morton thiokol, inc.morton thiokol inc. aerospace group space operations 4.2.5 kevlar stra_...

!

#

T

TWR- 17591VOL.

ECS #: SS 1004

Vll

QM-8 Field Joint Protection System Final ReportVolume 7

June 1989

Prepared for:

NATIONAL AERONAUTICS AND SPACE ADMINISTRATIONGEORGE Co MARSHALL SPACE FLIGHT CENTER

MARSHALL SPACE FLIGHT CENTER, ALABAMA 35812

Contract No. NAS8-30490

DR. No. 5-3

WBS No. HQ302- i0-I0

MORTON THIOKOL, INC.Space Division

PO Be,< F_24, Rri!lti,)r_t City, Ut,lt_ F_4302 (,_(')1} 8(,3 3511

FORM TC 4677 (REV 8-86)

(NASA-CR-18374_) _M-8 FIELD JOINT

PROTECTION SYSTFMv VOLUME 7 Fin_] Report

(Morton Thiokol) 23 p CSCL 21H

N90-13596

uncles

G3/20 0231739

https://ntrs.nasa.gov/search.jsp?R=19900004270 2020-01-21T17:53:15+00:00Z

MORTON _IOKOL INC.

Space Operations

TWR-17591 VOL. VII

QM-8 FIELD JOINT PROTECTION SYSTEM FINAL REPORT

VOLUME 7

FINAL REPORT

PREPARED BY:

• Ekg_E HAL_COMPONENT "DES I GN

, t g

APPROVED BY:

Jo--v_. OOSTY_3SOPERVlSORCOMPONENT DESIGN- SECTION

///) " ,

JAMES SE I L-ER - --

_ROJECT ENGINEERING

f

TEb OLSON

CERTIFICATION PLANNING

../'.,,.' ,._,".y _.<...[

R,K. WILKS, MANAGER

COMPONENTS

_ / _ ", . j

RONLAR EN.... ,1..; 7 ,;,>

SAFETY

(":'_.t/ - I /ti.r ' l

STEVE WEST "

RELIABILITY

/, ;1 /I .,

GARY _EPHENSPROGRAM MANAGE_

I ,"7 -v/.,,

m_EASE4-19 ":

R[VISION ooc_o TWR-I7591 f VOL VII

sEc t PAGE i

MORTON THIOI<OI. INC

Space Operations

ACRONYMS

JPS Joint Protection System

RSRM Redesigned Solid Rocket Motor

RTD Resistance Temperature Device

R[VtSION ,3o¢ NO TWR- ]7 5 9 [ _ votV [I

SEC =_ PAG[

MORTON TttlOKOt, ]NC

Aerospace Group

Space Operations

ABSTRACT

This report contains the pre-launch functioning data of the

Field Joint Protection System (JPS) used on QM-8. Also

included is the post fire condition of the JPS components

following the test firing of the motor. The JPS components

are:

i. Field Joint Heaters

, Field Joint Sensors

3. Field Joint Moisture Seal

4. Moisture Seal Kevlar Retaining Straps

5. Field Joint External _xtruded Cork _nsulation

6. Vent valve

7. Power Cables

8. Igniter Heater

RE'_ISiON

FORM TC 7994 310 (REV 2 8R)

__ TL4R.17591. L_'°' VII

\

MORTON THIOI<OI. INC.

Aerospace Group

Space Opera(ions

1 . 0 INTRODUCTION

Qualification Motor (QM) 8 was test fired on 20

January 1989. The three field joints of the motor were

protected by the Joint Protection Systems (JPS). See Figure

i. The JPS heaters were turned on prior to the test firing

to assure the joint O-ring temperature was between 85 and 122

degrees F at the time of ignition. The purpose of the

moisture seal is to prevent entry of rain into the joint.

The cork insulation provides thermal protection for the JPS

during flight.

2.0 OBJECTIVES

The objective of this report is to document the

performance of the JPS heaters and the post fire condition of

the JPS components.

The following objectives of CTP-0038 are addressed

in this report: (Numbers in parentheses identify CEI

specification paragraphs)

BE. Certify the igniter heater maintains the

igniter gasket rubber seal at the required

temperature (3.2.1.5.3)

BL. Certify the ability of the field joint heater

assembly to maintain the temperature of the

field joints (3.2.1.ii.a)

BR. Certify the reliability of the RSRM design

(3.2.3)

IlFVISION --

FORM tC 7994 ]10 {FILM 2 EH)

i'O,, !

