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NOTICE: When government or other drawings, specifications or other data are used for any purpose other than in connection with a definitely related government procurement operation, the U. S. Government thereby incurs no responsibility, nor any
obligation whatsoever; rnd the fact that the Govern-

ment may have formulated,

furnished, or in any way

supplied the said drawings, specifications, or other data is not to be regarded by implication or otherwise as in any manner licensing the holder or any other person or corporation, or conveying any rights or permission to manufacture, use or sell any patented invention that may Ji any way be related thereto.

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00

15 January 1963

__

A SURVEY OF INSULATION MATERIALS NO. AF 33(657)-8890 NO. 738103 PHASE I

C.-

SCONTRACT

CD .TASK
CD
1--J

I October 1962 Th rough 31 December 1962

C=O

0~,

AEROJET

AEROJET-GENERAL, COIRPORA1hZN
ROCKET PLANT SACr-AMY.N-O,
TIRI. &

GENEAK~SOLID

CALIFORNIA
COMPANY

A SUBSIDIARY

OF ThiE GENERAL

,UBBER

V. 0.

07',

Best Available Copy

15 January 1963

A SURVEY Ol INSULATION MATERIALS

I1
CONTRACT NO. AF 33(657)-8890
.-

I
jI

It
-PHASE

TASK NO.

738103

OCTOBER 1962 THROUGH 31 DECEMBER 1962

II

SOLID ROCKET PLANT

MENAL
A 81.U099 DIARv OP TH1 GARN9BRAL TIRE

SACRAMENTO, CALIFORNIA

&

RJuaOER

COMPANY

_.

FOREWORD

All data reported herein was originally released in Aerojet-General Corporation, Solid Rocket Plant, Materials and Fabrication Report No. 339, titled "A Suarvey of Insulation Mterials", dated 8 November 1961. en-

Data reported

in Appendix B was released in Aerojet-General Corporation, Solid Rocket Plant, Materials and Fabrication Report No. 289, "A Survey of Rocket Insulation Test Devices, insulation Performance, and Insulation Behavior" dated 23 April 1961.

Acknowledgement is made to the following named persons who contributed materially to the original reports: A. A. Stenersen, Supervisov', R. L. Keller, Development Engineer;

Insulation Application Resee-ch and Development P. Wilson, Technician.

Section; E. G. Gras, Metallurgical Engineer; and J.

__

This report Vas prepared under Contract No. Ar

33(657)-8890, TasIkNo.

738103, literature survey and rompilation of ui;published materials information for inert propulsion couponents generated by the Solid Rocket Plant. This task by

is being coordinated at Aerojet-General Corporation. Solid Rocket Plant, Alexander Kowzan, Nozzle Components and Project ,Spport Department.

!.

NOTICES

When U. S. Government drawings,

specifications,

or other data are used for

any purpose other than a definitely related goverrment pro-U~rement operation, the government thereby incurs no responsibility nor any obligation whatsoever; arid the fact that the government may have formulated, furnished, or in any way supplied the said drawings, specifications, or other data is not to be regarded by implication

or otherwise, as in any manner licensing the holder or any other person or corporation, or conveying any rights or permnisaion to men'factire, use, or sell any

"patented invention

that may in any way be related thereto. in' whole or in

This document may not be reproduced or published in any fopart, without prior approval of the government.

Since this is a progress report the corrections and modifica-

-information herein is tenative and subject to changes, ti Otr

rj _-

______

..

___

_..

ii

_ __.._

ABSTRACT

A review was made of published reports and ]Aiterat~re on tho Insulation. materialz to establish the status of the art in theoixr, formulation, testing, and. processing; to establisb the ty-pe of design data available and to provide an analysis of the available data. internal insulation materials. Discussed in this re-port are the common the!ory of the ablation pioceess, the A major effort was made to obtain information on

stat~u: of heat transfer anal~ysis of ablative materials, the test devices and testIng techniques presently used for material evaluation and the status of development and. processing of internal Insulation matpirials. in.sulation material from torch screening-tests, Perfozuance data of internal plasma generators, subscale------

p .'OP-llant test motors sand full scale motor firings- arc- presented.

Significwnt-

pe.0formance data of nozzle insulation materials and external insulation materialsq are included. Physi.cal and mechan~ical property data are. shown for some, nozzle and

internal insulation materials.

TABLE OF CONTENTS Page

I. II. IIT. IV. V.

INTRODUCTION OBJECTIVE AND SCOPE CONCLUSIONS RECOMMKNDATIONS DISCMSSION A. B. TERMINOLOGY THE ABLATION PROCESS 1. " Physical and Chemical Reactions in the' Ablating Zpnes Mechanical Factors 3

1 2

6 6 8 9
10

cExposure Conditions Formulation Variables

SC. " I.;

THEORETICAL IMAT TRANSFER AUALYSIS OF ABLATIVE MATERIALS 11 TEST DEVICES AND TESTING TECHNIQUES
. .

13
---

Literature Review

13' 13

._2, -3-.

Devices for Testing of Ablative Prpperties Differential Thermal Aunelysis- (.DTA)_

S-

. . - -4. The.zogravimetric AnalyiS (MA) 5, BOns _pentza and Chemical An27sis -5

14

-91S

v on

TABLE OF CONTENTS (CONT.) Page L.. INTERNAL INSUIATION MATERIALS

1. 2. Formulation Ablative Properties a, b. c. d. Oxyacetylene torch tests Plasma generator tests Sub-scale propellant motor tests Full-scale motor data

15
15 17

17
19 18 21

3.
F. G.

Kechanical and Physical PropertileT

EXTERNAL INSULATION MATERIALS NOZZLE INSULATION MATERIALS

23
21
-

H. I.
3.

CORRELATION OF PERFOWMCE DATA ABLATIVE NOZZLE THROATS

25

2-7
2,B

PROCESSING OF ABLATIVE INSULATION MA'YERIAZ

64
APPENDIX "A" APPENDIX GLOSSARY OF TERMS Ald A2

V!" - DESCRIPTION OF TEST DEVICES

P - B57

"_"

_,.

F4
__ __ _ _ __ _ _ _ _ __ _ _ _ __

S,.

_.

LIST OF TABLES Table I Chemical Thermodynamic Properties of Fillers ...... Testing Parameters for COyacetylene Torch Device, Materials, GT&R .............. . ......... .
*...

Page

a........
GT&R ..... ........

30 - 31
32
33 34

II

III IV V
VI

Oacetylene Flame Test Dlata for Internal Insulation Oxacetylene Flame Test Data (RIM) Plasmatron Test Data for Internal
Insulation Materials ....... RITE Motor Data ......................................
.............. ,.....

for

Internal Insulation Materials ..............................

35
36

VII

Performance- Data for the V-44, USR-3015 and NOL-3098. Materials in ABL, ARC and AGC Sub-scale Test Motors . Static Test Firing. Res.lts for First Stage
POLARISA2 Insulation ........ ......

37
38

VIIt IX X XI XII
_ _Second

Thickness Loss Rate vs Station of v-44 in Second Stage POLARIS A3 Aft Closure ...... Thickness Loss Rate vs Station of V-44 in Second Stage POLARIS.A3 Aft Closure .

...........

39 -40 41 42

Thickness Loss Rate vs Station of V-44 in F'?rst Stage POLARIS A3 Aft Closu.re .....-....................

S....

ThIckness Loss Rate vs Station of V-44 in Aft Closure, Engine od-2V4NUTEMAN and Mod 2.................... - Stage PThsical and Mechanical Properties ofInsulati.n materialse.....
.............

too. @@*too 0680#

43
44 4, 5

"XIIIS'Internal
-

.... . ~Insulation XIV Pla-smatron -Materials Test Data for External

vi

LIST OF TABLES (CONT.)

Table XV XVI XVII Thermal Properties of External Page

Insulation Materials ....................................

Physical and Mechanical Properties of
External Insulation Materials
..............................

46 47
.....
*.. o..8

Coyacetylene Flame Test Data for

Nozzle Insulation

Materials ...................

XVIII XIX

Plasmatron Test Data for Nozzle

Insulation

Materials .............
......
...............................

........

49
50

Plaumajet Test Data for Nozzle

Insulation Materials

vii

LIST OF' FIGURES Figure Page

1.
2.

Effect of Heat of Ablation orA Ablation Rate for Variou~s Ablation Tem~peratures .............
Effect of Specific Heat on Ablation Rate
................

51 52
...

3. 4.

Effect of Thermal Conductivity on Ablation Rate Solid Phase Temperature Dii~tribution for
Various Thermal Diffusivities,
..

53 5

..............

It........

5.

Percent of Total Heat Flux Transferred to Solid

Phase as a Function of Specific Heat .....................

55

6. 7,
8.

Cross-sectional Diagram of Atmospheric Furnace Thickness Lois Rate (TLR) and Density x TLR of Insulation Materialri in the RITE Motor'........... Thickness Los's Rate vs Chamber Pressure of
V-44k in RITE Motor Tests
. . . .... .,.......*** ........
*,

.57
5

9.
10.

Thickness Loss Rate- (TIR) via-Time. of -Mcposure

for V-14 4 Mtekial in the RITE Motor
.........

59

Location and. Typic.l Views of Cross-sectionedAreas,. andl Stations used in Reporting T (Thickness Loss ~ate)
of Insulation Materials for POLARIS A3

Motors

....

60 61
62
_ -

11. 12.
-

Stagnation Point Linear Ablation Rates of Samples ..... Exposea to High Heat Flux (1950 BTtJ/ft~sc Stagnation Point Linear Ablation JRatpa df Samples Exposed to Low Heat Flux (60BTq/;ft-s Av~erage T3 ess Loss1Ute)cknL in -l3. ... .. yacetyleneqlorch.Teat, -RITE Motor,- -First and. Second P0AIS A3 Motors) ani SoiItage ... ,......... 1.INUTEMULMot-or .. **
...... .

63

Viii

I.

INTRODUCTION Thermal protection of parts exposed to high temperatures is presently a

major problem in the development of solid rocket motors and space vehicles.

Nozzle

components and the fore and aft end of solid propellant motor cases are exposed to the erosive conditions of propellant flames at temperatured as high as 6600 0 F. The skin temperatures encountered on re-entry to earth of space vehicles and nose cones is estimated to reach temperatures in excess Of lO,0000 F. To provide thermal protection for the critical areas, a series of thermal protection systems such as heat sink, radi.ation, reflection, transpiration, ablation have been investigated to some extent. and

Ablative insulation is -currently

considered the simplest, the most effective and reliable method for thermal protection of the-exterior and interior of--motor-cases-and for the nozzle entrance--area and the exit cone. .... The feasibility of thermal protection of missile parts by Ablative insulaclearly demonstrated on re-entry of nose cones in 1958.

tion materials was at first

Since then extensive work has been conducted by governmentdl agencies and firms in testing and, evaiuation of the ablative properties of plastics and reinforced

plastics.

Some work has also- been done to analyze the mechanism of ablation and
Several hunded pertinent articles
--

-1

to formulate elastomeric AWAtive materiels,

have- been published.--- Th-ese articles contain primarily rItfoxmation- and test data
_onablative materials obtained by model studies and laboratory testing. Little

information has as yet been available on test data obtained at actual use conditions. A large number of solid propellant motors have, however, been test-firod

2-1

_____~~~_________

at the Aerojet-General Corporation using ablative insulation materials.

The

quantitative data reported on the performance of ablative insulation materials on test firings of solid rocket motors are useful as design information. The status

of work conducted on ablative insulation materials with regard to theory, formulation, testing and processing and quantitative performance data reported on insula.tion materials from full-scale motor firings, sub-scale propellant motor tests and material screening tests are discussed in this report. under Contract No. AF 33(600)-36610. This work was conducted-

ii..

2O3

ICTVE A4 SCOPE

The over-all objective of this survey was to collect, tabulate and analyze published data obtained by various governmental agencies and Aerojet-General facilities during-the testing of insulation materials intended for soild rocket

"motor.
The material design data of primary interest Included ablation rates aad erosion rates at varying exposure conditions, physical and mechanical properties, and data on heat transfer, formulations and processing. The scope of the analysis was to establisha asiTble correlation of to evaluate test

material performance data in the various tests 'and motor f.rings, .

equipment and attempt to establish the ma~n factors that affect the rate-of erosion and ablatvon atienand vary exposure conditiwon. The s-rveythermaor, -

"I...

Work conucted to determine the factors that affect the rate of erosion and ablation.

_______

2.

The development of test devices and testing techniques for ablatioo. materials.

3.

Performance data from full-scale firings, sub-scale test motors screening tests.

nd.

IF.

Physical, mechanical, and chemical properties of insulation systems and their components.

5.

Processing of insulation systems.

III". CONCLUSIONS,
A. The literature on ablative insulation materials reveals that extensive

effortashave been made in the development of test devices and in the evaluation of reinforced plastics for nose cone insulation. B. The main physical and chemical reactions that take place during the

-- ablation 2rocess are believed to be known, but the relative effect of the many parameters that determine ablation rates at given exposure conditions have not been determined experimentally.

C.

Analytical solutions have been derived for the heat transfer in

ablating materials assuming steady state conditions..

D.

A number of torch test devices have been developed for laboratory A ro'aai robin- test

screening and evaluation of ablative insultion materials.

program conducted tc standardize an oxyacetylene torch test reveals 'poor_ correla-

_-tion of test date obtained by the various devioes involved.

Ox acetylene torch

"testsdo

not-appear capable of screening insulators for rocket motors but have

been found useful as laboratory teets in the development of ablative insulation

materials,.

-3-

E.

Plasmajet tests appear to be useful for evaluation of nose cone and Plasmajet test data on internal insulation materials

external insulation materials.

do not correlate well with sub-scale motor data. F. The test data of primary interest for the design of internal insula-

tion profiles are the dimensional material loss rates or ablation rates. G. Sub-scale propellant motor tests, which simulate the environments appear to be the most useful tests for evaluation

producted in full-scale motors,

of internal chamber insulation materials. H. Detailed quantitative data on the performance of internal insulation

in full scale motors have been reported-only during the past two years and for

relatively few motors.

_. I
--

A series of rubber-based materials have recently been developed for. Sub-acale propellant motor tests show best

internal insiulation of rocket motors.

performance for insulation systems based on nitrile-rubber as binder with either asbestos or boric acid as filler. J. RITZ Motor tests on the V-44 insulation material (GT&R) show that The rate -.

this -material has a decreasing rate of ablation with time of exposure.

of ablation increases markedly with chamber pressure in the range from 200 to

IC. EAG~LE and

Polyu.rethane ineulation materials have shown good performance in'

GAM-87A motors.
Graphite-phenolic and glass-fiber phenolic insulationrsyetems are

L.

currently the best available materials for insulation of nozzle exit cone and entrance section respectively.

-4-

Ill.

RECOMMENDATIONS A. Programs for development and evaluation of internal insulation ss-rn

should include determinations of the thermophysical properties of promising materials. These properties are needed for heat transfer analysis used in the design of insula.tion profiles. B. In the development of ablative insulation materials, efforts should be

made to determine experimentally the main factors that affect tha rate of ablation and erosion and the experimental data correlated with theoretical heat transfer data .,and chemical thermodynamic property data of the material components used. --C.--- -The -development-of improved'i.nsulation-systems should be directed toward systems which can be more easily processed-.D. Improved teats are needed part,,ularly for screening of internal

insulation materials. . E.Sub-scale- propellant test motors such as the RITE Motor should be

used for evaluation of nozzle and internal insulation systems. F.. Efforts should be made to develop a, sub-scale test motor that iq,

more versatile and less costly to operate than the RITE Motor.

