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The specifications for the performance, design, development, and test requirements of the P2-156, S3-156, and S6-120 space shuttle booster solid rocket motors are presented. The applicable documents which form a part of the specifications are listed.
Additional technical data have been prepared to supplement the data supplied in the SRM shuttle booster final report. These data cover performance characteristics utilizing motor efficiencies of 0.960 and 0.947 with nozzle divergence half angles of 15 deg and 20 deg, respectively; PBAN propellant characteristics; parametric data to extend baseline designs to varying states of SRM's; summary of SRM mass properties; and SRM exhaust plume profiles.
Experimental tests were conducted on two stepping motors for application as reactor control-drum actuators. Various control-drum loads with frictional resistances ranging from approximately zero to 40 N-m and inertias ranging from zero to 0.424 kg-sq m were tested.
The ways are described by which propellant processing is affected by choices made in designing rocket engines. Tradeoff studies, design proof or scaleup studies, and special design features are presented that are required to obtain high product quality, and optimum processing costs. Processing is considered to include the operational steps involved with the lining and preparation of the motor case for the grain; the procurement of propellant raw materials; and propellant mixing, casting or extrusion, curing, machining, and finishing. The design criteria, recommended practices, and propellant formulations are included.
Review and appraisal of the status of the nondestructive tests applied to Scout solid-propellant rocket motors, using analytical techniques to evaluate radiography for detecting internal discontinuities such as voids and unbonds. Information relating to selecting, performing, controlling, and evaluating the results of NDE tests was reduced to a common simplified format. With these data and the results of the analytical studies performed, it was possible to make the basic appraisals of the ability of a test to meet all pertinent acceptance criteria and, where necessary, provide suggestions to improve the situation.
Because same magnetic flux is used to control rotor as to drive it, size, weight, and power required are minimized. Constant total current keeps motor torque invarient, and absence of mechanical bearings eliminates wear and reduces frictional power loss.
In order to test various components of a regenerative life support system and to obtain data on the physiological and psychological effects of long-duration exposure to confinement in a space station atmosphere, four carefully screened young men were sealed in space station simulator for 90 days. A tracking test battery was administered during the above experiment. The battery included a clinical test (critical instability task) related to the subject's dynamic time delay, and a conventional steady tracking task, during which dynamic response (describing functions) and performance measures were obtained. Good correlation was noted between the clinical critical instability scores and more detailed tracking parameters such as dynamic time delay and gain-crossover frequency. The comprehensive data base on human operator tracking behavior obtained in this study demonstrate that sophisticated visual-motor response properties can be efficiently and reliably measured over extended periods of time.
A systematic and standardized procedure for estimating life cycle costs of solid rocket motor booster configurations. The model consists of clearly defined cost categories and appropriate cost equations in which cost is related to program and hardware parameters. Cost estimating relationships are generally based on analogous experience. In this model the experience drawn on is from estimates prepared by the study contractors. Contractors' estimates are derived by means of engineering estimates for some predetermined level of detail of the SRM hardware and program functions of the system life cycle. This method is frequently referred to as bottom-up. A parametric cost analysis is a useful technique when rapid estimates are required. This is particularly true during the planning stages of a system when hardware designs and program definition are conceptual and constantly changing as the selection process, which includes cost comparisons or trade-offs, is performed. The use of cost estimating relationships also facilitates the performance of cost sensitivity studies in which relative and comparable cost comparisons are significant.
A technical analysis of the solid propellant rocket engines for use with the space shuttle is presented. The subjects discussed are: (1) solid rocket motor stage recovery, (2) environmental effects, (3) man rating of the solid propellant rocket engines, (4) system safety analysis, (5) ground support equipment, and (6) transportation, assembly, and checkout.
