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At least 1,171 records · Page 65
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Investigation Leads to Improved Understanding of Space Shuttle RSRM Internal Insulation Joints

The Space Shuttle Reusable Solid Rocket Motor (RSRM) uses an internal insulation J-joint design for the mated insulation interface between two assembled RSRM segments. In this assembled (mated) segment configuration, this J-joint design serves as a thermal barrier to prevent hot gases from affecting the case field joint metal surfaces and O-rings. A pressure sensitive adhesive (PSA) provides some adhesion between the two mated insulation surfaces. In 1995, after extensive testing, a new ODC-free PSA (free of ozone depleting chemicals) was selected for flight on RSRM-55 (STS-78). Post-flight inspection revealed that the J-joint, equipped with the new ODC-free PSA, did not perform well. Hot gas seeped inside the J-joint interface. Although not a flight safety threat, the J-joint hot gas intrusion on RSRM-55 was a mystery to the investigators since the PSA had previously worked well on a full-scale static test. A team was assembled to study the J-joint and PSA further. All J-joint design parameters, measured data, and historical performance data were re-reviewed and evaluated by subscale testing and analysis. Although both the ODC-free and old PSA were weakened by humidity, the ODC-free PSA strength was lower to start with. Another RSRM full-scale static test was conducted in 1998 and intentionally duplicated the gas intrusion. This test, along with many concurring tests, showed that if a J-joint was 1) mated with the new ODC-free PSA, 2) exposed to a history of high humidity (Kennedy Space Center levels), and 3) also a joint which experienced significant but normal joint motion (J-joint deformation resulting from motor pressurization dynamics) then that J-joint would open (allow gas intrusion) during motor operation. When all of the data from the analyses, subscale tests, and full-scale tests were considered together, a theory emerged. Most of the joint motion on the RSRM occurs early in motor operation at which point the J-joints are pulled into tension. If the new PSA has been weakened due to humidity, then the J-joint will partially pull apart (inboard side), and the J-joint surfaces will be charred by exposure to hot gases. After early operation, a J-joint that has been pulled apart will come back together as the J-joint deformation decreases. This J-joint heating event is relatively short and occurs only during the first part of motor operation. Internal instrumentation was developed for another full-scale static test in February 2000. The static test instrumentation did indeed prove this theory to be correct. Post-test inspection revealed very similar charring characteristics as observed on RSRM-55. This experience of the development of a new PSA, its testing, the RSRM-55 flight, followed by the J-joint investigation led to good 'lessons learned' and to an additional fundamental understanding of the RSRM J-joint function.

McWhorter, Bruce B.↗
NASA NTRS2003

Characterization of Effluents Given Off by Wiring Insulation

When an insulated wire is heated, the insulation emits a variety of effluents. This paper discusses the basis of emissions of effluents from wiring insulation. Several species are emitted at relatively low temperatures, while others are emitted when the wire reaches higher temperatures. We isolate the emissions by relative molecular weight of the effluents and measure the effluent concentration both as a function of time (temperature held constant) and by wire temperature. We find that the Law of Mass Action describes and predicts the time-dependence of the emission of a specific effluent caused by the heating. The binding energy is determined by performing an Arrhenius Plot on the temperature data. These dependencies are discussed and working equations are derived. Data collected from 20 gauge wire (MIL-W-22759/11-20) is used to illustrate and confirm the validity of the theory.

Yost, William T.↗
NASA NTRS2003

Cryopumping in Cryogenic Insulations for a Reusable Launch Vehicle

Testing at cryogenic temperatures was performed to verify the material characteristics and manufacturing processes of reusable propellant tank cryogenic insulations for a Reusable Launch Vehicle (RLV). The unique test apparatus and test methods developed for the investigation of cryopumping in cryogenic insulations are described. Panel level test specimens with various types of cryogenic insulations were subjected to a specific thermal profile where the temperature varied from -262 C to 21 C. Cryopumping occurred if the interior temperature of the specimen exhibited abnormal temperature fluctuations, such as a sudden decrease in temperature during the heating phase.

Johnson, Theodore F.↗
NASA NTRS2000

Characterization of an Integral Thermal Protection and Cryogenic Insulation Material for Advanced Space Transportation Vehicles

NASA's planned advanced space transportation vehicles will benefit from the use of integral/conformal cryogenic propellant tanks which will reduce the launch weight and lower the earth-to-orbit costs considerably. To implement the novel concept of integral/conformal tanks requires developing an equally novel concept in thermal protection materials. Providing insulation against reentry heating and preserving propellant mass can no longer be considered separate problems to be handled by separate materials. A new family of materials, Superthermal Insulation (STI), has been conceiving and investigated by NASA's Ames Research Center to simultaneously provide both thermal protection and cryogenic insulation in a single, integral material.

