d'andrea - srm materials&process_final
DESCRIPTION
materialTRANSCRIPT
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1212thth edition CVA Summer Schooledition CVA Summer School
SOLID ROCKET MOTORSSOLID ROCKET MOTORSSOLID ROCKET MOTORSSOLID ROCKET MOTORSSOLID ROCKET MOTORSSOLID ROCKET MOTORSSOLID ROCKET MOTORSSOLID ROCKET MOTORSMATERIALS AND PROCESSESMATERIALS AND PROCESSESMATERIALS AND PROCESSESMATERIALS AND PROCESSESMATERIALS AND PROCESSESMATERIALS AND PROCESSESMATERIALS AND PROCESSESMATERIALS AND PROCESSES
Bruno Bruno Bruno Bruno Bruno Bruno Bruno Bruno DDDDDDDD’’’’’’’’AndreaAndreaAndreaAndreaAndreaAndreaAndreaAndrea
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CONTENTS CONTENTS CONTENTS CONTENTS CONTENTS CONTENTS CONTENTS CONTENTS
• The SRM Structure and Components
• Motor Case
• Thermal Insulation
• The Bonding
• Solid Propellant
• Non Destructive Tests and Proof
• Igniter
• Nozzle
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GETTING STARTGETTING STARTGETTING STARTGETTING STARTGETTING STARTGETTING STARTGETTING STARTGETTING START……………………
FROM THE ENDFROM THE ENDFROM THE ENDFROM THE ENDFROM THE ENDFROM THE ENDFROM THE ENDFROM THE END
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……OUR TARGETOUR TARGET
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THE SOLID ROCKET MOTORTHE SOLID ROCKET MOTORTHE SOLID ROCKET MOTORTHE SOLID ROCKET MOTORTHE SOLID ROCKET MOTORTHE SOLID ROCKET MOTORTHE SOLID ROCKET MOTORTHE SOLID ROCKET MOTOR
Structure and ComponentsStructure and ComponentsStructure and ComponentsStructure and ComponentsStructure and ComponentsStructure and ComponentsStructure and ComponentsStructure and Components
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Motor Case
Thermal Insulation
Solid Propellant
Nozzle
Metallic
Composite (Carbon-Epoxy)
External Thermal Insulation(opt)
Filled Rubber
Reinforced Rubber
Polyurethane
Ammonium Perchlorate
Aluminum
Filled Rubber
Carbon-Carbon
Carbon-Phenolic
IgniterStanding
Consumable
COMPONENT MAIN TECHNOLOGY
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VEGA LAUNCHER ARCHITECTURE
-Structural Ratio
1500Reference mission performance [kg]
136811Mass at Lift-off [kg]
2.6002.600Fairing diameter [m]
3.005Maximum diameter [m]
30.152Height [m]Payload Payload
CompositeComposite
AVUM AVUM
& &
IS34IS34
Z9 SRMZ9 SRM Z23 SRMZ23 SRM
P80 SRMP80 SRM
IS 12IS 12
IS 23IS 23IS 01IS 01
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THE MOTOR CASETHE MOTOR CASETHE MOTOR CASETHE MOTOR CASETHE MOTOR CASETHE MOTOR CASETHE MOTOR CASETHE MOTOR CASE
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Solid Rocket Motor CaseSolid Rocket Motor Case
The Motor Case can be:
• Metallic
– The thermal Insulation are applied on the inner surface and bonded by vulcanization
• Composite
– The Thermal Insulation are manufactured together with the case
– The carbon-epoxy material is winded on the thermal insulation
– The rubber can be vulcanized before the filament winding or co-cured
• In any case, some thermal insulation parts are vulcanized separately and bonded successively
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Solid Rocket Motor CaseSolid Rocket Motor Case
3 - SANDBLASTING
2 - DEGREASING
1- CASE INCOMING
4 - ADHESIVES APPLICATION5 - UNCURED T.I. DEPOSITION
6 . MANUAL DEPOSITION
9 - MACHINING10-FINAL APPLICATION
11-SHIPPING
8 - ULTRASOUND CHECK
7 - VULCANIIZATION
METALLIC CASE MAIN STEPSMETALLIC CASE MAIN STEPS
KOUROU (GUY-F)
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Solid Rocket Motor CaseSolid Rocket Motor Case METALLIC CASE MAIN STEPSMETALLIC CASE MAIN STEPS
DEGREASING
AUTOCLAVESANDBLASTING
VERTICAL LATHE
U.S. EQUIPMENT
UNCURED T.I. DEPOSITION
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Solid Rocket Motor CaseSolid Rocket Motor Case METALLIC CASE INNER SURFACEMETALLIC CASE INNER SURFACE
AUTOMATIC UNCURED THERMAL INSULATION DEPOSITION AND MANUAL APPLICATION OF SOME PARTS : WORKING INSIDE THE MOTOR
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Solid Rocket Motor CaseSolid Rocket Motor Case COMPOSITE CASE MAIN STEPSCOMPOSITE CASE MAIN STEPS
PROOF TEST
MANDREL
INTEGRATION
EXTERNAL HOOP WINDING
THERMAL PROTECTION APPLICATION
ONTO THE MANDREL
CURE CYCLE
MANDREL
ESTRACTION
HELICAL WINDING
PTS© : Reinforced Thermal Protections (Avio patent)
To be winded by the same machine of the prepreg filament winding
Vulcanization
Machining
Skirt Mandrels
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HOW DOES THE CURING WORK?HOW DOES THE CURING WORK?