The motor must be

"capable of

simulating full-scale motor firing conditions and should be capable of . .

testing a series of materials-in one firing. G.

To provide useful design data, ablative insulation materiais Should

be tested forablation and erosion rates both by weight and dimensioni--

V.

DISCUSSION A. TERMNOLOGY The published literature on ablative materials shows that the termsa

used to describe ablation phenomena are different at various agencies.

At the

Aerojet-General Corporation, the terms differ to some extent with project and facility. The need for a standardized terminology is realia~ed at agencies such as

the Bureau of Standards and ASTM (American Society for Testing Materials).

Commit-

-. teea have therefore been-appointed to standardize the termino1pgy for ablation materials in conjunction with standardization of flame tests. \Jntil A standardized

terminology is available it is necessary to define the terms used, in publications-and reports. B. -1.

Definitions of terms used in this report are listed.~in Appendix A. TH-A.BIATION PROCES0 Physical and Chemical Reactions in the Ablatinj Zone The literature review showed that only some aspects of the---

mechanism of ablation have as yet been investigated.

The publications on ablative

materials (about 50O)-are primarily concerned with the high temperatu~rd properties.
_Some-studles,

however,- have-been-Aade~ on the heat transfer mechanism an&-the thermoOnly a few preliminary investi.gationsh -jaot - W-~ orma'~

physical state change reactions involved.

i'-eacio-

tive publications on the- a~lation. process, see reforefices,

a physical& and chemical reactions- involved--a'e, as follows:
__ .-

Udcatie~a

the-main

Absorptitin of Heat- to Reach the Abltio

Temperatures

When an ablative insulation material, consisting of a polymeric binder and an inorganic filler,' is exposed to an environment such a: the

-6-

propellant flame or exhaust,

some heat energy is at first

aboerbed by the Materiad

before any state changes take place.

The amount of heat energy absorbed depends

primarily on physical properties of the material such as thermal conductivity and specific heat. b. Absorption of Heat by State Change Reactions As soon as the surface layer of the material has reached a certain temperature, The initial uied. fizion, The filler binder and filler components start to decompose or ablate.

ablation temperatures vary greatly with type of binders and fillers absorbed during physical state changes such as sublimation, Concurrently, -a series of chemical reactions take-place.
-

Heat energy is

and: vaporization.

components formed react with each other and with components of the The heat energies absorbed and/or given off during

propellant combustion gases.

these reactions are dependent on the heat of decomosition and heat of formation of the reactions.4 predominant factor. However, the rate at which these reactions take place Is is

The chemical reactions that take place are dependent oA

Stemperature

and, pressure and may be governed to some extent by catalysts added to

the materials. sc Char Formation The result of the initial physical state changes and

"chemioa& reactions

is the formation of solid and liquid decomposition products at This char layer increases in thiokness Generally,

the outer layer of the ablating material.

and. changes in composition and physical properties with time of exposure.

the char layer formed provides increased thermal and mechanical protection with time of exposure.

-7--

d..

Transpiration Cooling The gases formed in the inner decomposing material

layer are emitted (transpire) through the pores of the char residue and provide a counter-flow of gases against the impinging particles. general relatively cool. The gases emitted are in

Therefore, mass transfer cooling takes place between the

gases emitted and the hot propellant combustion products (transpiration cooling),, thereby providing a protective shield or barrier against the impinging particles. The effectiveness of this shield as a protoctive barrier depends on the rate, amount, molecular weight, and the heat capacity of the gases formed. the

e.
F
-

Radiation Cooling In addition to the heat dissipated through absorption,

some heat is re-radiated.

The amount of heat re-radiated is influenced by the

Vproperties

of-the char and its surface temperature.- The incorporation of radiation

"blocking". agents have been found effective in Increasing the-radiation cooling effect Of insulation materials. 2. Mechanical Factors The rate of decomposition of the ablative material is an

factor in obtaining a minimun rate of ablation. important sition is very faa .the ao+4 .... 'eThceIf
_ _.n

the rate of deco0po-

. . .

. .

__j_ _ . . u. .

_b f o r c e d t0 ex pan d i n a s i mi l a r

manr

sexpaneion of plastic- foams.

On the other hand, if

-This -results general3lr In very li.ttle heat

'j..

-abaorption.

the decomposition as

very_slow, the material

aW

-be eroded away meohanically.before

heat absorption takes place.

The mechanicalo

properties of the ablative materials at high, elevated,

and ambient te'ieratures

-8

affect the insulation performance in several ways.

A highly crosslinked, rigid.,

structure has been found derirable to prevent decomposition of the binder into liquid components and for the formation of effective chars. However, an internal

insulation material which is bonded to the chamber sand the propellant may be subjected to high stresses. A flexible material has therefore been found to be Spalling, cracklng, or flaking

essential in order to avoid mechanical failur'.s.

may also occur below the material softeninrS temperature of rigid insulation materials due to vibrations. Separation of thermally softened material pieces may

be caused by impact erosion of particles in the propellant xhaust.

3.

Exposure Conditions a. Propellant Flames The environmental exposure conditions produced by

propellazt flames and exhaust differ considerably with the various type propellant currently used in solid rocket motors. An aluminized propellant produces generally An oxidizing atmosphere The

more erosive conditions than a non-aluminized propellant.

may be detrimental to some insulation systems and advantageous to others.

variables of this type environment may be divided into physical, chemical and mechanical factors. Some of the variables of propellant exhaust affecting the

rate of ablation are believed to be:-(I) Density .of constituents Concentration or constituenta

"(2)
(3)
(14)

Velocity of constituents
Temperature

"-9-

(5) (6)
b.

Total mass flow rate Atmospheric condition (reducing, oxidizing)

Aerodynamic Heating The environments encountered by nose cones on re-entry

differ widely from propellant exhaust conditions.

The main factors considered in

evaluation of nose cone materials are total heat flux and mass flow rate. 4. Formulation Variables The ablative insulation materials consist generally of an organic polymeric binder and an inorganic filler or fabric. Organic polymers are used as binders to provide the required mechanical properties over a wide temperature service range because of their low thermal conductivity and their ability to provide thermal and mechanical protection by the formation of an erosion resistant char. The char formation and properties incorporated as a pigment, filler,

of the char are influenced by such factors as the chemical structure of the polyneric binder, its crosslinking, unsaturation, relative concentration of aliphatic

and armomatic carbon atoms, polymer linkages.

concentration of H, 0 and other &lements, and type of

RlWg3lv croes'inked. binders ara geanaall

dCmiraDle because

these binders on heating to high temperatures do not melt but decompose primarily in the solid state, The partially degraded material inside of the char may thereA large concentration

fore have useful mechanical properties at high temperatures. of aromatic, condensed aromatic,

and certain cyclic rings in the binder is desirable

10 -

Il

because a relatively large amount of heat energy is chemical bonds.

required to break or alter their

The function of the fillers is to absorb heat energy primarily by state change reactions. d....--ecisive factor. The rate at which these reactions take place is a

Composition parameters that influence the rate of ablation may

therefore be divided into physical, chemical and mechanical properties and characteristics as listed in the following table:

FORMULATION VARIABLES

Physical Factors 1. Density 1.

Chemical Factors Chemical structure of binder and filler Crosslinking 1.

Mechanical Factors Tensile strength

2.

Thermal conductivity

2.

2.

Elongation

3.
ii..

Specific heat
Thermal diffusivity

3.
4.

Type polymer linkage

Elemental concentration of constituents (C, H, 0, N, etc.)

3. Binder-filler bond
strength 4. Filler and grain orientation

5.

Heat of sublimation,

C.

THEORETICAL HEAT TRANSFER ANALYSIS OF ABLATIVE MATERIALS The heat transfer mechanism of char-forming ablative materials is very

complex (25).

The char layer oomplicates the heat transfer problem because it

introduces a second phase between the solid and gaseous boundary layer and because of the flow of gases from the decomposing material through the char. A problem

11

encountered in conducting heat transfer analysis using the equations derived is the lack of accurate thermophysical property data such as thermal conductivity and specific heat at high temperatures and of heat and temperature of ablation. addition, the deconmosition products formed and emitted through the char are difficult to analyze and are generally not known. To conduct a heat transfer analysis for a material that ablates with formation of a char, it a. b. c. d. is necessary to make a series of assumptions including: A constant heat of ablation A constant temperature of ablation Steady state conditions No overall shrinkage in decomposing material and char In

By use of analytical model studies, equations have been developed and evaluated to show the relationship between ablation rates and char properties for various conditions simulating aerodynamic heating. Some of the conclusions

reached by model studies seem to agree with experimental data. The AeroJet-General Corporation has recently conducted a heat transfer analysis to investigate the relative effect of various thermophysical properties on the ablation rates. report. 5. It However, Th analytical solutions derived are not included in this

some results of this analysis are shown in Figures 1, 2, 3, 4 and

is noted that variations in the heat of ablation, the temperature of abla-

tion, and the specific heat greatly affect the rate of ablation while a variation in the thermal conductivity has a negligible effect.

12

D.

TEST DEVICES AND TESTING TECHNIQUES 1. Literature Review A review was made of test devices and testing techniques used

in the development,

evaluation,

and analysis of ablative insulation materials. to date, been done in the development of

This

review showed that major efforts have,

test devices to determine ablation rates at environments simulating aerodynamic heating and propellant exhaust. Attempts are currently being made in the design

and development of new improved test devices and instruments to analyze materials char forming ability, heat absorbing ability, gaseuus decomposition products formed during the ablation process, and composition and nature of propellant exhaust. The

literature revealed minor efforts to develop improved tests for evaluation of the physical properties of materials at elevated and high temperature. Such data are

needed in heat transfer analysis and analysis of the major factors that determine the rate of performance of ablative materials. Test devices to determine char

properties at the high temperatures encountered in exposure to propellant exhaust have not been reported. The test tools currently used in the development and

evaluation of ablative materials are briefly discussed below. 2. Devices for Testing of Ablative Properties a. Oxyacetylene Torches, Plasma-arcs and Sub-scale Motors

A comprehensive survey of torch test devices, plasma generators and subscale propellant motors was made and is discussed in Appendix B.

13

3.

Differential Thermal Analysis (DTA) DTA is used as a guide in material development to determine the

heat absorption potential of materials.

Essentially, this method involves the use

of reference and unknown materials heated in separate containers at a fixed rate, as illustrated in Figure 6. Comparison of the temperature difference, which is continuously

measured by using a differential thermocouple whose thermal e.m.f. is plotted by a recording potentiometer, usually versus time, tive heat absorption potential. recorded.

determires their compara-

Exothermic as well as endothermic processes can be

The use of DTA in determining absorption potential is

limited

due to the fact that many DTA patterns are too complex or diffuse to be quantitatively treated. The many parameters and unknown variables (experimental and

theoretical) result in uncertainty. 4. Thermogravimetric Analysis (TGA) Thermogravimetric Analysis is also used as a guide in material

development.

By this analysis the residual weight of sample material is measured In modern practice,

continuously as the sample is heated at a controlled rate.

a virtually linear function of residual weight is automatically recorded on a time basis or on a temneratitie basis. In aithe aut: the utizmate record is a plot of

residual weight fraction versus the environmental temperature in a region near the

sample.

The effect of different heating rates on the TGA, due to its

reproduci-

bility and correlation to the extent of degradation, is at present considered more reliable than DTA in obtaining the absorption potential of materials.

. 1Ji

5.

Emission Spectra and Chemical Analysis The initial comprehensive studies of the chemical reactions

involved in the ablation process have been made by Stanford Research Institute (26, 27). These studies include investigations of techniques for sampling the

gaseous boundary layer of an ablating resin in an argon-stabilized plasmajet and the use of emission spectra for analysis of the boundary layer. The gaseous

decomposition products of several resins were deter-mined by mass-spectrographic analysis. The results show, however, no particular correlation between ablation emission spectra or the products of

performance of a material and either its ablation. E.

INTERNAL INSULATION MATERIALS 1. Formulation Organic polymers have inherently good thermal insulation

properties and ablate when exposed to high temperatures.

Elastomeric polymers

such as polyurethanes and nitrile rubber have therefore been used for lining and internal insulation of solid rocket motors. In recent years it has been found that

the ablative properttes and the erosion resistance of such polymers can be greatly improved by the incorporation of fillers or reinforcing agents which have high heat absorption potentials. The approach used in the development of internal insulation ham to date primarily involved evaluations of binder-filler systems for heatabsorbing ability by DTA and for char-forming ability and ablative properties by TGA and oxyacetylene torch tests.

15

Nitrile rubber systems have been found particularly promising as binders by various rubber companies. The Garlock 7765 material, a nitrile

rubber-silica system, has been used as a referance internal insulation material for several years. Improved nitrile rubber systems have recently been developed by the Mare Island Naval Shipyard (compound 388-58 and 388-98) and by the General Tire and Rubber Company (V-44 and V-52). The improvement in ablative properties of

these systems are claimed to be due primarily to improved processing techniques. Phenolic resin-nitrile rubber binders have, by some companies,

including the U.S. Rubber Company and the Goodyear Tire and Rubber Company, been found to provide improved char properties for more efficient transpiration cooling.

II A series of fillerssuch as listed in Table I, have been investigated for these

binders. The chemical thermodynamic properties given for the fillers in circular

500, National Bureau of Standard are included in the table.

The filler

investiga-

tions have shown that boric acid and potassium oxalate provide better performance than asbestos in this type binder system. believed to be efficient filler Boric acid and potassium oxalate are

because of their low decomposition temperature and The temperature in

high rate of decomposition at the given exposure conditions. | the decom is iv layer of theso gystemt,

when exposed to an oxyacetylene torch flame,

reported to be approximately 800*F. Polyurethane systems have been investigated to some extent as

internal insulation materials by the Aerojet-General Corporation.

The systems

evaluated have been formulated primarily for use as chariber liners and not with regard to optimum ablation and erosion resistance.

S~16

=r

Internal insulation materials based on elastomeric phet.klic resins have recently been developed by Nobell Research Laboratory. developed contain a low filler The compounds The

concentration and are applied by spraying.

ablative properties of these systems are simiar to those of rubber-based systems. The reported programs for development of internal insulation materials include only a few attempts to formulate ablative materials with regard to the thermochemical and thermophysical prop"e.ties of fillers and binders. Such

an approach appears to be most useful in order tc advance the state-of-the-art and to achieve a significant improvement in the performance of ablative insulation materials. Research programs are in particular needed to provide experimental data Because of the

for confirmation of current theories of the mechanism of ablation.

many variables involved, a statistical design of formulations and a statistical aralysis of performance data appear necessary to establish the essential factors that determine erosion and ablation rates of the given environmental conditions. 2.
-

Ablative Properties a. Oxyacetylene torch tests A large number of rubber insulation compounds formulated

by RINS (Mare island Naval Shipyard) and by GT&R (General Tire and Rubber Company) have been screened for ablative properties by a torch device developed by GT&R. Test parmeters and exposure conditions of this device are shown in Table IIU. device has an oscillating feature that is not cmmon in torch testing. The

The main

performance criteria used sre the dimensional material loss rate, the thickness of the char formed, and the temperature rise on the back side of the 1/4 inch thick

17

test specimens used.