Salerno, L. J.↗
NASA NTRS2001

Investigating the Use of Ultrasound for Evaluating Aging Wiring Insulation

This paper reviews our initial efforts to investigate the use of ultrasound to evaluate wire insulation. Our initial model was a solid conductor with heat shrink tubing applied. In this model, various wave modes were identified. Subsequently, several aviation classes of wires (MIL-W- 81381, MIL-W-22759/34, and MIL-W-22759/87) were measured. The wires represented polyimide and ethylene-tetraflouroethylene insulations, and combinations of polyimide and flouropolymer plastics. Wire gages of 12, 16, and 20 AWG sizes were measured. Finally, samples of these wires were subjected to high temperatures for short periods of time to cause the insulation to degrade. Subsequent measurements indicated easily detectable changes.

Madaras, Eric I.↗
NASA NTRS2001

Ultrasonic Guided Waves for Aging Wire Insulation Assessment

Environmentally aged wire insulation can become brittle and crack and thus expose the underlying conductive wire to the potential for short circuits and fire. The feasibility of using ultrasonic guided waves to measure insulation condition was examined. First a simple model to study guided wave propagation in a bare and thin plastic coated wire was examined and then some aviation grade wire samples that had been heat-damaged. Initial measurements indicate that ultrasonic guided wave velocity can be used to monitor insulation stiffness.

Anastasi, Robert F.↗
NASA NTRS2005

Detection and Characterization of Flaws in Sprayed on Foam Insulation with Pulsed Terahertz Frequency Electromagnetic Waves

The detection and repair of flaws such as voids and delaminations in the sprayed on foam insulation of the external tank reduces the probability of foam debris during shuttle ascent. The low density of sprayed on foam insulation along with it other physical properties makes detection of flaws difficult with conventional techniques. An emerging technology that has application for quantitative evaluation of flaws in the foam is pulsed electromagnetic waves at terahertz frequencies. The short wavelengths of these terahertz pulses make them ideal for imaging flaws in the foam. This paper examines the application of terahertz pulses for flaw detection in foam characteristic of the foam insulation of the external tank. Of particular interest is the detection of voids and delaminations, encapsulated in the foam or at the interface between the foam and a metal backing. The technique is shown to be capable of imaging small voids and delaminations through as much as 20 cm of foam. Methods for reducing the temporal responses of the terahertz pulses to improve flaw detection and yield quantitative characterizations of the size and location of the flaws are discussed.

Winfree, William P.↗
NASA NTRS2005

Phase Contrast X-ray Imaging of Shuttle Insulating Foam

X-ray radiation has been widely used for imaging applications since Rontgen first discovered X-rays over a century ago. Its large penetration depth makes it ideal for the nondestructive visualization of internal structure of materials or objects unobtainable otherwise. Currently widely used nondestructive evaluation (NDE) tools-X-ray radiography and tomography are absorption-based, and work well in highly absorbing materials where density or composition variations due to internal structure or defects are high enough to be spatially distinguished in terms of absorption contrast. However, in many cases where materials such as insulating foam are light-weight, the conventional absorption-based X-ray methods for NDE become less effective. Indeed, the low-density shuttle insulating foam used for flight mission poses a great challenge to the standard NDE tools in that the absorption contrast arising from internal defects of such a low- density material is either weak or indistinguishable. In this presentation, the latest progress in phase contrast X-ray imaging of internal defects of insulating foam will be presented and discussed, demonstrating new opportunities to solve challenging issues involved in advanced materials development and processing for space exploration.

Hu, Zhengwei↗
NASA NTRS2002

Silicon-on-insulator (SOI) active pixel sensors with the photosite implemented in the substrate

Active pixel sensors for a high quality imager are fabricated using a silicon-on-insulator (SOI) process by integrating the photodetectors on the SOI substrate and forming pixel readout transistors on the SOI thin-film. The technique can include forming silicon islands on a buried insulator layer disposed on a silicon substrate and selectively etching away the buried insulator layer over a region of the substrate to define a photodetector area. Dopants of a first conductivity type are implanted to form a signal node in the photodetector area and to form simultaneously drain/source regions for a first transistor in at least a first one of the silicon islands. Dopants of a second conductivity type are implanted to form drain/source regions for a second transistor in at least a second one of the silicon islands. Isolation rings around the photodetector also can be formed when dopants of the second conductivity type are implanted. Interconnections among the transistors and the photodetector are provided to allow signals sensed by the photodetector to be read out via the transistors formed on the silicon islands.

