00000001 r_,.............................................................................. -----T-____ 'I . .,,i.',',_.i IJ]//. /,-";:;E--,'_:;J 4 N_:CR'I12119-3:" '_ ,. ,, EVALUAT_:"'"::IONOF COATEDOoiuMBiui ALLOY ,_I',,"'Y>,L. • :_'.. ; " "_:i;,-', ... :_' '"._. :'.,: .,] • ." !--.':"' !;_ 'F . ' " "._'_ ,_., :,:- '. ". _ ' ,, .HEAT SHIELDSFOR/SPACESHUTTLE" THERMAL-PROTEC-Ti0NSYSTE- MA_PLiCATiON .m ;. .:/ VOLUMEIii " . 41. PH_EIil IGU_sizE_ _ALUATioN ,,mINIRA r JlDYNAMI..... CS:: ' ;" ,.>'," CorlWlir A!ace _vi_on " "_. ; (NASA-eR-i1211_.31 BVALU/LTZON OF COAi'ND COLU_IuH ALLOy HEAT SHIELDS FOR SgACZ N7g-35278 SHUTZLF THZE_AL PROTECTION SYSTEM APPLICATION. (General Dynamics/Convair) 1E2 p HC $11.25 Unclas ; CSCL 22B GJ/JI 51035 • Ll - :_, 00000001-TSA03 NASA_CB.-.l12119-3 EVALUATION OF COATED COLUMBIUM ALLOY HEAT SHIELDS FOR SPACE SHUTTLE TKERMAL PROTECTION SYSTEM APPLICATION VOLUME DI i J ! PHASE 11I - FULL SIZE TI:_ EVALUATION ":; March 1974 By .... J.W. BaVr and W. E. Black .. Prepared Under _,_ Contract NA81-9793 ,:, Prepared by .,' CONVAIR AEROSPACE DIVISIONOF G_ENERAL DYNA3_ICS .. ,: SanDiego,.CalleorMa for : : ,o: National Aeronauflos and Space Admi_efla_tlon ",i'".: LANGLEY RESEARCH CENTER Hampt_p virginia • - :.- _'-._- ....."_................ ::_-_7........_- "_.--_ ......i- ." _ . ... .."j....._.r".._ri:..:_"_-i;_2"'C.2_:'".'_,':_"-_- ',-_ 00000001-TSA04 FOREWORD ._lis report was prepared by Convair Aerospace Division of General Dynamics -- San Diego Operation under Contract NAS1-9793 for the National Aeron_tics and Space • Administration, Langley Research Center, Hampton, Virginia. R was administered under the direction of the Materials Division, Materiels Research Branch, with Mr. D. R. Rummier acting as the Technical l_presentative of the Contracting Officer. •: The Convair program manager and principal designer through Phase I and Phase II was Wo E. Black. Mr. Black served as program manager during Phase HI until his resignation. J. W, Beer was appointed program manager for the completion of the 2: contract, Mr. Baer had previously served as deputy program manager and in program ..... process development. Other Convair persennel who participated in this program were :/ R.S. Wflsoll {structttral analysis), Ao M. Reberge _hermody_amles analysts), R. W. Gflbe1_ {environmental testing), O. H. Moore {acoustic testing), and G. L. Gefllne --? (acoustle fatigue analysis). In addition the subcontract support is acknowledged for :: _ W.G. Burnett 03urnett Industries - TPS component machining), L. _r. Robles (Electron Beam Welding, Inc., - TPS component welding), L. Sama (HtTemCo - coating appliea- • tion), and S. J. Gerardi (Vac-Hyd Processing Corporation - coating applioation), _,• This _eport cover,.s..the_Phase..IIL.performanee period from February 19"/3 to _: March 19"/4. - ? - c, _L' _'.- PRECEDINGPAGE BLA_K NOT FILMED 00000001-TSA05 CONTENTS / Page FOREWORD.. 2 INTRODUCTION ...... .......• • • • • •.....................',,,,,..• •,e • •,0•, • • • ..• ..•o • • .., . e.o 3 8.1 Ni_e-Pauel Test Specimen , ...... .... ..... ....... § 3.2 TPSTFSpecimen ........... .... .,............ 19 _. 3 Design Changes - Phase II to Phase HI • • •...... ....... 