"_' TWR-1759]. '-',:E- "' VllL ....

\\\

w

MORTON TttlOI<()I . INC.

Aerospace Group

Space Operations

BU. Certify that the shedding of external debris

is precluded (3.2.6.5)

3.0 CONCLUSIONS AND RECOMMENDATIONS

Maintain Field Joint Temperature

The JPS heaters performed per specification and

maintained the field joint temperatures within the required

temperature range at the time of motor ignition (3.2.1.ii.a).

Reliability of the RSRM Design

The JPS system performed its intended function

without failure (3.2.3)

Sheddin 9 of External Debris is Precluded

All components of the JPS system remained bonded in

place during the test. No debris was generated (3.2.6.5)

Maintain I_nitor Gasket Seals Temperature

The igniter heater performance was nominal

(3.2.1.5.3)

4.0 RESULTS/DISCUSSIONS

4.1 Pre-Fire Performance

4.1.1 Field Joint Heater System

The heater temperature control system operated as

predicted and maintained the temperature at the controlling

_uL i

.F_,_.,o. "" TWR-17591 . _ Vll

I ()IiM |1:1!1'14 I I(1 [Ill V / }HI)

MORTON lhlOKOL INC

Aerospace Group

SpaceOpera{ions

RTD at 86 ° with a maximum deviation of -0.6 ° to +0.5 ° The

four temperature sensors at each field joint were

continuously monitored and the coldest sensor was manually

selected for temperature control. Figure 2 is a plot of the

temperature of the controlling RTD of the three field joints.

The drop in temperature at 0600 and 1000 hours was due to

heater power shut off.

4.1.2 Igniter Hea£er System

The Igniter Heater was turned on at T-12 hours.

Temperatures at the sensors was maintained at 78 plus or

minus 1 degree F. Igniter heater was shut down at T-2

minutes.

4.2 POST-TEST INSPECTION

4.2.1 FJPS External Insulation

Post-test inspection was conducted prior to FJPS

removal from the motor no evidence of damage was observed.

See Table 1 for pre-dissasembly evaluation worksheet. All

the cork appeared to be intact and bonded te the case. After

the cork was stripped from the case, the bondlines were

inspected for voids.

Voids were found in the leading edge cork

insulation to case bondlines of all joints. These were

attribrited to improperly positioning of the cork during

installation and from insufficient adhesive. The improper

positioning of the cork occurred with one piece of cork on

the center joint. This cork was installed 1/2 inch forward

of it's intended position on the moisture seal, resulting in

i

._v,s,o. _" /WR-17591 ..... i .Z" --VI I

FOIRM TC 799_ 310 (REV 2 ga)

MOIl]ON THIOI<OI. IN(:

Aerospace Group

Space Operations

a long narrow void between the leading edge of the moisture

seal and the cork. Some of the voids resulting from

insufficient adhesive extended to the leading edge of the

cork. See Table 2 through 4 evaluation worksheet.

4.2.2 EPDM Moisture Seal-to-Cork Bondlines

To inspect this bondline, the moisture seal had to

be peeled off the cork with considerable force. The peeled

surfaces showed that the EA 934NA remained on the cork with

small black EPDM particles embedded in the adhesive surface,

indicating the EPDM to EA 934NA interface is the weaker of

the bond surfaces.

4.2.3 Kevlar Strap-to-Cork Bondline

This bondline was difficult to peel back. In some

areas, the EA 934NA was embedded in both the inside and

outside straps, especially where the pin retainer band

trunnions lift the Kevlar strap and allow adhesive to flow

underneath the band.

4.2.4 Moisture Seal Condition

The moisture seals showed no evidence of rips or

tears in the areas where the pin retainer trunnions contact

the moisture seal. However, because of the excellent bond

between the EA934NA and the moisture _ea], an occasional

piece of the moisture seal was ripped up duzing disassembly.

See Table 5 for the evaluation worksheets.

REVISION

FORM TC 7994 310 |REV 2 8R!

_'_)......JJ/R-175_I .... [ ",-,,: ,ox,T .... v_II_/

MORTON THIOKOL INC.

Aerospace Group

Space Operations

4.2.5 Kevlar Stra_ Condition

The straps were fully intact. There was no

evidence of fiber damage or adhesive cracking at the buckle

interfaces. The areas where the pin retainer trunnions raise

the strap showed no fiber distortion or breakage and had

adhesive underneath forming a smooth surface for the Kevlar

strap to ride on.

