ICBM OVERTEST TECHNOLOGY

FINAL REPORT
VOL II

HERCULES INCORPORATED
SYSTEMS GROUP
BACCHUS WORKS
MAGNA, UTAH 84044

AUTHOR: A. S. DANIELS
S. C. BROWNING
K. D. SMARTT
T. D. PAVELKA

OCTOBER 1975
3
0
APPROVED FOR PUBLIC RELEASE;
DISTRIBUTION UNLIMITED S

A I R FORCE ROCKET PROPULSION LABORATORY i Lu

D 1 RECTOR OF SC I ENCE AND TECHNOLOGY

A I R FORCE SYSTEMS COMMAND
EDWARD S, CALI FORN l A 93523 V
I.
 FOREWORD

This report was submitted by Hercules Incorporated, Bacchus Works, Magna, Utah
84044 under Contract F04611-73-C-0010, Job Order No, 305910LY w i t h the Air
Force Rocket Propulsion Laboratory, Edwards, CA 93523.
This report has been reviewed by the Information Office/DOZ and i s releasable
t o the National Technical Information Service (NTIS). A t NTIS i t will be a v a i l -
able t o the general public, including foreign nations.
This report i s unclassified and i s s u i t a b l e for pub1 i c release.
E

Project Engineer Chief, Surveillance & Mechanical

Behavior Secti on

FOR THE COMMANDER

NOTICES

When U. S. G o v e r n m e n t d r a w i n g s , s p e c i f i c a t i o n s , o r o t h e r d a t a are
u s e d for any p u r p o s e than a definitely r e l a t e d goverriment p r o c u r e m e n t
o p e r a t i o n , t h e G o v e r n m e n t t h e r e b y i n c u r s no r e s p o n s i b i l i t y n o r a n y
obligation w h a t s o e v e r , and the fact that the Government m a y have
f o r m u l a t e d , f u r n i s h e d , o r i n any way supplied the s a i d d r a w i n g s ,
s.pecifications o r other d a t a , is not to be r e g a r d e d by i m p l i c a t i o n o r
o t h e r w i s e , o r in any m a n n e r licensing the holder o r any o t h e r p e r s o n
o r c o r p o r a t i o n , o r conveying any r i g h t s o r p e r m i s s i o n to m a n u f a c t u r e .
u s e o r sell a n y patcntcd invention t h a t i n a y i n any way be r e l a t e d thereto.
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Citation Format: Full Citation (IF)

Accession Number:
A D A 0 17754
Citation Status:
Active
Citation Classification:
Unclassified
SBI Site Holding Symbol:
TAD
Fields and Groups:
160402 - Surface-launched Guided Missiles
210802 - Solid Propellant Rocket Engines
Corporate Author:
HERCULES INC MAGNA UTAH BACCHUS WORKS
Unclassified Title:
(U) ICBM Overtest Technology. Volume 11.
Title Classification:
Unclassified
Descriptive Note:
Final rept.,
Personal Author(s):
Daniels,A S
Browning,S C
Smam,K D
Pavelka,T D
Report Date:
Oct 1975
Media Count:
92 Page(s)
Cost:
$9.60
Contract Number:
F046 1 1 -73-C-00 10
Report Number(s):
AFRPL-TR-75-5 1 -Val-2
Project Number:
AF-3059
Task Number:
3059 10
Monitor Acronym:
AFRPL
Monitor Series:
TR-75-51-VOI-2
Report Classification:
Unclassified
Verity K2 Document Display Page 2 of 2

Supplementary Note:
See also Volume I , AD-A0 17 753.
Descriptors:
(U) *Surface to surface missiles, *Third stage engines, *Life expectancy, Aging(Materials), Solid
rocket propellants, Propellant grains, Cracking(Fracturing), Life tests
Identifiers:
(U) Minuteman, Minuteman 2 missiles, LGM-30 missiles, LGM-30G missiles, M-57 motors, M-
57AI motors, Failure analysis. Service life
Identifier Classification:
Unclassified
Abstract:
(U) This is the final report on the ICBM Overtest Technology Program which Performed by Hercules
Incorporated for the Air Force. The primary ob-jective of the program was to develop overtest
technology for the prediction of ICBM motor service life. An important secondary objective was to
make predictions of the M57A I motor life. Volume 2 contains part VI and appendices A and B.
Abstract Classification:
Unclassified
Distribution Limitation(s):
01 - APPROVED FOR PUBLIC RELEASE
Sorrrce Serial:
F
Source Code:
402250
Document Location:
DTlCANDNTlS

Priyacy & Security Notice I _Web Accessibility

A.

plivate-stinet@dti~.~i~il
 UNCLASSIFIED
SECURITY CLASSIFICATION O F T H I S P A G E (Ihbn D w r EntuL, - .-
READ INSTRUCTIONS
REPORT DOCUMENTATION PAGE BEFORECOMPLETING FORM
1. REPORT NUMBER 2. GOVT ACCESSION NO. 3. RECIPIENT'S C A T A L O G NUMBER

I AFRPL-T R-75-51 I . I I
I 4. T I T L E ( a d Subtitle)

I S. T Y P E OF REPORT a PERIOD COVERED

1
I 7.
ICBM OVERTEST TECHNOLOGY

AUTHOR(e)
. . Vol I1
6.
Final report
PERFORMING ORG. REPORT NUM8ER

0 . CONTRACT OR GRANT NUMBER(#)

A. S. Daniels K. D. S m a r t t F04611-73-C-0010
S. C. Browning T . D. P a v e l t a
9. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT, PROJECT. TASK
AREA & WORK U N I T NUMBERS
Hercules Incorporated
Bacchus W o r k s JON 305910LY

11.
Maena. Utah 84044
C O N T R O L L I N G O F F I C E NAME AND ADDRESS 1 12. REPORT D A T E I
A i r F o r c e Rocket P r o p u l s i o n L a b o r a t o r y O c t o b e r 1975
13. NUMBER O F PAGES
E d w a r d s , CA. 93523 96
14. MONITORING AGENCY NAME d AODRESS(If d l f f e r m t from Conlrolltna Otflce) IS. SECURITY CLASS. (Of i h l # report)

I I UNCLASSIFIED
I
15. DECLASSIFICATION/DOWNGRADING
SCHEDULE
N/A
16. DISTRIBUTION STATEMENT (01 thla Report)

I APPROVED F O R PUBLIC RELEASE: DISTRIBUTION UNLIMITED

I
17. DISTRIBUTION STATEMENT (01 the sb#tract entered In B l o c k 20, 11 different horn Repor?)

19. K E Y WORDS (Conllnue on reveree alde I f n e c e a a u y a d ldentlfy by b l o c k number)

Propellant Dissection
Su r v e i l l a n c e F a i l u r e Gages
F a i l u r e Modes Analogs
Aging Model
20. ABSTRACT (Conllnue on raverae aide If nacea#mry and fdentlfy b y b l o c k number)
T h i s is t h e f i n a l r e p o r t on t h e ICBM O v e r t e s t Technology P r o g r a m which
w a s P e r f o r m e d by H e r c u l e s I n c o r p o r a t e d f o r t h e A i r F o r c e . T h e p r i m a r y
objective of t h e p r o g r a m w a s t o develop o v e r t e s t technology f o r t h e p r e -
diction of ICBM m o t o r s e r v i c e life. An i m p o r t a n t s e c o n d a r y objective w a s
t o m a k e p r e d i c t i o n s of t h e M57A1 m o t o r l i f e . T h e m o s t c r i t i c a l f a i l u r e
m o d e s w e r e shown by a n a l y s i s and v e r i f i e d by a n a l o g s u b s c a l e a n d full-
s c a l e m o t o r t e s t s t o b e wing s l o t c r a c k i n g a n d aft' c e n t e r p o r t debonding i n I
DD , FORM
JAN 73 1473 EDITION OF 1 NOV 6s IS OBSOLETE
UNCLASSIFIED
SECURITY CLASSIFICATION O F THlS P A G E ( m e n D a t a Entarad)
 VOLUME I1
TABLE OF CONTENTS

Section Page

L i s t of F i g u r e s .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. iii
v
L i s t of Tables

VI OVERTEST METHODOLOGY FOR PREDICTION OF ICBM SOLID

ROCKET MOTOR SERVICE LIFE
A . Introduction ...................
B . Genera 1 Approach .................
C. Phase I .D e f i n i t i o n...............
1. .....
D e f i n i t i o n of C r i t i c a l F a i l u r e Modes
2. ........
Choosing t h e O v e r t e s t Approach
3 . ........
Selectionof theTestVehicle
D . ........
Phase I1 .O v e r t e s t and I n s p e c t i o n
E . ............
Phase I11 - I n t e r p r e t a t i o n
F . Propellant Characterization ............
.....................
G
H .. Analysis
Instrumentation ..................
1 . I n s t r u m e n t a t i o n f o r Use I n s i d e t h e Grain
Cavity ....................
2 . ........
E x t e r i o r Motor I n s t r u m e n t a t i o n
I . Analog T e s t s
1 .
...................
Design of Analog Devices ...........
2 . ..........
I n s t r u m e n t a t i o n o f Analogs
3 . T e s t Operations ...............
J . F u l l - s c a l e Motor T e s t s
1 . Preliminary Considerations
..............
..........
2 . .
I n s t r u m e n t a t i o n of F u l l - S c a l e O v e r t e s t Motors
3 . T e s t Operations ...............
LIST OF REFERENCES ...................
APPENDICES

A SPECIFIC TEST PLAN FOR PRESSURIZATION TESTING OF

SUBSCALE CENTERBORE CRACKING CYLINDER FAILURE MODE
MODEL FOR THE RPL ICBM OVERTEST TECHNOLOGY PROGRAM ...
B SPECIFIC TEST PLAN FOR HIGH RATE HYDROTEST OF M57-A1
MOTOR s / N 0033348 FOR THE RPL ICBM OVERTEST
TECHNOLOGY PROGRAM ....................
 V0Lu-m LI
LIST OF FIGURES

Number .
Title Page

6-1 ICBM Overtest Technology Program ............. 6-3

6 -2A Minuteman Third Stage S e c t i o n i n g Plan . . . . . . . . . .

. 6-19

6 -2B Minuteman Third Stage S e c t i o n i n g Plan .......... 6-20

6 -3 Humphrey R e c t i l i n e a r Potentiometer i n C r i t i c a l Wing S l o t . 6 -28

6 -4 Potentiometer Used i n Wing S l o t s ............. 6-29

6 -5 Linear Potentiometer I n s t a l l a t i o n . . . . . . . . . . . . 6-30

6 -6 S t r a i n Gage Deflectometer . . . . . . . . . . . . . . . . 6-31

6 -7 Casebond Analog Sample . . . . . . . . . . . . . . . . . . 6-38

6 -8 Candidate P a r t i a l M o t o r Analog f o r FM 7 ......... 6-39

6 -9 D i s c o n t i n u i t y Analog Sample . . . . . . . . . . . . . . . 6-40

6-10 P a r t i a l Motor Analog f o r Boot-Flap F a i l u r e . . . . . . . .

6-11 C y l i n d r i c a l Motor Analog . . . . . . . . . . . . . . . . .

6-12 Motor Analogs . . . . . . . . . . . . . . . . . . . . . .

6-13 C i r c u l a r Centerbore Model (Rubber Flap Design) . . . . . .

6-14 Wing S l o t Cracking F a i l u r e Mode S l o t t e d Model.

Instrumented Assembly ..................
Instrumented Aft Center P o r t F a i l u r e Mode Model . . . . .

S t r e s s R e l i e f Groove i n Motor Analog of Moderately

Strong P r o p e l l a n t....................
Leaf Deflectometer Assembly f o r - C e n t e r p o r t Cracking
Cylinder Test ......................
Overview of Model T e s t Arrangement . . . . . . . . . . . .

Subscale k o d e l ins~siiedLr; Test Arrangement .......

E x t e r n a l S t r a i n Gage Locations ..............
 LIST OF FIGURES (Cont)

Number .
Title Page

6-21 Grain Instrumentation Locations ............. 6-63

6-22 High Rate Pressurization System ..........,.. 6-64

6-23 Test SetupMotor 0032765 ................. 6-65

A- 1 Cracking Cylinder Failure Mode Model . . . . . . . . . . . 6-72

Subscale Pressurization System . . . . . . . . . . . . . .

Hydrotest Pressurization System .............

Internal Instrumentation Overtest High Rate Hydroburst . .

External Strain Gage Location (Cylindrical Section) ...

External Instrumentation. Aft Dome ............
 VOLUME I1
LIST OF TABLES

Number Title Page

6-1 F a i l u r e Mode Evaluation ................. 6-7

6-2 P r o p e l l a n t P h y s i c a l T e s t Matrix Six-Year O v e r t e s t

Motor (SIN 33348) .................... 6-22

6 -3 P a r t i a l Motor Analogs . . . . . . . . . . . . . . . . . . 6-42

A-1 Data A c q u i s i t i o n I n s t r u c t i o n s . . . . . . . . . . . . . . 6-74

B-1 Data A c q u i s i t i o n I n s t r u c t i o n s . . . . . . . . . . . . . . 6-84

 SECTION V I

OVERTEST METHODOLOGY FOR PREDICTION OF ICBM SOLID

ROCKET MOTOR SERVICE LIFE

A. INTRODUCTION

O v e r t e s t technology may be a p p l i e d t o ICBM motor s e r v i c e l i f e pro-

grams f o r t h e following p r i n c i p a l purposes:

(1) V e r i f i c a t i o n and/or i d e n t i f i c a t i o n of t h e most c r i t i c a l

f a i l u r e modes

(2) Experimental d e t e r m i n a t i o n of motor s t r u c t u r a l integrity

a f t e r s e l e c t e d p e r i o d s of aging

(3) V e r i f i c a t i o n of mathematical p r e d i c t i o n s of aging

e f f e c t s and motor s e r v i c e l i f e

O v e r t e s t i n t h e c o n t e x t of t h i s r e p o r t a p p l i e d t o t h e t e s t i n g of
s o l i d p r o p e l l a n t r o c k e t motors o r motor components by t h e a p p l i c a t i o n of
t h e same types of l o a d s and/or environments t h a t occur i n normal o p e r a t i o n
b u t t o l e v e l s more s e v e r e than normal. Although t h e concept i s g e n e r a l l y
a p p l i c a b l e t o a l l motor components, t h e methodology defined h e r e i n i s
p r i m a r i l y l i m i t e d t o t h e p r o p e l l a n t g r a i n f a i l u r e o r r e l a t e d f a i l u r e modes.
O v e r t e s t s may be performed on f u l l - s c a l e motors o r on analog d e v i c e s
a p p r o p r i a t e l y designed t o r e p r e s e n t t h e s t r e s s and s t r a i n c o n d i t i o n s
a s s o c i a t e d w i t h a p a r t i c u l a r f a i l u r e mode. I n e i t h e r c a s e , t h e o v e r t e s t
must be capable of i d e n t i f y i n g t h e c o n d i t i o n s of f a i l u r e and a means f o r
r e l a t i n g t h i s information t o r e s e r v e s t r e n g t h of t h e motor must be.avdi1-
able.

Overtesting should be considered a s complementary t o o t h e r techniques

e s s e n t i a l t o a meaningful s e r v i c e l i f e program. Major elements of a com-
prehens i v e p r e d i c t i v e a g i n g s u r v e i l l a n c e and s e r v i c e l i f e program encom-
pass l a b o r a t o r y c h a r a c t e r i z a t i o n , including a c c e l e r a t e d a g i n g , and
mathematical a n a l y s i s , i n a d d i t i o n t o f u l l - s c a l e and s u b s c a l e o v e r t e s t s .
Motor d i s s e c t i o n and a s s o c i a t e d m a t e r i a l s c h a r a c t e r i z a t i o n s a r e considered
a s an i n h e r e n t p a r t of o v e r t e s t technology.

The u s e of o v e r t e s t technology i n aging and s u r v e i l l a n c e programs

depends upon t h e time i n t h e l i f e of t h e motor system t h a t t h e concept i s
i n t r o d u c t e d . The program on which t h e technology given h e r e i n i s based
was planned around t h e Minuteman 11, s t a g e I11 motor t h a t has been
deployed s i n c e 1965 and i s no longer i n production. Therefore, t h e
r e s u l t s a r e d i r e c t l y a p p l i c a b l e t o t h e f i r s t type of motor system of
i n t e r e s t , namely, motors t h a t a r e i n an o p e r a t i o n a l f o r c e no longer i n
production. The second type of program of i n t e r e s t i s d i r e c t e d a t motors
t h a t a r e i n development, q u a l i f i c a t i o n , o r e a r l y production.
 The ICBM o v e r t e s t program r e p o r t e d i n Volume I , S e c t i o n s I throughV
was used a s t h e p r i n c i p a l b a s i s of t h e o v e r t e s t technology p l a n presented
i n t h i s s e c t i o n . Not a l l of t h e e s s e n t i a l elements of a g e n e r a l o v e r t e s t
plan f o r use i n p r e d i c t i n g ICBM motor s e r v i c e l i f e a r e supported by t h e
o v e r t e s t program r e s u l t s . Hawever, f o r completeness, o t h e r elements
recognized a s necessary based on experience and o t h e r program r e s u l t s a r e
presented such t h a t t h i s s e c t i o n of t h e ICBM o v e r t e s t f i n a l r e p o r t can be
used a s a guide f o r a p p l i c a t i o n of o v e r t e s t technology.