Table I11.

Performance data of some internal insulations are shown in

The newly developed V-52 has shown best performance in this torch test. A series of internal insulation materials have also been

evaluated by the RIME test, Aerojet-General Corporation,

Azusa, California.

The

RINE test has different and more severe exposure conditions than the GT&R torch. The oxygen-acetylene ratio is 1.2/1.0 as coaared to 1.0.76/1.0 for the GT&R torch and the total gas flow rate is torch. 720 cu ft/hr as compared to 72 cu ft/hr for the GT&R

Performance data for the best internal insulation materials evaluated by

this device are shown in Table IV. b. Plasma Generator Test Plasma generators are designed to produce very high flame temperatures and high gas velocities and are seldom used for evaluation of internal insulation materials. A few internal insulators have, however, been

evaluated in the plasmatron device, Azusa.

The test data obtained are of interest Some of the best test results

for comparison with sub-scale propellant motor data. reported are shown in Table V. c.

Sub-scale Propellant Motor Tests (1) RITE Motor Tests

ShtE(okt li-wulution !eat ~valuation)

motor was designed for evaluation of internal insulation materiale:. Exposure

conditions similar to those of full scale firings are obtained by use of same
Propellant and same fLiring parameters as in the fu.ll scale chambers. "

18

A total of 150 RITE Motors have been fired to evaluate the erosion resistance of a number of insulation materials. The test

date obtained for eight of the best materials evaluated u~ider duplicate conditions are shown in Table VI. The main performance criteria are the total losses in

weight and thickness of the material and the corresponding Thickness Loss Rate (TLR) and Mass Loss Rate (MLR). The TLR is of primary interest to the design engineer in

establishing the internal insulation profile and design safety factors. A rating of the eight materials tested at the established conditions with regard to TLB is shown in Figure 7. It is noted that two relatively new materials, V-52 (7242-IV-62A)

and M-707 show better performance than the V-44 material which has been test-fired and shown good performance in several 'ull scale motors. Figure 7 also illustrates X (density) product.

the importance of a low density insulation material by the (TLR)

This product is used as a guide in selection of the material that by weight provides the best insulation. The evaluated by RITE Motor tests.

v-44

material has in particular been

The effect of chamber pressure on the rate of erosion

(TLM) and the rate of erosion (TLR) vs time Of exposure for this material are illustrated in Figures 8 and 9 respectively. approximately eighty-five seconds. The firing durations used in Fiaure 8 are

The flame temperature of the propellant used at

Spressures "It
is

above 500 psig, is

approximately 400JOF higher than at the lower pressures.

noticed that the thickness loss rate increases rapidly with increasing -while an in-crease in

chamber pressure in a pressure range from 200 to 400 piid, pressure from

400 to 800 psig has only a slight effect on the thickness loss rate.

19

In Figure 9, thickness loss rate values are plotted vs time of exposure for the periods 6, 16, 33 and 45 seconds. The thickness loss rate is high during the first The

seconds of exposure and decreases with time for the firing durations used.

main reason for a decrease in the rate of erosion is believed to be due to increased thickness of the char layer with time of exposure providing increased thermal protection through transpiration or mass transfer cooling in the char layer. (2) ABL and ARC Test Motors The ABL (Alleghany Ballistics Laboratory) and ARC (Atlantic Resesrch Corporation) have evaluated a large number of internal insulation materials by their test motors. A "Round Robin" Test Program conducted to evaluate the relative performance of the V-44, USE-3015 and NOL-3098 materials in these and the RITE Motor gives some information as to the effect of different propellant exhaust on insulation material performance. POLARIS propellant was used in the BITE tests. Standard first stage

The TLR values (char rates) for The ABL test

the three materials in the three test motors are shown in Table VII.

data show best performance for the USR-3015 material and the poorest performance for the NOL-3098 material.
Andp oort

The ARC data show best performance for the V-44 material wN-3O15 xaterial.
The difference in material

peioz

for the

performance is believed to be due to differences in propellant flame temperature and composition of propellant exhaust.

-`0-

d.

Fuall Scale Motor Data (1) POLARIS Motors Erosion rate data on insulation materials

obtained at actual use conditions are of interest, both as material design data and in the development of useful screening tests and improved sub-scale test motors. A particular effort was therefore made to obtain quantitative performance data for correlation purposes. POLAP-iS 'est firings were of particular interest because of Practically all memos and reports on Performance data for POLARIS Motors

the relatively large number of motors fired. POLARIS insulations were therefore reviewed. are shown in Table VIII. table.

Data for nozzle insulation are also included in this

Firing reports issued during 1960 and. 1961 provide detailed information on

the amount and rate of erosion for the entire area of forward and aft end enclosures. These areas are divided into sectiois and stations as shown in Figure 10. The

dimensional material loss rate (MLR) for the V-44 material at the various stations of first and second stage A3 motors are shown in Tables IX, X, and XI. The average

MLR for the various stations in the second stage motor aft closure is approximately .06 in/sec. The value for the first stage motors is .18-in/see.

(2)

MINUTEMWN Motors

-7]
The configurations and profiles of the forward and aft closures of the secohd stage MINUMMAN Motor are similar to those of the POLARIS motors. The insulation systems evaluated in the MINUTEMAN-Motor -include material. The dimensional material loss (removal) rate

Garlock 7765, and the V-4f

of V-44 at the various stations in MINUTEMAN aft closures are shown for two motor

21

firings in Table XII.

The average dimensional. material loss rate for two motors is

0.18 in/see.
(3) Miscellaneous Motors

The performance data reported for the GAM-87A, the EAGLE and HAWK motors were also reviewed. A comparison cannot be made of the

material performance data in these motors with the POLARIS and MINUTEW motors because of the different propellant and the different firing durations involved. The polyurethane system used for insulation of the EAGLE and HAWK motors appear to have as good performance as nitrile rubber insulators and should be of particular interest for internal insulation of rocket motors because of their ease of process-

"ing, (casting, sprayIng) and their good mechanical properties at low temperatures.
j;, Mlechanical and. Physical Properties The mechanical property requirements of internal insulators

"vary considerably with the dimensions and type of motor cases.

A high elongation J

seems tobe essential for insulation materials used in filament wound chambers.

"This has, in particular, been demonstrated by ABL,

The use of insulators with a.

-

uniaxial elongation of approximately 15% in filament wound test chambers has repeatedly resulted in rupture in the insulation-on chamber hydrotesting at approxiuley2~p tg d in Nipture inte nulto

Investigations are therefore being made of the stress-strain behavior of rubber insulators by various missile firms._ Bi-ax.:.1 and tri-axial tensile-elongation tests have recently been given particular attention. To avoid

mechanical rupture in the internal insulation, material6 with a uniaxial elongation

-22-

of approximately 100%, at ambient temperature, wound motors.

are currently being used in filament

The reported mechanical properties of some of the best internal The NC-1 material has shown

insulations developed to date are shown in Table XIII.

good performance in ABL test motors but is apparently no longer considered a candidate internal insulation materials because of its low elongation. have not

Physical and thermophysical properties, in general,

been determined by the firms engaged in the development of internal insulation materials. The Aerojet-General Corporation, Azusa, has however, determined the specific heat, heat and temperature of ablation for some Available data on the thermal conductivity and

thermal conductivity,

internal insulation materials.

specifIc heat are included for the materials listed in Table XIII.

F.

MMXTAL INSULATION MATERIALS

The POLARIS and the MINUTEMAN missiles require external chamber

insu.lation for thermal protection against aerodynamic heating of second and third stage motors respectively. Underground launching of the MINUTEMAN missile also first stage motor. Ablative insulation is con-

necessitates insulation of its

sidered to be the most effective and reliable external insulation method because the skin temperature of these motors may exceed 1000 or 1500 0 F. Data from flight

tests are, however,

not yet available to confirm estimated skin tomperatures. and apparently the only major effort to develop an Sprayable

.'The first,

external instulation material has beenmade on the MINUTEMAN -Program.

ablative coatings have shown much promise with regard to ease of processing ourface smoothness, mechanical and ablative properties. An alternate type material,

23

also considered for external insulation of the second stage POLARIS A3 Motor is a cork compound that is prepared by molding and. cut into a tape. by adhesive bonding. The tape is applied

Apparent disadvantages of the cork tape is a high material

cost, and a problem in obtaining a satisfactory bond to the chamber as well as a smooth surface. Ablative properties of external insulation materials have been evaluated in plasma-are tests. The data for six materials in Table XIV 3how best Fnysical and mechanical properties for these

performance for the DC-61i. ma-werial.

external insulation materials are shown in Table XV and XVI. 0. NCMZ1X INSULATION MATEIAIS A review was made of the literature on nozzle insulation materials
to establish the status of material development and testing techniques. found that the literature gives very little It was

information on the chemical reactions

that take place during the ablation of these materials and that only minor efforts have been made to formulate insulators for the nozzle entrance section and exit, cone. A large number of tests have however been run to provide engineering data resin systems with

on the ablative properties and erosion resistance of coeraial organic and inorganic fiber reinforcement.
__

Oxyacetylene torch devices and plasma

generators have

mnomvor

been -uicd

,-these CVa

ions

'meTables

xviA

I,

and- XI:X show test' data for the best nozzle insulation materials evaluated at the GTER torch test facility and the Azusa and Sacramento plasma-arc facilities respectively. The phenolic resin-graphite cloth systems have in general shown best

performance as insulators for nozzle entrance sections while the phenolic resinsilica-cloth (fiber) systems have shown best performance in nozzle exit cones,

24

An evaluation of organic and inorganic fiber reinforcement in various resin systems was made by the University of Chicago using a plasma-arc test device. The results, illustrated in Figures 11 and 12 show that organic fiber reinforcement has superior erosion resistance (low ablation rates) at a high heat flux level while inorganic fibers provide the best erosion resistance at a relatively low heat flux level. The good performance of the organic fiber-reinforced resins at the high heat

flux level is 'believed to be due to transpiration cooling by low molecular weight gases such as hydrogen, that are formed on decomposition of the organic fibers. rate of decomposition of the fibers into small molecular weight gases, which is a function of temperature, is too low to be effective at the low heat flux level used. H. CORRELATION OF PERFORMANCE DATA A comparison has been made of the discussed performance data from oxyacetylene torch tests, plasma generator tests, sub-scale and full-scale propellant motors to establish the most useful tests for insulation material evaluation. Oxyacetylene torch test data from a number of torch test devices have in particular been investigated in conjunction with the NOL-ASTM standardization program for oxyacetylene torch testing.' Special Project Office, This program, sponsored by the Navy's The

involves panel tests on different ablative insulation

materials and a.statiaib1

analysis of the test data.

Test data from the RI1M

Facility and the GT&R torch test facility are included in this correlation study. Results to date show a poor correlation of performance data between all- torch test devices involved,

-5

A similar test program is underway for evaluation of plasma-arc test devices. able. Attemptu to establish a correlation between published plasma-arc performance data from different facilities showed that a comparison could in general, not be made of the reported data due to lack of information on the materials compositions, differences in testing conditions, and differences in the type of data reported. Ablation rates are in general reported as dimensional values. Analytical data from this correlation study have not yet been made avail-

However, ablation rates are by some facilities reported as average weight loss values. A good correlation could not be established between either oxyacetylene -torch-test data and plasma-arc test data with sub-scale propellant motor data. It is

to be noted that materials such as SMR.6-11 showed outstanding performance in the

I-plSmatron

test, and relatively poor performance in the RTE motor. Sub-scale propellant test motors seem to provide reliable insulation

1;

materials performance data that can be correlated with full-scale motor data. Sub-scale motor tests are used extensively by the Alleghany Ballistics Laboratory, the Atlantic Research Corporation and the Aerojet-General Corporation.
Me RITE motor is t-%

-Mt

b-sew-e tuat motor designed by the

Aerojet-aenaral Corporation for evaluation of internal insulation materials at simulated full-scale motor firing conditions. Comparative test data from the RITE

motor and full-scale motors are to date available only for the V-44 material.

Figure 13 sLows the average TLR values obtained for this material in the RITE motor

26 -

at simulated first and second stage POLARIS A3 test conditions and the average TLR for aft head insulation of the corresponding full-scale POLARIS motors. A good

correlation seems to exist between the TLR in the RITE motor and the full-scale motors with regard to the firing parameters used. The average TLR data for V-44

in the second stage MINUEMAN motor and in the GT&R torch device are included for c omparison. Z. ABLAT.VE NOZZLE THROATS The evaluation of fiber-reinforced plastics and rubber insulations in torch test and plasma generators have indicated that it ablative nozzle throat s. 1. is feasible to develop

The following type ablative materials may be considered:

Materials that Ablate with a Constant Rate of Ablation Some materials, such as fluorocarbon polymers, have been

reported to ablate without the formation of a char.

Other materials ablate with

the formation of a very weak char that is immediately removed from the ablative surface by high velocity propellant exhaust. These type materials will apparently A problem

assume a constant rate of ablation at constant environmental conditions.

involved in such a development is to achieve a sufficiently low ablation rate. -2. Materials with Decreasing Rate of Ablation Insulationimaterials based on rubber and phenolic resin-rubber binders appear to have a decreasing rate of ablation with time of exposure (Fig. 9). The decrease in rate of ablation seems to be a function of char formation, char properties and thickness of the char formed. This type ablative material seems to

offer some promise in nozzle throat applications.

27

3.

Intumescent Ablative Materials The U.S. Rubber Company has recently indicated that it appears

feasible to develop an ablative nozzle throat that will maintain nearly constant dimensions during exposure to propellant flames by intumescense (expansion of char layer).. The development of such a material would involve an extensive investiga-

tion of char properties. J1 PROCESSING OF ABLATIVE INSULATION MATERIAULS The primary factors considered in the processing and application of ablative insulation material are: 1. Time and cost of operations involved. 2. Effect of processing variables on mate ;.ial performance.

3.

Inspection and quality assurance.

The processing methods generally used in the application of internal insulation materials are: 1. Hand lay-up. 2. Molding and adhesive bonding. Casting Spraying aTh han_!layr-up ".roc-ss h1s beia-uoed in theapplication of the

3.
4.

epoxy-asbestos insulation for POLARIS motors. expensive.

This method' is time-consuming and

However, the performance of the epoxy-asbestos insulation is not

greatly affected by material impw:.t'ies, catalyst levels and variation in curing conditions. Rubber insulations have also been applied by the hand lay-up process.

-28-

The cure and consequently the performance of rubber insulators may be affected considerably by impurities picked up on handling and by small variations in the concentration of catalyst and antioxidant. time may also affect their performance. The use of molded rubber closures for the forward and aft end chamber insulation offers an advantage to the hand lay-up method in that a molded part can be pre-inspected before the bonding operation. bonding of rubber insulators. A problem is introduced in adh1evc' Variations in curing temperature and

The use of molded rubber closures is also limited to

a certain size chamber because of limitations in the size of molding equipment. The application of internal insulation materials by casting and spraying offer some advantages to the hand lay-up and the molding-bonding procedure with regard to the time and the cost of the operations involved. Casting and

spraying can also be used for application of the insulation in very large motors. The effect of processing variations on the performance of rubber insulators has been studied to some extent by several firms. The performance of

the nitrile-rubber asbestos system has in particular been improved by new processing teohniques. It has been shown that the size and distribution of filler particles

and the orientation of fiber reinforcement are important factors. Company has, for example,

The U.S. Rubber

demonstrated that one five-minute mixing cycle of asbes oa

(Plastibest 20) in styrene-butadiene rubber results in good flame performance. Repetition of the five minute mixing cycles up to twenty times shows that the rate of erosion for this system increases with time of mixing. The processing of nozzle insulation involves, molding and adhesive bonding. in general, compression.