4.2.6 JPS Heater

The heaters showed no evidence of delamination,

cracking, or overheating. See Table 6 for evaluation

worksheet.

4.2.7 JPS Sensor

The sensor could not be observed until after the

cork insulation was removed. There were no anomalies such as

cracking, except that which was caused by the removal of the

cork insulation. See Table 6 for the evaluation worksheet.

4.2.8 Heater Cables

The heater cables were in excellent condition

following the test. No voids are missing material, debonds,

or charred material were found. Table 7 is the pre

disassembly and Table 8 is the post disassembly worksheets

for the heater cables.

REVISION

FOI_M TC 7994 3 _0 (REV 2 8B)

DOC i

_'_ TWR_I2591 J L .... VII'1t C _AG! 5

MORTON Tt IIOKOL INC.

Aerospace Group

SpaceOperations

4.2.9 Vent Valves

One vent valve was installed on each of the three

field joints at the 135 ° location. All three vent valves

were open to back pressure following the test. See Table 9

for the evaluation worksheet.

4.2.10 Igniter Heater

During post fire inspection the igniter heater

installation and components were inspected. Igniter heater,

cork insulation, T-bolt latch band clamp, and heater power

cables were intact and properly secured on the igniter

adapter and forward dome with no anomalies noted. There was

a .030 inch air gap approximately .50 inch long between the

heater and case at the location of the clamp buckle, however,

no buckling or warpping of the heater was noted. After

removal of the igniter heater components the heater was

carefully inspected. No disco]oration, charring, warpping,

or buckling of the heater was noted. See Tables 10 and ii

for the evaluation worksheet.

IJOC !

.Ev,_,o. "'_ TWR-17591 ...... [ -!!'- VII

FO_%'_ TC 7994 llO (R[V 2 88)

Ne_

TWR-17591 VOL. V] I

Page 7

TemperatureF

0000i

0100

0200 -

0300 -

0400 -

0500 !_-_ 0600(1)

0700 -

0800 -

0900 -

1000 -

1100-

12O0 -

"4O'1 O Oi

! I ! 1 ! i ! I I

CD

('3

.1

¢._O

t--t-,

Figure 2 TWR-17591 Vol. VII

Page 8

Morton Thiokol Inc.

Space Operations

Table 1

Field Joint External Insulation Condition - Evaluation Checkoff Worksheet Pre-disassembly

Inspector(s): Elgie Hale ]

Motor No.: QM-8 Date: 1/23/89

Field Joint: [] Forward (FWD) _ Canter (CTR) _ Aft (AFT) I

Component: JPS t

I. External Cork Insulation

A. Voids or Missing Material (TPSVD)?

B. Debonds (DEBND)?

C. Charred Material (HTAFF)?

tf any of the above conditions exist, note:

Axial Starting Ending

Condition Location Degree Degree

(Observation (Station) Location Location

Code) (In.) (Deg.) (Deg.)

yes xX

yes

yes x

Circumferential

Width

(in.)

no--m

no

no

Axial

Length

(in.)

Radial

Depth

(In.)

Notes / Comments

REV.DOC

No TWR-17591

sEc p_G£ 9

Morton Thiokol Inc.

Space Operations

OR;GINAL PAGE 18OF POOR QUALITY

Table 2

Field Joint External Insulation Condition - Evaluation Checkoff Worksheet

Inspector(s): Elgie Hale


Field Joint: [] Forward (FWD) []Canter (CTFI) [] Aft (AFT)

Component: JPS

External Cork Insulation


B. Debonds (DE=IND)?


If any of the above conditions exist, note:




Code) (In.) (Deg.) (Deg.)

DEBONDS 851 ] 18 ] 22

DEBONDS 851 258 282

DEBONDS 851 298 _()?

DEBONDS 851 3o8 311

yes x no

x yes no

yes x no

Circumferential

Width

Axial

Length

(In.) (In.)

.5 case next to _M.S.

•2 case next to M.S.

4" 1ending_edge

i" case next tn M-S.

Radial

Depth

(Tn.]

Notes I Comments

[Nterm]ttant smaller voids (less than I in. D) wre observed around the joint.

REV. DOC '/CL_o, TWR-I 7591 VI[

SEC ]>_G_10

Morton Thiokol Inc.