I n t h e following p r e s e n t a t i o n , t h e d e s i r e d (and perhaps somewhat

i d e a l i s t i c ) approach t o o v e r t e s t i s presented. It i s recognized t h a t
p a r t i c u l a r problems may a r i s e which make i t i m p r a c t i c a l o r impossible t o
follow t h e p r e s c r i b e d approach. Therefore, s p e c i f i c problems a r e considered
and a l t e r n a t e approaches a r e recommended. The g e n e r a l approach is given
f i r s t . This i s followed by a p r e s e n t a t i o n and e x p l a n a t i o n of t h e main
elements of an o v e r t e s t program. O v e r t e s t procedures p l u s t h o s e elements
necessary f o r i n t e r p r e t a t i o n of t h e o v e r t e s t r e s u l t s c o l l e c t i v e l y provide
t h e e s s e n t i a l i n g r e d i e n t s of a meaningful p r e d i c t i v e s u r v e i l l a n c e program
f o r ICBM motors.

B. GENERAL APPROACH

The g e n e r a l approach f o r a p p l i c a t i o n of o v e r t e s t technology i s

diagrammed i n Figure 6-1. The program d i v i d e s l o g i c a l l y i n t o t h r e e
p r i n c i p a l phases which a r e :

Phase I - Definition
Phase I1 - O v e r t e s t and I n s p e c t i o n

Phase I11 - Interpretation

The d e f i n i t i o n phase encompasses a review and d e f i n i t i o n of f a i l u r e

modes and t h e s e l e c t i o n of a p p l i c a b l e o v e r t e s t s . Phase I1 i s d i r e c t e d t o
t h e a c t u a l performance of t h e o v e r t e s t s and t h e p o s t t e s t examinations and
m a t e r i a l s c h a r a c t e r i z a t i o n s . The f i n a l phase i s t h e i n t e r p r e t a t i o n of
o v e r t e s t r e s u l t s i n a s s o c i a t i o n w i t h r e s u l t s from mathematical a n a l y s e s
and o t h e r s u r v e i l l a n c e and aging t e s t s . The approach depends upon t h e
system being evaluated. Motors t h a t a r e a l r e a d y i n s e r v i c e and a r e no
longer being produced r e q u i r e s one type of planning, whereas those s t i l l
i n production r e q u i r e another.

I n planning a n o v e r t e s t program f o r t h e motors no longer being

produced, i t i s necessary t o c o n s i d e r motors t h a t a r e being removed from
t h e f o r c e , u s u a l l y f o r reasons o t h e r than f o r s u r v e i l l a n c e t e s t i n g . Con-
s e q u e n t l y , t h e r e i s l i m i t e d f l e x i b i l i t y i n planning a program because
s e l e c t i o n of a p a r t i c u l a r age o r c l a s s of motor and p r o p e l l a n t l o t i s
u s u a l l y p r o h i b i t e d . Moreover, the h i s t o r y of a p a r t i c u l a r motor removed
 PHASE I - DEFINITION I PHASE I1 - OVERTEST AND INSPECTION I PHASE I11 - INTERPRETATION

I I
CONSTRUCT FM DEVEW ANAL
i I1
MODELS I I
LIST
4 4 I I
SELECT CRITICAL PERFOM HDTOR I
Fn ANAL I
I
I I
LIST POTWTIAZ.
OT APPROACHES I I
C w I DEFINEMECII
SCREW OT ANALOT DESIGN ANALOG I
APPROACHES APPROACHES UNITS PROPERTIES -
I VS AGE
k DEFINE OT SELECT MOTORS -.
COMPARE OT AND I DEFINe MADS (PW:
OPERATIONAL LOADS
RESULTS I AND ANALYSIS INPUT
C
& I INSPECT OT
SELECT OT HOTORS
APPROACH a • I I PERFORM
&
PERFORM ANALOG
?- - - - - - - OT VERIFICATION I
TESTS
I
k
SPECIPY OT P R E P 4 OT
APPROACH TEST PIAN
(
TEST SAMPLES
y+I
I 4
DISSECT AND
ABBREVIATIONS USED IN TABLE: I INSPECT MX'ORS
OT OVERTEST TESTS
En FAILURE MODE I C -
STV STRUCTURAL TEST VEHICLE OBTAIN PROPELZANT
SL SERVICE LIFE PROPERTIES PROM DEFINE FAILURE
,+
FP FAILURE PROBABILITY
I OT MOTOR DISTRIBUTIONS I RESULTS.
PRESEWJ MS.
FSU FULL-SCALE UNIT I I 1 I FP VS AGE
MS MARGIN OF SAFETY I -
FP FAILURE PRESSURE I I

Figure 6-1. ICBM Overtest Technology Program

from t h e f o r c e rnay n o t be s u f f i c i e n t l y w e l l known t o permit c o n f i d e n t
c o n t r o l l e d experimentation. Usually, t h e s p e c i f i c p r o p e l l a n t p r o p e r t i e s
of a p a r t i c u l a r o v e r t e s t motor taken from t h e f o r c e w i l l n o t be known
beforehand and p r o p e l l a n t f o r f a b r i c a t i o n of analog t e s t devices w i l l n o t
be a v a i l a b l e . For some types of l o a d i n g , t h e p o t e n t i a l f o r a d d i t i o n a l
u s e f u l i n s t r u m e n t a t i o n e x i s t s f o r motors s t i l l being manufactured, b u t
motors a l r e a d y completed have l i m i t e d i n s t r u m e n t a t i o n p o s s i b i l i t i e s .

The i n i t i a l t a s k i n planning t h e o v e r t e s t program i.s t o d e f i n e t h e

f a i l u r e modes t h a t a r e t o be i n v e s t i g a t e d . This i s u s u a l l y accomplished
by i d e n t i f y i n g t h e p a t e n t k l modes and screening t h e l i s t t o a r r i v e a t
t h o s e considered a s c r i t i c a l . Once t h e c r i t i c a l modes have been d e t e r -
mined i t i s then necessary t o choose o v e r t e s t approaches t h a t a r e a p p l i c a b l e
t o each of t h e s e modes. Analyses of t h e motor and c a n d i d a t e o v e r t e s t
v e h i c l e s a r e performed t o confirm t h e o v e r t e s t approach and t h e t e s t pro-
cedures. The o v e r t e s t approach should be demonstrated and f a i l u r e modes
v e r i f i e d p r i o r t o c m i t i n g t o a long-range t e s t program such a s a g i n g and
surveillance. The i d e a l o v e r t e s t program should involve a combination of
f u l l - s c a l e and analog t e s t v e h i c l e s .

A d e t a i l e d log of o v e r t e s t motor ( o r analog device) h i s t o r y should

be maintained. It i s d e s i r a b l e t o know p r o p e r t i e s , geometry, previous
loading, and o t h e r s i m i l a r c h a r a c t e r i s t i c d a t a f o r a p a r t i c u l a r v e h i c l e
s o t h a t r e s u l t s may be i n t e r p r e t e d r e l a t i v e t o a t o t a l mator population.
This d e s i r e l e a d s t o d e t a i l e d b e f o r e and a f t e r i n s p e c t i o n s and p r o p e r t i e s
t e s t s from d i s s e c t e d motors following t h e t e s t . Plans should encompass
s u b s c a l e t e s t s t o p r e d i c t v a r i a b i l i t y of f e i l u r e loads and d e f i n e f a i l u r e
distributions.

I n t e r p r e t a t i o n of t h e o v e r t e s t r e s u l t s involves r e s u l t s from a
small number of f u l l - s c a l e o v e r t e s t s and a l a r g e r number of s u b s c a l e o r
p a r t i a l motor analog o v e r t e s t s . Each of t h e s e t e s t s a r e designed and
instrumented t o provide q u a n t i t a t i v e v a l u e s which can be d i r e c t l y r e l a t e d
t o s t r u c t u r a l i n t e g r i t y r e l a t i v e t o a p a r t i c u l a r f a i l u r e mode. Theore-
t i c a l a n a l y s i s a r e a l s o performed using p r o p e r t i e s f o r t h e p r o p e l l a n t s
used i.n t e s t v e h i c l e s . E x t r a p o l a t i o n of r e s u l t s t o o t h e r motors and time
p e r i o d s i s based on c o r r e l a t i o n s between a n a l y t i c a l and experimental
r e s u l t s and t h e necessary mechanical p r o p e r t i e s f o r t h e o r e t i c a l a n a l y s i s
of t h e population n o t r e p r e s e n t e d by t h e o v e r t e s t .

The g o a l of t h e g e n e r a l o v e r t e s t l p r e d i c t i v e s u r v e i l l a n c e program i s
t o provide r e l . i a b l e p r e d i c t i o n s of t h e motor s e r v i c e l i f e . I n doing
s o , t h e . o b j e c t i v e i s t o involve t h e l a t e s t experimental and a n a l y t i c a l
methodology i n a complementary a n a l y t i c a l and experimental program.

The major elements of t h e o v e r t e s t program approach a r e presented i n

t h e following paragraphs. The p l a n i s f i r s t presented according t o t h e
rhree nl-;n.ci.pa 1 ??lsenr, -I.$!?nt; f j r d !??-m~s. T?I!.s f s Fol.!.o~~edby a more
comprehensive coverage of s p e c i f i c segments which a r e considered t o be t h e
key t o t h e success of t h e program. These key program elements a r e : (1)
Propellant c h a r a c t e r i z a t i o n , (2) a n a l y s i s , ( 3 ) instrumentation, ( 4 ) analog
t e s t s , and (5) f u l l - s c a l e t e s t s .

C. PHASE I - DEFINITION
The following t a s k s should be accomplished during Phase I:

(1) S e l e c t i o n and Screening of F a i l u r e Modes

(2) Overtes t Program D e f i n i t i o n

(a) Overtest Approach

(b) Test Vehicles

(3) Program Plan

1. D e f i n i t i o n of C r i t i c a l F a i l u r e Modes

The i n i t i a l o b j e c t i v e of an a v e r t e s t program i s t o determine

t h e c r i t i c a l f a i l u r e modes. This o b j e c t i v e i s extended f o r purposes of
s e r v i c e l i f e p r e d i c t i o n s t o d e f i n e those modes which a r e most l i k e l y t o
l i m i t t h e o p e r a t i o n a l l i f e of t h e motor i n question. This i s accomplished
by mathematical a n a l y s i s and r e l a t e d experience. For a motor t h a t has
completed development, the p o t e n t i a l modes may be i d e n t i f i e d by a s s o c i a t -
ing them with development problems. Problems encountered during t h e develop-
ment and o p e r a t i o n a l l i f e of s i m i l a r motors may a l s o suggest p o t e n t i a l
f a i l u r e modes. S t r u c t u r a l analyses should he performed f i r s t using unaged
m a t e r i a l s p r o p e r t i e s . The l a t e s t s t a t e - o f - t h e a r t f o r s t r u c t u r a l a n a l y s i s
should be applied with a complete c h a r a c t e r i z a t i o n of m a t e r i a l s p r o p e r t i e s .
This a n a l y s i s should provide margins of s a f e t y f o r a l l c r i t i c a l f a i l u r e
modes such t h a t a r e l a t i v e ranking of f a i l u r e modes can be accomplished
by comparison of margins of s a f e t y . A d e f i n i t i o n of t h e c r i t i c a l loading
environments and mission requirements should be determined i n t h e develop-
ment program and applied i n t h e b a s i c system a n a l y s i s .

I n d e f i n i n g c r i t i c a l age-related f a i l u r e modes, a n t i c i p a t e d
aging of m a t e r i a l s and t h e e f f e c t s on t h e margins of s a f e t y must b e con-
s i d e r e d . Aging of m a t e r i a l s could possibly reduce a comparatively l a r g e
margin of s a f e t y t o an unacceptable value during t h e desired l i f e t i m e of
t h e motor. Thus, a p a r t i c u l a r mode could become more c r i t i c a l than one
e x h i b i t i n g a smaller margin of s a f e t y i n t h e unaged condition b u t which
i s not a f f e c t e d by aging. The r e s u l t i s a change i n ranking of f a i l u r e
mode c r i t i c a l i t y with age. S t r u c t u r a l analyses should be repeated i n t h e
same manner a s i n t h e b a s e l i n e a n a l y s i s b u t w i t h p r o p e r t i e s a c c o u n t i n g
f o r aging e f f e c t s . This n e c e s s i t a t e s s a n e t y p e of a c c e l e r a t e d a g i n g
program t o complement t h e o v e r t e s t program. The g e n e r a l p r e d i c t i v e s u r v e i l -
l a n c e program should be planned t o p r o v i d e p r o p e r t i e s a t s e l e c t e d a g i n g
t i m e s s u f f i c i e n t t o a l l o w a complete a n a l y s i s a t each a g i n g time chosen.
The s e l e c t i o n of key a g i n g p a r a m e t e r s and t h e approach f o r c o n d u c t i n g a n
a c c e l e r a t e d a g i n g program t o s u p p o r t a n a l y s e s t o p r e d i c t a g i n g e f f e c t s
on f a i l u r e modes i s beyond t h e scope of t h i s r e p o r t .

To e s t a b l i s h which f a i l u r e modes a r e most l i k e l y t o become

c r i t i c a l , t h e following b a s i s g u i d e l i n e s should be recognized i n screening
f a i l u r e modes f o r t h e o v e r t e s t program:

(a) Low margins of s a f e t y o b t a i n e d by a n a l y s i s i n d i c a t e s

t h a t o n l y s m a l l d e g r a d a t i o n due t o a g e c a n t a k e p l a c e
w i t h o u t c a u s i n g a problem. Theref o r e , f a i l u r e modes
f o r which margins of s a f e t y a r e low o r a r e p r e d i c t e d
by a n a l y s i s t o f a l l below a c c e p t a b l e l e v e l s d u r i n g
a g i n g should be t r e a t e d a s c r i t i c a l .

(b) I f m a t e r i a l s s u s p e c t e d of b e i n g s e n s i t i v e t o a g i n g a r e
i n v o l v e d , a n a g i n g problem s h o u l d b e c o n s i d e r e d a l t h o u g h
t h e p r e d i c t e d margins of s a f e t y a r e r e l a t i v e l y h i g h .

(c) Problems known t o have o c c u r r e d i n t h e motor p r e v i o u s l y

o r i n s i m i l a r motors s h o u l d b e c o n s i d e r e d c r i t i c a l
u n t i l i t c a n b e s a t i s f a c t o r i l y proven t h a t t h e problems
\ , r i l l n o t a r i s e i n t h e s u b j e c t motor a s a r e s u l t of age.

The i n f o r n ~ a t i o nn e c e s s a r y t o e v a l u a t e f a i l u r e modes by t h e above

c r i t e r i a should be o r g a n i z e d i n t a b u l a r form a c c o r d i n g t o T a b l e 6-1.

Normally, t h e r e a r e o n l y one o r two c r i t i c a l f a i l u r e modes i n

a t y p i c a l ICBM motor and by t h e end of a development program t h e y a r e
u s u a l l y known. T h i s i s n o t t o s a y , however, t h a t t h e o v e r t e s t program f o r
s e r v i c e l i f e p r e d i c t i o n should b e s o l i m i t e d . A d i s c u s s i o n of g r a i n and
case-bond f a i l u r e modes i s g i v e n i n R e f e r e n c e 1. I n o r d e r t o l i m i t t h e
o v e r t e s t program t o a n economically f e a s i b l e s c o p e , p a r t i c u l a r l y i f
f u l l - s c a l e o v e r t e s t s v e r s u s a g e a r e t o be performed, i t w i l l b e n e c e s s a r y
t o s c r e e n t h e f a i l u r e mode l i s t and r e d u c e i t t o o n l y t h e most c r i t i c a l
ones f o r f u r t h e r s t u d y .

