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A series of subscale tests are shown to suggest that a lower-cost ablative material than the rayon-based carbon ablative currently used in the Space Shuttle Solid Rocket Motor (SRM) may be used as a substitute. Six such ablatives with outstanding performance characteristics, using spun PAN and continuous pitch and PAN fibers instead of the present, continuous rayon, were identified in the course of tests with HTPB/AL/AP solid propellant grains with a burn time of 12 sec. The test nozzle features an initial throat diameter of 2.2 in. and a 6.1 expansion ratio. In addition to nozzle structural feature drawings, extensive test data tables and propellant formulation and properties tables are provided.

In order for the shuttle tug or interim upper stage (IUS) to capture all the missions in the current mission model for the tug and the IUS, an auxiliary or kick stage, using a solid propellant rocket motor, is required. Two solid propellant rocket motor technology concepts are described. One concept, called the 'advanced propulsion module' motor, is an 1800-kg, high-mass-fraction motor, which is single-burn and contains Class 2 propellent. The other concept, called the high energy upper stage restartable solid, is a two-burn (stop-restartable on command) motor which at present contains 1400 kg of Class 7 propellant. The details and status of the motor design and component and motor test results to date are presented, along with the schedule for future work.

Known electromagnetic wave absorbing structures found in nature were first studied for clues of how one might later design large area man-made radiant-electric converters. This led to the study of the electro-optics of insect dielectric antennae. Insights were achieved into how these antennae probably operate in the infrared 7-14um range. EWEC theoretical models and relevant cases were concisely formulated and justified for metal and dielectric absorber materials. Finding the electromagnetic field solutions to these models is a problem not yet solved. A rough estimate of losses in metal, solid dielectric, and hollow dielectric waveguides indicates future radiant-electric EWEC research should aim toward dielectric materials for maximum conversion efficiency. It was also found that the absorber bandwidth is a theoretical limitation on radiant-electric conversion efficiency. Ideally, the absorbers' wavelength would be centered on the irradiating spectrum and have the same bandwith as the irradiating wave. The EWEC concept appears to have a valid scientific basis, but considerable more research is needed before it is thoroughly understood, especially for the complex randomly polarized, wide band, phase incoherent spectrum of the sun. Specific recommended research areas are identified.

Two-burn restartable solid propellant rocket motors for the kick stage (auxiliary stage) of the Shuttle Tug, or Interim Upper Stage, are described, with details on features and test results of the ignition and quench (thrust termination) systems and procedures, fabrication of propellant and insulation, explosion hazards of propellants, and comparative data on present and future motor design. These rocket motor systems are designed for upper stage augmentation of launch vehicles and possible service in Shuttle-launched outer planet spacecraft.

Recent subscale nozzle tests have identified new and promising carbon phenolic nozzle ablatives which utilize staple rayon, PAN, and pitch based carbon cloth. A 4-inch throat diameter submerged test nozzle designed for the 48-inch Jet Propulsion Laboratory char motor was used to evaluate five different designs incorporating 20 candidate ablatives. Test results indicate that several pitch and PAN-based carbon phenolic ablatives can provide erosion and char performance equivalent or superior to the present continuous rayon-based SRM ablative.

A Kevlar 49/epoxy chamber has been developed for the advanced propulsion module motor. This chamber was successfully designed, fabricated, and hydroproof-tested at 511.6 N/sq cm. The fabrication, interior dimensional inspection, and proof test are discussed, showing that the chamber will be capable of achieving the design burst pressure of 639.8 N/sq cm. The projected chamber growth at 448.2 N/sq cm is presented based on the strain gage and volumetric growth data collected in that proof test.

Camera protecting device for use in photographing rocket engine nozzles or other engine components

Large booster nozzle reuse, discussing design, refurbishment, performance, costs and test evaluation

Large booster nozzle reuse, discussing design, refurbishment, performance, costs and test evaluation

Protective enclosure for a camera, located on the exhaust stream of a rocket engine, permits continuous recording of erosion processes of materials used in nozzle throat structures. The system uses a standard camera in a water-cooled, pressurized enclosure having a unique, inert gas-swept viewing duct.

Electromagnetic wave energy is converted into electric power with an array of mutually insulated electromagnetic wave absorber elements each responsive to an electric field component of the wave as it impinges thereon. Each element includes a portion tapered in the direction of wave propagation to provide a relatively wideband response spectrum. Each element includes an output for deriving a voltage replica of the electric field variations intercepted by it. Adjacent elements are positioned relative to each other so that an electric field subsists between adjacent elements in response to the impinging wave. The electric field results in a voltage difference between adjacent elements that is fed to a rectifier to derive dc output power.

Device converts wave energy into electric power through array of insulated absorber elements responsive to field of impinging electromagnetic radiation. Device could also serve as solar energy converter that is potentially less expensive and fragile than solar cells, yet substantially more efficient.

Advanced composite material used to fabricate pressure vessel is prepeg (partially cured) consisting of continuous, parallel boron filaments in epoxy resin matrix arranged to form tape. To fabricate chamber, tape is wound on form which must be removable after composite has been cured. Configuration of boron--epoxy composite pressure vessel was determined by computer program.