Space Operations

Table 3


Inspector(s): ELGIE HALE


Field Joint: [] Forward (FWD) [] Center (CTR) [] Aft (AFT)

Component: JPS



B. Debonds (DEBND)?



Axial

Condition Location

(Observation (Station)

Code.) (In.)

DEBND ] 171

DEBND 1171

1171

DL 1171

DEBND ] l 7 I

DF.RNI_ I l 7 1

yes X no

yes no

yes _ no

Starting

Degree

Location

(Deg.)

0 o

270 °

25 °

54 °

90 °

180 °

Ending

Degree Circumferential Axial

Location Width Length

(Deg.) (In.) (In.)

_° _274° $ 3

28 ° I/4 3

69 ° 3 12 NA

105 o 3 12 NA

184 ° 3 4 NA

Radial

Depth

(In.)

I_ANA

NA

Notes 1 Comments

REV. ooc jNo TWR- ] 7591 VOL V [ ,_

SECPAGE

11

Morton Thiokol Inc.

Space Operations

OR:GINAL PAGE IS

OF POOR QUALITY

Table 4

Field Joint External Insulalion Condilion - Evaluation Checkoff Worksheel

h_"IH:_;l_i(';): l*;l,(;ll'; IIAI,I';


Field Joint: [] Forward (FWD) []Center (CTR) [] Aft (AFT)

Component: JPS



B. Debonds (DEBND)?


yes _E___ no

yes no

yes x no


Axial Starting Ei_ding



Code) (In.) (Deg;) (Deg.)

I)I';BN IY' 1401 t_ ,_ '>6

_..L).Ejj_Li I _ I ;' '>9 :' ,'i 1

I)I-BNII 149 1 214 220

Circumferential Axial Radial

Width Length Depth

tin.) (In.) (In.)

"_, 6 N / A

I/:' 20 N/A

1 16 N/A

Holes / Commenls

REV.

DOG

NO

SEC

TWK-I 759

i PAGE

Mt,rton Thiokoi Inc.

Space Operations

Table 5


Inspector(s): Elgie Hale/Mike Walsh

Motor No.: QM-8

Field Joint: [] Forward (FWD)

I Component: JPS Date: 1/23/89

[] Center (CTR) [] Aft (AFT)

Moisture Seal

A. Discolored (DSCLR)?

B. Charred Material (HTAFF)?

C. Moisture Under Seal (WATER)?

D. Loose Retainer Band (LOOSE)?

yes

yes

yes

yes

× no

-..L_ no

x no

x no


Affected Starting Degree

Part Condition Location

(I, or II) (Code) (Deg.)

Ending Degree

Location

(Deg.)

Circumferential

Width

0n.)

Degree

Arc

Notes / Comments

REV.

DOC

NO TWR- I /'i*i I1:rot VI ;

sEc I PAGE 13

Morton Thiokoi Inc.

Space Operations

Table 6

Joint Heater Condition - Evaluation Checkoff Worksheet

I

Inspector(s): Elgie Hale

Motor No.: QM-8 IC°mp°nent: JPS Date: 2/3/89

r

Field Joint: [] Forward (FWD) [] Center (CTR) [] Aft (AFT)

I. Heater Element

A. Delamination (DLHTR)? yes x no

B. Adhesive to Case Separation (DEBND)? yes __x no

C. Discoloration (DSCLR)? yes x no

Heater Sensor Assembly

A. Evidence of Separation (DElaND)? yes x no

B. Delaminations (DLHTR) ? yes × no

11.


Affected Starting Degree

Part Condition Location

(I, 11 or III) (Code) (Deg.)

Ending Degree Circumferential

Location Width Degree

(Deg.) (In.) Arc

Notes / Comments

REV. lNO TVR-175_I v_EI.r

SECPAGE

|J

Morton Thiokol Inc.

Space Operations

Table 7 Post Test

Field Joint Heater Cable Condition - Evaluation Checkoff Worksheet

Inspector(s): Duane Hanson

QM-8 [ Date: i/l/89Motor No.:

Component: TPS

[. External Cork Insulation

A. Voids or Missing Material (TPSVD)? yes x no

B. Debonds (DEBND)? yes × no

C. Charred (HTAFF)? yes _L no

II. Cables Debonded (DEBND)? yes _w_ no



Segment Condition Location Degree Degree

(FWD, FCS, (Observation (Station) Location Location

ACS or AFT) Code) (In.) (Deg.) (Deg.)