2. Choosing t h e O v e r t e s t Approach

The o b j e c t i v e of t h i s segment of t h e o v e r t e s t program i s t o

s c r e e n t h e p o t e n t i a l o v e r t e s t methods and t o d e f i n e a p p r o p r i a t e t e s t s
f o r d e t e r m i n i n g motor i n t e g r i t y w i t h r e s p e c t t o f a i l u r e modes i d e n t i f i e d
a s be in,^ c r i t i c a l . ,

1
R e f e r e n c e s a r e p r e s e n t e d a t t h e end of t h i s s e c t i o n
 TABLE 6- 1

FAILURE MODE EVALUATION'

Typical Modes of F a i l u r e C r i t i c a l Physical P r o p e r t i e s Load o r Environment

-
Grain cracking o r unbonding P r o p e l l a n t long-term s t r e s s o r s t r a i n ; r e l a x a t i o n Temperature c y c l i n g
modu?us, case-bond s t r e n g t h a t temperature extremes

Debonding due t o degradation of Short time s t r e n g t h of c a s e bond a t e l e v a t e d temperature Aerodynamic h e a t i n g

c a s e - g r a i n bond s t r e n g t h and case
expans i o n

Slump, debonding, checking of flaw Case-bond s h e a r s t r e n g t h , p r o p e l l a n t r e l a x a t i o n Axial a c c e l e r a t i o n

modulus

Slump, c a s e o v a l i t y Case s t i f f n e s s p r o p e r t i e s , p r o p e l l a n t modulus fiansverse acceleration

Autoignition, p r o p e l l a n t degradation, P r o p e l l a n t b a l l i s t i c p r o p e r t i e s , notch s e n s i t i v i t y , Vibration

fatigue fracture fatigue properties

Debonding, c a s e bending Case and case-bond s t i f f n e s s and s t r e n g t h , p r o p e l l a n t Shock

modulus

Case bending, debonding P r o p e l l a n t and case-bond f a t i g u e p r o p e r t i e s T r a n s p o r t a t i o n and

hand1 ing

Grain cracking, debonding Endurance t e n s i l e s t r e n g t h of p r o p e l l a n t , b i a x i a l Cure shrinkage

tension, case-bond t e n s i l e s t r e n g t h

Grain cracking, debonding F a i l u r e s t r a i n from p r e s s u r i z e d b i a x i a l t e n s i o n a t Pressurization

appropriate r a t e s

1
See L i s t of References a t end of t h i s s e c t i o n
 There a r e s e v c r a i . o v e r t e s t s wh:lch may be d e v i s e d t o s t u d y g r a i n
s t r u c t u r a l i n t e g r i t y . O f t e n 2 t c s t wnich i n v o l v e s one p a r t i c u l a r t y p e of
l o a d i n g may b e u s e d e f f e c t i . t r c l y t o r e p r e s e n t a n o t h e r l o a d . A l l p o t e n t i a l
o v e r t e s t approaches should be c o n s i d e r e d . Some such c a n d i d a t e a p p r o a c h e s
a r e p r e s e n t e d i n f o l l o w i n g p a r a g r a p h s . b n a l y t i c a l models s h o u l d be
d e v i s e d f o r a n a l y s i s of t h e most p r o n i s i n g o v e r t e s t a p p r o a c h e s and a c t u a l
motor o p e r a t i o n . S e l e c t i o n of tile o v e r t e s t approach w i l l depend upon
t h e r e p r e s e n t a t i o n of a c t u a l c r i t i c a l motor c o n d i t i o n s by t h e o v e r t e s t .

S t r u c t u r a l ana1ysi.s methods a r e a v a i l z b l e by which motors may

b e a n a l y z e d f o r o p e r a t i - o n a l J oads and o v e r t e s t and f o r meaningful com-
p a r i s o n s of t h e two. O v c r t e s t parameters which c a n b e monitored d u r i n g
t e s t can b e a n a l y t i c a l l y predictscl f o r use i n t h e t e s t planning. The
a n a l y s e s should emphasize a l l p o t e n t l a 1 f a i l u r e nodes of t h e g r a i n and
c a s e bond and t h e p o s s i b i l i t y cf the o r d e r of c r i t i c a l i t y of modes c h a n g i n g
w i t h age.

S i n c e t h e f u l l - s c a l e motor t e s t i s g e n e r a l l y planned around a

s p e c i f i c f a i l u r e mode, scme a s s u r n r . c e i s r e q u i r e d t o d e m o n s t r a t e t h a t
f a i l u r e c a n b e made t o o c c u r a s p r e d i c t e d . T h i s may b e accomplished by
t e s t s - t o - f a i l u r e of s u b s c a l e o r a n a l o g specirnens r e p r e s e n t a t i v e of t h e
f u l l - s c a l e u n i t and t h e motor f a i l u r e c o n d i t i o n s . The s u b s c a l e s t r u c t u r a l
t e s t s must be r e l a t e d t o Eul 1 - s c a l e o v e r t e s t s and a c t u a l motor s t r u c t u r a l
performance by s t a t e - o f - t h e - a r t a n e l v s i s t e c h n i q u e s . Instrumentat ion
t e c h n i q u e s and f a i l u r e d e t e c t i o n s h o u l d be demonstrated i n t h e s u b s c a l e
v e r i f i c a t i o n t e s t s i f possible. T h i s phase of t h e o v e r t e s t t e c h n o l o g y
program may b e c o n s i d e r e d a s v e r i f i c a t i o n t h a t t h e a n a l y s l s can p r e d i c t
and i d e n t i f y c o n d i t i o n s of f a i l u r e i n t h e motor.

Although vzr-ious t y p e s of o v e r t e s t s have been a p p l i e d i n p a s t

programs, n o t a l l :re p a r t i c u l a r l y appLicab1.e t o I C B M programs. The
o v e r t e s t approach i s g e a r e d t o t h c~ r i t i c a l l o a d i n g c o n d i t i o n s which
s h o u l d b e i d e n t i f i e d a s a p a r t of t h e f a i l u r c modes d e f i n i t i o n t a s k . The
o v e r t e s t l o a d i n g program f o r f u l l - s c a l e (and a n a l o g ) u n i t s must r e p r e s e n t
r e a l i s t i c l o a d s . Loads .r\~hichare c r i t i c a l . t o one t y p e of s o l i d p r o p e l l a n t
motor a r e n o t n e c e s s a r i l y c r L t i c a ? t o a n o t h e r .

The p r i n c i p a l Loads of C n t c r e s t f o r ICBM motor o v e r t e s t c o n s i d e r a -

t i o n are:

(a) Transvcrsr- a d a x i a l a c c e l e r a t i o n s

(b) Vibrzticn

(c) D i f f e r e n t i a l c u r e a n d / o r thermal s h r i n k a g e

(d) InterxaL Fressurc

 Those l o a d s known t o be of concern i n ICBM motors which c o n t a i n
CMDB p r o p e l l a n t s such a s t h e M57A1 a r e p r i m a r i l y due t o i n t e r n a l p r e s s u r e .
Some motors must w i t h s t a n d s i g n i f i c a n t r e s i d u a l thermal and c u r e shrinkage
s t r e s s e s ; however, once they a r e deployed i n t h e f i e l d , t h e combination
of long-term s t o r a g e under s t r a i n followed by p r e s s u r e becomes t h e p r i -
mary concern. A c c e l e r a t i o n h a s been of major s i g n i f i c a n c e i n a number
of Hercules f l e x i b l e - c a s e motor designs ( S p r i n t and HIBEX) b u t p r e s e n t
ICBM a c c e l e r a t i o n s a r e r e l a t i v e l y l o w and have n o t been shown a s c r i t i c a l
i n p a s t ICBM motor f a i l u r e s t u d i e s . V i b r a t i o n , p a r t i c u l a r l y d u r i n g t r a n s -
p o r t a t i o n and h a n d l i n g , has r e c e i v e d much a t t e n t i o n b u t has n o t a p p a r e n t l y
been a problem w i t h ICBM motors. Acoustic v i b r a t i o n s a r e of s i g n i f i c a n c e
w i t h regard t o a t t a c h e d motor hardware b u t do n o t a p p a r e n t l y r e p r e s e n t
any problem t o t h e motor g r a i n s t r u c t u r a l i n t e g r i t y .

Experience, t h e r e f o r e , h a s shown t h a t t h e major concerns f o r

ICBM motors a r e a s s o c i a t e d w i t h h i g h r a t e p r e s s u r i z a t i o n and shrinkage
loading. From a n o v e r t e s t p o i n t of view t h e p r e s s u r e t e s t s a r e more
c h a l l e n g i n g and a r e emphasized h e r e . Mention i s made of t h e o t h e r over-
t e s t s b u t d e t a i l e d c o n s i d e r a t i o n i s more w i t h i n t h e scope of o t h e r programs.

a. A c c e l e r a t i o n Loading

A c c e l e r a t i o n t e s t s normally a r e performed by mounting a

s u b s c a l e o r f u l l - s c a l e motor on t h e arm of a c e n t r i f u g e w i t h t h e a x i s of
t h e motor p o s t i t i o n e d properly w i t h r e s p e c t t o t h e c e n t e r of r o t a t i o n t o
g i v e t h e d e s i r e d a c c e l e r a t i o n d i r e c t i o n . Magnitudes of a c c e l e r a t i o n f o r c e s
depend upon t h e r a t e of r o t a t i o n . For a s i g n i f i c a n t t e s t , t h e l e n g t h of
t h e c e n t r i f u g e arm should be l a r g e r e l a t i v e t o t h e motor dimensions. This
t y p e of t e s t was used a s a development t e s t and check on t h e a n a l y s i s i n
t h e development of t h e second s t a g e S p r i n t motor. I n t h e S p r i n t t e s t s ,
t h e a c c e l e r a t i o n s were l e s s than f l i g h t a c c e l e r a t i o n s . Longer loading
times on t h e c e n t r i f u g e were r e l a t e d t o f l i g h t times by taking i n t o
account r e l a x a t i o n of t h e p r o p e l l a n t . Damage r e s u l t i n g from a low l e v e l
of loading a p p l i e d over a long d u r a t i o n can be equated t o damage due t o
h i g h e r loading a p p l i e d over a s h o r t e r period.

I n u s i n g p a r t i a l - m o t o r analog d e v i c e s , t h e loads a r e o f t e n
a p p l i e d i n t h e l a b o r a t o r y by conventional type t e s t equipment. I n such
c a s e s i t becomes necessary t o d u p l i c a t e t h e s t r e s s f i e l d c r e a t e d by t h e
a c c e l e r a t i o n s . The problem then becomes a problem of analog d e s i g n
around a v a i l a b l e methods of loading i n s t e a d of developing a s p e c i a l load-
ing technique.

b. Vibrations

V i b r a t i o n loading o r d i n a r i l y r e p r e s e n t s no p a r t i c u l a r
d i f f i c u l t y ; most motors a r e s u b j e c t e d t o v i b r a t i o n t e s t i n g a s a normal
p a r t of environmental q u a l i f i c a t i o n t e s t s d u r i n g development and many
f a c i l i t i e s a r e equipped t o o v e r t e s t i n t h e v i b r a t i o n a l modes. However,
c a r e f u l a t t e n t i o n must be given t o p o s s i b l e l o c a l i z e d h e a t i n g and r e s u l t -
i n g f a i l u r e of t h e g r a i n o r i g n i t e r . Unlike o t h e r l o a d s , t h e e f f e c t s of
v i b r a t i o n l o a d i n g a r e dependent upon h e a t t r a n s f e r c o n s i d e r a t i o n s r e s u l t i n g
from v i s c o e l a s t i c behavior of t h e p r o p e l l a n t i n a d d i t i o n t o s t r e s s l e v e l s .
A r e g i o n w i t h r e l a t i v e l y lower s t r e s s l e v e l compared t o a n o t h e r r e g i o n
may be more c r i t i c a l from a p o i n t of view of i n t e g r i t y because i t may n o t
l o s e t h e h e a t generated by t h e s t r e s s e s r e s u l t i n g from v i b r a t i o n s .

c. Shrinkage Loads

There has been much t e s t i n g of f u l l - s c a l e and analog

motors under c u r e and thermal l o a d i n g s . No unusual problems a r e expected
i n performing t h i s type of t e s t o t h e r than those r e l a t e d t o i n s t r u m e n t a t i o n
and r e l a t i n g t e s t r e s u l t s t o a c t u a l o p e r a t i o n a l loads. Once t h e tempera-
t u r e l i m i t s and r a t e s of c o o l i n g a r e known, t h e o v e r t e s t program can be
planned around c o n d i t i o n i n g equipment a v a i l a b l e a t most rocket motor
facilities.

One problem t o be addressed and forwhich a d i r e c t o v e r t e s t

approach i s n o t immediately obvious i s r e d u c t i o n i n r e s e r v e s t r e n g t h
r e s u l t i n g from long-term s t o r a g e w i t h t h e p r o p e l l a n t s u b j e c t e d t o r e s i d u a l
l o a d s c r e a t e d by cooldown during manufacture. Other A i r Force programs
such a s t h e LRSLA and SLIM programs p o s s i b l y could be sources f o r a p p l i c -
a b l e o v e r t e s t technology i n t h i s a r e a . Subscale and p a r t i a l motor analogs
should f i g u r e s t r o n g l y i n o v e r t e s t programs involving long-term s t o r a g e
under l o a d s .

The thermal c o o l i n g o v e r t e s t approach should b e considered

a s a p o s s i b l e means f o r a n a l y s i s of p r e s s u r e loading. I t has been, shown
t h a t a d e f i n i t e analogy can be drawn between thermal and p r e s s u r e loads.2
P a r t i c u l a r p r o p e r t i e s of t h e p r o p e l l a n t and t h e f a i l u r e mode i n q u e s t i o n
determine whether t h e thermal t e s t i s f e a s i b l e a s a p r e s s u r e o v e r t e s t .
I n some s i t u a t i o n s t h e p r o p e l l a n t s t r e n g t h c a p a b i l i t i e s may p o s s i b l y
i n c r e a s e w i t h reduced temperature a t a r a t e r e l a t i v e t o t h e load t h a t
makes i t i m p r a c t i c a l t o achieve f a i l u r e a t r e a s o n a b l e temperatures.

d. P r e s s u r e Loading

P r e s s u r e t e s t i n g i s not a s s t r a i g h t f o r w a r d a s o t h e r s c i t e d .
Not only must t h e p r e s s u r i z a t i o n r a t e s and l e v e l s be r e p r e s e n t e d , b u t
s a f e t y i s a prime c o n s i d e r a t i o n . The success of a t e s t t o s i m u l a t e t h e
i g n i t i o n t r a n s i e n t which i s u s u a l l y t h e c r i t i c a l period depends upon how
w e l l t h i s load c o n d i t i o n i s d u p l i c a t e d . The period between time z e r o and
achievement of f i r i n g p r e s s u r e i s of p r i n c i p a l concern. Since propel-
l a n t response i s h i g h l y dependent upon l o a d i n g r a t e , a low-rate p r e s s u r i z a -
t i o n t e s t (which would e l i m i n a t e many of t h e problems a s s o c i a t e d w i t h t h i s
type of t e s t i n g ) i s n o t s u f f i c i e n t . On t h e o t h e r hand, improperly designed
t e s t s and equipment have r e s u l t e d i n dynamic overshoot and s h o r t - term
p r e s s u r e s p i k e s much i n excess of t h e d e s i r e d maximum p r e s s u r e , i n a d v e r t e n t
i g n i t i o n of t h e g r a i n s , and n o n r e p r e s e n t a t i v e g r a i n cracking because of
too-rapid loading. Gas p r e s s u r i z a t i o n , such a s w i t h n i t r o g e n , should be
avoided i f p o s s i b l e because of c o m p r e s s i b i l i t y of t h e g a s and r e s u l t i n g
l o s s of c o n t r o l of loading and t h e i n h e r e n t s a f e t y problem, i f a motor
c a s e should f a i l during t e s t i n g .
I

Hercules has resolved most of t h e problems w i t h h i g h - r a t e

p r e s s u r i z a t i o n t e s t s and has developed s p e c i a l techniques and equipment
f o r t h i s purpose. T e s t s have been performed up t o 50,000 p s i l s e c .
Minuteman 11, s t a g e I11 (M57A1) p r e s s u r i z a t i o n r a t e s have been d u p l i c a t e d
very c l o s e l y , and motors have been t e s t e d t o p r e s s u r e l e v e l s , i n excess of
f a i l u r e . I t i s important t h a t p r e s s u r i z a t i o n r a t e s be confirmed i n check-
out t e s t s p r i o r t o overpressure t e s t s t o e n s u r e c l o s e agreement between
t e s t r a t e s and p r e s s u r e s and t h o s e of t h e motor during operation.

An important r e s u l t of t h e ICBM o v e r t e s t technology program

i s t h e demonstration of t h e c o l d p r e s s u r i z a t i o n t e s t a s a v i a b l e o v e r t e s t
f o r i g n i t i o n r a t e loading. F u r t h e r confirmation f o r t h e approach h a s
been obtained from t h e LRSLA program and, i n subscale d e v i c e s , from t h e
T r i d e n t C-4 program.

e. Miscellaneous Loads

Other o v e r t e s t methods should be considered and evaluated

based on t h e requirements of a p a r t i c u l a r program. Analog devices loaded
by conventional l a b o r a t o r y equipment and designed t o d u p l i c a t e s t r e s s
f i e l d s due t o p r e s s u r e a r e e s s e n t i a l t o a good s t a t i s t i c a l approach. The
r e p r e s e n t a t i o n of p r e s s u r e loads by thermal t e s t i n g was mentioned i n t h e
d i s c u s s i o n of thermal o v e r t e s t s .