• At the cycle startup, the resin flows through the composite thickness, following the temperature � decreasing of viscosity for temperature raising
• After the gel time, the curing reaction dominates the resin rheology � increasing of
viscosity for temperature raising
• It is important not to harden the composite before the maximum mandrel expansion
RHEOLOGYRHEOLOGY
Solid Rocket Motor CaseSolid Rocket Motor Case
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HOW DOES THE CURING WORK?HOW DOES THE CURING WORK?
GLASS TRANSITIONGLASS TRANSITION
Solid Rocket Motor CaseSolid Rocket Motor Case
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Solid Rocket Motor CaseSolid Rocket Motor Case COMPOSITE CASE MAIN STEPSCOMPOSITE CASE MAIN STEPS
VEGA-
Zefiro 9 - DM00
Insulated Case
manufacturing
Winding
mandrel
PTS deposition
Vacuum bag applicationVulcanization in autoclave
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1212thth edition CVA Summer Schooledition CVA Summer School
Solid Rocket Motor CaseSolid Rocket Motor Case COMPOSITE CASE MAIN STEPSCOMPOSITE CASE MAIN STEPS
Zefiro 23 DM00 FW production campaign
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Solid Rocket Motor CaseSolid Rocket Motor Case COMPOSITE CASE FILAMENT WINDINGCOMPOSITE CASE FILAMENT WINDING
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THE THERMAL INSULATIONTHE THERMAL INSULATIONTHE THERMAL INSULATIONTHE THERMAL INSULATIONTHE THERMAL INSULATIONTHE THERMAL INSULATIONTHE THERMAL INSULATIONTHE THERMAL INSULATION
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The Thermal InsulationThe Thermal Insulation
The Thermal Insulation are composite materials:
• Base rubber
– The most common is EPDM : Ethylene-Propylene-Diene Copolymer, stable until 290°C
• Anti-flame Filler
– Can be silica-based, heavy metals oxides or cyclic hydro carbide, stable until275°C
• Structural Reinforce / Filler
– Can be anisotropic (spherical), tyxotropic, chop (fiber orientation during manufacturing) or structural as for PTS (fabric), in general selected to be stable until 500°C
• Additives
– Plasticizer, vulcanization agents (commonly peroxides)
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Thermal InsulationThermal Insulation
THE VULCANIZATIONTHE VULCANIZATION
• The vulcanization creates cross-links inside the polymeric chain of the rubber matrix
• The reactivity can be studied by rheology, to optimize the vulcanization cycle (take care the scale up effect)
• The final thermal insulation shows mechanical properties to be measured for fitting the requirement and check the good vulcanization:
– Hardness (shoreA)
– Tensile strength
– Shear strength
– Compression strength
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Thermal InsulationThermal Insulation HOW DOES IT WORK?HOW DOES IT WORK?
