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Report documents development project aimed at improving design and load-carrying ability of complicated corner fitting for optical bench. New fitting made of graphite filaments in epoxy-resin matrix. Composite material selected as replacement for titanium because lighter and dimensions change little with temperature variations.

This report describes the design, analysis, fabrication, and test of a complex bathtub fitting. Graphite fibers in an epoxy matrix were utilized in manufacturing of 11 components representing four different design and layup concepts. Design allowables were developed for use in the final stress analysis. Strain gage measurements were taken throughout the static load test and correlation of test and analysis data were performed, yielding good understanding of the material behavior and instrumentation requirements for future applications.

The shuttle external tank thermal design presents many challenges in meeting the stringent requirements established by the structures, main propulsion systems, and Orbiter elements. The selected thermal protection design had to meet these requirements, and ease of application, suitability for mass production considering low weight, cost, and high reliability. This development led to a spray-on-foam (SOFI) which covers the entire tank. The need and design for a SOFI material with a dual role of cryogenic insulation and ablator, and the development of the SOFI over SLA concept for high heating areas are discussed. Further issuses of minimum surface ice/frost, no debris, and the development of the TPS spray process considering the required quality and process control are examined.

The feasibility of using a scrim-reinforced, single metallized, 4-mil Tedlar film as a replacement for the Teflon coated Beta-cloth/single metallized 3-mil Kapton film presently used as the protective cover/light block for multilayer insulation (MLI) on the Orbiter, Spacelab, and other space applications was demonstrated. The proposed Tedlar concept is lighter and potentially lower in cost. Thermal analysis with the proper concept was much simpler than with the present system. Tests have already demonstrated that white Tedlar has low alpha (adsorption) degradation in space from U.V. The proposed concept was 4400 percent cheaper with nominal weight savings of 50 percent.

A polyurethane resin with paste activator, capable of providing useful bond strengths over the temperature range of -184 C to 149 C, is described. The adhesive system has a pot life of over one hour. Tensile shear strength ratings are given for various adhesive formulations.

This paper covers the development and evaluation of the HT-S/710 graphite/polyimide system and initial evaluations of high modulus graphite and boron reinforced polyimide systems. Detail design properties of the HT-S/710 graphite/polyimide systems, test results of test sheet stringer components, and initial test evaluations of high modulus graphite and boron reinforced polyimide composites are presented. Preliminary design applications utilizing the basic processing and design data from this development program are presented as to their utilization in aircraft and space applications.

A number of tests are required to evaluate both multilayer high performance insulation samples and the materials that comprise them. Some of the techniques and tests being employed for these evaluations and some of the results obtained from thermal conductivity tests, outgassing studies, effect of pressure on layer density tests, hypervelocity impact tests, and a multilayer high performance insulation ambient storage program at the Kennedy Space Center are presented.

This paper covers the characterization of the HT-S/RS6234 graphite/polyimide system. Processing techniques for vacuum bag, vacuum bag-press augmented, and vacuum bag-autoclave augmented have been developed under sponsorship of the NASA Marshall Space Flight Center (MSFC). Preliminary design properties for the HT-S/RS6234 resin system were developed at -320, 75, and 600 F. The processing techniques and the materials developed during this program are all directly applicable to the fabrication of large structural components such as would be required for the space shuttle and other advanced space vehicles.

Multilayer insulation panels for cryogenic liquid containers

Multilayer insulation coverings with low conductivity foam spacers are interleaved with quarter mil aluminized polymer film radiation shields to cover flight type liquid hydrogen tankage of space vehicles with a removable, structurally compatible, lightweight, high performance cryogenic insulation capable of surviving extended space mission environments.

Development of thermal insulation material for insulating liquid hydrogen tanks in spacecraft

Cryogenic technology research reviews at Marshall Space Flight Center

High performance multilayer insulation and micrometeoroid protection system for cryogenic tanks in outer space

Dual seal insulation, consisting of an inner layer of sealed-cell Mylar honeycomb core and an outer helium purge channel of fiber glass reinforced phenolic honeycomb core, is used as a thin, lightweight insulation for external surfaces of cryogenic-propellant tanks.

Lightweight external insulation system for liquid hydrogen stages of Saturn V vehicle