Other o v e r t e s t p o s s i b i l i t i e s include motor f i r i n g s wherein

an oversized i g n i t e r i s used o r t h e nozzle t h r o a t i s reduced t o r a i s e t h e
p r e s s u r i z a t i o n r a t e and/or t h e f i r i n g p r e s s u r e t o achieve an o v e r t e s t .
Higher p r e s s u r e s may a l s o be achieved by m o d i f i c a t i o n of t h e g r a i n sur-
f a c e i n a n o n c r i t i c a l a r e a of t h e g r a i n . F i r i n g a t a temperature t h a t
causes higher than normal s t r e s s e s i s a l s o a n o v e r t e s t p o s s i b i l i t y . A l l
of these t e s t s wherein a h o t f i r i n g i s used have t h e disadvantage t h a t
e x a c t f a i l u r e l e v e l s a r e not i d e n t i f i e d s i n c e t h e t e s t s a r e n o t normally
designed t o o b t a i n f a i l u r e . Rather, t h e g r a i n i n t e g r i t y i s demonstrated
a t a p r e s e l e c t e d l e v e l of o v e r t e s t dependent upon t h e load. The advantage
i s t h a t t h e t e s t i s o r d i n a r i l y considered more r e a l i s t i c .

Emphasis has been placed on o v e r t e s t s of motors i n " a s - b u i l t "

c o n d i t i o n , i . e . , a t z e r o burn. F a i l u r e modes t h a t become c r i t i c a l a t
intermediate burn times could p o s s i b l y be evaluated i n a f i r i n g wherein motor
f i r i n g u t i l i z i n g small nozzles i s terminated by c u t t i n g o f f t h e dome and
quenching t h e p r o p e l l a n t a t a p r e s e l e c t e d time. Success i n performing
t h i s type of o v e r t e s t depends upon s e l e c t i n g a time t o e x t i n g u i s h such
t h a t g r a i n f a i l u r e would have begun b u t not progressed t o t h e p o i n t of
t o t a l f a i l u r e of t h e motor. Hercules has been s u c c e s s f u l i n performing
t h i s type of t e s t w i t h subscale and f u l l - s c a l e u n i t s .
 3. S e l e c t i o n of t h e T e s t V e h i c l e

The b a s i c t e s t v e h i c l e o r v e h i c l e s f o r an ICBM o v e r t e s t program

should be chosen on t h e b a s i s of t h e f o l l o w i n g c o n s i d e r a t i o n s :

(a) Objective - Is t h e o v e r t e s t t o conf i n n f a i l u r e

modes, demonstrate adequacy of a n a l y t i c a l t e c h n i q u e ,
o r provide f a i l u r e l e v e l s and s t r u c t u r a l c a p a b i l i t y
d i r e c t l y ? W i l l t h e t e s t s be performed throughout a
l o n g - d u r a t i o n a g i n g and s u r v e i l l a n c e program? Is
t h e t e s t t o be t h e p r i n c i p a l s o u r c e of a g i n g d a t a o r
does i t s e r v e t o complement o t h e r methods? Can
r e s u l t s be c o r r e l a t e d w i t h o t h e r phases of t h e
program.

(b) Safety - W i l l t h e methods of o v e r t e s t o r i n s t r u -

mentation c r e a t e a hazard f o r l i f e o r property?
W i l l e x t r a o r d i n a r y (and expensive) p r e c u a t i o n s be
n e c e s s a r y t o guard a g a i n s t such p o s s i b i l i t i e s ?

(c) Motor and Loads S i m u l a t i o n - How much f l e x i b i l i t y

i s a f f o r d e d i n v a r y i n g l o a d s ? Are t h e c r i t i c a l condi-
t i o n s t r u l y s i m u l a t e d ? Can r e p r e s e n t a t i v e s t o r a g e
conditions be applied p r i o r t o the t e s t ? W i l l
f a i l u r e occur i n what i s p o s t u l a t e d t o be t h e c r i t i c a l
mode? How c e r t a i n i s t h e s i m u l a t i o n ?

(d) Instrumentation -
Can t h e d e v i c e be instrumented t o
d e t e c t f a i l u r e l o a d s and d e t e r m i n e i n i t i a l f a i l u r e
location? W i l l instrumentation a f f e c t c r i t i c a l
stress fields?

(e) Statistics - Can t h e d e v i c e s be s t o r e d and t e s t e d

economically i n s u f f i c i e n t numbers t o provide
s t a t i s t i c a l s i g n i f i c a n c e ? Can i t be made t o r e p r e -
s e n t v a r i o u s p o p u l a t i o n s a n d / o r motors a s n e c e s s a r y ?

(f) Manufacturing - Can i t be manufactured by r e p r e s e n t a -

t i v e p r o c e s s e s , o r , i f f o r an o p e r a t i o n a l motor, can
i t be manufactured from a n a c t u a l motor?

(g) Interpretation -
This c o n s i d e r a t i o n i n v o l v e s most
of t h e above. The primary concern i s t o a s s u r e t h a t
t h e method of i n t e r p r e t a t i o n i s n o t m i s l e a d i n g . I s
i t c a p a b l e of r e l i a b l e a n a l y s i s ?
 Following t h e s e l e c t i o n of a p a r t i c u l a r device f o r use i n t h e
o v e r t e s t program, i t should be j u s t i f i e d f o r u s e i n a comprehensive aging
and s u r v e i l l a n c e program t o t h e g r e a t e s t e x t e n t p o s s i b l e by a n a l y s i s and
experiments.

Two b a s i s types of t e s t devices may be considered f o r u s e i n

an ICBM o v e r t e s t program. These a r e : ( a ) F u l l - s c a l e motors, and (b)
motor analogs. Each of t h e s e d e v i c e s i s discussed b r i e f l y i n t h e follow-
ing subparagraphs.

a. Full-Scale Motors

T e s t s t o study motor s t r u c t u r a l c a p a b i l i t i e s w i t h regard t o

t h e c r i t i c a l f a i l u r e modes must be r e p r e s e n t a t i v e of t h e a c t u a l motor,
i t s l o a d s , and i t s environments. The l e a s t q u e s t i o n a b l e approach, assuming
i t i s s u c c e s s f u l l y c a r r i e d o u t , i s t h e f u l l - s c a l e motor o v e r t e s t . Haw-
e v e r , t h e expense a s s o c i a t e d w i t h f u l l - s c a l e ICBM motor o v e r t e s t s can be
g r e a t due t o handling, i n s t r u m e n t a t i o n , and t e s t s e t u p , even when s u r p l u s
motors a r e a v a i l a b l e . Therefore, t h e f u l l - s c a l e t e s t i s n o t expected t o
b e an optimum approach f o r o b t a i n i n g d a t a i n s u f f i c i e n t q u a n t i t i e s f o r
s t a t i s t i c a l i n t e r p r e t a t i o n . The p r i n c i p a l uses of t h e f u l l - s c a l e motor
o v e r t e s t a r e t o : (1) Demonstrate o r v e r i f y more a p p l i c a b l e and economical
approaches, ( 2 ) v e r i f y t h e c r i t i c a l f a i l u r e mode s e l e c t i o n , and ( 3 )
i d e n t i f y f a i l u r e modes o t h e r than t h o s e p o s t u l a t e d a s t h e c r i t i c a l ones.

There a r e g e n e r a l l y fewer q u e s t i o n s i n r e l a t i n g f u l l - s c a l e
motor o v e r t e s t d a t a t o a c t u a l a p p l i c a t i o n s . Fewer a n a l o g i e s w i t h t h e
r e a l o p e r a t i o n a l c o n d i t i o n s a r e required assuming loads a r e adequately
d u p l i c a t e d by t h e t e s t . Also, t h e f u l l - s c a l e motor o f f e r s more f l e x i b i l i t y
i n load s i m u l a t i o n i n t h a t some o v e r t e s t s can be developed around e x i s t i n g
handling, s t o r a g e , and f i r i n g procedures. The f u l l - s c a l e motor can be
used i n a l l load s i m u l a t i o n s previously discussed p l u s i t can be modified
s l i g h t l y and f i r e d t o achieve an o v e r t e s t .

The u s e of f u l l - s c a l e motors i n a p r e s s u r e o v e r t e s t program

i s described i n Paragraph J of t h i s s e c t i o n .

b. Analog T e s t s

B a s i c a l l y , t h e r e a r e two choices i n s e l e c t i n g analog

t e s t devices. One i s p a r t i a l s i m u l a t i o n by partial-motor-analog t e s t s .
Several p a r t ial-motor analogs i n combinat ion provide confirmation of t h e
t h e o r e t i c a l a n a l y s i s o r , a l t e r n a t i v e l y , an experimental a n a l y s i s of t h e
motor. The second i s s u b s c a l e motor analogs i n which a l l c r i t i c a l regions
and loads of t h e f u l l - s c a l e motor may be simulated. Generally, p r a c t i c a l
l i m i t a t i o n s prevent t h e use of complete s u b s c a l e a n a l o g i e s of l a r g e
motors wherein a l l s i g n i f i c a n t f e a t u r e s w i t h r e s p e c t t o a l l p o t e n t i a l
f a i l u r e modes a r e simulated. Development of such an analog i s paramount
t o developing a new motor. Consequently, s u b s c a l e motor analogs ( o r
analog motors, a s they a r e o f t e n c a l l e d ) a r e r e a l l y p a r t i a l - m o t o r analogs.
They a r e u s u a l l y d i s t i n g u i s h e d from t h e p a r t i a l - m o t o r analogs i d e n t i f i e d
above i n t h a t they provide a three-dimensional analogy and, t h e r e f o r e ,
a more r e a l i s t i c r e p r e s e n t a t i o n of one f a i l u r e mode of a motor. I n t h i s
r e p o r t , when r e f e r e n c e i s made t o s u b s c a l e motor a n a l o g s , what i s meant
i s some t y p e of s u b s c a l e c y l i n d r i c a l device which could be a p a r t i a l -
motor analog emphasizing one o r more c r i t i c a l f a i l u r e modes.

Both b a s i c types of motor analogs a r e recommended f o r

ICBM s u r v e i l l a n c e and w e r t e s t programs. Both a r e considered v i t a l t o t h e
success of a p r e d i c t i v e s u r v e i l l a n c e program. Partial-motor analogs
s e r v e a s an economical device which can be t e s t e d i n l a r g e numbers t o
o b t a i n s t a t i s t i c a l l y s i g n i f i c a n t d a t a ( d e s c r i p t i v e of t h e e n t i r e motor
p o p u l a t i o n ) . Subscale motor analogs provide a n i n t e r m e d i a t e check
between t h e f u l l - s c a l e motor and t h e p a r t i a l - m o t o r analogs. The s u b s c a l e
motor analogs t o be n e c e s s a r i l y l i m i t e d i n number w i l l provide f a i l u r e
d a t a r e p r e s e n t a t i v e of t h e mean v a l u e of f a i l u r e p r o b a b i l i t y d i s t r i b u t i o n s ;
whereas p a r t i a l - m o t o r analogs w i l l d e f i n e t h e v a r i a t i o n s about t h e mean.

The design and a p p l i c a t i o n of p a r t i a l - m o t o r analog d e v i c e s

t o an o v e r t e s t program a r e presented i n Paragraph I of t h i s s e c t i o n .

D . PHASE I1 - OVERTEST AND INSPECTION

The f a i l u r e modes, o v e r t e s t approach, and t e s t v e h i c l e types were
d e f i n e d i n Phase I. The o b j e c t i v e of Phase I1 of t h e o v e r t e s t program
i s t h e design and conduct of t h e experimental program.

The major elements of Phase 11 a r e :

(1) Design of analog devices

(2) Instrumentation p l a n

(3) Motor s e l e c t i o n
(4) T e s t planning

(5) P r e t e s t and p o s t t e s t i n s p e c t i o n

(6) Overtest

(7) P r o p e l l a n t mechanical c h a r a c t e r i z a t i o n

Analog d e v i c e s a r e designed t o determine g r a i n i n t e g r i t y f o r t h e

l o a d s , environments, and l o c a t i o n s of concern. Analysis methods f o r t h e
motor and analog should be fundamentally t h e same. A p p l i c a b i l i t y of t h e
analogy i s based on t h e a n a l y s i s r e s u l t s . Absolute q u a n t i t a t i v e v a l u e s
obtained by t e s t i n g of t h e analogs w i l l not n e c e s s a r i l y be used d i r e c t l y
i n a s t r e n g t h a n a l y s i s ; t h e r e f o r e , t h e major concern should be t o d e f i n e
a d e v i c e t h a t w i l l possess t h e same type of s t r e s s f i e l d under load a s
t h e r e a l motor. Loading of t h e analog may n o t b e t h e same a s t h e motor.
For example, a t e n s i l e load may be a p p l i e d t o a p a r t i a l motor analog t o
g e n e r a t e a s t r e s s f i e l d which d u p l i c a t e s (according t o a n a l y s i s ) t h e motor
s t r e s s f i e l d i n t h e r e g i o n of i n t e r e s t . The success of t h e analog t e s t
program depends upon being a b l e t o o b t a i n a r e l a t i o n s h i p between analog
f a i l u r e loads and motor f a i l u r e loads. F a i l u r e of t h e analogs can then
be i n t e r p r e t e d i n terms of s t r u c t u r a l c a p a b i l i t y of t h e motor without
t h e b e n e f i t of a p r e c i s e f a i l u r e c r i t e r i o n f o r t h e p r o p e l l a n t .

The analog t e s t approach should be v e r i f i e d f o r t h e p a r t i c u l a r f a i l u r e

mode it i s supposed t o r e p r e s e n t . This should be one of t h e f i r s t s t e p s
i n Phase 11. V e r i f i c a t i o n involves demonstration t h a t t h e analog can be
made t o f a i l a s d e s i r e d , t h a t t h e f a i l u r e l e v e l s can be c o n f i d e n t l y
measured and a c o r r e l a t i o n w i t h motor f a i l u r e loads can be achieved.
Since a r e l a t i o n s h i p between motor and analog f a i l u r e loads i s being
sought, i t t h e r e f o r e becomes necessary t o accomplish a f u l l - s c a l e motor
t e s t e a r l y i n t h e program. I f p o s s i b l e , t h e analog t e s t specimen should
be made from p r o p e l l a n t removed from a l m e r - s t r a i n (undamaged) r e g i o n
of t h e f u l l - s c a l e motor which was o v e r t e s t e d .

I n checking out a p a r t i a l motor analog, i t may be necessary t o v e r i f y

a p p l i c a b i l i t y by checking i t a g a i n s t a b e t t e r ( b u t probably l a r g e r and
more expensive) analog v e h i c l e . This would occur when a f u l l - s c a l e motor
i s n o t a v a i l a b l e , t h e v e r i f i c a t i o n analog i s unacceptable f o r a large-
volume program and confidence i n t h e v e r i f i c a t i o n analog a s a s u b s t i t u t e
f o r t h e f u l l - s c a l e motor h a s a l r e a d y been e s t a b l i s h e d .

Following t h e development of t h e b a s i c analog d e v i c e , a s u f f i c i e n t

number of analog t e s t s should be performed f o r each f a i l u r e mode t o o b t a i n
a b a s i s f o r determining p r o b a b i l i t i e s of f a i l u r e .

The g e n e r a l approach t o Phase I1 has been presented thus f a r . I n

summary, i t involves d e s i g n of t h e a n a l o g , demonstration of t h e function-
ing of t h e d e v i c e i n checkout t e s t s , performance of a f u l l - s c a l e motor
( o r s u i t a b l e s u b s t i t u t e ) , o v e r t e s t t o v e r i f y t h e analog and e s t a b l i s h
c o r r e c t i o n s f o r i n t e r p r e t a t i o n . F i n a l l y , a p p l i c a t i o n i s made by over-
t e s t i n g t h e analog d e v i c e s t o o b t a i n s u f f i c i e n t d a t a t o s t a t i s t i c a l l y
e v a l u a t e p a r t i c u l a r f a i l u r e modes.

It i s important t o recognize t h a t i t u s u a l l y i s n o t p o s s i b l e t o
p e r f o n enough f u l l - s c a l e motor o v e r t e s t s t o o b t a i n a r e a l i s t i c statement
of g r a i n s t r u c t u r a l c a p a b i l i t y of t h e e n t i r e motor population. The
tendency t o overemphasize r e s u l t s from a s i n g l e o v e r t e s t should be
r e s i s t e d . The key t o a s u c c e s s f u l o v e r t e s t program i s i n a c h i e v i n g a
good economical analog device. Therefore, t h e g r e a t e s t s i g n i f i c a n c e of
t h e f u l l - s c a l e o v e r t e s t i s i n t h e v e r i f i c a t i o n of t h e analog.
 I n d i v i d u a l paragraphs i n t h i s r e p o r t a r e devoted t o t h e d i s c u s s i o n
of analog and f u l l - s c a l e o v e r t e s t s (Paragraphs I and J , r e s p e c t i v e l y ) .
A n a l y s i s (Paragraph G ) , i n s t r u m e n t a t i o n (Paragraph H ) , and p r o p e l l a n t
c h a r a c t e r i z a t i o n (Paragraph F ) , which a r e e s s e n t i a l t o t h e work performed
i n Phase 11, a r e a l s o p r e s e n t e d i n d i v i d u a l l y . T e s t p l a n s and o p e r a t i n g
procedures a r e c o n t a i n e d i n t h e t e s t s e c t i o n s .