External insulation is genarally applied by spraying.

-29-

CQ

-1.

UN " -

Z.~fl~

II

0)
H;

00

00Ut

Ru

C;
I~OD

I~ I

jI

Cil~ '-4

Cui

1K~~~~
C/3ca

00 00A r uu0~u

a Qu~u

e~1

ON~ o2

cq

OM

-30-

10,

In

I
~
+:

I~
'1OI
~II
4-1

to

C-'I

CIC

en

L\

HUNW

I\
0.
m:

'

'

ID.

r\H

CQ

u (

CQ

Lr

ci cr Ol

$ I','A
0.

H H. Hld I0) CuC3 to ,

to-

9 rk

C o

Io ?i t-O

' P4 a

Co

31C

TABLE II TESTING PARAMETERS FOR OXYACETYLENE TORCH DEVICE, GT&R.

I. 2.

Oxygen-acetylene ratio Total gas flow rate Flame temperature Test specimen dimensions Specimen distance from torch tip Specimen location Torch oscillation onto specimen

1.029/1.00 72 scuf/hr 5600*F 2 in. dia., 0.25 in. thick 1 inch parallel position 60 angle, 10 cyoles/min,

3.
4,. 5. 6.

7.

0r
H

Ur*

Ur\

oo~co

(ON

-A
0 0 4n 04UC~o 0

0
H

0
LC%* 0O

HO

~0
4

1
-i

$*

K. lii

""'On

A,

0
flirni >
330

-0

0)
0 0 . )

bf (4 I

4u

C.)

-.

S p 4

CT

~4

-4 C"4

c 0

343

I.
alI,

RLl

0)0)p

UN-

Il~
000 00
43 c .o a

94

0)e

-35-

TABLE VI RITE MOTOR DATA

terial
res-ig. nation Vendor Density g/cm3

Fir

Parameters
Av PH .

Weight
Loss g
---

Av Thickness
LosS Plate in/sec

Daraton sec.

Av
Char in.

Av Degraded
Material in$

(Density)
X (Av TLR)

V-52 M-707 v-44

F-33

GT&R

1.318

92

355 341. 328

322

.0067 .0078 .0085

.137 .100 .158

.233 .641

.033 .043 .0312 440

,0X22

.0088 .0093 .0102 0124

p0116

GoOdyr 1.187
GT&R 1.29

85 80 86 75 88 78
82

750

Narmco 1.47
AGO, Azusa
-1. 29

601

.0084

9001 1126 3015

SMR611I

325 344
340

701 936
---

.0097, .0105
.01a6 .0129

Nobel.
USR Stoner

1.19
1.27 1.227

.0121 Om..
.185 .119 .029 ,051 .0135 .0158

40

-889

-36

{1

I
"Z--

.'0,

O U
cm~

)-

to

37

15
..'

ha
s

'2 8 1
'I
DCiI

'

a
N

'

'

I
.3
..

.z'
-''

S
-

ro &

'2 N.

v'
V
n IC':i
C'C N C.

.C,.to

t'

C ucS

it
a1S
NJJ.4J

.41
P..

00 AC"t.3S SCON .4C4C* 2 1 j5 .- Q

:1

IQ r2
-C

C3 .3i..

dAB .L...
ig

.-d1A5

0 43 b
.- iBrio

rio

b. 0

CC

a
SQl

Ci

'rl
.

'1'-

CA

:+

4
.4

.1

42o' 5S&s.9
CC

RZ

p
P
1I

I- j

iiPh >
ML

!I bii
I

b
-

ii
__

4
3343 I04I

__

K
1!

a do
:iC3

A'

P
C

M--4

a--

5
0.

'

*f.
.
C

.vi
'-C I N.

L 4

A
B.

I
18

TABLE IX THICKESS LOSS RATE ve STATION OF V-44 IN SECOND STAGE POLARIS A3 AFT CLOSURE

SECTION

Station 35 30 33 32 31 30 29 28 27 26 25 24
23

0CI 0 o .0002 .0013 .0017 .0027 .0030 .0037 .0035 .0o4o .0058 .0069
.0078

4_*

600

75*

90V

1050

120_

135_

0 0

.0004 .0008 .0011 .0010 .0015 .0033 .0022 .0024 .0035 .0037 ,0039 .0045
.0047

.0015 .0011 .0010 .0008 .0012 .0016 .0015 .0018 .0019 .0030 =0042 ,0050
.0053

0 0 0 .0017 .0021 .0022 .oo17 .0024 .0027 .0022 .0033 .0035

.0-029

0 0 0 0 0 o0004

0 0 0 0 0 0 o 0 .0005 .0009 .0021 .0023

.0033

0 0 0 0

0 0 .0004 .0012

*ooo6
,0010 .0019 .0017 .0037 .0035
.0041

.oo06
.0025 '40037

.0004
.0014 .0033 .0045 .0051 .0053
.0055

.0055
.0066 .0063
.0065

22 21 20 19
18

.0078 Nozzle
Area

..0052 .0050 .0064 .0058

.0054

.0067 .0080 .0089 .0074

.0056

.0053 .0057 .0079 Nozzle

Area
Nozzle Area

.0069 Nozzle
Area

,o024 .0083

60059 .0066 .0063 .0054

.0050

.0042 o0043 .0048 .0052

.0051

Nozzle
Area

Nozzle . .0097
Area

Nozzle
Area
Nozzle Area

Nozzle
Area
Nozzle Area

Nozzle
Area
Nozzle Area

39

TABLE IX

:ontinued

SECTION

Station 17 16
15

00 Nozzle
Area

45__
.0051 .0051
.0044

600o
.0037 .0032
Nozzle Area Nozzle Area

7
Nozzle
Area

90_
Nozzle
Area

1050 Nozzle
Area

1200 .0041 Nozzle

Area Nozzle Area Nozzle Area

135__ .0065 .0061

.0054

Nozzle
Area Nozzle Area Nozzle Area

Nozzle
Area Nozzle Area Nozzle Area

Nozzle
Area Nozzle Area Nozzle Area

Nozzle
Area Nozzle Area Nozzle Area

14

.0038

.0045

13
12

Nozzle
Area Nozzle Area Nozzle Area

.0033
.0037

Nozzle
Area Nozzle Area Nozzle Area

Nozzle
Area Nozzle Area Nozzle Area

Nozzle
Area Nozzle Area Nozzle Area

Nozzle
Area Nozzle Area Nozzle Area

Nozzle
Area Nozzle Area Nozzle Area

.0043
.0050

11

.0040
.0040 .0033 .0028

.0045

10

Nozzle
Area

Nozzle
Area

Nozzle
Area

Nozzle
Axea

Nozzle
Area

Nozzle
Area

.0043 .0040 .0050

9
8

Nozzle
Area

.0066 .0060

Nozzle
Area

Nozzle
Area

Nozzle
Area

.0049 .0051

Nozzle
Area

.0044

Nozzle
Area

Nozzle
Area

7 6 5
4
-....

Nozzle
Area

.0033
.0039

.0054
.0041 .0042 .0039 .0038

.0052
o44

.0032
.0049 .0032
.0026

.0044
.0030
.0028

,0044
.0043 ,0040

.0058

oo49
.0019
.0023 .3 0037

.0054
.0053

.0035
.0038 .0048

.0037
.0032

.0032

.0016

.0034 .0049

.0o44
.0049

.0058
.o066

-40

TABLE X
THICKNESS LOSS RATE vs STATION OF V-44

IN SECOND STAGE POLARIS A3 AFT CLOSURE

Station No.

900.1050 .0022 .0023 .0066 .0047 .0067 Nozzle Area "

t

120.,

60_o

1350

450

4 -5
6

1 2 3

7
8

.0025 .0023 .0055 .0050 .0022 Nozzle Area

"
t

.0025 .0024 .oo64 .0062 .0088 .0056 Nozzle Area

" " " " "
t

.0025 .0024 .0064 .0043 .0034 .0056 Nozzle Area

if t
ti -

.0012 .0012 .oo66 .0050

0oo87
.0091 .0099
.0061

9 .0
1" 13

"1
If I1

t t

"
t
t

"

" " "

.0012 .00.2 .oo6, oo4., ,006:3 .0050 .0031

.0028 -0035

"

.0063 "
" " It .0061

t
I
t

"
t

"
" "

"
" "

.0057
. 0067

0052

.0052

.0057
.0097
.012
.0110

14

"

"

15
16

'
"

I
"
,,

17 18

If If
,t

"t
it
,, " It

!1 i "

.0078 .0076
.0086
.0101

.0051 .0079 .0093

19
22 23 24 25 26 27 28 30

It
t50 21

"f
"

it
" t
t It t

.0131

.0114
"
I

.0085.

.0059
.0060

.0108

0095

.0113
.01o2 0 o0094 .0088, .0081. .0085 .0118 .0125.0127 .0130 .0082 .oo82 .0077 ,0039 .0026 .0029

.0123

.01:2
o212
X0107

2At .0078 .0069 .0060 .0060 .0058 .0078

.0059 .0032 .0010 .0016 .0011 .0012 .0010 .0020 .oo14 .0020 .0017 .0012 .0013

0105 .0089 .0065 .0043 .0033 .0029 .o028 .0058

.0038 .0045 .0043 .0033 .0029 .0028 .0058

.0038

.0102 .0098 .0098 .0118 .0=5 .o027 .0130 .0082 .00o8 .0077 .0039 "02 .,00.9

31
3V 33
-

.0050
.0047 .0043 .0029 .0022 .0018
-

.0039
-

.0039
.0036 .0032 .0027 .0021 .0014

34
35

.0036 .0032 .0027 .0021 .0014

.0059

Average TLR (Thickness Lose Rate)

41

.".

,--

__,_

___

.-

__

TABLE XI THICKNESS LOSS RATE vs STATION OF v-44

"IN FIRST STAGiE POLA1IS A3 AFT CLOSURE

Station 1. 2. 3. 4. Section Between Nozzles Across Nozzle .008 .0093 .0078 .0074 .0100 .0145 .0173 .0176 Station 24. 25. 26.Section Between Noz;:1a_ Across Nozzle Nozzle Area .021 . 021 .019 .018 0193 .018 -027 0274 .024 .O191 .0212

.0o6
.0139 Nozzle Area " " " "
-

27.
28. 29. 30. 31.

I.
-

5.
6.

7.

.0169
.0161

30

* "

28.

.020

.0297 ,031L

S9."
10. " " "
--

"

.0171
.0190

32..o19
33. 34. 35. 36. 37. 38. .016. .0105 .0103 .0089 .0097

11.
12. 13. 14. 15.

"

.0216 .0270 .0263

,o184 .012

.oo64
.0106 .OL)2

"

"

.0259 .0275

17. -18.
19.

.0325 "
"

43..
44.,
46-,

.oo:

"
"

.0312
.0312

.oo44
.10,3 .r025

20. 21. 22. 23. NOTE:

"
"

"
"

.0306
.0294 .0264

47.

"

.0245
-

Average Thickness Loss Rate

.0183

Distance between stations

one inch
-

42

TABLE XII THICKESS LOSS RAT vs STATION OF V-44 IN SECOND STAGE INUTEMAN APT CLOSUE, ENGINE 44 FW-45 MOD 2 AND MOD 2X TLR/in./sec. Section Through 00 "" Station 15 14 13 12 Mod. 2 .000. Mod 2X .006 .011 .015 .022

.003

" "
. .. II

"i
I
I1I II I! II
-

11 10 9
8 7

.032 Nozzle port II II

I1 II TI t II II II II It

.008 .017

.038 Nozzle port TI I! ,

II II I II II II It II "

6! " ."

"I
I....'2

.020 .011 ..
-*.

.024
".006 ..

.008

"I

tbouh

"I

1.. 0
4.008

007,
.007

.009-.013

.o10.
" "** .009.006
". 011
.013 .020

.007'

.oo7

.007

. ."10

"I"I "I "I "II*

I"

" 6 7 8 9
".042
" ii

.008 012 . -

.005

"
,

.
-

.033
40 .0o43 .0o4.7

.018.037
' .040 -

'

"- "1 Ave ra4e

-1.3 4 -15 "

12

".o045

.0,47
,020"

"

.038
.0o18 0. 019

. 016 0.0178

43

ur4J *f*. O

A--1
H
rPr4 --

4H laI
tDUV

q~4-4

TABLE XIV PLASMATRON TEST DATA* FOR EXTERNAL INSULATION MATERIALS Argon Stagnation Enthalpy (BTU/lb) 248 438

Material Avcoat I

Density (lb/ft-) 70.0

Cold-wall Heat Flux (BTU/ft 2 sec) 7 33

Brightness Temerature (O)

M6ss t~b/ft2-sec) 0.00015 0. 00182

867 Dyuel-Acrylic 66.0 248 438

867 Thermolag 500 '92.5 248 867 Aerocoat I 69.2 248 438 867 248

78 7 33
78 7

1930 1600
1663

0-0:2330 0.00034 0.00327

0.01710 0. 000-2

,38

33

.48o0 1663194o 2020 ' 1730 <,)4oO 1730

.o054 o.0o048

78 7 33 78

0.0110 0-003570.02820 0.,0704

Dynatherm

D-65

63.3

438
867

33
78

0.01090
0.01530

DC-651

7T66

248

438

33

<4oo0

0.000023 -0.00129

o.oooo,,5

867

.78

140 Plamatron, argon ga5s

-45

t\

Lr*

Lt*A

T-

00

00

000

'V 5

IRH

AA
P4
00 0 0 0 00

r-8 8

-.

00R

cUl\

Lt% 0 Lt46

Lt

OO~CQ

1:0

U.14
-

AI

41I

-<1 )47

C-42

o0~0

00

~18,

Lr~~~
C Y
9 4 4

j
.4 .4I.44

~ju:~ur

:0

4.1

OH.
:00 qigo 2

--

,-i

-48-

AO

Lo1\

I)
I Eq
000 0 00

0
orlr
0 0 00

IL
4J 4N

49

C',

Cu

Cu

Cu

0.0

c uC.) (

q.44

A10I Jk4i II u
S r4u r,-

j
C,

4z,

50

.50

,.-V

77
.. .
I

i... L /

-... ...

_ _. . .

I/

I.-- I.... 1. .

-/

" i- ',-- - ' ':...-

i.

... . . -. . -,.. . .-

.... ...-

I'

I--

2.-.2

iLi iJ* 2

I--I

C-1

e4

c4

oC

cm

A
.4gU)

--

T----

"Udmur
53

--

I.*w

54

V.
I.0
4

____ --

0
* __

S 2
44

-P
III1
-4-.---

I-------------I,
I
@4 '4.

*1
-------------

BM

&

1*
I

IA

I IIL1 inLK
COt
Z

[1

AOL

.uuqd pfloO

FIGURE 6 CROSS -SECTIONh.L DI.AGRAM OF ATMOSPHERE FURNACE FOR DTA

SAMPLE HOLDER

PRESSUR VACUUM

OFUFURACC P0JE

CONTROL-RING DI~i'ERNTSEAL~

COOING R WATERe:

AIOU? WD R5-3

FIGURE 7 TICiUESS LOS RATE (TLR) AND DENSITY X TILR

OF' INSULATION MATERIALS IN THE RITE MOTOR r?242-.IV-.62As Genrjr2q ir'. (V-52) & Rubber .