Circu referential _,xial

W[dt_ Length

(In.) (In.)

Notes I Comments

REV.

OOCNO

$EC

TWR- 1 7 5 61 I'/OL VI T

Morton Thiokol Inc.

Space Operations

Table 8 Pre-l)isassemb] y

Field Joint Heater Cable Condition - Evaluation Checkoff Worksheet

Inspector(s): E]gie Hale

Motor No.: QM-8 I Date: 1/23/89

Component: TPS

I. External Cork Insulation

A. Voids or Missing Material (TPSVD)? yes x no

B. Debonds (DEBND)? yes x no

C, Charred (HTAFF)? yes _ no

II. Cables Debonded (DEBND)? yes x no



Segment Condition Location Degree Degree

(FWD, FCS, (Observation (Station) Location Location

ACS or AFT) Code) (in.) (Deg.) (Deg.)

Circumferent al Axial

Width Length

(In.) (In.)

Notes / Comments

REV. NO TWR-175oI VOL V] [SEC

D

Morton Thiokol Inc.

Space Operations

Table 9

Field Joint Vent Valve - Evaluation Checkoff Worksheet

Inspector(s): I:. ttAI,K

Motor No.: QH-8 Date: 2/2/8ci

Field Joint: [] Forward (FWD) [] Canter (CTR) [] Aft (AFT)

Component: JPS

I. Vent Valves Open to Back Pressure (VVCBP)?

A. 45 ° Degrees N/A yes N/A no

B. 135 ° Degrees X yes no

I Case End: Targ

Notes / Comments

The vent on each of the three field joints was open to b:lck pressure.

REV.

DOG

F_O,

SEC%4R- 1 7 5 .I I

Morton Thlokoi Tnc.

, Spat,. Operations

Table 1 0

Igniter Heater Installation Condition - Evaluation ChecKoff Worksheet

tnsoector(s): Charles Greatwood

Mol-or No.: (,)H-8 I Date: 1/'27/,_'11

Joint: Igniter (IGN_ I Case End: Igniter AdaPter (FWD) ! Comoonent: JPSs

t. Igniter Heater

A. Securely heid in place (LOOSE)?

B. Proper position (DISCP)?

tl. Cork Insulation

A. Securely heid in place (LOOSE)?


;11. T-aolt Latch Band Clamp

A. Securely held in place (LOOSE)?


IV. Igniter Heater Power Cables

A. Securely held in place (LOOSE)?


!f any of the above conditions exist, note:

yes x no

yes x no

yes x no

yes _ no

yes >_ no

yes X no

yes x no

yes x no

Starting Ending

Affected Conaition Degree Degree Circumferential Axial

Part (Observation Location Location Width Length

(I, II, III or IV) Code) (Peg.) (Deg.) (In.) (In.)

Notes CommentsOvera]1 condition _f _gniter heater installation is e:,cellent _,,Tithno anomalie,_ noted.

a---= t VREV _ I'WR- I 591 veL II

._(or_on Thiokoi _nc.

Space Operations

Taole 1 t

Igniter Heater Comoonent - Evaluation Checkoff hVorKsheet

Tnspector(s): Charles Creatwood

Motor No.: QM-8

Joint: Igniter (IGN) i Case End: Igniter Adapter (FWD)

Date: 1127/89

Component: JPS

I. T-aolt Latch Band Clam o Assembly Intact (BAND)?

If. Igniter Heater

A. Delaminations (DLHTR)?

B. Discolorations (DSCLR)?

C. Charred (HTAFF_,?

O. Warped (HTAFF)?

_11. HeaTer Power Cables

A. Intact (LOOSE_,?

B. Charrea (HTAFF_,?


Axial Starting

Affected Conaition Location Degree

Part (Observation (Station) Location

(I, Jl or ill) Code) (In.) (Deg.)

yes

yes

yes

yes

yes

yes

yes

Enaing

Degree

Location

(Deg.;

x no

x no

x no

no

X no

x _o

x no

Circumferential

W;dth

fin.)

AxlaJ

Len_jth

(In.l

Notes Comments

Overa]] condition o[ igniter heater components is exce|lent.

REV

DOC

NO Tt4k- I 759 II

! vC_ VII

sEc j _E 19

morton thiokol, inc.morton thiokol inc. aerospace group space operations 4.2.5 kevlar stra_...

Documents