The u s e f u l n e s s of o v e r t e s t technology depends upon t h e c a r e w i t h

which i t i s c a r r i e d o u t . T h e r e f o r e , i t i s e s s e n t i a l t h a t motors made
a v a i l a b l e t o t h e program a r e a p p l i c a b l e . They must be r e p r e s e n t a t i v e of
t h e p o p u l a t i o n of motors b e i n g e v a l u a t e d . T h e r e f o r e , t h e u s e of motors
t h a t have been r e j e c t e d f o r o t h e r purposes (which i s o f t e n t h e s i t u a t i o n )
should be e v a l u a t e d thoroughly t o avoid misleading r e s u l t s . Motors should
b e chosen f o r a n aging and s u r v e i l l a n c e program from s u b s e t s of o p e r a t i o n a l
motors based on t h e time of manufacture. P r o p e l l a n t should be withdrawn
from t h e production program a t t h e same times a s f u l l - s c a l e u n i t s f o r u s e
i n a n a l o g t e s t s and f o r c h a r a c t e r i z a t i o n t e s t s . G e n e r a l l y , i t w i l l be
d e s i r a b l e t o make p r o v i s i o n s f o r analog t e s t s and c h a r a c t e r i z a t i o n t e s t s
on p r o p e l l a n t s which a r e r e p r e s e n t a t i v e of s e v e r a l manufacturing t i m e s
i n a d d i t i o n t o t h o s e r e p r e s e n t e d by f u l l - s c a l e motors. Obviously, t h i s
i d e a l i s t i c p l a n cannot be a p p l i e d t o motors which a r e no l o n g e r i n produc-
t ion.

Motors, p r o p e l l a n t , and analog d e v i c e s from t h e v a r i o u s manufacturing

s u b s e t s should be s t o r e d and t e s t e d i n e x a c t l y t h e same way. A program
planned i n t h i s way w i l l make p o s s i b l e t h e s e p a r a t i o n of aging e f f e c t s
and changes r e s u l t i n g from manufacturing d i f f e r e n c e s . It a l s o provides
f o r f a i l u r e d a t a a p p l i c a b l e t o i n d i v i d u a l s u b s e t s of motors a s w e l l a s t h e
e n t i r e p o p u l a t i o n of o p e r a t i o n a l motors; a l t e r n a t i v e l y , a program d e f i n e d
i n t h i s way can i n d i c a t e whether t h e motor p o p u l a t i o n i s homogeneous
o r composed of d e f i n a b l e s u b s e t s .

For a new motor program t h e number of analog t e s t s and f u l l - s c a l e

t e s t s should be planned t o provide s t a t i s t i c a l s i g n i f i c a n c e . The a b s o l u t e
number w i l l depend upon t h e performance ( r e p e a t i b i l i t y , e t c ) of t h e t e s t
d e v i c e s and t h e p a r t i c u l a r p r o p e l l a n t . The t o t a l scope of t h e o v e r t e s t
program t o s u p p o r t a p r e d i c t i v e s u r v e i l l a n c e program should be d e f i n e d
i n Phase I1 immediately following t h e a c c e p t a n c e of analog d e v i c e s f o r
t h e program. It should be completed by no l a t e r t h a n t h e beginning of
t h e p r o d u c t i o n program.

It i s e s s e n t i a l t h a t each u n i t of t h e o v e r t e s t program be completely

c h a r a c t e r i z e d . The e x a c t c o n d i t i o n of f u l l - s c a l e u n i t s must b e known
p r i o r t o t e s t and t h e e f f e c t s of t h e o v e r t e s t must be a d e q u a t e l y docu-
mented. P r o p e l l a n t s from t h e e x a c t t e s t u n i t s must be c h a r a c t e r i z e d by
a p p r o p r i a t e mechanical p r o p e r t i e s t e s t s . A s e c t i o n i n g and t e s t p l a n must
be developed based on t h e s t r u c t u r a l response of i n d i v i d u a l motor d e s i g n s .
Ir. plartning t h i s phase of t h e o v e r t e s t program i t should be recognized
t h a t t h e o v e r t e s t motors must s e r v e a s a s o u r c e f o r p r o p e r t i e s t o be used
i n complementary a n a l y t i c a l s t u d i e s t o p r e d i c t s e r v i c e l i f e .
 S e c t i o n i n g and v i s u a l inspec t i o n i s t h e most, and perhaps t h e only,
r e l i a b l e means f o r determining t h e e x t e n t of f a i l u r e from a motor o v e r t e s t .
Other i n s p e c t i o n techniques t h a t a r e a v a i l a b l e a r e presented i n t h e f u l l -
s c a l e motor o v e r t e s t s e c t i o n of t h i s r e p o r t (Paragraph J ) .

E. PHASE I11 - INTERPRETATION

Phase I11 i s t h e i n t e r p r e t a t i v e phase. Not only w i l l i t be neces-

s a r y t o i n t e r p r e t each o v e r t e s t i n d i v i d u a l l y and t h e o v e r t e s t program
t o t a l l y , b u t t h e r e s u l t s must be i n t e r p r e t e d along w i t h complementary
p o r t i o n s of t h e p r e d i c t i v e s u r v e i l l a n c e program. The major i n t e r f a c e s
w i l l be w i t h f u l l - s c a l e motor f i r i n g s , environmental t e s t s during develop-
ment, and t h e o r e t i c a l a n a l y s e s . Motor s e r v i c e l i f e p r o j e c t i o n s should be
made w i t h due c o n s i d e r a t i o n of a l l of t h e s e p o t e n t i a l sources of informa-
tion.

I t i s t o be assumed t h a t t h e f u l l - s c a l e o v e r t e s t t o f a i l u r e of an
i n d i v i d u a l motor i s t h e a b s o l u t e base a g a i n s t which a l l o t h e r methods of
o b t a i n i n g t h e s t r u c t u r a l c a p a b i l i t y of t h a t p a r t i c u l a r motor a t t h e
p a r t i c u l a r time w i l l be evaluated. Subscale and p a r t i a l motor analogs and
a n a l y t i c a l r e s u l t s must be a d j u s t e d t o o b t a i n agreement w i t h t h e f u l l -
s c a l e u n i t . This assumption i s based on t h e premise t h a t a completely
s u c c e s s f u l o v e r t e s t i s achieved. Moreover, i t depends on a r e l i a b l e
c o r r e l a t i o n between analogs and f u l l - s c a l e u n i t s .

A second b a s i c assumption i s t h a t t h e s u b s c a l e and partial-motor

analog t e s t s supported by a minimum number of f u l l - s c a l e w e r t e s t s a r e
s u f f i c i e n t t o provide f a i l u r e l e v e l s versus age. To accomplish t h i s it
must be p o s s i b l e t o d i f f e r e n t i a t e between e f f e c t s r e l a t i n g t o d i f f e r -
ences i n motors (such a s w i t h d i f f e r e n t l o t s of p r o p e l l a n t ) and t h o s e
r e s u l t i n g from age.

The o v e r t e s t r e s u l t s a r e obtained f o r each motor s u b s e t a t s e l e c t e d

t e s t f r e q u e n c i e s over a period of time. The r e s u l t s w i l l be a v a i l a b l e
from p a r t i a l motor analog t e s t s i n terms of p r o b a b i l i t y of f a i l u r e a t
p a r t i c u l a r motor ages by each of t h e p r i n c i p a l f a i l u r e modes. I n
p r i n c i p l e , i t i s p o s s i b i e t o e x t r a p o l a t e t h e f a i l u r e p r o b a b i l i t i e s beyond
t h e age range of t h e d a t a by s t a t i s t i c a l methods f o r manipulating d a t a .
This approach depends upon p a s t r e s u l t s t o d e f i n e expected t r e n d s i n
f u t u r e r e s u l t s . T h e r e f o r e , changes i n t r e n d s cannot be accounted f o r .
Furthermore, i t i s very d i f f i c u l t t o p r o j e c t over a 10- t o 20-year period
based on r e s u l t s obtained i n t h e f i r s t y e a r o r two. I t i s recommended
t h a t a n a l y t i c a l techniques be a p p l i e d along w i t h a c c e l e r a t e d aging
mechanical p r o p e r t i e s d a t a t o p r e d i c t t h e aging t r e n d s . These t r e n d s
should t h e n be used t o e x t r a p o l a t e t h e mean v a l u e s of o v e r t e s t r e s u l t s
i n aging time t o determine when t h e motors a r e no longer a c c e p t a b l e f o r
s e r v i c e . Since t h e r e l i a b i l i t y of d i f f e r e n t motor s u b s e t s w i l l be known
a t i n c r e a s i n g a g e , i t i s s t a t i s t i c a l l y p o s s i b l e t o p r e d i c t , based on
t h e aforementioned e x t r a p o l a t i o n s , t h e r e l i a b i l i t y a s a f u n c t i o n of time
of a p a r t i c u l a r s u b s e t of motors o r t h e t o t a l motor population.
 The i n t e r p r e t a t i o n of t h e o v e r t e s t program i s aided by r e c o g n i t i o n
of t h e primary o b j e c t i v e s of each of t h e p r i n c i p a l elements of t h e program
which a r e b r i e f l y summarized below:

(1) F u l l - s c a l e motor o v e r t e s t -
A b a s i s f o r development and
e v a l u a t i o n of t h e analog devices

(2) Motor Analogs - To provide f a i l u r e d a t a r e p r e s e n t a t i v e of

p a r t i c u l a r s u b s e t s of motors w i t h r e s p e c t t o a g e - c r i t i c a l
f a i l u r e modes ( l o t s ) and aging times

(3) Analysis - A means of d e f i n i n g t h e analog d e s i g n , planning

t h e o v e r t e s t program, and e s t a b l i s h i n g t r e n d s f o r e x t r a p o l a -
t i o n of f a i l u r e r e s u l t s

Each element of t h e o v e r t e s t / p r e d i c t i v e s u r v e i l l a n c e program i s t o

be i n t e r p r e t e d i n l i g h t of t h e s e o b j e c t i v e s .

F . PROPELLANT CHARACTERIZATION

Mechanical c h a r a c t e r i z a t i o n of t h e p r o p e l l a n t i s r e q u i r e d t o d e t e r -
mine t h e e x a c t p r o p e r t i e s of p r o p e l l a n t used i n t h e analog and f u l l - s c a l e
motors. The d a t a a r e necessary f o r a n a l y s e s t o e v a l u a t e t h e adequacy of
t h e a n a l o g devices i n t h e analog development p o r t i o n s of Phase 11.
P r o v i s i o n s should be made f o r d a t a t o support analyses of a l l s p e c i f i c
f u l l - s c a l e motors and motor analogs a t v a r i o u s aging times. Analyses of
t h i s type may be required t o a s s u r e t h a t t h e r e l a t i o n s h i p between motor
f a i l u r e load and analog f a i l u r e load which i s e s t a b l i s h e d e a r l y , and
perhaps checked w i t h a small number of f u l l - s c a l e t e s t s l a t e r i n
t h e aging program, i s maintained w i t h age.

The p r o p e r t i e s a r e t o be obtained from s e c t i o n e d f u l l - s c a l e motors

and s p e c i a l c h a r a c t e r i z a t i o n c a s t i n g s . A s e c t i o n e d p l a n must be defined
f o r t h e motor. The c h a r a c t e r i z a t i o n c a s t i n g s should be i d e n t i c a l t o those
used i n preparing t h e analog devices o r , i f t h a t i s not p o s s i b l e , they
should be prepared a t t h e same time and should follow t h e same procedures
a s much a s p o s s i b l e .

It i s not p o s s i b l e t o d e f i n e a general s e c t i o n i n g plan t h a t would be

a p p l i c a b l e t o a l l motors. It w i l l be necessary t o o b t a i n t e s t samples
from l o c a t i o n s i n t h e motors t h a t have n o t been damaged by t h e o v e r t e s t .
Therefore, it i s mandatory t h a t t h e l o w - s t r a i n regions of t h e motor be
used f o r f u l l - s c a l e motor c h a r a c t e r i z a t i o n t e s t s . As a g e n e r a l guide,
Figures 6-2A and 6-2B d e p i c t a s e c t i o n i n g p l a n f o r the Minuteman 11, Stage:
111 motor.
 PROPELLANT TENSILE &
STRESS RELAX,
oO F I V E SUB-SCALE

2 lo0

4 PLACES

PROPELLANT TENSILE L800

& STRESS RELAX,
LOW STRAIN AREA

CASE BOND SAMPLES

V I E 4 A-A

<

F i g u r e 6-2B. Minuteman T h i r d S t a g e S e c t i o n i n g P l a n

6-20
 I f t h e o v e r t e s t and s e r v i c e l i f e program i s d i r e c t e d a t motors t h a t
a r e no l o n g e r i n p r o d u c t i o n , t h e only s o u r c e of p r o p e l l a n t i s l i k e l y t o be
motors withdrawn from t h e f o r c e . T h e r e f o r e , s u h s c a l e a n a l o g d e v i c e s a s
w e l l a s c h a r a c t e r i z a t i o n specimens must h e prepared from p r o p e l l a n t taken
from t h e f u l l - s c a l e motor.

Table 6-2 d e s c r i b e s t h e t e s t m a t r i x f o r c h a r a c t e r i z a t i o n of propel-

l a n t removed from t h e f u l l - s c a l e motor and f o r c h a r a c t e r i z a t i o n of propel-
l a n t used i n t h e manufacture of s u b s c a l e d e v i c e s . The t a b l e a l s o i d e n t i -
f i e s t e s t s t h a t should be performed a t c e r t a i n a g i n g times when n e i t h e r
a n a l o g n o r f u l l - s c a l e t e s t s would be performed. The o b j e c t i v e of t h e s e
i n t e r m e d i a t e t e s t s i s t o p r o v i d e a s u r v e i l l a n c e check between t e s t p e r i o d s .
Table 6-2 a l s o i n c l u d e s recommendations f o r a l i m i t e d c h a r a c t e r i z a t i o n
program on p r o p e l l a n t s u b s e t s n o t covered by a n a l o g t e s t i n g . Included
w i t h t h e t e s t i d e n t i f i c a t i o n and number of t e s t s i s a n e x p l a n a t i o n of t e s t
frequency and purpose of t h e t e s t s .

It i s assumed t h a t unaged p r o p e l l a n t mechanical p r o p e r t i e s w i l l be

a v a i l a b l e from a g e n e r a l c h a r a c t e r i z a t i o n program performed d u r i n g develop-
ment. That program should p r o j e c t t h e e f f e c t s of p a r t i c u l a r environments
on unaged p r o p e l l a n t s . I t is f u r t h e r assumed t h a t a n a c c e l e r a t e d a g i n g
program c o n s i s t e n t w i t h t h e c u r r e n t s t a t e of knowledge w i l l have been
completed o r w i l l be underway t o s u p p o r t t h e i n t e r p r e t a t i o n of o v e r t e s t
results.

G. ANALYSIS

S t a t e - o f - t h e - a r t a n a l y s i s methodology1 should be a p p l i e d t o d e f i n e
c r i t i c a l f a i l u r e modes i n t h e motor, a n a l y z e t h e motor a n a l o g a r t i c l e s
and r e l a t e them t o t h e r e a l motor, and t o perform a n a l y s i s of aged motors
based on p r e d i c t e d p r o p e r t i e s . The a n a l y s i s method should be k e p t t h e
same throughout t h e a g i n g program. I f s i g n i f i c a n t advancements i n a n a l y s e s
a r e made, they should be i n c o r p o r a t e d i n a d d i t i o n t o t h e b a s e l i n e approach,
o r a l l p r e v i o u s a n a l y s e s should be r e p e a t e d . This i s r e q u i r e d t o keep t h e
e x t r a p o l a t i o n procedure on a connnon b a s i s .

A t h e o r e t i c a l a n a l y s i s based on t h e p r o p e r t i e s p r e d i c t e d by a c c e l e r a t e d
a g i n g models should be performed c o v e r i n g t h e p e r i o d up t o t h e t i m e when
u n a c c e p t a b l e performance i s p r e d i c t e d , o r f o r t h e s p e c i f i e d s e r v i c e l i f e
whichever i s s h o r t e r . I n performing t h e a n a l y s i s i t should be recognized
t h a t t h e a p p l i e d l o a d s (e.g., P - t ) may change w i t h age a s w e l l a s t h e
properties. The a c c e l e r a t e d a g i n g a n a l y s i s i s used t o determine t r e n d s
i n f a i l u r e l o a d s f o r e x t r a p o l a t i o n of t h e o v e r t e s t r e s u l t s .