Pain, Bedabrata↗
NASA NTRS2005

Silicon-on-insulator (SOI) active pixel sensors with the photosite implemented in the substrate

Active pixel sensors for a high quality imager are fabricated using a silicon-on-insulator (SOI) process by integrating the photodetectors on the SOI substrate and forming pixel readout transistors on the SOI thin-film. The technique can include forming silicon islands on a buried insulator layer disposed on a silicon substrate and selectively etching away the buried insulator layer over a region of the substrate to define a photodetector area. Dopants of a first conductivity type are implanted to form a signal node in the photodetector area and to form simultaneously drain/source regions for a first transistor in at least a first one of the silicon islands. Dopants of a second conductivity type are implanted to form drain/source regions for a second transistor in at least a second one of the silicon islands. Isolation rings around the photodetector also can be formed when dopants of the second conductivity type are implanted. Interconnections among the transistors and the photodetector are provided to allow signals sensed by the photodetector to be read out via the transistors formed on the silicon islands.

Zheng, Xinyu↗
NASA NTRS2008

Aerogels Insulate Missions and Consumer Products

Aspen Aerogels, of Northborough, Massachusetts, worked with NASA through an SBIR contract with Kennedy Space Center to develop a robust, flexible form of aerogel for cryogenic insulation for space shuttle launch applications. The company has since used the same manufacturing process developed under the SBIR award to expand its product offerings into the more commercial realms, making the naturally fragile aerogel available for the first time as a standard insulation that can be handled and installed just like standard insulation.

Source record↗
NASA NTRS2008

Extreme High and Low Temperature Operation of the Silicon-On-Insulator Type CHT-OPA Operational Amplifier

A new operational amplifier chip based on silicon-on-insulator technology was evaluated for potential use in extreme temperature environments. The CHT-OPA device is a low power, precision operational amplifier with rail-to-rail output swing capability, and it is rated for operation between -55 C and +225 C. A unity gain inverting circuit was constructed utilizing the CHT-OPA chip and a few passive components. The circuit was evaluated in the temperature range from -190 C to +200 C in terms of signal gain and phase shift, and supply current. The investigations were carried out to determine suitability of this device for use in space exploration missions and aeronautic applications under wide temperature incursion. Re-restart capability at extreme temperatures, i.e. power switched on while the device was soaked at extreme temperatures, was also investigated. In addition, the effects of thermal cycling under a wide temperature range on the operation of this high performance amplifier were determined. The results from this work indicate that this silicon-on-insulator amplifier chip maintained very good operation between +200 C and -190 C. The limited thermal cycling had no effect on the performance of the amplifier, and it was able to re-start at both -190 C and +200 C. In addition, no physical degradation or packaging damage was introduced due to either extreme temperature exposure or thermal cycling. The good performance demonstrated by this silicon-on-insulator operational amplifier renders it a potential candidate for use in space exploration missions or other environments under extreme temperatures. Additional and more comprehensive characterization is, however, required to establish the reliability and suitability of such devices for long term use in extreme temperature applications.

Patterson, Richard↗
NASA NTRS2008

New Materials for the Repair of Polyimide Electrical Wire Insulation

Two viable polyimide backbone materials have been identified that will allow the repair of polyimide electrical wire insulation found on the Space Shuttle and other aging aircraft. This identification is the outcome of ongoing efforts to assess the viability of using such polyimides and polyimide precursors (polyamic acids [PAAs]) as repair materials for aging polyimide electrical wire insulation. These repair materials were selected because they match the chemical makeup of the underlying wire insulation as closely as possible. This similarity allows for maximum compatibility, coupled with the outstanding physical properties of polyimides. The two polyimide backbone materials allow the polymer to be extremely flexible and to melt at low temperatures. A polymer chain end capping group that allows the polymer to crosslink into a nonflowable repair upon curing at around 200 C was also identified.

Source record↗
NASA NTRS2009

Improved Aerogel Vacuum Thermal Insulation

An improved design concept for aerogel vacuum thermal-insulation panels calls for multiple layers of aerogel sandwiched between layers of aluminized Mylar (or equivalent) poly(ethylene terephthalate), as depicted in the figure. This concept is applicable to both the rigid (brick) form and the flexible (blanket) form of aerogel vacuum thermal-insulation panels. Heretofore, the fabrication of a typical aerogel vacuum insulating panel has involved encapsulation of a single layer of aerogel in poly(ethylene terephthalate) and pumping of gases out of the aerogel-filled volume. A multilayer panel according to the improved design concept is fabricated in basically the same way: Multiple alternating layers of aerogel and aluminized poly(ethylene terephthalate) are assembled, then encapsulated in an outer layer of poly(ethylene terephthalate), and then the volume containing the multilayer structure is evacuated as in the single-layer case. The multilayer concept makes it possible to reduce effective thermal conductivity of a panel below that of a comparable single-layer panel, without adding weight or incurring other performance penalties. Implementation of the multilayer concept is simple and relatively inexpensive, involving only a few additional fabrication steps to assemble the multiple layers prior to evacuation. For a panel of the blanket type, the multilayer concept, affords the additional advantage of reduced stiffness.

