Investigation of Super*Zip separation joint

An investigation to determine the most likely cause of two failures of five tests on 79 inch diameter Lockheed Super*Zip spacecraft separation joints being used for the development of a Shuttle/Centaur propulsion system. This joint utilizes an explosively expanded tube to fracture surrounding prenotched aluminum plates to achieve planar separation. A test method was developed and more than 300 tests firings were made to provide an understanding of severance mechanisms and the functional performance effects of system variables. An approach for defining functional margin was developed, and specific recommendations were made for improving existing and future systems

Determination of pyrotechnic functional margin

Following the failure of a previously qualified pyrotechnically actuated pin puller design, an investigation led to a redesign and requalification. The emphasis of the second qualification was placed on determining the functional margin of the pin puller by comparing the energy deliverable by the pyrotechnic cartridge to the energy required to accomplish the function. Also determined were the effects of functional variables. This paper describes the failure investigation, the test methods employed and the results of the evaluation, and provides a recommended approach to assure the successful functioning of pyrotechnic devices

Ignitability test method and apparatus

An apparatus for testing ignitability of an initiator includes a body having a central cavity, an initiator holder for holding the initiator over the central cavity of the body, an ignition material holder disposed in the central cavity of the body and having a cavity facing the initiator holder which receives a measured quantity of ignition material to be ignited by the initiator. It contains a chamber in communication with the cavity of the ignition material and the central cavity of the body, and a measuring system for analyzing pressure characteristics generated by ignition of the ignition material by the initiator. The measuring system includes at least one transducer coupled with an oscillograph for recording pressure traces generated by ignition

Performance of blasting caps

Common blasting caps are made from an aluminum shell in the form of a tube which is closed at both ends. One end, which is called the output end, terminates in a principal side or face, and contains a detonating agent which communicates with a means for igniting the detonating agent. The improvement of the present invention is a flat, steel foil bonded to the face in a position which is aligned perpendicularly to the longitudinal axis of the tube

Ignitability test method and apparatus

An apparatus for testing ignitability of an initiator includes a body with a central cavity, initiator holder for holding the initiator over the central cavity of the body, an ignition material holder disposed in the central cavity of the body and a cavity facing the initiator holder which receives a measured quantity of ignition material to be ignited by the initiator and a chamber in communication with the cavity of the ignition material holder and the central cavity of the body. A measuring system for analyzing pressure characteristics is generated by ignition material by the initiator. The measuring system includes at least one transducer coupled to an oscillograph for recording pressure traces generated by ignition

Integration of pyrotechnics into aerospace systems

The application of pyrotechnics to aerospace systems has been resisted because normal engineering methods cannot be used in design and evaluation. Commonly used approaches for energy sources, such as electrical, hydraulic and pneumatic, do not apply to explosive and pyrotechnic devices. This paper introduces the unique characteristics of pyrotechnic devices, describes how functional evaluations can be conducted, and demonstrates an engineering approach for pyrotechnic integration. Logic is presented that allows evaluation of two basic types of pyrotechnic systems to demonstrate functional margin

Augmented shock wave fracture/severance of materials

The present invention related generally to severing materials, and more particularly to severing or weakening materials through explosively induced, augmented shock waves. Explosive cords are placed in grooves on the upper surface of the material to be severed or weakened. The explosive cords are initiated simultaneously to introduce explosive shock waves into the material. These shock waves progress toward the centerline between the explosive cords and the lower surface of the material. Intersecting and reflected waves produce a rarefaction zone on the centerline to fail the material in tension. A groove may also be cut in the lower surface of the material to aid in severing or weakening the material

A manual for pyrotechnic design, development and qualification

Although pyrotechnic devices have been singularly responsible for the success of many of the critical mechanical functions in aerospace programs for over 30 years, ground and in-flight failures continue to occur. Subsequent investigations reveal that little or no quantitative information is available on measuring the effects on performance of system variables or on determining functional margins. Pyrotechnics are considered to be readily available and, therefore, can be managed by any subsystem in which they are applied, such as structure, propulsion, electric power, or life support. The primary purpose of this manual is to alter the concept that the use of pyrotechnics is an art and refute 'justifications' that applications do not need to be understood by providing information on pyrotechnic design, development, and qualification on an engineering basis. Included are approaches to demonstrate functional reliability with less than 10 units, how to manage pyrotechnic-unique requirements, and methods to assure that the system is properly assembled and will perform the required tasks

Development of a NASA standard gas generator

The goals of the NASA Standard Gas Generator (NSGG) Program are to create a NASA standard gas generating cartridge, characterize its performance, and make it readily available to users. A cartridge within the same envelope as the NASA Standard Initiator (NSI) has the greatest potential use. This potential use is described in viewgraph form. Our approach for NSGG development and qualification was planned to be conducted in several phases. Test methods were developed to evaluate output performance for a variety of potential applications. A feasibility study using modified NSI's was accomplished. Preliminary and final development will be conducted with a delta qualification to evaluate the effects of manufacturing lots and environments. Feasibility study results, feasibility study conclusions, and future plans are presented

Fracture/Severance of Materials

A method for severing or weakening materials is discussed. Explosive cords are placed in grooves on the upper surface of the material to be severed or weakened. The explosive cords are initiated simultaneously to introduce explosive shock waves into the material. These shock waves progress toward the centerline between the explosive cords and the lower surface of the material. Intersecting and reflected waves produce a rarefaction zone on the centerline to fail the material in tension. A groove may also be cut in the lower surface of the material to aid in severing or weakening the material