S t a t i s t i c a l a n a l y s e s of t h e o v e r t e s t r e s u l t s and t h e i n d i c a t e d t r e n d s
should be performed t o provide s e r v i c e l i f e r e s u l t s i n terms of r e l i a -
b i l i t y v e r s u s motor a g e and accounting f o r l o t d i f f e r e n c e s .
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 TABLE 6-2 (Cont)

PROPELLANT PHYSICAL TEST MATRIX SIX-YEAR OVERTEST MOTOR )S/N 33348)

. Test Conclusions
Samp1e Rate or
~ r e a / Temperature Pressure Displacement Type o f Number o f
Material Property (OF) (psi) (in. /nin o r % s t r a i n ) Specimen Specimens Purpose ,

. Low S t r a i n Tensile .
77 30 0 2 4
Area/Propellant Failure Failure
70 600 2 4 criteria
70 600 20 2 required f o r
70 300 20 2 analysis
70 300 200 2
70 600 200 2
70 3 00 45 0 1
77 3 00 450 8
70 300 7 00 2
70 300 2000 2
70 600 2000 2
70 600 1.2 Biaxial S t r i p 3
70 600 13.6 4
54 600 13.6 4
70 300 300 7
 TABLE 6-2 (Cont)
PROPELLANT PHYSICAL TEST MATRIX SIX-YEAR OVERTEST MOTOR (S/N 33348)

T e s t Conclusions
Sample Rate o r
Area / Temperature Pressure Displacement Type o f Number o f
Material Property (OF) (psi) (in./min or Z Strain) Specimen Specimens Purpose
TT P o r t A r e a / Tensile Uniaxial Compare w i t h
Propellant Failure 77 Ambient 2 Tension 2 propellant
l o t acceptance
data

77 3 00 2 4 Study e f f e c t
of superim-
posed p r e s s u r e

77 Ambient 20 2 Failure
77 3 00 20 2 criteria
77 300 200 2 required for
77 Ambient 2 00 4 analysis &
d i r e c t compa-
rison with
LRSLA d a t a

A f t Dome Area/ Relaxation Stress Required f o r

Propellant Modulus 70 Ambient 1% Relaxation 4 analysis
20 Ambient 1% 2

Tensile Uniaxial Failure

Failure 70 600 2 Tension 2 criteria
70 600 20 4 required f o r
70 3 00 200 2 analysis

A f t Dome Bond Shear 70 Ambient 0.2 Bond Shear 2 Criteria for

Area /Boot- Strength 70 Ambient 2.0 Specimen 2 secondary
F l a p Bond 70 300 2.0 (W/O P r o p e l l a n t ) 3 f a i l u r e mode
70 Ambient 20. 2
70 300 20. 2
70 600 20. 2
70 Ambient 2 00 3
70 600 200 2
70 3 00 2000 3
 TABLE 6-2 (Cont)

PROPELLANT PHYSICAL TEST MATRIX SIX-YEAR OVERTEST MOTOR (SIN 33348)

Test Conclusions
Rate o r
Area/ Temperature Pressure Displacement Type o f Number o f
Ibterial Property (OF) (psi) (in./min o r % Strain) Specimen Specimens Purpose
A f t Dome / Case Bond 70 6 00 2 Case Bond 3 Failure
Case Bond Shear 70 Ambient 20 S h o r t Shear 2 criteria for
Failure 70 300 20 Specimen 7 secondary
70 600 20 2 failure
70 3 00 200 6 mode
70 Ambient 2000 3

Case Bond 70 1000 20 Case Bond 3 Failure

T e n s i 1e 70 3 00 20 Tensile 2 criteria for
Failure 70 300 200 Specimen 2 secondary
70 600 200 3 f a i l u r e mode
70 6 00 2000 2

Cylindrical Case Bond 70 ln90 20 Case Bond 1 Failure

Section/ Tensi l e 70 3 00 200 Tensile 1 criteria for
Failure mode
H . INSTRUMENTATION

Considerable effort has been expended in the area of propellant

grain instrumentation. References 3, 4, and 5 include explanations of
the state-of-the-art for particular gages up to 1972. Additional work
is being conducted under the C-4 program and in the RPL program, "Develop-
ment of Improved Normal Stress Transducers for Propellant Grains" (UTC).
The instrumentation possibilities existing at the time of planning of an
overtest should be reviewed to determine which methods best fulfill the
requirements of the particular test.

Much of the recent work on instrumentation development has been

directed at embedded transducers. For motors or analogs that are manu-
factured especially for an overtest program, it may be possible to incor-
porate these developments to advantage. However, for motors that are
already built, the instrumentation is limited to that which can be mounted
external to the case or grain surfaces. The ICBM overtest program was
thus limited. Therefore, the discussion herein on instrumentation apply
to externally mounted (to the grain) instrumentation and generally to
pressure testing.

The major instrumentation challenge is finding a method for detecting

grain or case-bond failures during high-rate loading. Location of the
gage can be critical. A lag in response such as may result if a gage is
located an appreciable distance from the location of failure may cause
misleading results and errors in interpretation.

Failure detection is made difficult by not being able to incorporate

instrumentation applicable to failure detection at the time of manufacture.
Although grain failure has been observed repeatedly using only external
instrumentation, this area of overtest technology should be given high
priority and gage redundancy should be incorporated into the tests.
Instrumentation plans should recognize potential failures other than
those postulated.

In the following discussion consideration is given first to gages

for use inside the grain cavity. These are linear potentiometers, leaf
deflectometers, pressure gages, strain gages, event gages, and LVDT's.
Following these a discussion is given of instrumentation for use on the
exterior of the motor case, including strain gages, linear potentiometers,
LVDT's, and through-the-case gages.

This section on instrumentation applies in varying degrees to both

the subscale and full-scale motor overtests. It will be referred to in
the presentation of the analog test program, Paragraph I, and in the
full-scale overtest program, Paragraph J.
 1. Instrumentation f o r Use Inside the Grain Cavity

a. Linear Potentiometers

Reliable and accurate measurements of c a v i t y d e f l e c t i o n

may be obtained by the use of l i n e a r potentiometers. Special bracketry
can be f a b r i c a t e d t o mount potentiometers i n most g r a i n c a v i t y locations.

Special potentiometers must be f a b r i c a t e d f o r use i n a r e a s

where the expected d e f l e c t i o n i s equal t o o r g r e a t e r than 4/10 of the
i n i t i a l c a v i t y dimension. I f the expected d e f l e c t i o n i s l a r g e r than
314 of the i n i t i a l dimension, l i n e a r potentiometers cannot be used.

Potentiometers a r e r e s t r i c t e d t o locations where they w i l l

not be exposed t o l a r g e f l u i d impact forces r e s u l t i n g from the pressure
t r a n s i e n t , i.e., no gages can be i n s t a l l e d i n the center core i f the
motor i s t o be pressurized through a centerport.

An e l e c t r i c a l l y nonconductive f l u i d (gas o r mineral o i l )

must be used t o pressurize the motor,or l i n e a r potentiometers w i l l s h o r t
out.

A l l l i n e a r potentiometers must be provided with pressure

r e l i e f holes through the gage case t o prevent gage crushing or a f a l s e
r e t r a c t i o n of the gage.

I f gages ae t o be mounted i n a highly s t r e s s e d ( o r

s t r a i n e d ) a r e a , the mounting bracketry must not c r e a t e a s t r e s s concen-
t r a t i o n s u f f i c i e n t t o cause appreciable s t r e s s concentration. For, '
example, i f a gage i s bonded t o the propellant i n a c i r c u l a r centerport,
g r a i n cracking w i l l p r e f e r e n t i a l l y occur next t o the bond between the
propellant and the bracket.

I n addition t o t h e l i n e a r d e f l e c t i o n t h a t i s t o be measured,
angular d e f l e c t i o n s of g r a i n surfaces must be considered i n bracketry
design. (See Figure 6 - 3 f o r the e f f e c t of angular deflection.) Fig-
ures 6-4 and 6-5 i l l u s t r a t e a l i n e a r potentiometer used t o obtain grain
d e f l e c t i o n i n the o v e r t e s t program.

b. Leaf Def lectometers

Leaf deflectometers can be fabricated t o respond t o a

l a r g e r d e f l e c t i o n than i s possible within l i n e a r potentiometers. Appli-
cations a r e not limited t o stock gage s i z e s . Also, l e a f deflectometers
do not require vent holes since they a r e not contained i n a case. Figure
6-6 shows a leaf d e f l e c t m e t e r used i n the o v e r t e s t of a Minuteman 11,
stage 111 motor. Although leaf d e f l e c t m e t e r s have been used exten-
s i v e l y i n pressure o v e r t e s t s , the demonstrated accuracy and r e l i a b i l i t y
a r e not a s good f o r l i n e a r potentiometers. These deflectometers have a
F i g u r e 6-4. P o t e n t i o m e t e r Used i n Winn Slots
0.140 D I A
BREAK SHARP EDGE BOND ASSEMBLY T O
CSK FOR - --

SCREW HEAD PROPELLANT WITH DUCO CEMENT

/

0
0.510

0.25

INSTALLATION VIEW STAPLE R E M V E D

IN WING SLOT AFTER INS TALLA~ ION

- RED STRAIN GAGE

A I N TENSION

E
BLK
F - \STRAIN GAGE
IN COMPRES~ION
INS ID^
WHT

PCOlA-1OP (SR)
STANDARD TWO ARM
CONNECT ION

F i g u r e 6-6. S t r a i n Gage D e f lectometer

tendency t o f l u t t e r when exposed t o t r a n s i e n t f l u i d flow f o r c e s . A l l
o t h e r problems applying t o l i n e a r p o t e n t i m e t e r s a l s o apply t o l e a f
potentiometers.

c. P r e s s u r e Gages

The technology of b o t h c r y s t a l - t y p e and s t r a i n gage (dia-

phragm) p r e s s u r e gages i s w e l l advanced and many commercially a v a i l a b l e
a r t i c l e s w i l l s e r v e t h e needs of a p r e s s u r e o v e r t e s t .

P r e s s u r e gages should be i n s t a l l e d w i t h i n t h e motor c a v i t y

adjacent t o c r i t i c a l f a i l u r e regions i f possible. Especially i n l a r g e
motors, s i g n i f i c a n t p r e s s u r e drops occur d u r i n g t h e p r e s s u r e t r a n s i e n t ,
s o t h a t p r e s s u r e measured a t an end c l o s u r e may only be a n approximation
of t h e p r e s s u r e w i t h i n t h e motor c a v i t y .

The major problem w i t h p r e s s u r e gages i s "ringing" during

t h e h i g h - r a t e a p p l i c a t i o n of p r e s s u r e . "Ringing" responses have been
obtained on a l l p r e s s u r e gages used i n a l l h i g h - r a t e t e s t s . This makes
d a t a i n t e r p r e t a t i o n q u i t e d i f f i c u l t . Redundant gages a r e recommended.

d. Event Gages

Event gages have been developed e s p e c i a l l y f o r u s e i n

d e t e c t i n g g r a i n c r a c k s during p r e s s u r e t e s t s . B a s i c a l l y , they a r e con-
d u c t i v e c o a t i n g s w i t h mechanical p r o p e r t i e s s i m i l a r t o t h e p r o p e l l a n t .
The gage c r a c k s a s t h e p r o p e l l a n t c r a c k s t h u s i n t e r r u p t i n g an e l e c t r i c a l
circuit.

Event gages have proven t o g i v e good f a i l u r e information,

and a r e reasonably r e l i a b l e , when used on double-base o r composite propel-
l a n t s . Reference 6 i n c l u d e s a r e p o r t on t h e development of a n event gage
f o r t h e ICBM o v e r t e s t program; i t s a p p l i c a t i o n and performance c h a r a c t e r -
i s t i c s a r e d e s c r i b e d a l s o . Event gages can be i n s t a l l e d on any a c c e s s i b l e
l o c a t i o n . The a c q u i s i t i o n c i r c u i t i s simple and well-understood.

Conductive c o a t i n g event gages must be p r o t e c t e d from

p e n e t r a t i o n by t h e motor p r e s s u r i z i n g f l u i d . Also, gage l e a d w i r e s must
be p r o t e c t e d from damage by t h e f l u i d flow f o r c e s during t h e p r e s s u r e
transient .
Gage m a t e r i a l s have been proven on a l i m i t e d number of
propellants. They have n o t been used on XLDB p r o p e l l a n t s .

The connection of t h e leadwires t o t h e event gage i s t h e

most f r a g i l e p a r t of t h e system. F u r t h e r , t h e same problems of c r e a t i n g
s t r e s s c o n c e n t r a t i o n s on t h e p r o p e l l a n t ( s p e c i f i c a l l y a t t h e leadwire-
to-gage c o f i x c t i ~ n )e x i s t f o r event gages a s w e l l a s l i n e a r p o t s and
l e a f deflectometers.
 e. S t r a i n Gages

Elastomeric s t r a i n gages have been considered,.497 they

shaw promise f o r the measurement of p r o p e l l a n t s t r a i n s , although no
off-the-shelf device i s p r e s e n t l y a v a i l a b l e . Elastomeric s t r a i n gages
must be i n d i v i d u a l l y c a l i b r a t e d and then bonded i n t o place. There i s a
question a s t o t h e s t r e s s - c o n c e n t r a t i o n e f f e c t of t h e bond between t h e
p r o p e l l a n t and t h e gage.

Neither conventional wire nor f o i l s t r a i n gages a r e s u i t -

a b l e f o r use on p r o p e l l a n t . The e f f e c t i v e e l a s t i c modulus of t h e s e gages
i s t o o high r e l a t i v e t o t h a t of p r o p e l l a n t t o avoid d i s c o n t i n u i t y s t r e s s e s
and unbonding of t h e gage from t h e p r o p e l l a n t .

f. Determining t h e Extent of Grain Cracking

This i s n o t instrumentation per s e ; however, i t w i l l be

considered here a s i t i s a means of obtaining d a t a which a r e c r i t i c a l
f o r t h e i n t e r p r e t a t i o n of o v e r t e s t r e s u l t s .

The use of s o l u a b l e dye i n t h e p r e s s u r i z i n g f l u i d i s t h e

p r e f e r r e d method of determining t h e e x t e n t of g r a i n cracking caused by
h i g h - r a t e t e s t i n g . I t s use has been s u c c e s s f u l l y demonstrated on one
motor i n t h e LRSLA program. Extensive d i s s e c t i o n of a f a i l e d motor i s
necessary t o map t h e e x t e n t of c r a c k i n g , even i f dye i s used during t h e
t e s t . Unless exceptional a t t e n t i o n i s given t o ensure t h a t t h e motor
p i e c e s a r e handled c o r r e c t l y , cracking w i l l be extended during d i s s e c t i o n
and inspec t i o n o p e r a t i o n s .

Visual and NDT i n s p e c t i o n techniques have not been accept-

a b l e i n t h e p a s t programs f o r d e f i n i n g the e x i s t e n c e or e x t e n t of crack-
ing even i n small motors. X-ray of motors a f t e r h i g h - r a t e t e s t i n g i s
i n s u f f i c i e n t t o determine t h e e x t e n t of cracking. Dimensional i n s p e c t i o n
of t h e g r a i n c a v i t y b e f o r e and a f t e r h i g h - r a t e t e s t i n g i s i n s u f f i c i e n t
t o determine t h e e x t e n t of g r a i n cracking.

g. LVDT's
8
The LVDT has i n f i n i t e s e n s i t i v i t y , as opposed t o a linear
pot whose s e n s i t i v i t y i s l i m i t e d by t h e s i z e of w i r e used i n t h e r e s i s t a n c e
element. The moving p o r t i o n of an LVDT i s i n h e r e n t l y pressure-balanced.
It can be operated i n water o r o t h e r conductive medium. LVDT's should
b e s a t i s f a c t o r y t o r e p l a c e l i n e a r p o t s i n any o v e r t e s t a p p l i c a t i o n . How-
e v e r , t h e r e seems t o be no h i s t o r y of s u c c e s s f u l use i n a pressurized
s i t u a t i o n . The e f f e c t of p r e s s u r e on t h e c o i l element has not been
determined o r reported.
 2. E x t e r i o r Motor Instrumentat ion

a. S t r a i n Gages

S t r a i n gages a r e p r e f e r r e d a s t h e e x t e r n a l instrumentation
t o d e t e c t p r o p e l l a n t g r a i n f a i l u r e . Although s t r a i n gage response t o
f a i l u r e i s n o t a s p o s i t i v e a s t h a t of i n t e r n a l event gages, i t i s b e t t e r
t h a n i n t e r n a l o r e x t e r n a l potentiometers. BLH Type PA-3 p o s t y i e l d gages
have proven s a t i s f a c t o r y f o r measuring c a s e or dome s t r a i n s . They a l s o
respond t o changes i n c a s e s t r a i n s a s s o c i a t e d with g r a i n cracking.

S t r a i n gage d a t a , e s p e c i a l l y t h a t obtained on t h e domes,

i s not d i r e c t l y of value i n v e r i f y i n g t h e accuracy of t h e math model
used i n t h e g r a i n a n a l y s i s . They serve p r i m a r i l y a s f a i l u r e event gages.

b. Linear Potentiometers and LVDT's

This i s t h e p r e f e r r e d type of instrumentation f o r use i n

measuring d e f l e c t i o n a t one p o i n t on t h e c a s e r e l a t i v e t o another point.
D e f l e c t i o n d a t a a r e u s u a l l y more a p p l i c a b l e t o v e r i f y i n g t h e a n a l y s i s
model than s t r a i n gage d a t a .