M707, Goodyear TLre & Rubber Co,. V-4h, General Time & Rubbpr Co. F33p Narmco Industriam, Inc.9001, Aerojet-OCen~eral Oorporati,-r,, AUwsm 1126, Nobell. Hrmie,rch Laboratorlc!;

_ __ _ _ __ _ __ _ _ _ _ _ _ __ _ __

__

__

_ _U

.S .R . 3 01 5 , Un i t e d s i Rubber Cq.

X -

.10SMR6-11, Stoner Rubber

'~

Thickness

i oan

Rate, in./see

ThIckness Loss RaLe X Density

IT

qpq

.. |

5, si S-I ssw o m

8:;

__________

__________

__________

I
64

'A
K.

I
I

z C)

____

____

__2
C
1 'A

1
S
F

p4

S
0 0446/UT

ILTU 9901 SWOIRAL

FIGURE 10 LOCATION AND TYPICAL VIEWS OF CROSS SECTIONED AREAS AND STATIONS USED IN REPORTING TLR (THICKNESS LOSS RATE) OF INSULATION MATERIALS FOR POLALRIS AND M'INUTEMAN AFT CLOSURES

"View Looking Forward

180o

No

.00 .50 Oa"

1650
1507

135
120

\ 600

900 typical

900 Section

AA

Typical 450 and 1350 Section

S... K,,,.H60

60

rzoGaz n
STAGNATION PO1W! LINA ASIATION RATES OF BANPLES 71PU (195O BTU/tt -e00)
2

mmoi

To MEO RUT

32Phanolie-Nylarn R3 90Phenolic-Cott~on A 3Phoncllc-Nylon1 Fernolc-C,)tton Fabria 1

11Phenolic 96Phenaltc-Asbeetom 3Phenol.ic-Nylon 15Phenol 21Epuy'G.Odag 34Phenolio-Asibeata soPhenolie-Refreuil

-B Irahwood1 2 I to-Reftass1-Nylon' Fiber-Qersnio Fiber. 4

3
2 4

Phevy2.sflane-42aia Fiber 19Pher~lic-RefsAeil 79 23Ptenolits-Asbealtos 19Phenolic'Quartz 15 henolic-Quartz hanolito-feNassei

-

3 4 4 2 5 5

A4Phfnolie'-Clasa
16Phenolio-Fibertrax 98Phenollo-Asbesstom 10Epoxy 91Phermlio-Asbestra. 129

Fiber

3
2 2 4 2

-Retrm.Ail. Fiber

301case-Rfteramil Phuny'1aihane-41ans Tape an.4,frasmi Tape

4 3 4

10P11Any.1Ci 92Pheno'1io-Refrail 17Phenolie-Refrassil, 89Phenol .8Phenol 87muaamjim-cattan 1.Phefloto-Asbeator 35Siioane-Assbeeton 85Si! 94Sit

4 ic -Asbatoo. 2

Pten28-erai
ic-Retruilei Phanolic-Aabentoo

4 4

2 2 Ione-Glasa ?abviia toone-Glag. Roving P~wmlia-Aabae~to Teflon-Aliuajria S1ilcate

3
2

MSlicane-Ce

ram c-Wamra

3 Stagnation join~t lin!"r ablation rate, 1lain,/e#e.

References WADD TR 60-1016.

FTGURE 12

STAGMAT!ON P01? LIArM AILAT70K RATES OF SNPUCS

2 FIPOS3M TO LOW HEAPT FLUX (600 "a/ft - se)

Samiple~ No. 1.08

Y Phenolii-Refrasil4 1.4Phenolic-Refrasil

class

4 Phonolio-Quartz Phenoli~c-Quar'tz

199 160

5 5 4 4
4 4 4 4

'02

Phenolio-Refrasil Phenolio-RefrauI-Nylon
Phenolio-Rerrasil Phenr'1silane-Re1f'aai Phenolio-Refrasil-Nylon Phenolio-Refrasil

131
132 158 127 126

1.07
112 103 50 109Phenolic-Asbestos n1

Phenolio-Glasa F~iber
Phenolio-flylon Phanolio-Nylon Pherolic-Asbeatos-N~ylon

3
1 L. 2 2

Phenolia-Aubestos. Mealmirie-Nylozn

106 162 99
i1l 101

Phenolic-Birchwood
Silicono-Asbestoe Phenoli-Aabobt~da Melamine-Cotton1

100 113 0 4 8 1~16 go

Phenolico-Asbestos
Poyst.h.ezie

2
1

Stagnation point lUnpar ablation ra~te, 10-3 in./see.

Reference:

WADD TR 60-101

62

FIGJrRE 13
,;'urago TLR (Thi,Ar.ess Loss Rate) of V-44 In Oxyacetylene Torch Test, Rite eir, A'Irst .nd Second Stage POLARIS A3 Mctors, and Second Stage Minuteman Motor

Oxyacetylene Torch Test (Geneial Tire & Rubber Co.)

RITE Mota A3 Second- Stage Condition (1)

RITE Motor A3 First Stage Condition (2)

Seoond.Stage POLARIS A3

Motor #10 (3)

Second-.Stage POLARIS A3
Motor #17 (4)

" ____

First-Stage POLARIS A3 Motor (5)

MINUTEMW Second Stage Motor (6)

.
"(. Yf,
(.C0050

I
0.0100

I
0.0150

I
0.0200

'L (T"ckn-.mT Lossi Rate) in/see. ':v:,r.e -if 10 specimens 1.165 tube diameter, 328 psig, 80 see duration. !rcr-1ge n^ 3 specimens .39 tube diameter, 716 psig, 85 see duration " ( ,'or #n, 235, psig, S5 see 4urlon.

" "'.or ,#17, 251 yi'sgo6, avc:duration. ' otor ,35, 703 psig, 7.4 see duration.
,.d 2 '-, d '.:,d 2X. 63

.)'

REFERENCES

1.

Thermal Parameters of Re-entry Ablative Plastics D. L. Schmidt, Wright Air Development Division, WADD YR (Technical ]leport)60-14Ci The effects of Thermal Environmental Parameters on Ablation Thr~ct~risti W. P. Manos and D. E. Taylor, The University of Chicago, WADD TR 60-101. The Erfects of Material Parseters on Ablation Characteristics H. Halle and S. J. Nicolosi- The University of Chicago, WADD TR 60-101. Studies on Plastics Exposed to High Mass Flow Thermal Environments H. S. Schwartz and R. W. Farmer, Wright Air Development Division,

2.

3.

4.

WADD TR 60-101.
5.
A brief Review of the A3MA Ablation Materials Program W. R. Lucas and J. E. Ktigsbury, Army Ballistic Missile Agency, WA")f TR 0 - 11,.

.6. The Importance Of Char Structures in the Ablation Performance of organic poljrrer,
W. T. Barry and W. H. Sutton, 0eneral Electric Comrany.

7.

Thermal Stability of High-temperature Carbon-chain Polymer$s

S. L. Madorsky and S. Straus, National Bureau-of Standards, WADD TR 60-i10. C. D. Doyle, General Electric Company, WADD TM 60-101.

.8. Use of TGA in Studying Thermal Decomposition of Polymers

9. A study of Hypersonic Ablation S. M. Scala, General Electric Company, WALD TR 60-101. The Ablation of Plastics During Hypersonic Re-entry Part If:
Reaction Rates from TGA Data "H. -L. Friedman, General Electric Company, WADD TR 60-101..

10.
.1.

Chemical

The Infrared Emission Spectra of Plastics Ablating in a Low Enthalpy Air Stream:
Measurements of Surface Temperatures and Temperature Profiles Behind the Surfase.e P. L. Hanst and A. C. Walker, Jr., AVCO Corporation, WADD TR 60-i01.

12.

Plastics in Rocket Nozzle Environments A. M. Cecka, G. Epstein and D. L. Robbins,

Aerojet-Goneral Corporationr

WADD TR 60-101. 13.

i4.

Solid Propellant Rocket Motor Insulation J. D. Batchelor and N. Vasileff, Atlantic Research Corporation) WADD TR 60-101.
Structural and Insulative Characteristics of Ablating Plastics J. L. Beal, F. A. Vassallo, N. E. Wahl, and G. A. Sterbutzel, Cornell Aeronautical Laboratory, WADD TR 60-101. Thermal Diffusivity - Its Significance and a Method for Determination R. W. Farmer; Wright Air Development Division, WADD TR 60-101.

15.

..-.-.

-.-

..

--

References (Cont.) -16. Effrcts of Rapid Heating on Meth&ticJ Froperties of Conmosites C. A. Haudenchila, Gow-.a Arraft Corporation, WADD TR 60-101.
Effects of Ultraviolet and Vacuum on Propertle. of P11.-tcs

"17.
18.
-'A.

N. E. Wahl, Cornell Aeronautical Laborratory, WADD TR 60-101. WADD High Temperatur. Polymer Progrram M. Lovelace, Wright Air Dev-lopmt'nt Idvi~ion, WADD TR 60-101. A Study of the Mechanism of Ablation of Reinfor;ed P1.utics. )D.L. Chamberlain, Jr., D. E. Van Sicole and 0, W. Marynowski "
'

19.

" WADO TR p59-668, Part II

20. 21.

...

Behavior of Reinforced Plastics at Very High Temrer.tures I. J. Gruntfest and L. H. Shemcer Modenrn Plastics, June 1958.

Research on Criteria for Plastics Ablation Materials as Functions of Environmental Parameters S. Brelant, B. McFarland and P. Joerg, Aerojot-Gennral Corporatlon Suarterly.Report No. 4.01-01-3, AF 33(616)-746i, Mar 1960 A Theoretical Study of-Stagnation Point Ablation L. Roberts, National Aeronautics and Space Administration,
Report R-9. Ablation, Heat, Sink and Badiation

"22.

STechnical
23.;

"J. 0. Coll4ns and S. Spei-l,--Joh.ns-Manville,-Matedrials in Design-Engineeri_

.Mrch 1961

2 4.

Five Ways to Control High Heat Flux SH. A. King, Western Backing Corporation, Mat..i.ls in Design Engineering, Feb 1961.

-25." Analysis of the Ablation of Plastiam Heat Shield that Forms a Charred Surface Layer R. J.--Barriault andJ. You, Ameriosm. Rocket,. Society Journal, Sept 1960,
.... -. ."-

26.

Research on the Mechanism of Ablation of Po.lymeric Materi.l

C. E. Lapple, A. P. Brady-and D. L, Chaerlb Institute, ASD TR 61-2o0.27.

.'lD.

zia, Jr., Stanford Research

A Study of the Mechanism of Ablation of Reinforc3 Plastics L. Chamberlain, R. Y. Mixer, and C. W. bArynowski, Stanford Research Institute, WADD TR 60-101.

APPENDIX "A" GLOSSARY OF TERMS

Ablation: A surface degradation process involving decomposition and detachment of material.

Ablating Zone:

The ablating zone consists generally of a decomposing

material layer and a: protective char layer through vhich the decomposition products are emitted...

Char Layer:. ---. -remains ..

A protective layer of carbon and other particles that' as an integral part of the eroding material, The char layer may vary in composition relative to

the surface -of the protective layer.. Rate of Ablation: Rate of thickness reduction of virgin.(nohd:egraded) material.

Char Rate:

Rate of thickness reduction of virgin-material.

(rate of ablation.), Rate of Erosion: . Rate of thickness-reduction of charred material.. The char layer-is included as an integral nArt nf tIK-.
eroding material.

Heat of Ablation:

The heat energy dissipated through the thermochemical and thermophysical reactions involved in the ablation

process.

AI

Appendix "A" (Cont.)

Effective Heat of Ablation:

"Q

6A Heat input Btu/ft 2 sec as measured with aold water calorimeter. A

-

Where Qo

sI

Test specimen area

ft 2 Lb/'se-

..
I

w-

Weight lose with -char layer included

Reference:

RD-Rl61-211 Aerojet-4eneral Corp rrtt on Structural Material Division, Azuae

S.'Transpiration
Cooling:
-

Mass trArn,r.eooling

between the impinging part:il.l s

(of propellant eXhaust and particles from the de-zomposing layer that transpires through the char layer.

Internal Insulation:

Thf. insulation items generally included in this term the forward and aft chamber closures, boots and heads0

A2

APPENDIX B DESCRIPTION OF TEST DEVICES

I.

DESCRIPTION OF TEST DEVICES

The following pages contain a description of. test devices, their oprati.ng conditions, and test procedures used by various organizations for the evaluation of materials, Test equipment..included in this report are as follos:. Oxyacetylene Torch Test Oxy-kerosene Torch Test .Gaseous Test.Motors Plasma Jets Subscale Solid Rocket Test-Motors

Equipment and organization is shown in Table I. A.

Oxacetylene Torch Teat Facilities
I. Atlantic Research. Corporationa
.

-1
.

"
".

a.

Appartus-, (see Figure 1)

Torch Body - Airco Style -h800 Torch Tip - Airco Style-8, No-lO,../8" Dia. Tip Opening High Flow Mixer - Air Reduction Co., .No, -831-0899 Acetylene and Oxygen Manifold and Tanks "Two-Staae Regulators ..

-Flowmeters
Pressure Gauges

I)metalliinsgaicrn

Torch Carriage.- Air Cylinder Actuated

Air Cylinder - 5" Strike. Double Action with Manual and Four-Way Solenoid Control, A. Schroder's Son Company Micrometer Screw & Locks for Torch Positioning

BI

APPENDIU B

Sample Holder Assembly Photocell and Thermocouple Rapid-Response Chart Recorder, Varian Associates, Inc. Timing Clock, 100th of a Second Iron-Constantan Thermocouples (24 Gauge) Soldered to I" Dia., .009" Thick Metal Discs Enclosed Test Chamber with High Speed Exhaust System b. Test Procedure

Specimen thickness and weight are measured before the test. The specimen is placed on top of the metal disc of the thermocouple assembly Ir. the specimen holder. Between the metal disc and sample is a thin conta.it fil.m. of conductive oil. A cover plate is placed over the sample h6lder. The therm.ocoouple-connectiond, Jack and plug type, are made. The torch tip. is adjusted to 1.00 inch distr-4nt from spe.-ie, surface with micrometer screw. The torch is retracted to a standby positior. The torch is ignited and adjusted to a preset acety!,r-. to oxygen ratio. The torch is manually actuated to the test positicn. The timer -nd recorder are turned on when the torch I- tK(-, test position contacts a mocroswitch. The test is continued until the spe cnle" is burned through. At the instant of burnthrough the photocell actuates, a air cylinder, retracting the torch,, stopping the timer and temperature ,wecorder. This completes the test.

c.-

TXe-st cond~itionsSpecimen Size Torch Distance 2.50"x2"x2" or 2.250" dia. 1.00 inch

Angle of Impingement 900 Oxygen/Acetylene Ratio 2.50

B 2

APPENDIX B

Total Gas Flow Flame Temperature Flame Condition Duration of Test d. Calculations

300 .cu. ft/hr. 5400F" Highly oxidizing Specimen burnthrough

Initial and final weight ratio. Initial thickness (inch) Specific gravity Total exposure time
-

1 E. time to burnthrough

.The temperature of the unexposed. side of the sample during the-total-exposure time. (OF) Erosion Index: mils/sec, Ie Insulation Index: ii Weight Ratio: e. Where to.= Original thickness, inch E (400) = Time of exposure for thermocouple to reach 4000F, sec. Ebt Time of exposure for specimen burnthrough to + E bt + to

E (40ooF)

WR = Wf + Wo

Wf= Final weight. Wo =Original Weight.