19 4 FABRICATION ...................... ..... • ......... 33 4.1 General .................... .... .... ...... 33 '+'" 40.2 Materials • • • e" ''6" 0 0 "''O'' ".0 O O. O • .0...• . 35 :_ 4. 2.1 Metals ................ .... ....... .... 35 _ 4 2 2 Coatings 3r 4 • 2• 3 Insulation @ @ • • • • • . o . o o @ . $ . $ • • e 4. $ Test Hardware :, 4.4 FabricationSequen;; _ _ _ i _ _ i i _ _ _ _ _ i i i _ _ _ _ _ _ _ _ _ i _ J.8 4. 4. i Welding ............................. .. 46 +,+'+ 4 • 4• 2 Heat treatment • @ " @ • • • $ • @ • • • @ $ . • • • • . • @ • • @ 51 4. 4.3 Brazing............ .................... 51 ,_ 5 SYSTEM WEIGHTS AND COST ....... .................... 53 ,:+ ":' 5• I System Weight • • o o • "• $ • • • • o • • o o o $ • o • • • _l, o o o $ • • • 53 5. 2 System CoSt .................................... 53 6 TESTING ........................................... 59 '_, 6 @ 1 Test SpechnenS @ • • @ • • • • @ • • @ . • • • $ • • • • • . • @ e-. • • • 59 6.2 TeSt Facftit/es and Procedures .............. • • • •.. 61 ] 6 " 2• 1 Acoustics " • • • • • • • " • • • • • • • 6 • • • • • • . @ • . 61 6.2.2 Thermal-Mechar_cal ............ • • ....... 66 6 8 Test Results 80 " 6 • 3• 1 Acoust/c testing • •@0••...0 ••O• • •o .q,.•• • 0• 80 _ 6 • 3• 2 Thermal testing • 60,0•09,0 •0000.9,099• • 000 81 " , 6 • _ • 3 Disassembly " • ' • • • • • • • • • • • • @ • @ • • • • • • • @ • • 81 6.8. 3, I Condition of panels .. .... •. • • • • .... 85 --. 6.3.8.2 Condition of lnsulaflen.. ....... • • •. • • 88 6.A. Dama_ Assessment. ..... • • •. • • • ............... 85 6.4.1 Heat shield panel fl/ght hardware.. .... ...... 98 6.4.2 Panel 1_Iner flight hardware.... .... • •... • • 98 6.4. 3 Post filler plugs flight hardware .............. 102 6.4.4 Upper post flight lmrdware ,.................. 102 6.4.5 Damage assessment summary................ 102 L ' " " 00000001--I:SA06 : Page 6.5 Materials Problems.................... ...... • 104 6.6 AcoustteAnalysts ................. ...... ..... 106 6.7 ThcrmalAnalysls............................. 107 6. 7. 1 Method of analysis ............... °....... 107 6 • 7 • 2 Thern_l sizing • • • • • • • $ • • • • qP • • • • • • e • • • • • 109 6.7. 3 Thermal correlation.. ........... • ....... • 113 6.7.4 Thermal/structuralperformance .o........... 117 7 REFURBISHMENT AND REPAIR ........................ 121 8" CONCLUDING REMARKS • • ee @e @ooe oo o# qt@ooe eooo$ • oeo • 123 • 8. 1 Conclusions ............. .................. 123 8,2 Reeommendattons .. ........... ..... ..... • .... 124 APPENDIX A: CONVERSION OF U.S. CUSTOMARY UNITS TO SI UNITS 127 APPENDIXB: ACOUSTIC TEST DATA ...................... 131 : APPENDIX C: RECOMMENDED TPSTF TEST PARAMETERS • • ** •• • 141 . REFERENCES....................... • •• • • • • • •• • • • • •• • 151 FIGURES ! 3-1 Tee-Stlffened TPS Exploded Assembly 6 :: 3-2 Nine-Panel TPS Test Specimen and Holding Fixture .......... 6 3-3 View Looking DoWn on Nine-Partel Array Holding Fixture ...... 7 3-4 Exterior Vicw of Nine-Panel Array Holding Fixture .......... 7 3-5 Nine-P.-mel TPS Assembly (sheets I and 2) ................ 8 3-6 TPS Component Details (sheets 1 and 2) .................. 