Thermal Protection System Application to Composite Cryotank Technology Demonstrator

The EM41 Thermal Protection System (TPS) team contributed to the success of the Composite Cryotank Technology Demonstrator (CCTD) manufacturing by developing and implementing a low-cost solution to apply cryoinsulation foam on the exterior surface of the tank in the NASA Marshall Space Flight Center (MSFC) TPS Development Facility, Bldg. 4765. The TPS team used techniques developed for the smallscale composite cryotank to apply Stepanfoam S-180 polyurethane foam to the 5.5-meter CCTD using a manual spray process. Manual spray foam technicians utilized lifts and scaffolding to access the barrel and dome sections of the large-scale tank in the horizontal orientation. During manufacturing, the tank was then oriented vertically, allowing access to the final barrel section for manual spray foam application. The CCTD was the largest application of manual spray foam performed to date with the S-180 polyurethane foam and required the TPS team to employ best practices for process controls on the development article

Performance Improvement of Friction Stir Welds by Better Surface Finish

The as-welded friction stir weld has a cross section that may act as a stress concentrator. The geometry associated with the stress concentration may reduce the weld strength and it makes the weld challenging to inspect with ultrasound. In some cases, the geometry leads to false positive nondestructive evaluation (NDE) indications and, in many cases, it requires manual blending to facilitate the inspection. This study will measure the stress concentration effect and develop an improved phased array ultrasound testing (PAUT) technique for friction stir welding. Post-welding, the friction stir weld (FSW) tool would be fitted with an end mill that would machine the weld smooth, trimmed shaved. This would eliminate the need for manual weld preparation for ultrasonic inspections. Manual surface preparation is a hand operation that varies widely depending on the person preparing the welds. Shaving is a process that can be automated and tightly controlled

Additive Manufacturing Infrared Inspection

The Additive Manufacturing Infrared Inspection Task started the development of a real-time dimensional inspection technique and digital quality record for the additive manufacturing process using infrared camera imaging and processing techniques. This project will benefit additive manufacturing by providing real-time inspection of internal geometry that is not currently possible and reduce the time and cost of additive manufactured parts with automated real-time dimensional inspections which deletes post-production inspections

Composite Dry Structure Cost Improvement Approach

This effort demonstrates that by focusing only on properties of relevance, composite interstage and shroud structures can be placed on the Space Launch System vehicle that simultaneously reduces cost, improves reliability, and maximizes performance, thus providing the Advanced Development Group with a new methodology of how to utilize composites to reduce weight for composite structures on launch vehicles. Interstage and shroud structures were chosen since both of these structures are simple in configuration and do not experience extreme environments (such as cryogenic or hot gas temperatures) and should represent a good starting point for flying composites on a 'man-rated' vehicle. They are used as an example only. The project involves using polymer matrix composites for launch vehicle structures, and the logic and rationale behind the proposed new methodology

Low-Profile Diffuser

The propellant tanks used in liquid rockets require pressurization gases in order to maintain tank pressure while the tanks are being drained during engine operation. The pressurization gas, which is typically much warmer than the relatively cold propellants in the tank, must be introduced into the empty ullage space at the top of the tank. The purpose of the diffuser is to control the flow of the gas into the tank in order to prevent direct impingement of the gas on the liquid surface and/or the tank walls. If the diffuser did not perform those tasks, the warm gas can create excess heat transfer causing an increase in the amount of pressurization mass required. Typical diffusers are long vertical cylinders that create a large exit area in order to minimize gas velocities. However, long vertical cylinders limit the amount of liquid that can be loaded into the tank in order not to have the liquid surface near the diffuser. A design goal for a pressurization diffuser is to create uniform flow in order to prevent jets that can impact the liquid surface and/or tank walls. The purpose of the task was to create a diffuser design that had a lower vertical profile (in order to be able to raise the liquid surface) while still maintaining uniform flow

Cryoinsulation Material Development to Mitigate Obsolescence Risk for Global Warming Potential Foams

Cryoinsulation foams currently being qualified for the Space Launch System (SLS) core stage are nonozone- depleting substances (ODP) and are compliant with current environmental regulations. However, these materials contain the blowing agent HFC-245fa, a hydrofluorocarbon (HFC), which is a Global Warming Potential (GWP) substance. In August 2014, the Environmental Protection Agency (EPA) proposed a policy change to reduce or eliminate certain HFCs, including HFC-245fa, in end-use categories including foam blowing agents beginning in 2017. The policy proposes a limited exception to allow continued use of HFC and HFC-blend foam blowing agents for military or space- and aeronautics-related applications, including rigid polyurethane spray foams, but only until 2022

Advanced Booster Composite Case/Polybenzimidazole Nitrile Butadiene Rubber Insulation Development

The NASA Engineering and Safety Center (NESC) was requested to examine processing sensitivities (e.g., cure temperature control/variance, debonds, density variations) of polybenzimidazole nitrile butadiene rubber (PBI-NBR) insulation, case fiber, and resin systems and to evaluate nondestructive evaluation (NDE) and damage tolerance methods/models required to support human-rated composite motor cases. The proposed use of composite motor cases in Blocks IA and II was expected to increase performance capability through optimizing operating pressure and increasing propellant mass fraction. This assessment was to support the evaluation of risk reduction for large booster component development/fabrication, NDE of low mass-to-strength ratio material structures, and solid booster propellant formulation as requested in the Space Launch System NASA Research Announcement for Advanced Booster Engineering Demonstration and/or Risk Reduction. Composite case materials and high-energy propellants represent an enabling capability in the Agency's ability to provide affordable, high-performing advanced booster concepts. The NESC team was requested to provide an assessment of co- and multiple-cure processing of composite case and PBI-NBR insulation materials and evaluation of high-energy propellant formulations

Hot-Fire Test of Liquid Oxygen/Hydrogen Space Launch Mission Injector Applicable to Exploration Upper Stage

This task is to hot-fire test an existing Space Launch Mission (SLM) injector that is applicable for all expander cycle engines being considered for the exploration upper stage. The work leverages investment made in FY 2013 that was used to additively manufacture three injectors (fig. 1) all by different vendors.

Testing of Selective Laser Melting Turbomachinery Applicable to Exploration Upper Stage

This task is to design, fabricate, and spin test to failure a Ti6-4 hydrogen turbopump impeller that was built using the selective laser melting (SLM) fabrication process (fig. 1). The impeller is sized around upper stage engine requirements. In addition to the spin burst test, material testing will be performed on coupons that are built with the impeller

Advanced Booster Liquid Engine Combustion Stability

Combustion instability is a phenomenon in liquid rocket engines caused by complex coupling between the time-varying combustion processes and the fluid dynamics in the combustor. Consequences of the large pressure oscillations associated with combustion instability often cause significant hardware damage and can be catastrophic. The current combustion stability assessment tools are limited by the level of empiricism in many inputs and embedded models. This limited predictive capability creates significant uncertainty in stability assessments. This large uncertainty then increases hardware development costs due to heavy reliance on expensive and time-consuming testing