B3

APPENDIX B

2.

Naval Ordnance Laboratory a. Appartus, (see Figure 2)

Victor No. 7 Torch Tip, Water cooled specimen holder assembly. Specimen positioning control mechanism. Remote controlled solenoid actuated torch mount. Fume removal system. Instrumentation panel. Control panel Chromal Alumal. Thermocouple, Oxygen and acetylene tanks and mixing manifold. Pressure gauges, flow meters and regulators. Chart recorder. Timing clock. b. Test Procedurese Insulation test specimen thickness and weight are before each test. The specimen is secured to the watered cooled speiMr-, holder and thermocouple connections are made. T1he test specimen is positioned .750" from the. tor,h The torch is then retracted to a with the positioning control mechanism. standby position by a pivot assembly. The torch is oxygen/acetylene ratio. then ignited and adjusted to a present -11 me. r.d

The torch is actuated to tne test position which star-.a the timer and recorder by means of a microswitch. Visual and optical pyrometer observations are made diring V testing and any unusual- effects noted. The test is continued until the specimen is burned thrc.-o-eY At the instant of burnthrough the solenoid retracts the torch to standby This completes the. t;t position, stopping the timer and temperature recorder.

APPENDIX B

c.

Test Conditions Specimen Size, Torch Distance, Angle of Impingement, Oxygen-Acetylene Ratio, Gas Flow Rate, Flame Temperature, Flame Condition, Duration of Teot, .250" x 2" x 2" .750" 9gQ 1.28 253 scfh 554
0

F.

Oxidizing Specimen burnthiluugh.

ad.

Calculations Original thickness, mils

9Exposure (2000C). 392"F

time for specimen back temperature .to reach Total exposure time for specimen burnthrough, sec.

Index of Performance, 392 0F + E (392-P) x ER

Erosion Rate, mils/sec, to + Ebt e. Where to Original thickness, mile. Exposure time for specimen back temperature

E (3920F)

to reach 3920 F, sec.

Ebt Total exposure time for specimen burnthrough, sce.

B5

APPENDIX B

f.

Rating of Materials

Index of Performance (iP) is defined as the nrnmt. n th, erosion rate (i.e., original specimen thickness divided by the burnthrough time) and the average temperature gradient between room temperature and .,oc obtained on the cool face of the specimen (i.e., 2000C divided by the time required to reach.200eC). Thus, the I.P. is a composite measure of the spec'IM&n. A low IP is obviously desirable and the materials are ranked by this criterion.

burnthroug -time.
3.,

Erosion Rate (ER)

original specimen thickness dividec-A by the

Allegheny Ballistics Laboratory,

Torch - Aii.co Welding, Style 800

Tip - Airco No. 6 Flow Meters
-

Matheson No. 206

Temperature Indicator - Tempilac paint directly on sample back.

b.

Test Conditions Specimen Size

Torch Distance

--

.375 x 3" x 3"

.500"

Angle of ImpingementAcetylene, Oxygen Ratio Gas Flow Rate

Flame Temperature Flame Condition

900 0.87 53 scfh

5110F Reducing

B6

APPENDIX B

c.

Calculations Original thickness, in.

Exposure time for specimen back temperature to reach

200*F, sec.
Total exposure ti'me Z'.v Char depth, in. (to - tv) + 2 or Erosion depth, in (to - tf) + 2 burnthrough, scc.

'd.

Where

Sto

Original thickness, in. in.

tv 0 Virgin layer thickness, tf = Final thickness, in.

E (200*F) = Exposure time for specimen back temperature

to 200*F, sec. Eb= Total exposure time .for specimen. burnthrough,, sec.

.4. U.
a.

S.- Rubber Corporation Apparatus

-Torch

Body

Airco, Style 800 No. 10 Air Reduction Co.

Torch Tip EHigh Flow Mixer Torch Adapter Thermocouple Recorder

No. 811-0899
Air Reduction Co.

No. 811-0390
Iron-Constanten L&N Recording Potentiometer

The torch tip is equipped with a water cooled jacket.

B7

APPENDIX

'hie acetylene tanks are tapped. througi' a iiAo 2I. regulators, the f~irst a two stage, and th6 second a single stage.

The. gas flows are measured with Brook~s rotometers and through cheok val~ves and a q~uick shut-off valve before the torch to prev.e(.t c,, accidental back flow from the torch. b. Conditions specimen Size Torch to Specimen Distance, Angle of Impingemenxt, Total Gas Flow, Oxygen/Acetylene Ratio, Flame Temperature,Flame' Condition, Duration of Test,
00
.

250 k~"2"X 2.0

9086

300 scfh
1.17 5450LF Slightly -oxidizing Burnthroughi or ~4Qc"F back temp~eratu~re.< M

Cal.cul.ations. Insulation Index, sec:/in, Ii -- E -(400r) + to -1e~~lsscI to-+

.~Erosion

d.

TALJ.

iE(~4ooF) *E-.
t.0

Exposure time for back surfacetemperature to reach J+o08J Exrosure time for specimen to burnthrough, sec. Original thickness of specimen, inab.

APPM1IX B

S5.

Aerojet-General Cormoration a, Apparatus, (see Figure 3),

Airco No. 7 Oscillating torch holder aesembly Specimen holder assembly

"Torch Tip

Springloaded-thermocouple assembly
-. S---.'-

Electric motor, 1/4.horsepover

Oscillating drive mechanismTimer Ampliflier

ma

. : : ........ .

" Temperatureprecorder and Potentiomater

Start-Stop and Micro-Std.itches d Thermos botle .. ~Pressure gauges and-regulators . . t e h -- .. i ...

"te"Portable console c unit d

-

b.

S. Test'cProcedures
Sam pl.. eo hiscilltnmckne

o.

"

"

....
.,,and

and hn weight are meas

ued

fore eonh ... aosemtbly .

The test specimen is inserted ins he specimen, holdert

thermocouple connections made.

.. Sa-surface

The torch-tip iscadnusted f erpendcular. to the speciment and thenpretracted rte-csanbya. i

S .......... ..

is ignited ,djustedand 1cond.tio0"n to the desired ~ The ~thentorch Manually actuated .to. the te st position after-the
"switch is turned on. ... ............. ...

-xmwt(-'r.......

AnThe oscillating mechn,

to

rre

tued

on-by a1

Testd Contion -"microswtch when thetorch is actuatedto the test 'position.

.

"

" c.

The test-is continued-for -. 0, 60-0r go seconds or when'"th(. back surface temperature reache-a 4060F.. Test Conditions
Spcm e ,20xx Sie

a.d artaimef120 (totsm

1.0O" 300 to 1500 (tota! are angle of 12,0)

Torch Distance, Angle of Inpingement,

B9

-L-.B

APPENDIX B
.. - ... . .

Cycles per minute, Oxygen/Acetylene Ratio, Gas Flow Rate,

10 cpm (may be varied) 1.2. to 1.0 71 cu.ft./hr

V
I
.reaches

Flame Temperature, Flame Condition,

5270F
Slightly reducing 30,60,90 seconds or when back temperature4006P.

"Duration of Test

I,-

d.
.

Calc;Iations_

Total weight loss, lbs. V

..Total temperature rise, OF,

Wo 0

Wf,
-

T 3 Tf

T +td) t

Degraded laypr thiokness,-nt._t

(
4 ) -tv)

Char-thi-akness, Duch to
Material loss rate, inches/seconds

(t'+t

t
+ E

MLR-= (to

o= Original weight- lbs. Wf= FinaL- eight- 160s.

"Tu Final backside temperature,

i - Exposure time total seconds to - Original thickness, inch

t* w Virgin layer thickness, inch td = Degraded layer thickness, inch tf = Final thickness, inch to = Char thickness, inch B I0

APPENDIX.B

B.

Oxyg~en
1,

-Kerosene

'Torch Test

Bendix A~iation Corporation

a., Description

.J.of

The-oxygen-kerocene toch.. test is used f'or initial. screenjlhigh insulating material1s, prior to subscale and fill,1 . . imotoa: testing. This test device consists of an- oxygen-ke'rosene tor'ch operated at supersonic gas. velocities.
.temperature

b.
-

Test Conditions.

Torch Nozzle Diameter Torch Dlistance

Angle of--Impingement Flame-Teniperature Mauh Velocity
.

.5001, 2"1
-600-

l+500F

. Specimen burnthrough
-

Duration of' Test c. Calculations

Original thickness, Inch "3 0

*

~
-

_--

---

ifla- thicknu~s-io~

tf-

_,x~pore time,) seoo-nds

IJ0

Ablation rate, inches/second AV. t~ t0 I- b

B IT

C.

Plasma Test Devices 1. Atlantic Research Corporation a. Plasma Jet (1) DescriptIon

'.AtlanticResearch is currently experimenting with. a plasma jet to develop a ccrccning test more closely simiulating rocket 'i*Jh-

spray nozzle and powder hopper are used to intr(AI2-.n solid particles into the flame- to sliulate the-condensed phases present in s me solid propellant rocket combustion products': A mixing nozzle is used to bWe=d gases into 'the plasma past the are so that reactive plasma composeltioim *reactive may be obtained vithout-eledtrode corrosion and contamination. An expansioni_ flame exposure at reduced flow velocities,,is-used -to--simulate roc-etA 9(', temperatures wi-tb low eros-ion.
-A -(2)

'62Lar~tus

---

PcmaTorch, Model R 1-680 KW 7(Thevi&l--Dynamic~s- Corporatlo'n)

--

- -

Contr~ol console for reguilation of multiple gas flow and-electr'ic power input.

77>--------------

..power SUPP3Y Dmits.

Two 40 KW-reotifter-otype Do .
M
,.--

~-

(3)Conditions---

The 'plasma torch is oneraotAd

tri'Ii

nitrogem., argon, or helium gas atany mixture of thea6 gases.' Power input with diatomic gases, to the arc, 40 - 80.
-Enthalpy

level vith diatomic or noble gases, BTU/lb,li2-16,ooo.

B 12

'.

APnHDIX B

2.

Aerojet-(enera]. Corporation a. Plasma Jet (1) Description, (see Figure 4)

The plasma jet is an drc-gas device capable. of heating gases to extremely high temperatures. No combustion is involved. An electric arc is contained within a water cooled tube through vhich-gas is blown. The gas issues f.om the plasma Jet and resembles an open welding flame. Since no combustion is involved, the gas temperatures are not limited by internal heats of reaction. --y continually adding.-electrIcal energy, gas temperatures in the range of 39,000*F with some gases can be achieved, while hydrocarbon oxygen flame temperatures are limited to approximately 56600F. ' The'unit used by AGC is a Gas Sheath Stabilized Plasma Jet ,-manufactured-by -the The.fta-lm Dynamics -Corporation, ab -hovn in Figure- 4#. -The arc ath is between.-the solid tungsten -catlhofe:and, the 4Iol.vr, .. water _ cooled copper an~e&,. is unit operatds on.both mondotmic and diAtomic gases. The arc remains within the nozzle and is prevented from prematurely

"I

"-strikingthe
..... ..
-

wall by a sheath-.of-gas which is-much-thicker than the arc. er- _The-arcl-is--al-lowed to--stArike-thr-dugh- .thisga- -6hethoonly--after passing considerable ddistance down the nozzle. Vortex flowis. not gonervall used and arc positioning is aceomplishe& through gas flow pattern:and cc'trol of turbulence.

. .
..

d.

..

(2)

Condition .Powe

Infti, _KW .80

39,000 "

"...
. .. .. . . ..

Gas Temp.,
Maximum Enthalry .
--

-/ Gas Flow,

..

0
0,00~42
0.63"

. .60

lbs/sec N2
Test Section @Mach P 4 -(5 mm pressure) Test Section
@ Mach= 1

1.75"

(5 mm pressure)
B 13

b.

Plasmatron, (see Figgre 5) (1) Description

Itesting I
*of
-

The pi.asinatron has recently been. adapted for ablation Wiibsonia plaafflas. -It has' beer, oUnd-in alumina-containing of materials th~at alumina-containing plasmas adequately simulate inteznal rocket'motor. environtnents. Therefore, they are able to~prdvide a qu~alitative test for zmateri~Jls. Alirted over a wide range The plasma jet has be heat fluxes with the entha3.py range Ldesigned to be as high as possible anA~ still maintain-the alumhina particles in the liquxid-phas~d. --

--

~--

Inorder to prevenit--the -bui-ldup' of &'pfoteective alxnina

--

be~tween-.:the_-argonL and alumin4 occurs4 plasma before thermal -equilibrium. P., nae ~o 6pass off~ arny &deosi -4 alumina r netdit *allows the a-lma baigoistesecmn

This fte-

77gscaigote

Ill
-.........

-.

S~~tagnation anthalPy

lQI.OBttrb 549700K

-.

Free-Stream temperature, 7350

Stagnation pressure,

1. 0

1. 5 atm.

I
.

.Heat. flux to--a100 -*815-l685 Bt~-t'tr-sea gall ---------~ ~~Aluminum conitent,-_ e P _ '- L-1 ''. _bit _--. Mass nowrate, _ ~l_~~Usual working mad~ii,Aro

-a .(1.)

Myerthermal Environmental Simulator, aIS, (see Flaire.6)

Description

Ithe

The Hyperthermal Enviro~IIental.Simulator, HES, is t device that will simulate the internal enviroment of a solid rocket motor fcr purpose -of determining the heat transfer and ablation characteristics cof

B1

I
APPENDIX B

The HES shown in Figure 6 will handle six candidate insulation materials. j:cTm4 gases: C0 2 , CO, N2 , H2, H20, HU1 and A1203 particles simultaneously The gases are portional to the desired theoretical prope lant gas composition. brought up to the desired erthalpy level by a gas stabilized. arc plasma. gr:nerait, (2) Conditions The HES operational limits are as follows and are based on the available power supply of 1.0 megawatt:

Stream Temperature,
Gas Velocity,

5640-6040-F
100-800 ft/sec 0.15 lb/sec 8000 Btu/lb 4.000 Btu/lb 1330 BTU/Ib-----------------1 300-500 lb/in2 .750 in. 900 diameter

"Gas Flow,
Stagnation Enthalpy S 0.05 ib/sec. Stagnation Enthalpy @ 0.10 lb/sec, Stagnation Enthalpy @ 0.30 ib/sec. Stagnation Pressure Test Specimen Size Angle of :mpingement B..-......

...-..

.................................. :... .....

. . .. . . . . ...

...

B IS

Dl. Propane

-Air

Gas Motor

1.

Atlantic Research Corporation a. Description, (see Figure 7)

The propane air gas motor, FAG, test facility has been usred. noze fr pri.ncipal.ly frstudying efet foperational conditions upon insulationan nozeperormance. This facility could provide a screening techn~que whiieh simulates rocket motor conditions and configurations. The test inclu~des extensive temperature measuring instrumentation.
..