Measurements made r e l a t i v e t o ground ( r a d i a l chamber

d e f l e c t i o n , f o r example) g e n e r a l l y include rigid-body motion of t h e
chamber, and, t h e r e f o r e , may be u n r e l i a b l e . Girth band measurements
have proved t o be l e s s s e n s i t i v e than c a s e g r a i n gages a s event i n d i c a t o r s
i n detecting grain failure.

c.- Through-to-Case Gages

Normal s t r e s s t r a n s d u c e r s , e i t h e r p i s t o n o r diaphragm type,

should be of value i n high-rate t e s t i n g although they have not been proven
a t t h i s time. They appear t o have p o t e n t i a l both f o r d e t e c t i n g g r a i n
f a i l u r e and f o r v e r i f y i n g t h e math model f o r g r a i n a n a l y s i s .

Consideration should be given t o simple f a i l u r e i n d i c a t o r s

f o r s p e c i a l types of c r i t i c a l f a i l u r e modes. For example, such a f a i l u r e
i n d i c a t o r ( a pipe c l e a n e r i n s e r t e d through a small hole d r i l l e d through
t h e dome i n t o t h e c a v i t y between i n s u l a t o r and shrinkage l i n e r ) was
s u c c e s s f u l l y used t o determine whether o r not a p a r t i c u l a r bonded i n t e r -
f a c e had debonded during t e s t .

I. ANALOG TESTS

1. Design of Analog Devices

Analog devices a r e e s s e n t i a l t o a complete o v e r t e s t program.

It i s economically impractical t o base a complete program on f u l l - s c a l e
t e s t s alone. Therefore, analog devices should be used t o o b t a i n f a i l u r e
d a t a r e p r e s e n t a t i v e of o v e r t e s t conditions. They should be performed i n
s u f f i c i e n t q u a n t i t y t o provide s t a t i s t i c a l s i g n i f i c a n c e t o o v e r t e s t
r e s u l t s . They may a l s o be a p p l i e d t o advantage t o v e r i f y methods of
a n a l y s i s which a r e , i n t u r n , used t o analyze t h e motor. Analog d e v i c e s ,
p a r t i c u l a r l y those termed s u b s c a l e motor analogs, a r e a l s o u s e f u l f o r
a s s e s s i n g instrumentation f o r use i n f u l l - s c a l e and analog t e s t programs.

It has been considered h e r e i n t o be beyond t h e scope of t h e

o v e r t e s t program t o develop f a i l u r e c r i t e r i a f o r p r o p e l l a n t s . Hcwever,
t h e analog devices considered h e r e , when t e s t e d t o f a i l u r e , may be used
t o e v a l u a t e p r e s e n t f a i l u r e c r i t e r i a a s w e l l a s s t r e s s a n a l y s i s techniques.

P a r t i a l motor analog devices may be used i n a program i n

development o r f o r a n a l y s i s of an o p e r a t i o n a l f o r c e . I n t h e l a t t e r c a s e ,
t e s t a r t i c l e s a r e prepared from p r o p e l l a n t removed from f u l l - s c a l e motors.

The design of t e s t devices f o r providing f a i l u r e d a t a and f o r

v e r i f i c a t i o n of s t r e s s a n a l y s e s should be capable of providing s t r u c -
t u r a l conditions analogous t o c o n d i t i o n s i n c r i t i c a l regions of f u l l - s c a l e
motors subjected t o c r i t i c a l loads e i t h e r s i n g l y o r i n combinations.

P r i n c i p a l loads of concern (see Paragraph C) a r e :

(a) I n t e r n a l pressure

(b) Cure and thermal shrinkage

(c) Acceleration ( a x i a l and t r a n s v e r s e )

(d) Vibration

As a g e n e r a l r u l e , t h e s e a r e t h e governing design loads f o r

ICBM motor g r a i n designs although a l l a n t i c i p a t e d prelaunch, launch, and
f l i g h t loads should be considered i n e v a l u a t i n g g r a i n s t r u c t u r a l i n t e -
g r i t y . The test must be capable of being performed a t d i f f e r e n t r a t e s
a s a p p r o p r i a t e t o t h e type of loadings. I n t e r n a l pressure simulation
t e s t s must involve high loading r a t e s ; a c c e l e r a t i o n loads a r e normally
a t intermediate t o low r a t e s (ABM a c c e l e r a t i o n s a r e an example of excep-
t i o n s ) and thermal loads a r e u s u a l l y l o w r a t e . The ICBM motors a r e
commonly provided w i t h c o n t r o l l e d environments; consequently, t h e tempera-
t u r e l i m i t s and c o o l i n g r a t e s a r e n o t high. The v i b r a t i o n loads a r e
dependent upon t h e imposed frequencies and may occur concurrently with
another load.

Analog devices must simulate s t r u c t u r a l c o n d i t i o n s a t c r i t i c a l

l o c a t i o n s i n t h e motor under i n v e s t i g a t i o n . To ensure s i m i l i t u d e , analog
devices must d u p l i c a t e t h e e x a c t c o n d i t i o n s a t t h e c r i t i c a l regions of t h e
motor o r c o n d i t i o n s must be a c c u r a t e l y s c a l e d i n t h e analog devices by
maintaining v a l u e s of s i g n i f i c a n t dimensionless parameters c h a r a c t e r i s t i c
of t h e f u l l - s c a l e u n i t . The s i g n i f i c a n t dimensionless q u a n t i t i e s can be
d e r i v e d by dimensional a n a l y s i s t a k i n g i n t o c o n s i d e r a t i o n t h e v a r i o u s
p h y s i c a l q u a n t i t i e s a f f e c t i n g t h e problem (Reference 1 ) .

Regions of concern t h a t o f t e n occur i n ICEM motors a r e c l a s s i -

f i e d i n t h e o r d e r of importance a s follows:

(a) Flap (shrinkage l i n e r ) terminations

(b) P r o p e l l a n t bond t e r m i n a t i o n s (on dome o r c y l i n d e r )

(c) Adapter t i p c o n c e n t r a t e d s t r a i n r e g i o n s (glass-epoxy

c a s e s w i t h p r o p e l l a n t bonded t o domes)

(d) Bore s u r f a c e . o n c i r c u l a r p o r t g r a i n d e s i g n s

(e) S l o t t i p s i n slotted-bore designs

a. P a r t i a l Motor A n a l o ~ s

T e s t specimens which s i m u l a t e bond t e r m i n a t i o n s , f l a p

t e r m i n a t i o n s and a d a p t e r t i p s t r a i n r e g i o n s have been used i n ICBM
development programs.9 Using t h i s approach, t h e same a n a l y t i c a l methods
a r e a p p l i e d t o t h e d e s i g n of t h e sample a s i s used f o r t h e r e g i o n of t h e
motor b e i n g simulated. Local d e s i g n f e a t u r e s , such a s i n s u l a t o r , propel-
l a n t , t e r m i n a t i o n geometry, e t c , a r e made i d e n t i c a l or s c a l e d t o t h e
motor. The s t r e s s - s t r a i n c o n d i t i o n i n t h e sample i s a d j u s t e d by varying
t h e method of loading o r geometric parameters of t h e t e s t specimen.
Loading i s o r d i n a r i l y accomplished by conventional l a b o r a t o r y equipment.
The specimen i s judged t o r e p r e s e n t t h e c r i t i c a l r e g i o n of i n t e r e s t i n
t h e motor when t h e s t r e s s - s t r a i n c o n d i t i o n s , determined by t h e a n a l y s i s ,
a r e equal. The s u c c e s s of t h i s approach depends upon being a b l e t o v a r y
enough parameters t o a c h i e v e t h e d e s i r e d s i m u l a t i o n . The response of t h e
t e s t specimen t o loading and t h e time of f a i l u r e i n i t i a t i o n can be d e t e r -
mined more d e f i n i t e l y than w i t h u s u a l methods of i n s t r u m e n t a t i o n r e q u i r e d
i n analog and f u l l - s c a l e motors because t h e d e s i r e d information can
o f t e n be determined by d i r e c t o b s e r v a t i o n .

The v a l i d i t y of t h e a n a l y s i s i s e v a l u a t e d on t h e b a s i s
of c a p a r i s o n of s t r a i n (deformations) measured i n t h e specimen t e s t s and
those c a l c u l a t e d i n t h e specimen f o r t h e p a r t i c u l a r s e t of loading
conditions. I f t h e a n a l y s i s i s v e r i f i e d by t h e specinen r e s u l t s , it i s
c o n s i d e r e d a c c e p t a b l e f o r a n a l y s i s of t h e motor r e g i o n being simulated.
By loading t h e specimen t o f a i l u r e , t h e a l l o w a b l e s t r e s s - s t r a i n condi-
t i o n f o r t h e r e g i o n of i n t e r e s t i s determined. The f a i l u r e p r e d i c t i o n
t h u s o b t a i n e d i s c o n s i s t e n t w i t h t h e a n a l y s i s approach and does n o t
depend upon a p r e c i s e knowledge of such undefined c o n s i d e r a t i o n s a s
n o n l i n e a r behavior o r f a i l u r e c r i t e r i a . Furthermore, combinations of
l o a d s can b e r a p i d l y s t u d i e d .
 Hercules has achieved success with t h e partial-motor simu-
l a t i o n approach i n development programs. C r i t i c a l s t r e s s regions of
motors which c o n t a i n composite and double-base p r o p e l l a n t s were simulated
with analog samples r e p r e s e n t a t i v e i n c r o s s s e c t i o n of f l a p terminations
and bond terminations. Agreement was achieved between t e s t and a n a l y t i c a l
r e s u l t s and a n a l y t i c a l p r e d i c t i o n s f o r t h e f u l l - s c a l e motor and t h e analog
device.

Figures 6-7 through 6-10 i l l u s t r a t e some t y p i c a l p a r t i a l

mote+ analog devices t h a t have been used by Hercules. A c u r r e n t AFRPL
program should provide a d d i t i o n a l d a t a on t h e design and a p p l i c a t i o n of
t h i s type of device.

There a r e various o t h e r devices which may be considered

a s analogs of s p e c i f i c motor conditions. The b i a x i a l - s t r i p t e s t i s a
reasonable r e p r e s e n t a t i o n of t h e centerbore s t r e s s condition and pro-
p e l l a n t s t r e s s e s i n the v i c i n i t y of bond terminations. The poker c h i p
t e s t i s an analog of case-bond a r e a s removed from termination regions.
The s c a r f j o i n t t e s t i s an attempt a t an analog of case-bond termination
regions i n t h a t i t provides a c o n d i t i o n of shear plus tension; however,
t h e shear plus t r i a x i a l tension condition does n o t reasonably simulate
any region of a r e a l motor. Various o t h e r t e s t devices provide d a t a
under v a r i o u s s t a t e s of s t r e s s none of which simulate a c t u a l motor s t r e s s e s
b u t which c o l l e c t i v e l y provide f a i l u r e d a t a on s t a t e - o f - s t r e s s e f f e c t s
u s e f u l i n motor s t r e n g t h a n a l y s i s .

Table 6-3 p r e s e n t s some of t h e p o s s i b l e p a r t i a l motor

analog devices t h a t have been used t o varying degrees i n motor g r a i n
a n a l y s i s . The f a i l u r e modes t o which they have been applied a r e l i s t e d
also.

b. Subscale Motor Analogs

A subscale motor analog should provide t h e types of

information normally d e s i r e d from a s t r u c t u r a l t e s t v e h i c l e (STV);
namely, (1) a n evaluation of t h e a n a l y s i s techniques, and (2) an experi-
mental a n a l y s i s of t h e motor design and s t r u c t u r a l i n t e g r i t y which
supplements t h e t h e o r e t i c a l a n a l y s i s . The c r i t i c a l s t r e s s and s t r a i n
conditions e x i s t i n g i n t h e r e a l motor must be simulated. The design
should be s u i t a b l e , w i t h minor modifications, f o r t e s t i n g under a
v a r i e t y of loading conditions. It should be l a r g e enough t o allow f o r
adequate instrumentation y e t not be p r o h i b i t i v e l y expensive o r d i f f i c u l t
t o handle. I f p o s s i b l e , i t should be small enough t o permit s t o r a g e of
s e v e r a l u n i t s f o r f u t u r e t e s t i n g i n a n aging program. Boundary condi-
t i o n s and r e s i d u a l e f f e c t s from c a s t i n g o r manufacturing which a r e
p e c u l i a r t o t h e scaled motor but not t h e r e a l motor should be known o r
eliminated i f possible. As i s shown i n the following discussion, i t i s
necessary t o compromise some of t h e s e o b j e c t i v e s .
 TABLE 6-3

PARTIAL MOTOR ANALOGS

Analog Type F a i l u r e Mode

Biaxial s t r i p Centerport cracking during storage

Biaxial s t r i p plus Centerport cracking during i g n i t i o n

'
superimposed p r e s s u r e

Biaxial s t r i p with center crack Crack p r o p a g a t i o n

Biaxial s t r i p with Void c r a c k i n g d u r i n g s t o r a g e

e l l i p t i c a l center hole

Biaxial s t r i p with center Void-induced c r a c k i n g d u r i n g burning

c r a c k p l u s superimposed
pressure

Poker c h i p Casebond f a i l u r e d u r i n g s t o r a g e

Case bond a n a l o g Casebond f a i l u r e d u r i n g s t o r a g e

( F i g u r e 6-7)

Uniaxial tension Grain c o l l a p s e during i g n i t i o n

. .
F l a p t e r m i n a t i o n c a s e bond F l a p t e r m i n a t i o n casebond f a i l u r e
sample (Ref 9 ) under p r e s s u r e

Adapter t i p a n a l o g Casebond f a i l u r e a t a d a p t e r t i p s
( F i g u r e 6-8)

Discontinuity analog Right a n g l e bond t e r m i n a t i o n f a i l u r e

sample ( F i g u r e 6-9)

Bond d i s c o n t i n u i t y sample B o o t - f l a p f a i l u r e under s h e a r ,

a x i a l s t r e s s , and p r e s s u r e
b
 The f i r s t problem i s i n dimensionally s c a l i n g t h e f u l l - s c a l e
motor such t h a t conditions a r e simulated i n t h e subscale u n i t . Conven-
t i o n a l laws governing dimensional a n a l y s i s r e v e a l t h a t t h i s i s n o t a good
approach t o s i m p l i f i c a t i o n of t h e problem. The f i r s t r u l e of dimensional
a n a l y s i s governs t h e number of dimensionless parameters which must be
d u p l i c a t e d i n s c a l i n g from one model t o another. The number i s equal t o
t h e d i f f e r e n c e between t h e number of physical q u a n t i t i e s a f f e c t i n g t h e
problem and t h e number of fundamental dimensions. I n t h e m a j o r i t y of
s t r u c t u r a l problems t h e r e i s an abundance of s i g n i f i c a n t physical quan-
t i t i e s , but only two fundamental dimensions (e.g., f o r c e and l e n g t h ) .
For t h e more general problem, f o r instance, t r a n s i e n t thermal s t r e s s i n
a v i s c o e l a s t i c m a t e r i a l , one can add only two more fundamental dimensions,
temperature and time. Following t h e Buckingham P i theorem, i t can be
shown t h a t t h e t r a n s i e n t thermal s t r e s s problem required n i n e d i f f e r e n t
nondimensional parameters f o r s c a l i n g . It i s impossible t o s c a l e f o r
equivalency of t r a n s i e n t thermal s t r e s s over a f i n i t e time period a t a
s i n g l e p o i n t i n t h e s i m p l i e s t of motor c o n f i g u r a t i o n s . However, f o r a
complete subscale analog of a motor, i t i s necessary t o simulate condi-
t i o n s a t s e v e r a l c r i t i c a l l o c a t i o n s . Even i f t h e t r a n s i e n t thermal
problem i s excluded, t h i s i s d i f f i c u l t t o achieve f o r general loading
requirements.

A lower l i m i t on physical dimensions i s imposed based on

instrumentation. The c r i t i c a l r e g i o n being instrumented f o r study i n a
subscale u n i t must be l a r g e r e l a t i v e t o t h e measuring device. It i s
u s u a l l y d e s i r a b l e t o instrument f u l l - s c a l e motors and analog devices with
t h e same types of gages. However, t h e c r i t i c a l region of t h e subscale
u n i t s a r e reduced r e l a t i v e t o t h e f u l l - s c a l e u n i t i n proportion t o t h e
dimensional reduction of t h e subscale u n i t . The gage s i z e cannot be
scaled downward; t h e r e f o r e , t h e gage s i z e r e l a t i v e t o t h e s i z e of t h e
c r i t i c a l r e g i o n i s g r e a t e r i n t h e analog. Since t h e gage w i l l i n d i c a t e
an average v a l u e over a f i n i t e l e n g t h and s t r a i n s / s t r e s s e s a r e normally
r a p i d l y varying i n t h e c r i t i c a l r e g i o n s , d i f f e r e n t r e s u l t s a r e t o be
expected from t h e gages. The d i f f e r e n c e i n r e s u l t s should i n c r e a s e a s
the d i f f e r e n c e i n analog motor and r e a l motor s i z e i s increased.