Preliminary parametric studies were performed to establish size, weight and packaging arrangements for aerodynamic decelerator devices that could be used for recovery of the expended solid propellant rocket motors used in the launch phase of the Space Shuttle System. Computations were made using standard engineering analysis techniques. Terminal stage parachutes were sized to provide equilibrium descent velocities for water entry that are presently thought to be acceptable without developing loads that could exceed the boosters structural integrity. The performance characteristics of the aerodynamic parachute decelerator devices considered are based on analysis and prior test results for similar configurations and are assumed to be maintained at the scale requirements of the present problem.
This supplement to Task lB-Large Solid Rocket Motor Case Fabrication Methods supplies additional supporting cost data and discusses in detail the methodology that was applied to the task. For the case elements studied, the cost was found to be directly proportional to the Process Complexity Factor (PCF). The PCF was obtained for each element by identifying unit processes that are common to the elements and their alternative manufacturing routes, by assigning a weight to each unit process, and by summing the weighted counts. In three instances of actual manufacture, the actual cost per pound equaled the cost estimate based on PCF per pound, but this supplement, recognizes that the methodology is of limited, rather than general, application.
A high torque motor with improved servo mechanism is reported. Armature windings are cast into an epoxy cylinder and armature conductors are integrally cast with an aluminum mounting ring which provides thermal conductance directly into the structure. This configuration eliminates magnetic hysteresis because there is no relative motion between the rotating magnetic field and any stationary iron. The absence of destabilization forces provides a fast electrical response compared with a typical torquer of conventional construction.
A voltage controlled oscillator circuit is reported in which there are employed first and second differential amplifiers. The first differential amplifier, being employed as an integrator, develops equal and opposite slopes proportional to an input voltage, and the second differential amplifier functions as a comparator to detect equal amplitude positive and negative selected limits and provides switching signals which gate a transistor switch. The integrating differential amplifier is switched between charging and discharging modes to provide an output of the first differential amplifier which upon the application of wave shaping provides a substantially sinusoidal output signal. A two phased version with a second integrator provides a second 90 deg phase shifted output for induction motor control.
Three 71-cm-diameter boron/epoxy composite rocket motor chambers were filament wound. The first chamber was hydrostatically tested; the second failed in proof test as a result of fabrication deficiencies. The third chamber obtained a successful proof test, but deformed later in processing because of hydrolysis. In spite of the deformation, this chamber was test fired and then burst tested.
A new analytical technique for the solution of nonlinear longitudinal combustion instability problems in rocket combustors is developed. Using relatively little computation time, this technique is capable of predicting the transient and limit cycle behavior of the combustion instability oscillations as well as the disturbance amplitude required to trigger an instability in a linearly stable motor. The limit cycle waveforms are found to exhibit shock wave characteristics for most unstable engine operating conditions. It is shown that the characteristics of the resulting instability are independent of the nature of the initial disturbance and they depend solely upon the engine operating conditions and the characteristics of the unsteady combustion process.
Acoustic emission (AE) patterns were measured during pressure testing of advanced composite rocket motor cases made of boron/epoxy and graphite/epoxy. Both accelerometers and high frequency AE transducers were used, and both frequency spectrum and amplitude distribution were studied. The AE patterns suggest that precursor emission might be used in certain cases to anticipate failure. The technique of hold-cycle AE monitoring was also evaluated and could become a valuable decision gate for test continuation/termination. Data presented show similarity of accelerometers and AE transducer responses despite the different frequency response, and suggest that structural AE phenomena are broadband.
Four 71-cm-diameter rocket motor chambers were designed and fabricated with advanced composite materials. The first three chambers were filament wound from boron/epoxy tape, and the fourth from graphite/epoxy tape. The first boron/epoxy chamber was 74 cm in length and was successfully hydroburst tested. The other three chambers were 57.6 cm in length for a smaller propellant load. The first shortened boron/epoxy chamber failed in proof test as a result of fabrication deficiencies. The last boron/epoxy and the graphite/epoxy chambers were successfully proof tested.
Method demonstrates inexpensive, safe, and foolproof concept for solid propellant rocket motors, using simple handpump to deliver air. Flueric ignition was accomplished using system without stored energy and with complete absence of electrical energy and wiring.