• The Thermal Insulation shows low thermal conductivity and high specific heat
• The Thermal Insulation has a endothermic thermal decomposition under non oxidative environment �
small contribution for heat absorption
• At the steady state, the multiple layer of : charred – decomposing – neat material ensure to keep the insulation
ABLATIVE EFFECTABLATIVE EFFECT
CHARRED
DECOMPOSING
NEAT
Thermal Insulation
COMBUSTION GASES
TGA analysis
Thermal Conductivity
analysis
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Mixing by means: Open mixer or Bambury
Components weighting
Calender phase
Deposition or
Loose part shapingVulcanization
Sheets of differentthickness
Bobbins
Thermal InsulationThermal Insulation MATERIAL MANUFACTURING MAIN STEPSMATERIAL MANUFACTURING MAIN STEPS
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THE BONDINGTHE BONDINGTHE BONDINGTHE BONDINGTHE BONDINGTHE BONDINGTHE BONDINGTHE BONDING
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The Bonding The Bonding -- 11
Almost everything inside the Solid Rocket Motor is bonded, creating several interfaces:
• Thermal Insulation to Case
• Propellant to Thermal Insulation
• Nozzle parts (c-c to carbon-phenolic or c-ph to c-ph)
• Nozzle to case (igniter)
• External Thermal Insulation to case
• Harness to SRM External Surface
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The Bonding The Bonding -- 22The base principles of a good bonding are:
• Surfaces preparation
– Suitable Roughness (sandblasting or sandpaper)
– Cleaning
• Adhesives selection
– Chemical affinity with the interfaces for high strength bonding
– If interfaces are not of the same chemical nature (i.e. metal vs rubber), use substances to promoting the adhesion � primer
• Cycle
– Select to use warm or cold bonding
– Fine characterize the materials and adhesives reactivity
– Be careful to scale up from Lab to full scale
– Choose the suitable tests (U.S., X-Ray, follow up specimens or in-situ check)
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The Bonding The Bonding -- 33
THERMAL INSULATION
PRIMER EPOXY ADHESIVE
METALLIC
CASE
THERMAL INSULATION
EPOXY ADHESIVE
COMPOSITE
CASE
THERMAL INSULATION
PROPELLANT
POLYURETHANE ADHESIVE
CARBON PHENOLIC
ACRILIC or EPOXY ADHESIVE
CARBON PHENOLIC
CARBON CARBON
CARBON PHENOLIC
ACRILIC or EPOXY ADHESIVE
METALLIC
CASE
COMPOSITECASE
WARM B
ONDING
COLD B
ONDIN
G
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The Liner application is 3-4 weeks cycle:
• automatic cycle
– degreasing by suitable solvent
– drying
• liner batch preparation and control
• liner spray application and specimens
– liner pre-curing
– Insulated case control
• transportation to the casting pit
The Bonding The Bonding –– 44STRUCTURE PREPARATION FOR PROPELLANT CASTINGSTRUCTURE PREPARATION FOR PROPELLANT CASTING
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THE SOLID PROPELLANTTHE SOLID PROPELLANTTHE SOLID PROPELLANTTHE SOLID PROPELLANTTHE SOLID PROPELLANTTHE SOLID PROPELLANTTHE SOLID PROPELLANTTHE SOLID PROPELLANT
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The Solid PropellantThe Solid Propellant
The main properties are:
• Specific Impulse
– Driven by the formulation
– Imposed by the Design
• Burning Rate
– To fit the SRM combustion requirement
• Mechanical Properties
– To withstand the mechanical stress of ignition and storage
• Processability / Castability
– To be manufactured at industrial scale with no defects
– Defects are source of potential hazard and uncontrolled combustion
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THE COMPOSITE PROPELLANTSARE CONSTITUTED BY:
Active ComponentsActive Components
AluminumAluminum
FUELFUEL
0% (tactics) 15 - 20%(aerospace)
amount anddiameter
influence:
BURNING RATE TUNING
SPECIFIC IMPULSE
CASTABILITY
OXIDIZER
Ammonium Perchlorate (A.P.)
65 - 80%
amount andparticle size
affect:
CASTABILITY
BURNING RATE
MECHANICAL PROPERTIES
Polymer (HTPB)Plasticizer
Curing System
Polymer (HTPB)Plasticizer
Curing System
BINDERBINDER
10 - 14%amount andcomposition
drive:
SPECIFIC IMPULSE
CASTABILITY
MECHANICAL PROPERTIES
11-14%
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The Solid Propellant StructureThe Solid Propellant Structure
Propellant at time 0
HTPB cured by ISOCIANATE=
BINDER(including PLASTIFIER AND BONDING AGENT)
A.P. (200 � 4-5 µm)
Aluminum (35 to 5 µm)
Burning rate Mod. (< 3 µm)
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The Solid PropellantThe Solid Propellant
The chemical reactions among the components are not completely known
Others?
Ammonium
Perchlorate
Aluminum
Ballistic
Modifiers
HTPB-
3 units
Isocianate
Plasticizer
Bonding
Agent
Curing
Catalyst
Aziridine
Ammine
Esther
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The Solid Propellant The Solid Propellant –– Current TechnologyCurrent Technology
Either for the process as for the combustion, there is no modeling for completely design, tuning and characterize the solid propellant
No possible to theoretically design a propellant formulation, BUT, nevertheless, it is not a KIND OF MAGIC
EXPERIMENTAL AND CHEMISTRY ARE THE UNIQUE WAYS TO ASSESS
PERFORMANCE AND PROCESSABILITY
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The Solid PropellantThe Solid Propellant ENERGETIC PERFORMANCEENERGETIC PERFORMANCE