficiency in the lubrication system. Based upon the materials and gimbal operating conditions, a lubricant of MoS2 and graphite with a ceramic binder was the best lubricant candidate for this particular application; however, the decision to implement the change was not made without verification testing. Scaled down simulation testing was performed. Four different substrate materials and eight different dry film lubricants were subjected to tests under simulated SSME environmental and stress load conditions. The test specimens were evaluated for friction and operating life. Each test specimen was subjected to cyclic operation under load until failure. The force required to move the bearing surfaces relative to each other was monitored throughout the test, thus providing analytical data for derivation of the coefficient of friction. Results indicate that the MoS2/graphite lubricant with ceramic binder proved to be superior from the standpoint of endurance and also from the standpoint of friction reducing capabilities when applied to the titanium substrate material used on SSME. Endurance of this lubricant was approximately 16 times that of the lubricant which was being used when the SSME gimbal failed.
Harp, J. A.↗
Space Shuttle 1976 into mainstream development - Program commitments on schedule to insure careful progress
A progress report is given on various systems, noting conformity to schedule or changes in design. The Orbiter thermal protection system, the Space Shuttle main engine, the intertank for the structural test article (STA), thrust vector control systems, the Kennedy Space Center launch processing system, and Orbiters No. 1 and No. 2 are discussed.
Malkin, M. S.↗
TVC actuator model
A prototype Space Shuttle Main Engine (SSME) Thrust Vector Control (TVC) Actuator analog model was successfully completed. The prototype, mounted on five printed circuit (PC) boards, was delivered to NASA, checked out and tested using a modular replacement technique on an analog computer. In all cases, the prototype model performed within the recording techniques of the analog computer which is well within the tolerances of the specifications.
Baslock, R. W.↗