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The characteristics and applications of various materials for fireproofing aerospace vehicles are discussed. Materials described are: (1) fibrous materials, (2) nonflammable paper and paperboard, (3) elastomers, (4) foams, and (5) plastics. The suitability of the various materials for specific applications are investigated.
The development of a nonflammable elastomer for use in Apollo spacecraft is discussed. The requirements for the material to be foamed, extruded, compression molded, and cast into various configurations are examined. A fluorine-based hydrocarbon is considered a promising candidate. An acceptable material known as Fluorel is examined. Procedures for applying fluorel to a flood light glare shield are presented. The process for preparing 20 percent homogenized Fluorel is analyzed.
A study program is discussed which includes a survey of industry and government laboratories and was undertaken to determine the state of the art in dealing with problems of high power levels in reentry antenna design. A laboratory program to develop techniques for testing dielectric materials for effects on RF transmission is also considered, with emphasis on high power applications in space and reentry flights. The study program resulted in a set of guidelines for avoiding breakdown in antenna design. A discussion of temperature effects on dielectric breakdown is also given. From the laboratory program, a description is presented of techniques for (1) heating with a carbon arc image furnace, (2) temperature measurement (using thermocouples and an infrared pyrometer), (3) mass spectrometric monitoring of outgassing, (4) testing for RF breakdown in both heated dielectrics and the dielectric/air and dielectric/plasma interfaces. Data and observations are reported from technique development using candidate shuttle materials falling into three categories: (1) lightweight refractory foams, (2) dense RF window materials, and (3) ablative materials.
A variety of silicon-carbide treated carbon and graphite products were prepared, and oxidation and strength properties determined. Carbon and graphite materials used in the preliminary study include fiber, tape, felt, foam, bulk, and laminar configurations. The silicon-carbide treatment used in preparing the oxidation resistant specimens employs either vacuum or ultrasonic impregnation of various silicone-silicon mixtures into the matrix material. The impregnation phase is followed by controlled thermal reaction at which time the silicon carbide is synthesized and takes the form of an integral protective boundary layer. Thickness of the layer ranges from a fraction of a mil to 10 mils, depending on the matrix material and processing parameters. Oxidation resistance of all the silicon-carbide-treated specimens investigated was found to be significantly improved. Mechanical strengths of the laminar composites were also found to be somewhat improved. At room temperature the specific strength of the silicon-carbide treated fibers and tapes was degraded to some extent; however, their relative strengths were significantly increased at elevated temperatures in oxidizing atmosphere.
An investigation into the electrostatic phenomena associated with the manufacturing and handling of explosives is discussed. The testing includes measurement of the severity of the primary charge generation mechanism, triboelectric effects between dissimilar surfaces; refinement of equivalent circuits of the XM15/XM165 and E8 fuse trains; evaluation of the electrostatic spark discharge characteristics predicted by an equivalent circuit analysis; and determination of the spark ignition sensitivity of materials, components, junctions, and subassemblies which compose the XM15/XM165 and E8 units. Special studies were also performed. These special tests included ignition sensitivity of the complete XM15 fuse train when subjected to discharges through its entire length, measurement of electrostatic potentials which occur during the E8 foaming operation during fabrication, and investigation of the inadvertent functioning of an XM15 cluster during manufacturing. The test results are discussed and related to the effectiveness of suggested modification to reduce the electrostatic ignition sensitivity.
Manufacturing development studies have been conducted to provide information on the fabrication and handling characteristics of a number of candidate multilayer insulation systems. The application of these complex, lightweight insulation systems to large-scale, flight-type cryogenic tankage and other structures has of necessity required the development of new methods, processes, and tooling concepts. Results of some of the studies that have contributed to the advancement of cryogenic technology are presented. The insulation systems that are of primary importance for future application are those using the sliced foam spacers, the net type spacers, the glass fiber paper spacers, and the Superfloc system which consists of tufts of dacron fibers flocked on the surface of the radiation shields.
Passive microwave measurements were studied for determining sea state. It was found that the brightness temperature increases due to the foam produced by winds, and that the surface wind can be determined by the brightness temperature.
A torsional pendulum apparatus designed for testing in situ in vacuum, the dynamic mechanical properties of materials is described. The application of this apparatus to an experimental program to measure the effects of vacuum on the mechanical properties of two ablator materials (a foamed material and a filled elastomer) and a solid rocket propellant (a filled elastomer) is presented. Results from the program are discussed as to the effects of vacuum on the mechanical properties of these three materials. In addition, time-temperature-superposition, as a technique for accelerating vacuum induced changes in mechanical properties, is discussed with reference to the three materials tested in the subject program.
The equations which describe the emissivity of a rough ocean surface are developed. The theory includes effects of large scale and small scale wave structure and the influence of shadowing by the large ocean waves. Also included are investigations of the emission properties of foam and the influence of the thermal boundary layer on the brightness temperature characteristics of the ocean surface.