12 3-7 Heat Shield Panel - Sheet Metal ....................... 14 3-8 Heat Shield Panel - SubassembLies ..................... 16 3-9 Heat Shield Panel - Final Machined ..................... 18 : 3-10 View of TPSTF Array'Holding Fixture .................... 20 3-11 Bottom View of TPSTF Arl_ty fielding Fixture .............. 21 3-12 TPSTF Test Specimen Assembly and Details ................. 22 :: 3-13 TPSTF Edge Heat Shield Panels ....................... 24 : 3-14 TPSTF Test Specimen and Holding FiXture ............ ... 25 4-i Welded Columblum Panel Retainers and Upper Support Posts .... 34 : 4-2 Coated Tee-Stiffened Heat Shield Panel - Skin Side .......... 40 -_ 4-3 Coated Tee-Stiffened Heat Shield Panel - Interior Side ........ 41 : 4-4 Welditlg Fixture for Tee-Stiffened Heat Slticld Panel - Cap to : Rib Weld. ................................... .... 43 _ 4-5 toWeldBibingWeldFixture..........for Tee-Stiffened•............. Heat Shield Panel. ..........- Skin ... 43 _ 4-6 Det_ls of Closure Welds - Welded Panel to Beam .. ......... 44 vt 0000000I -TBA07 +i!rl, ! _ Page i iI__ 4-7 Details of Closure Welds - Welded Panel to Beam - %_ Ready to Weld ........ • • • • •. • • ........... • • • • • • • 45 :=_+i'_ Fabrication Sequence for TPS Heat Shield Panels... ..... • • • • 47 _ 4-9 Fabrication Sequence for Edge Retainers ........ ...... .. 48 4-11 Fabrication Sequence for Upper Support Posts ..... ....... 49 _ii 4-14-102 Fabricationcation SeSequencequence fforor LowerCenter SupRetainersport Posts............. ..... • ..... ..., • 4849 _]i 4-13 Tee-Stiffened TPS Components Prior to Testing ............ 50 5-1 . Tee-Stiffened TYS Cumulative Average Cost ...... • ........ 57 6-1 Nine-Panel TPS Test Specimen Ready for Test..... • ........ 60 6-2 TPSTF Test Specimen Ready for TeSt .......... • ........ 62 : 6-3 Acoustic Test Facility with Nine-Panel TPS Test Specimen Mounted ....................................... 63 6-4 Nine-Panel TYS Test Specimen blounted in Acoustic Test Chamber • • • • • • • • • • • • •q, • • • • • • • • • 4b o • o • • • • • • • • • o 4D o ¢ 64 6-5 Accelerometer Locations .................. .......... 65 6-6 Boost Acoustic Environment .......................... 68 6-7 Boost Vibration Spectrum ............................. 68 6-8 Acoustic Test ConSole and Recording Equipment ............. 69 6-9 Facility for Thermal, Load_nd Environmental Testing Multi-Panel TPS ..................................... 70 , 6-10 Facility for Thermalt Load+ and Environmental Testing Multi-Panel TPS .................................. 71 +_ 6 tl Schematic for Multi-Panel TPS Test FaciLity ............... 72 F'r 6-12 Nine-Panel TPS Test Specimen Mounted for Thermal, Load and Environmental Testing ........... ....... ......... 73 !: 6-13 Test Console and Oxygen Analyzer for Multi-Panel TPS Test Facility .......... .... .... ..... ........ 75 6-14 Desirer and Test Profile ... ............ .............. 76 6-15 Thermocouple Location in Nine-Panel Test Specimen ......... 77 6-16 Thermal Test Parameters ....,.,,..,.,...,... ....... 79 6-17 Nine-Panel TPS Test Specimen after 100 Cycles of Acoustic and 50 Cycles of Thermal Flight Simulation ........ ...... • • • • 82 6-18