Ruemmele, Warren P.↗
NASA NTRS2009

Insulating Foams Save Money, Increase Safety

Scientists at Langley Research Center created polyimide foam insulation for reusable cryogenic propellant tanks on the space shuttle. Meanwhile, a small Hialeah, Florida-based business, PolyuMAC Inc., was looking for advanced foams to use in the customized manufacturing of acoustical and thermal insulation. The company contacted NASA, licensed the material, and then the original inventors worked with the company's engineers to make a new material that was better for both parties. The new version, a high performance, flame retardant, flexible polyimide foam, is used for insulating NASA cryogenic propellant tanks and shows promise for use on watercraft, aircraft, spacecraft, electronics and electrical products, automobiles and automotive products, recreation equipment, and building and construction materials.

Source record↗
NASA NTRS2006

Microsphere Insulation Panels

Microsphere insulation panels (MIPs) have been developed as lightweight, longlasting replacements for the foam and vacuum-jacketed systems heretofore used for thermally insulating cryogenic vessels and transfer ducts. The microsphere core material of a typical MIP consists of hollow glass bubbles, which have a combination of advantageous mechanical, chemical, and thermal-insulation properties heretofore available only separately in different materials. In particular, a core filling of glass microspheres has high crush strength and low density, is noncombustible, and performs well in soft vacuum.

Mohling, R.↗
NASA NTRS2011

Thermal Analysis of Low Layer Density Multilayer Insulation Test Results

Investigation of the thermal performance of low layer density multilayer insulations is important for designing long-duration space exploration missions involving the storage of cryogenic propellants. Theoretical calculations show an analytical optimal layer density, as widely reported in the literature. However, the appropriate test data by which to evaluate these calculations have been only recently obtained. As part of a recent research project, NASA procured several multilayer insulation test coupons for calorimeter testing. These coupons were configured to allow for the layer density to be varied from 0.5 to 2.6 layer/mm. The coupon testing was completed using the cylindrical Cryostat-l00 apparatus by the Cryogenics Test Laboratory at Kennedy Space Center. The results show the properties of the insulation as a function of layer density for multiple points. Overlaying these new results with data from the literature reveals a minimum layer density; however, the value is higher than predicted. Additionally, the data show that the transition region between high vacuum and no vacuum is dependent on the spacing of the reflective layers. Historically this spacing has not been taken into account as thermal performance was calculated as a function of pressure and temperature only; however the recent testing shows that the data is dependent on the Knudsen number which takes into account pressure, temperature, and layer spacing. These results aid in the understanding of the performance parameters of MLI and help to complete the body of literature on the topic.

Johnson, Wesley L.↗
NASA NTRS2011

Spray-On Foam Insulations for Launch Vehicle Cryogenic Tanks

Spray-on foam insulation (SOFI) has been developed for use on the cryogenic tanks of space launch vehicles beginning in the 1960s with the Apollo program. The use of SOFI was further developed for the Space Shuttle program. The External Tank (ET) of the Space Shuttle, consisting of a forward liquid oxygen tank in line with an aft liquid hydrogen tank, requires thermal insulation over its outer surface to prevent ice formation and avoid in-flight damage to the ceramic tile thermal protection system on the adjacent Orbiter. The insulation also provides system control and stability with throughout the lengthy process of cooldown, loading, and replenishing the tank. There are two main types of SOFI used on the ET: acreage (with the rind) and closeout (machined surface). The thermal performance of the seemingly simple SOFI system is a complex of many variables starting with the large temperature difference of from 200 to 260 K through the typical 25-mm thickness. Environmental factors include air temperature and humidity, wind speed, solar exposure, and aging or weathering history. Additional factors include manufacturing details, launch processing operations, and number of cryogenic thermal cycles. The study of the cryogenic thermal performance of SOFI under large temperature differentials is the subject of this article. The amount of moisture taken into the foam during the cold soak phase, termed Cryogenic Moisture Uptake, must also be considered. The heat leakage rates through these foams were measured under representative conditions using laboratory standard liquid nitrogen boiloff apparatus. Test articles included baseline, aged, and weathered specimens. Testing was performed over the entire pressure range from high vacuum to ambient pressure. Values for apparent thermal conductivity and heat flux were calculated and compared with prior data. As the prior data of record was obtained for small temperature differentials on non-weathered foams, analysis of the different methods is provided. Recent advancements and applications of SOFI systems on future launch vehicles and spacecraft are also addressed.

Fesmire, J. E.↗