Review of the results of some experimental and theoretical investigations of various limiting factors in microwave measurements of thermal emission from the sea, ranging from instrumentation to surface properties of the ocean. It is shown that absolute measurement of the thermal emission from the sea can be made at 2.69 GHz, with accuracies of better than plus or minus 1 K within the present state of microwave instrument development. The principal uncertainties on interpretation of such observations in terms of molecular temperature of the sea involve: (1) surface contamination such as oil slicks, (2) spray and foaming, (3) salinity variation, and (4) surface waves.
Data was obtained on silicone-bonded fiberglass, isocyanurate foam, and two dozen other insulators. Materials were selected to withstand heat sterilization, outer space, and the Martian atmosphere. Significant environmental parameters were vibration, landing shock, and launch venting.
Pretreatment of urine prevents micro-organism growth in boiler and kills micro-organisms in condenser. Chemicals also clean evaporation surface, fix ammonia in boiling chamber, and suppress foaming.
A study of internal insulation materials and fabrication processes for space shuttle LH2 tanks is reported. Emphasis was placed on an insulation system capable of reentry and multiple reuse in the Shuttle environment. Results are given on the optimization and manufacturing process scale-up of a 3D fiberreinforced foam insulation, BX-251-3D, derived from the Saturn S-4B internal insulation. It is shown that BX-251-3D can be satisfactorily installed in large-scale tanks under conditions that will permit a significant cost saving over the existing S-4B technology.
A study to define promising materials, significant processing criteria, and the related processing techniques and apparatus for the preparation of composite materials in space was conducted. The study also established a program for zero gravity experiments and the required developmental efforts. The following composite types were considered: (1) metal-base fiber and particle composites, including cemented compacts, (2) controlled density metals, comprising plain and reinforced metal foams, and (3) unidirectionally solidified eutectic alloys. A program of suborbital and orbital experiments for the 1972 to 1978 time period was established to identify materials, processes, and required experiment equipment.
An experimental study to determine the acoustic fatigue characteristics of a flat multi-layered structural panel is described. The test panel represented a proposed design for the outer skin of a research application module to be housed within the space shuttle orbiter vehicle. The test specimen was mounted in one wall of the Wyle 100,000 cu ft reverberation room and exposed to a broadband acoustic environment having an overall level of 145 db. The test panel was exposed to nine separate applications of the acoustic environment, each application consisting of 250 seconds duration. Upon completion of the ninth test run, the specimen was exposed to a simulated micrometeoroid impact near the panel center. One additional test run of 250 seconds duration was then performed to complete the overall simulation of 50 flight missions. The experimental results show that no significant fatigue damage occurred until the test specimen was exposed to a simulated micrometeoroid impact. The intermediate foam layer forming the core of the test specimen suffered considerable damage due to this impact, causing a marked variation in the dynamic characteristics of the overall test panel. During the final application of the acoustic environment, the strain and acceleration response spectra showed considerable variation from those spectra obtained prior to impact of the panel. Fatigue damage from acoustic loading however, was limited to partial de-bonding around the edges of the composite panel.
The author has identified the following significant results. Three successful ERTS-1 satellite passes have produced synoptic imagery showing distribution of suspended matter and aquatic interfaces over Delaware Bay and adjacent Atlantic coastal regions. The interfaces are a major hydrographic feature in Delaware Bay and frequently include regions of high convergence. In the upper and middle bay the interfaces tend to align along the flow axis of the river and parallel to the shoreline. A correlation has been found between the concentration of sand particles in suspension and the depth, suggesting that most of the heavier particles are lifted into temporary suspension over shoals and shallow areas by currents and waves. The second type of interface is primarily a tidal intrusion of shelf water into the bay during incipient flood tide, with associated discontinuities in salinity and temperature. The convergence properties of such fronts attract heavy accumulations of foam which were found to contain strong concentrations of heavy metals and other toxic substances.
The extremely lightweight, low power design of the cosmic radiation experiment is obtained by using less than 10 percent of the total weight for the mechanical system. Both the baseplate and the top plate are aluminum honeycomb, the side panels are magnesium trusswork, and the inside circuitry is stacked like a sandwich and interleaved with polyester urethane foam for vibration damping. The flight performance of the experimental hardware is excellent.
Major ocean currents such as the Loop Current in the eastern Gulf of Mexico have surface manifestations which can be exploited for remote sensing. Surface chlorophyll-a concentrations, which contribute to the shift in color from blue to green in the open sea, were found to have high spatial variability; significantly lower concentrations were observed in the current. The cyclonic edge of the current is an accumulation zone which causes a peak in chlorophyll concentration. The dynamics also cause surface concentrations of algae, which have a high reflectance in the near infrared. Combining these observations gives rise to an edge effect which can show up as a bright lineation on multispectral imagery delimiting the current's boundary under certain environmental conditions. When high seas introduce bubbles, white caps, and foam, the reflectance is dominated by scattering rather than absorption. This has been detected in ERTS imagery and used for current location.