-Insulation specimens in the form of a sleeve-are iia-serted in the motor aft of the combustion chamber. Nozzle materials are tested-by using a-throat insert-fitte'l on the aft end of -the motor.. _b, Apparatus Air compressors Propane gas supply-in pressure tanksgas supply for pilot flame DOdgn-hydrogen Piping..Mixcing valve Control valves Therm~omete rs Pressure gauges Manometers * Fl 'mets
--

--

---

Water supply for water J~acket cooling

TY~~~~
4-

Dessicators-

Settling - Chamber. nozzle X4A.ad0kUIV

Verticle Vfn-?_test chamber 1. V2 inch

~Cone type f2.aaestabilizer

Htigh- voltage ignition spark eq~uipment for pilot light Vent stock

B 16

APPDMU B

Cylindrical water cooled chamber for insulation test tubes 4" x 1-1/2" ID Water cooled chamber for nozzle inserts 2-3/41" long with 3/4" throat Special minature high temperature thermocouples for test specimens.. Timers and 12 channel visicorder recorders c. Test Conditions

The test conditions for-each specimen are selected within the ranges of the following parameters: Temperature Propane gas
-

air mixture flame temperatUr4

to 25900K (404O0F).

el ,Air Mixture
This can be manipulated through a limited stable range from

rich to lean. Mass Flowj

Mass flow rate of gas isavariable uiy to 1.0 rIb/sec -at pressure. up to 100 psi. The approach velocity is variable up-to 400 ft/sec, sonic or .3000 ft/sec if a nozzle is used. Time. any desired period. The duration of test is controllable and may extend to Experience test range extends from 60 seconds-to-lO--ni-nutes -. Turbulence The degree of turbulance in the flame can be changed by insetting qcreens of varying mesh in the approach channel of the test chamber. Abrasive Particles Solid or molten particles can be injected into the flame; the relative concentration of the particles is controllable.

B 17

S::1

d.

Flow Characteristics at Half Capacity are as follows:

Nozzle diameter Test Chamber Diameter Mass Flow Rate (1/2 capacity) Pressure (absolute) Approach Velocity, .VU Hot Gas Velocity, Vb Density of gas in tube, cold .750 inch 1-1/2 inches 0.50 lb/ft 71.3 psi 60 ft/sec 520 ft/sec 0.356 lb/ft 3 A

"(G) in tube W/a

V e. Calculations

41 ib/secft 2

Conditions of gaseous flow.

Air
-

Fuel Ratio,

Og F

Gas Temperature,

Mass Flow Rate-, lb/sec. -Pressure, psia Temperature as a function of time at two or three depths

in all specimens.
Conditions of cooling water flow. Inlet temperature as a function of time. Outlet temperature as a function of time.

Continuous flow rate. .Duration of test, seconds.

B 18

APPF IX B

Observattnr

of

.i.

Original weight, Final weight, lbs Weight loss, %

ibs, =Wo Wf

Original thickness,

inch,
-

t/ t

Final thickness, inch Char thickness,

tf/

inch = t: inch t

Virgin material thickness, Nature of surfaces

S.

Analysis of Results

The structural properties of the insulat:_on specimen are determined from measurement of thickness) weight change, and -fwo visual . " ovoervation. The rate of heat transfer within and out of the insulation Combined with the values of gas determined from the temperature records. flow, this data- furnished relationship for mass and heat exchange between the hot gases and the insulation specimen. It is possible to observe the temperature and time t,at the various phase and material changes take place in the materials by tudyjng This permits an empirical correlation. the shapt of tbe- time-temperartue curves. of the erosion and ablation heat transfer as funictions of the flow parameters

__-is

And

_he.tA

reOf +.,He M+a.erals.

Generalized oxidant fraction (Og) is the ratio of the mass of air to mass of fuel divided by the sum of.the ratio of mass of air to Mass of fuel plus the ratio of mass of air to mass of fuel at stoichiometric. Fo.r all air Og-O, for all fuel Og-l.O and at stoichiometric Og - 0.5.

(air/fuel)

Og

air/fuel+ (air/fuel) stoichiometric

B 19

APPENDIX B

3.

Hydrogen-Oxygen Test Motors 1. Naval Ordnance Laboratory

a.

Description
The hydrogen oxygen test motor facility is an"intermediate

test device used principally for studying effects of operational conditions upon throat insert materials prior to solid rocket motor firings. b. Test Conditions
-Firing conditions are -controlled by varying .the throat insert,
___

dimensions as follows: Nozule Configurations A .350

1.278

B 350-,
,i.578

SNozzle Throat Diameter, inches

Nozzle Length, inches
-

.350
2.2.14.3 .1.000 588 ..280 3-0 32335C 6310oR

Nozzle Exit

Diameter. inches

.62 200 .095 g-2 31728C 6200oR

.759 397 .497 5..3216C0" 62800 R

Chamber Pressure, psia Total Mass Flow Rate, lb/sec Exit Mach No. In Stoiohibmetric Mixture O-/H 2m 8.0 (weight ratio)
-

Calculations
Throat diameter increase afte,, firing, mils. Time from design chamber pressure to 200 pusg, seconds. Erosion resistance, mils/sec.

B 20

S~APPSI.TX

PB

2.

Avco Manufacturing Company

a*

Description.

The hydrogen-oxygen motor was designed to evaluate materials to be used for fabrication of rocket nozzles. The facility is used to perform preliminary material evaluation. The engine consists of three separate units: An injector Combustion chamber Exhaust nozzle. Each unit is water cooled. Depending on the test to be performed, any unit can be replaced readily by one that is solid-uncooled such as found on solid-propellant rocket systems. The fuel is gaseous hydigoen and the oxidizer is gaseous oxygen.

One special feature ofthe facility is that foreign powders,

liquids, or gases can be introduced, (at the:i-injector plate) into the main stream-...-.... of gas to simulate particle impingeaent, chemical and other effects. Rocket nozzle material evaluation consists of exposing the inner diameter of blast tube or rocket nozzles to exhaust gases of the motor -and aciparing the performance of the various materials.-

"b.i Test Conditions "Dimenslon and performance of hydrogen-oxygen rocket test

motor. as, Dimensions Combustion Chamber diameter, inches 4,.o 1.70 2.13 Throat diameter, inches Exit diameter, inches

B 21

AMDXB1
d. Performance Exit Velocity, ft/sec Nozzle Exit Mach No. Thrust, lbs Specific Impulse, lb force/lb, mass, sec. MemB Flow Rate, lb/sec StagnationTemperatuxe, Mixture Ratio, E2 :02 Heat Flux, .Btu/ft OF 9000 1.8 182 256 .685 50000 41aV -

400 to1~
(for-_waivrange of 100 to 1 OOOF)

e.

General Chamber pressure from 1 to 20 atmospheres. 7Adiabatic flame temperature from 3800 to 5800dF 'Thfoat diameter from 0'700 to 3.0 inches _Combustion-chamber diate fro- 3.5 to 4+.0 inches

f.

Calculations Original throat djametero inches. Final throat diameter, inches, Time at fulal pressure, seconds. Chamber iressure, operating and. final., psia. Surface temperature, OF. Effective heat of ablation, BTU/lb. Ablation rate) inches/see.

B 22

APPENDIX B

3.

Aerojet-General Corporation, Azusa a. Description

The structural plastics ablative rocket, SPAR, test motor is a gaseous hydrogen-oxygen motor for evaluation of materials under rocket nozzle condltons.u Sonic orifices located upstream in the propellant lines provide a constant propellant flow rate into the combustion chamber over a wide range of chamber pressures. The flame temperature is controlled by thcI fuel mixture ratio. Initial chamber pressure is controlled by propellant fl:ow rate4 Ignition is accomplished by a spark wire inserted on the test nozzler. Instrumentation provides a continuous record of nozzle throat erosion rate, as well as the motor performance parameters that influence nozzle environmental conditions. Chemicdl attack on test materials may be studied by the introduction of contaminants. The SPAR motor, however, does not reproduce the actual, environment of a specific motor. b. Conditions

Chamber Pressure, "Up to 800 psat, 500 psia with .5C0"

dia. throat. 6100*F Up to 200 seconds -Nozzle throat insert, usually /2" dia. throat
-

Flame Temperature, Duration, Test Specimens, -

Thrust Approximate, 130 lbs. using a .500" dia. throat Much-No. 1.0 at the throat

B 23

APPENIX B

F.

Oxygen-Acetylene Motor 1.. Aerojet-General C6rporation, Azusa a. Description, (see Figure 8) .

The RIMI, Rocket Insulation Material Evaluation facility-is basically a gaseous fuel rocket motor d$signed primarily for the thermo-physical evaluation of materials in a high temperature, high heat flux, moderate velocity .enmrorment. Acetylene and gaseous oxygen are combusted in an enclosed flame head. Provisions are made for aspiration of metallic-or other particles into the flame to simulate the flame composition resulting from the combustion of solid propellants.

b.

mau
Control Devices Oxygen and acetylene pressure regulators Mixing chambers -Chamber-pre s sure regulatorChemical particle asperator Measuring-Dev-ices Oxygenracetylene flow meteri Chamber water flow meter Thermocouple pickup and recorder Chamber water calorimeter

"Safety Devices
--Flame arresters Nitrogeft purging gas
c.

.
.

Calibration ..Temperature: Heat Flux:

..

Flame temperature is calculated from stoichiometric combustion. Heat flux is measured by a water cooled calorimeter having the same relationship to the flame as the test specimens. Chamber pressure is measured manometrically. Determined from differential pressure pitot tube).

____

Chamber Pressure: Flame Velocity:

- - .'[

" :'.

"

'"

. .

,'

' i

IV' ''

.. . ..

":

, ..

. . .

... " ..... - ....

APPENDIX B

d.

Special Features of the RINE

Heat flux, flame temperature, flame velocity and chamber pressure may be cccurately measured arid reproduced. Flame composition resulting from combustion-of solid propellants may be simulated. /'Specimens are tested in an enclosed chamber. Firing duration is controllable to within 0.2. second.

Combustion gas flow Is measured with an instrument Variat, on of o.25%. 0

Specimen back surface temperature determined by spring loaded thermocouple and recorded for direct read out. Nitrogen purge before and after test firing. e. Test Conditions Pressure Temperature To 30 psia . ..

3800OF to 63oo0F

To 650 BTU/ft 2 , sec.-Heat Flux Flame Vplocity -Mach 0.1 to 0.7

Flame Characteristics

Reducing, Neutral or-

Oxidizing (as required)..

-----------.

4P

(Vlhl

wFr

Test specimens surface area, ft

2, A

Heat input, (as measured with a calorimeter)Qo - BTU j ft 2 /eec. Heat of Ablation:

BTU
-

Q. AEE
W

B 25

APPUDIX B

ficposure time, seconds Total weight loss, lb Char thickneus, inch W t 0 140 W tf. - (tv + td)
4

Physical.appearance before and after testing.

B 26

APPNDIX B

G.

Suspensoid Propellant Motor (Slurry Test Motor) 1. Aerojet-General Corporation, Azusa a. Description The slurry test motor was developed to more closely simulate
The propellant is in the

the chemistry of aluminized solid propellant fuels.

form of a thixotropic paste containing suspended aluminum particles, and.the fuel composition closely resembles the solid propellant from which it is derived. The combustion products of the slurry propellants duplicate those of the parent solid propellant. The motor is fired vertically, with the pool burning pro-

pellant encased in an insulatepd-shell.

Instrumentation is used providing a

continuous record of chamber pressure and thrust. The use of slurry propellant provtdes the possibility for voluntAry termination of .a test firing, so that failure patterns may be studied from the post-fired specimens.

b.

Conditions
The suspendoid motor is currently operable for firing

durations of 15 seconds maximum, at 1000 psia using-a nozzle insert with a

.500" diameter throat. Modifications may be made to the existing facility

-in order to obtain longer firing durations and voluntary termination of the

test Oyole.
Chamber-pressure
*..

1000 psia
5l100F. ' 1..0 at the throat

flame-Temperature Mach No.,

B 27

APPMNIX B

H.

Subscale Solid Propellant Test Motors 1. Atlantic Research Corporation a. Description, (see Figure--9)

(1) Test Motors; For maximumn flexibility, end.-burning test tM to Va.ed by varying grain length, and pressure is motors are used. Burning varied by changing the btirning rate or the throat area, The burning rate is changed by embedding fine axially-oriented wires in the propellant. are custom made in the ARC laboratories. Special. refactory metal. thermocouples are used above the chromel-alumel temperaftre range. Recording equipment inecludes Minneapolis-Honeywell Visicorders, Midwestern Instrumnt Company records- and Alinco K-4l B-allistic Computer.
-Thermocouples

(2) Pro ilants: One of the most important variables in testing is the propellan- incethe -effects of -flame- temperature and. cheica2. reactdvity of'the gas are crit~ical. A single propellant could be used. fo?-a specific test-.program where the objective iso to simulate a specif'ic rocket motor condition) but because of these effects, itb is not possible to conduct any general testing with a single propellant. X- group -of three propellants have been selected for general material stud~ies. These propellants range from Arcite 368 containing no aluminul, to Arcite 373 containing.21 percent aluminum. An intermediate propol~lant, Arcite 394p. pontains 7.751'percent aluminum. Mat~a1.als which react with C06, H120- or ROL will undergo erosion-in--Arcite 368 exhaust because of its high content-of these three constituents. Materials which react with molten aluminum-oxide or which melt between 11600or and 5600Fr are likely to-per-Porni poorly in the gas of Arc ite 33 b.
Einsert;

_t

Component Testing

Motor tube insulation, nozzle insulation, nozzle throat expansion cones and jetevator impingement bars are tested in the test motors. All of these components can be tested simultaneously during a motor firing if desired.

B 28

APPENDIX B

(1)

Motor Tube Insulation

The testing of insulation materials as chamber liners is conducted in a hybrid test motor (so-called because of-its unique construction features). A schematic drawing of this motor is shown in Figure 9. Previous testing has generally been with the 64-inch long, 6-inch diameter propellant section vhich operates for 60 seconds at 1000 psi. The motor-tube insulation section is 24 inches long, with a nominal inside diameter of four inches. The test specimen tubes have matched tapered joints and are cemented to form one internally-smooth, continuous tube. Dimensions of the tube can be changed. Normally six.cylindrical specimens are tested during each firing and temperatures are mearured at diametrical points on a cross-section taken through the mid-point" of each tube. The thermocouples and a magnified sketch of thermocouple a~ssembly are .4houn in Figure 9. / -(2)
-"Insulation

Nozzle Insulation

materials are tested on the conuvergent face of the nozzle, and in the aaction of the nozzle. A nozzle assembly for the

6-inch motor is shown in Figure 10.

The nozzle insert is thermally insulated

f-rm the wi6zzle assembly to duplicate light-weight flight conditions. Six Danel specimens are tested sim~ultaneously on the. convergent face with each specimen being independantly embedded and instrumented for temperature measurement. After testing, these specimens are removed from the bedding cement and measurements are taken of the surface erosion, depth of degradation, and amount of unaltered material. The firing results are coordinated-with data from the continuous temperature measurements. The nozzle test assembly can be used..in any length motor to obtain a-comprehensive evalu"ation of insulation materials for many exposure conditions. (3) _Nozzle Insert Insulation

_ Testing insulation materials for the throat inser+. follows a simple techni~que. The insulation is incorporated in the nozzle assembly around the insert as shown in Figure I0. Reeults are evaluated by temperature readings on the cold side of the insulation and by the insulator's ability to retain effectively the insert and form a gas seal around it.

B 29

APPENDIX B

(.)

Expansion Conee (Exit Cones)

The divergent test section is a simple conical piece

several thermocouples are inserted into test pieces. Results of testing are measured in a manner similar to that for convergent test parts. (5)
Jetevator Impingement Testing

separately mounted in the expansion section of the nozzle. Although Figure 10 does not show thermocouple instrumentation of the expansion-cone test piece,

.
-,

"Jetevator tests are made at ARC. The specimens ara bars, 1/4" x 3/8" x 1-i/4", bounted in such a way that they can be introduced into and removed from the motor exhaust at will; normally they are exposed for two seconds and then out for two seconds. The number of cycles employed during a-run is dependant on the firing duration of the motor. The 3/8" wide face .. i s exposed approximately 1/16" into the flame at 73.5o to the cone edge. The specimen is backed up with a micro-quartz insulator and molybdenum backup bar.
Changes of profile indicates the effects of the exposure to the specimen.

I
i
:

C.
c.

Calculations

(1) Insulation
Erosion depth, in.

r?1cuChar depth,

in.

Exposure time, sec. Weight loss,

Temperature, cool side, OF "Chamber pressure, psi

Physical appearance after test

(2) Throat Ingerts

Chamber pressure, psi Firing duration, see. Throat diameter, before and after

firing, in.

B 30

AkPPfDIX B

2.

Allegheny Ballsitics Laboratory

a.

Description
Several types of subscale test motors are used for the

evaluation of nozzle and insulation materials. Test motors are "erd burning". and use a solid propellant fuel. Conditions are controlled by the selection of propellant, nozzle design and size of the motor used. Characteristics of the propellant used most frequently are as follows:
Propellant CDT 80

Identification
-

Theoretical 6000

Flame Temperature
.- 63736F
.'I

Percent 20.0

Aluminum

CDT - 80 is a modified double base propellant containing aluminum and ammonium

perchlorate.

Tet methods used for the evaluatl6n, of nhambpr inmut.tonn nozzle insulation, and nozzle throat inserts are described as follovs: b. Chamber Insulation (1) Slab Test, (see Rgigue 11)
This test consists of exposing a .375" x 2" x 4.375" insulation specimen to hot gasco on the approach nozzle section of a subscaLe

test motor as illustrated on Figure 11. following conditions:

Gas Velocity
-

CDT-80 propellant is used to yield the

Temperature Burning Time..

Pressure
-

100 - 130 ft/sec. 3000C K (63750F) uP to 30 seconds 250 - 1000 psi

At the end of the firing tho motor is flushed with CO 2 to prevent spontaneous ignition of the hot insulation residue.

B 31

APPEJD'X B

(2)

Peripheral Slab Test

The peripheral slab .test consists of exposing a single face, of a 2" x 4" x 3/8" slab of insulation to rocket combustion gases, Eight

spec'imens may be tested simultaneously as they are fastened to the inside of the/ inaulation sleeve placed in the aft section of a single end burning motor. NThos test apparatus permits convenient evaluation of material over the following
ranges of variables: Exposure Time 10 tQ 60 seconds

Pressure Gas Velocity

200 to. 2000 psi 30 to 80 ft/sec

At the end of the firing the motor is flushed with CO 2 to prevent spontaneous ignition of the hot insulation residue. -'-This test was divised.to avoid the difficulty enoonte~ in the regular slab test with certain materials, particularly at high pressures (700 psi). This difficulty is manifested as a tendency toward steam lining of the specimen as shown below:
Slab Cross Section

Gag Flow of char or erosion depth difficult or .impossible.

The presende'of this phenomenon makes the evaluation.

()Blast Tube
In order to study the profound effect of gas velcoity

Son insulating materials, a blast tube containing the insulation specimen is fitted to the sft end of the -five inch test motor illustrated in Figure 11.

B 32

The -specimen consists of a tube, the diameter of which may vary bct~;cw; 14 and 1-1/2" depending upon the velocity desired. The blast tube in zcn-.ntU.r with the peripheral slab test permits the evaluation of insulation perforn.ar," over throat-to-port area ratios ranging from .009 to .9 or gas velocities of 500 to 1200 ft/sec with VH1 propellant.. The major disadvantage of this test method; namely, the inability to maintain constant velocity across an erodable material in the blast-tube. At 250 psi the char rate for asbestos phenolic almost doubles going from 50 ft/sec to 1200 ft/sec. c. Nozzle Insulation Test, (see Figure 12)

Nozzle insulation materials are tcoted on the entrance ava exit sections of the nozzle assembly. This testing involves the use of a vevy high impulse propellant, CDT-80, in a 9" test motor illustrated on Figunre 12. d. Throat Inserts, (see Figure 13)

The evaluation of nozzle throat materials are called out by testing the throat inserts in the three, five and nine inch diamet.r subscalee test motors using a double base: aluminized propellant eontainirxg anmionitm. perchlorate. Fi-gure 13 illustrates the five inch diameter test motc used. most f re quently. e. Calculations (1) Insulating Materials Char depth, inch CD = (to (to-.

tv) 4 2

Erosion depth, Expocure-time,

inch EDf see.

tf)41 2

-Temperature cool side, -F

Char rat~, mils/sec -CR

Erosion rate,-mils/sec ER Chamber pressure, psi

(t-.
(to

t,,,)
-

ri

tf)

.E

B 33

A.PFEIX B

Total weight loss, lb,

Wc.

WV.,

Physical appearance after test Ideally, materials tested by the above methods are evaluated in terms of char deptb or the depth of the altered material. This coucept is based on the premise that a material is behaving as an effective heat barrier as long sE unaltered organic material remains. Some materials degrade in such a fashion that it becomes inconvenient or impossible to rate them cordngt.. rate of char. (2) Nozzle Throat Inserts, Chamber pressure, psi Firing duration, see. Throat inserb diameter before firing, in. Throat insert diameter after firing, in. A1 2 03

---

deposits) in.

Physical appearance after test.

517

B 34

3.

Aerojet-General Corporation a IMEWM (i) Description, (see Figure 1i)

The Material Evaluation Rocket Motor, MERM, is a subscale test motor used for the evaluation of candidate nozzle and insulating
materials. The MKRM has an end burning, 8-inch diameter, case bonded grain.

Test conditions are controlled by changing the nozzle insert design and the choice of propellant type. Changes are made as required to simulate the latest POLARIS operating conditions. Figure 14 illustrates the NERM assembly. Insulation materials are tested on the convergent section of the nozzle assembly in the form of a throat insert entrance cap as shown in Figure l. .. ( -Conditionhs Duration, 60 seconds

Chamber Pressure, 1000 psia

*olenie Temperature) 5200-6500OF Velocity, ach. No. 1.0 at the throat.489"

Throat Diameter

*Varied. dependant on project requirements and propellant developments. 'b. . U ..

.t

RIM (1) Description,_(see Figure 16) .

Material candidates for RIM. motor tests are formed into bell mouthed straight
blast tubes of various diameters which produces the same range of gas velocities facilities selecting the proper thickness of material for various velocity regions in the full scale motors. The aft end of the extended-motor casing employs a po.r.,us graphite throat insert fitted with a water tap. Chamber pressure is conarolled by maintaining a constant water- pressure, on the throat isert%, ,hiah eliminates or reduces erosion of the throat. Figure 16 illustrates the RET test motor.

The RI .. motor is a subscale rocket motor similar to i... -.. with an extended motojwhc-horigs,

present in full scale motors.

Plots of material loss rate versus velocity

B 35

APPNDII B

()Conditions *Flamne Temperature, Chamber Pressure Throat Diameter, Gas Velocity, 6o0ooe Approximately 350 puia

.58311
Pending on iris!de diameter of test speciten Mach .03 to .30.

()Calculations
A
=Test

specimen surface area, f t, /eo as measured

Rest Inp

vrith a cal.orimeter. G* Effective beat of ablation in LB.

M~LR

uMaterial

lose rate)

_y-

see. -

*Var'ied dependaint on project req~uirements and-propel2.ant'developments.

B336

11. CaREftson of Test Devices and Test racilities

A. Test Devices

1.

Oxacetylene Torch

a. The most general accepted laboratory screening test for the evaluation of insulation materials is the oxyacetylene torch test. Testing is rapid,, econcical, and does not require elaborate equipment. However, a wide range of operating conditions exist between each test orgainzation and as a result, test data differs between each facility for a given material. Also, materials showing superior performance In torch tests often fail in solid propellant teat firings. The need for standardization has been recogaized by the b. various test laboratories and as a result a proposed standard ham been drafted by a Joint ASI4-Navy Comuittee for the standardisation of oxyscetylene torch testing. (A brief sumary 6f the proposed standard is included below.) The author's analysis of the results obtained during this survey, indicates that correlation will be difficult between oxyacetylene torch and subscale testing using the proposed test conditions. However, by using a high gas flow in the order of supersonic velocities, a correlation can be established between torch and subseale motor testing. c. The oxyacetylene torch apparatus used by the AGC POLARIS ProJuA utilizes an oscillating mechanism secured to the torch to create a more turbulent condition at the specimen surface to test the resistance of the spalling characteristics of the material. d. The following proposed standard has been drafted as of 1 December 1960, by the Joint ASTK-NAVY Ccemittee for the standardization of oxymacetylene torch testing. APPAXATUS Oxyacetylene Torch, Capable of supplying specified has flow rates. Torch Tip, Single port Total Gas Flow Rate
- - - - - - - - - .. .. - - - - - - - - - -

0.130 in. ID 225 Scfh. *

B 37

APPINDIX B

Volume Ratio of Oxygen to Acetylene

.....-

1.20 # 28B and S gage or smaller i second full scale or faster

Thermocouple Wire Size - ----------------

Temperature Record Pen Response Time ... Temperature Record Chart Speed, Min .,

. . . . 8-10 in/min

Traneiont Calorimeter for Heat Flux Measurements Pressure Probe for Flame Pressure Measurements SPECIMEN Size, 0.250 inch thick, remaining dimensions and configuration not specified. PROCEDURE Angle of Impingement - ---------------900

Specimen to Torch Tip Distance -----------. 750 in. Maximum allowable to bring flame onto specimen-l/2 second Termination of Test, after of 800Bc (147p.oF) has been optional procedure permits for measurenent of erosion MEASUREMENTS Thickoess. walgh't and -enzIty of apaiumen prior to test. CALCULATIONS Insulation indices at 100, 200, )WO, and 80O0C (212, 392, 752 and Tlr Ty dividing the time to reach these temperatures by the original thickness of the specimen. Erosion Rate, original thickness of the specimen divided by the a backface temperature reached (when possible). An complete burnthrough of panel rate.

fie to' rnthrou3h. : B 38

Insulation to Weight Ratio,

Insulation Index divided by the

original density of the specimen. Arithmetic average of items 1-3 inclusive for five replicates. Root means square deviation of items 1-3 inclusive for five replicates. *Stanard cubic feet per hour, 70'F, 14.7 lbs/sq. in. 2. Plasma Test Devices

a. The plasmajet, a more elaborate and versatile test device is capable of producing higher pressures, velocities, teuperatures, and heat fluxes than those produced by any other test device discussed in this report. A wide range of operating conditions exist between the various units which is primarily dependant on the power output. Some units are capable of simulating the products of combustion found in solid propellant motor conditions by injection of mixed gases and solid particles in the plasmarc. The plasmajet is considered a good device for research purposes, but the cost of equipment and operating expenses, its use for insulation screening and intermediate testing should be carefVlly amalyzed. Listed below is a comparison of the various plasma units and their applications used by the various test organizations. (1) Plasmatron A unit used by AGC, Azusa, for obtaining thermal data on prospective materials. Low pressure unit, 60 KW available power, cran only simulate a narrow range of thermal conditions.

(2)

Plasmajet

Both AGC-ARC units are similar and have a higher power output, 80 KW, than the Plasmatron. Capable of simulating rocket motor combustion products by injection of mixed gases and solid particles in the plasmarc.

To operate at the same pressures, and heat fluxes as the POLARIS rocket motor. Gaseous products of combustion in solid rocket motors can be simulated by injection of gases and solid particles in the plasmsrc. (1000 KW high pressure plasma generator) Unit still operating in the near future. in the construction stage. Expected to be

B 39

APPENDIX L

3.

Gaseoua Test Motors*

Gaseous test motori are elaborate torch test devices, enclosi a. in a combustion chamber, where the test specimen is completely submerged in tVt gaseous products of combustion and subjected to a greater area of diffused heat transfer. Test motors are usually instrumented to measure the control operating conditions and to obtain specimen thermal data. Certain units are capable of injecting solid particles into the gas stream to test the characteristics of erosioa However, insufficient heat flux is obtained which affects thermal on the specimen. reactions and their combustion products are different than those produced by solid rocket motors.

The cost of the equipment and its construction hardly warrante b. the use of the apparatus for screening and intermediate testing of insulation
materials since screening tests can be accomplished with the inexpensive torch teat. Insufficient heat flux and different combustion products than those produced by

solid propellant test motors limit its use for intermediate or screening tests. 4.
Subscale Solid Propellant Test Motors

a. The subscale solid propellant motor has been proven to be a versatile test device by offering a wide selection of propellants to give a range of time, temperature and pressures. Both nozzle insert and external insulation materials may be b. tested simultaneously while some units, such as the RITE, utilizes a Wlast tuba. for the testing of internal insulation at high gas velocities. c. Test results are closely related to full scale firings when firing conditions are duplicated. d. The subscale solid rocket test motor has the 6isadvanteges over laboratory test devices by relying on outside laboratory control for scheduling. Drocessing, assembly and firing of the tA-A+. motors, The subscale test motor is considered the better test device e. for testing of materials prior to full scale firings. However, considerable improvement could be obtained by the standardizatlon of test specimens, conlitlow.. motors and propellants.
* Gaseous test motors defined in this report are test devices using a gaseous

medium for producing combustion in an enclosed chamber, such as, the hydxogeLoxygen motor, acetylene-oxygen motor, and the propane-air-gas motor.

B 40

f. T1he following outline is a comparison of a subscale test motor used by the various test organizations: (1) Atlantic Research Corporation Well organized test program with a wide selection of Reporting of propellants and motor sizes for obtaining test conditions desired. However, no program has been established for test data is also well organized. Test reports are not the testing of insulation materials at high velocities. always consistent in reporting the source of test material. (2) Allegheny Ballistics Laboratory

Excellent for their ctad.ieu on the effects of operating First facility to incorporate a blast tube or, conditions on insulation materialss. their test motors for determining the effects of velocity on insulation performance. Nominal test conditions often vary and test data is inconsistent with no continuity from one quarterly report to the following. often.

(3)

Aerojet-General Corporation

RITE - Capable of producing the same range of gas velocities as those occurring at various locations and times in full scale motors. Plots of material loss rate vs. velocity or mass flow rates facilitate the selection of material of adequate thickness for various velocity regions in the full scale motors. Constant chamber pressure can be obtained by controlling the erosion of the throat insert by use of water pressure on the porous graphite insert. Established methods of reporting test data which is kept up to date in a firing log book. MERM - Primarily used for evaluation of throat inmext Close correlation to full scale motors by selecting material combimamaterials. tions and thickness based on heat transfer and thermal stress studies. Results on insulation testing are limited to relative comparisons between materials.

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