Some of t h e more c r i t i c a l problems a r e dependent upon

a c t u a l physical dimens ions and cannot be s c a l e d . For example, i n a f i b e r -
g l a s s c a s e t h e p r o p e l l a n t s t r a i n s near the p o l a r a d a p t e r (bonded domes)
depends upon t h e amount of f i b e r g l a s s outward motion r e l a t i v e t o t h e
a d a p t e r and n o t upon t h e l o c a l c a s e s t r a i n s . It may be impossible t o
o b t a i n e q u i v a l e n t r e l a t i v e d e f l e c t i o n s i n a subscale motor although t h e
s t r a i n s a r e d u p l i c a t e d . To s imulate a c t u a l f i b e r g l a s s , outward def lec-
t i o n s a t t h e adapter would impose unacceptable s t r a i n s on t h e m a t e r i a l .

An a d d i t i o n a l c o n s t r a i n t i s imposed i f t h e i d e n t i c a l c a s e
m a t e r i a l i s t o be used. Due t o t h e high s t r e n g t h of filament-wound
chambers, they can be made r e l a t i v e l y t h i n even i n l a r g e diameters. To
o b t a i n equal case s t r a i n s a t equal load a s t h e diameter i s reduced
r e q u i r e s t h a t t h e c a s e be made thinner. A point i s reached a t some
c r i t i c a l diameter t h a t the case thickness becomes l e s s than t h e thickness
of a l a y e r of f i b e r g l a s s . A t t h a t p o i n t , of course, the u n i t becomes
impossible t o build. Use of t h e same i d e n t i c a l case m a t e r i a l i s n o t
a b s o l u t e l y necessary i f m a t e r i a l modulus and thickness a r e scaled i n
inverse proportions t o one another.

It i s d e s i r a b l e t o d u p l i c a t e the deformation character-

i s t i c s of t h e domes t o simulate c r i t i c a l propellant s t r a i n conditions
i n p r o p e l l a n t g r a i n s which a r e bonded t o t h e domes. The growth character-
i s t i c s of a filament-wound case dome depend upon t h e filament winding
p a t t e r n and dome shape. Proper filament-wound case design r e q u i r e s
c a r e f u l matching of winding angle and dome shape t o ensure a balanced
s t r u c t u r e . The winding angle and thickness v a r i e s with r a d i a l p o s i t i o n
over t h e dome with a maximum a n g l e of go0, r e l a t i v e t o t h e motor a x i s ,
and maximum thickness occurs a t the g l a s s termination point on t h e
polar adapter. E l a s t i c constants such a s modulus and Poisson's r a t i o
a r e d i f f e r e n t i n d i f f e r e n t d i r e c t i o n s a s well a s a t d i f f e r e n t l o c a t i o n s .
Therefore, t o simulate a domed motor e x a c t l y r e q u i r e s a n exact scale-
down of t h e dome shape and t h e use of e x a c t l y t h e same winding angle a s
t h e f u l l - s c a l e motor. Use of anything o t h e r than the c o r r e c t dome shape
o r winding a n g l e w i l l give misleading ' r e s u l t s . This i s p a r t i c u l a r l y
t r u e near t h e dome-cylinder-skirt junction where due t o t h e l o c a l
increased s t i f f n e s s and abrupt change i n geometry t h e dome o r d i n a r i l y
r o t a t e s during p r e s s u r i z a t i o n r e l a t i v e t o the s k i r t . I n many f i b e r g l a s s
motors the dome d e f l e c t i o n may be inward upon i n i t i a l p r e s s u r i z a t i o n and
outward a s the dome assumes a new shape and pressure i s increased.
Unfortunately, i n many motor d e s i g n s , t h e dome i s a c r i t i c a l region of
t h e g r a i n design.

The n e c e s s i t y f o r t h e type of a t t e n t i o n t o d e t a i l pre-

sented i n t h e preceding discussion w i l l c o n t r i b u t e g r e a t l y t o c o s t s of
thoroughly-scaled motor analogs. Mandrels must be made f o r winding of
t h e cases (including t h e s k i r t s ) ; and c o n s i d e r a t i o n must be given t o
incorporating i n s u l a t o r s , f l a p s , e t c , which adequately represent these
components i n the f u l l - s c a l e motor. I n summary, development of an
a c c u r a t e l y scaled-dawn filament-wound motor case i s not g r e a t l y d i f f e r e n t
from development of t h e r e a l case.

Most of t h e d e s i r a b l e f e a t u r e s of a complete analog motor

can be achieved i n a c y l i n d r i c a l u n i t . (See Figure 6-11.) Conditions i n
t h e dome a r e n o t geometrically simulated, but the s i g n i f i c a n t conditions
of tension plus shear can be simulated by varying t h e bond termination
design parameters on t h e end of t h e c y l i n d r i c a l u n i t . S t r e s s / s t r a i n
f i e l d s a t t h e end a r e made s i m i l a r t o t h e f u l l - s c a l e dome bond termina-
t i o n point by matching a n a l y t i c a l r e s u l t s i n t h e analog and f u l l - s c a l e
motor. Conditions a t a l l o t h e r l o c a t i o n s ( i . e . , c y l i n d r i c a l f l a p
termination and centerbore) a r e scaled from the f u l l - s c a l e u n i t using
conventional s c a l i n g laws.
 Three s u b s c a l e motor a n a l o g t e s t v e h i c l e s a r e shown i n
F i g u r e 6-12. Fundamentally, t h e u n i t s a r e v e r y s i m i l a r . F a i l u r e s a r e
achieved a c c o r d i n g t o p l a n by v a r y i n g b a s i c s t r u c t u r a l parameters such
a s length-to-diameter r a t i o , f l a p l e n g t h , l i n e r t h i c k n e s s e s , c a s e t h i c k -
n e s s , f l a p l e n g t h , and web f r a c t i o n . Voids and c r a c k s o r s l o t t e d d e s i g n s
can be i n t r o d u c e d w i t h o u t s i g n i f i c a n t l y changing t h e b a s i c u n i t s .

S i n c e t h e ICBM Overtes t Technology Program emphasis was

d i r e c t e d a t t h e c e n t e r p o r t c r a c k i n g mode, spec i f i c d e t a i l s a r e provided
f o r t h e c e n t e r p o r t c r a c k i n g c y l i n d e r (CCC) t e s t v e h i c l e only. Informa-
t i o n p r e s e n t e d h e r e should b e used a s a g u i d e only a s s p e c i f i c d e s i g n
d e t a i l s w i l l depend upon t h e p a r t i c u l a r motor a p p l i c a t i o n .

A s was demonstrated i n t h e s u b j e c t program, t h e CCC can

be c a s t , manufactured by machining from f u l l - s c a l e motors, o r machined
from c a s t p r o p e l l a n t s l u g s . Thus, they a r e a p p l i c a b l e t o o p e r a t i o n a l o r
development motors.

The CCC i s a p r e s s u r e a n a l o g u n i t designed p r i m a r i l y f o r

s t u d i e s of t h e bore c r a c k i n g f a i l u r e mode. The b a s i c u n i t can b e extended
w i t h s l i g h t o r no m o d i f i c a t i o n t o long-term s h r i n k a g e o r case-bond f a i l u r e
(bore o r f l a p t e r m i n a t ions) modes. By i n t r o d u c t i o n of s u b s u r f a c e v o i d s
o r c r a c k s t h e u n i t c a n b e a p p l i e d t o f r a c t u r e mechanics s t u d i e s . Three
p r e s s u r e analog c o n f i g u r a t i o n s a r e shown by F i g u r e s 6-13 through 6-15.

Two of t h e c o n f i g u r a t i o n s a r e a p p l i c a b l e t o a wing s l o t
c r a c k i n g f a i l u r e mode and one a p p l i e s t o a n a f t c e n t e r p o r t debonding
f a i l u r e mode. A l l t h r e e models a r e g e n e r a l l y s i m i l a r t o c e n t e r p o r t
c r a c k i n g c l i n d e r s which have been p r e v i o u s l y used f o r f a i l u r e t h e o r y
a n a l y s i s . l8 The models c o n s i s t of c a r t r i d g e - l o a d e d p r o p e l l a n t g r a i n s i n
filament-wound c a s e s . Heavy metal end p l a t e s a r e bonded o n t o t h e ends
of t h e g r a i n , and t h e e n t i r e assembly i s h e l d t o g e t h e r w i t h t i e b o l t s .
The d i f f e r e n c e s between t h e t h r e e t y p e s of models is achieved w i t h v a r i o u s
c e n t e r b o r e d e s i g n s . One model t o t e s t t h e w i n g - s l o t c r a c k i n g - f a i l u r e
mode had a c i r c u l a r c e n t e r b o r e , and t h e o t h e r was a s t a r g r a i n con£ i g u r a -
t i o n of f o u r shallow s l o t s .

High-rate p r e s s u r i z a t i o n r a t e s have been achieved i n

l o a d i n g t h e s e models t o f a i l u r e . Models were instrumented w i t h s t r a i n
gages on t h e c a s e and w i t h event gages f o r d e t e c t i n g p r o p e l l a n t c r a c k i n g
on t h e g r a i n b o r e s u r f a c e s . Measured p r e s s u r e a t which model f a i l u r e
o c c u r r e d was i n good agreement w i t h a n a l y t i c a l p r e d i c t i o n s .

To a c h i e v e g r a i n c r a c k i n g a s d e s i r e d , i t i s n e c e s s a r y t o
produce high c e n t e r b o r e s t r a i n s w i t h o u t f i r s t inducing o t h e r f a i l u r e
modes. A f l e x i b l e c a s e i s , t h e r e f o r e , d e s i r e d t o a l l o w h i g h c e n t e r p o r t
s t r a i n s . This can be accomplished w i t h a law-modulus, h i g h - s t r e n g t h
c a s e m a t e r i a l a n d / o r a t h i n case. Very t h i n c a s e s a r e n o t expected t o
b e r e l i a b l e enough due t o t h e accuracy l i m i t of t h e manufacturing
techniques.
 RPD-150 PHENOLIC CASE (0.2 IN. THICK)

0.5 I N . UNBOND
(BETWEEN RUBBER

V45 RUBBER
(0.2 I N . THICK)
PROPELLANT

Figure 6-12a. Motor Analog f o r Centerport Cracking

Due t o Thermal Loading

RPD- 150 PHENOLIC CASE

PROPELLANT V45 RUBBER

IN. THICK)

Figure 6-12b. Motor Analog f o r Case Bond F a i l u r e Due t o

Thermal Loading

HERCULON-RAYON CASE

PROPELLANT

F i g u r e 6-12c. Motor Analog f o r Case Bond F a i l u r e Due t o I g n i t i o n

-
Figure 6-12. Motor Analogs

6-47
 MATL: TRANSPARENT

UBAS SEMBLY

SUBASSEMBLY

END PLATE

Figure 6-15. Instrumented Aft Center Port Failure Mode Model

 Rigid end p l a t e s bonded t o t h e g r a i n and held together w i t h
r i g i d t i e b o l t s i s a method of producing p l a n e - s t r a i n conditions. Many
motors have bonded ends making t h e s t r e s s c o n d i t i o n n e a r l y t h a t of plane
s t r a i n ; hawever, some a x i a l s t r a i n s a r e f e l t . D i f f e r e n t end p l a t e arrange-
ments can be achieved which w i l l allow varying amounts of a x i a l s t r a i n i n
t h e subscales t o reproduce t h e motor hoop-to-axial s t r a i n r ~ t i o . The
design should be analyzed by state-of - t h e - a r t a n a l y s i s methods and t h e
c e n t e r p o r t s i z e d t o achieve s t r a i n s r e p r e s e n t a t i v e of t h e r e a l motor.

A major problem i s t o keep t h e c e n t e r p o r t l a r g e enough

t o allow i n s t a l l a t i o n of necessary instrumentation while making i t small
enough t o produce d e s i r e d s t r a i n s thus permitting c e n t e r p o r t cracking t o
t a k e p l a c e b e f o r e end p l a t e debonding o r o t h e r f a i l u r e modes t o occur.
The s m a l l e s t c i r c u l a r c e n t e r p o r t diameter allowable from t h e instrumenta-
t i o n standpoint i s approximately l inch.

S l o t t e d g r a i n s r e s u l t i n higher s u r f a c e s t r a i n s and a r e
more r e p r e s e n t a t i v e of some motors than t h e c i r c u l a r bore. The s l o t t e d
g r a i n s should a l s o be constrained t o a t l e a s t a 1-inch diameter centerbore
and r e l a t i v e l y wide s h a l l m s l o t s f o r instrumentation purposes. The
s l o t t e d designs produce s i g n i f i c a n t l y higher s t r a i n s than t h e c i r c u l a r
c e n t e r p o r t models, but they a r e more d i f f i c u l t t o machine.

A bore s u r f a c e cracking analog r e q u i r e s some type of s t r e s s

r e l i e f t o prevent end bonding. For p r o p e l l a n t s of moderate s t r e n g t h an
end s t r e s s r e l i e f g r o w e of t h e type s h w n i n Figure 6-16 w i l l s u f f i c e .
For s t r o n g e r p r o p e l l a n t s i t may be necessary t o r e s o r t t o end f l a p s a s
was done i n t h e ICBM Overtest Technology Program. Thus, i t can be seen
t h a t t h i s subscale u n i t can be used f o r evaluation of c e n t e r p o r t cracking
o r c e n t e r p o r t end termination debonding depending on t h e design a t the
end p l a t e s .

The following d e s c r i p t i o n a p p l i e s t o models used i n t h e

s u b j e c t program. With some modification, i t should apply t o c e n t e r p o r t
f a i l u r e mode a n a l y s i s of o t h e r p r o p e l l a n t types.

The model cases were filament-wound of Herculon/rayon

(50/50) f i b e r and C7/W (50/50) r e s i n , employing only hoop windings. After
winding and c u r e t h e cases were machined t o a w a l l thickness of 0.080 inch
nominal, except f o r a 0.75-inch length a t each end which was l e f t t h i c k e r
t o f i t t h e grooves i n t h e end p l a t e s . Each c a s e was pressure t e s t e d t o
determine i t s deformation-versus-pressure c h a r a c t e r i s t i c s .

The propellant g r a i n s were machined from aged p r o p e l l a n t ,

taken from a f u l l - s c a l e motor. I n o t h e r programs t h e subscale u n i t s have
been machined from s l u g c a s t i n g s . It should a l s o be p o s s i b l e t o c a s t
d i r e c t l y i n t o t h e subscale case. Each g r a i n was machined t o a s l i p f i t
i n t o i t s assigned case. The centerbore and s t r e s s r e l i e f grooves were
machined i n t h e c i r c u l a r bore model w i t h conventional b o r i n g t o o l s . To
f a b r i c a t e a s l o t t e d model, a c i r c u l a r bore was f i r s t machined and then
t h e model was s e t up on a m i l l i n g machine and a d r i l l guide was i n s e r t e d
i n t o t h e c e n t e r b o r e . A f l a t - p o i n t e d d r i l l was then a l i g n e d by u s e of t h e
d r i l l guide, and one s l o t was d r i l l e d out from end-to-end of t h e g r a i n .
The g r a i n was indexed 90' and t h e second s l o t was d r i l l e d , and s o f o r t h .
The g r a i n was r e t u r n e d t o t h e l a t h e , and a s t r e s s r e l i e f gr'oove was c u t
i n each end using a formed t o o l on a boring bar. Each g r a i n was then
bonded i n t o i t s c a s e w i t h EA 913.1 adhesive and allowed t o c u r e f o r
48 hours a t ambient c o n d i t i o n s .

Event gages were t h e n i n s t a l l e d i n t h e g r a i n c e n t e r b o r e .

C i r c u l a r bore models were equipped w i t h one event gage inboard from t h e
s t r e s s r e l i e f groove a t each end of t h e g r a i n . An event gage was
i n s t a l l e d a t each end of t h e model and a t t h e c e n t e r of t h e model i n
each groove of t h e s l o t t e d models f o r a t o t a l of 12 gages i n each s l o t t e d
model.

End p l a t e s were bonded onto t h e model u s i n g EA 913.1

adhesive. The t i e r o d s and n u t s were i n s t a l l e d and l i g h t l y t i g h t e n e d
u n t i l t h e adhesive was observed squeezing out from between t h e end p l a t e
and t h e g r a i n . The end p l a t e bond was then cured f o r 48 hours a t ambient
c o n d i t i o n s . The assembled instrumented models a r e s h m i n F i g u r e s 6-13
and 6-14.

2. I n s t r u m e n t a t i o n of Analogs

I n s t r u m e n t a t i o n i s d i s c u s s e d i n Paragraph H f o r both f u l l -
s c a l e and s u b s c a l e o v e r t e s t u n i t s . F i g u r e 6-13 shows instrumentati'on and
l o c a t i o n s f o r a t y p i c a l s u b s c a l e p r e s s u r e o v e r t e s t . The model was i n s t r u -
mented w i t h 12 hoop s t r a i n gages. I n t e r n a l event gages and c e n t e r b o r e
d e f l e c t o m e t e r s were provided f o r i n t e r n a l measurements. The l e a f
d e f l e c t o m e t e r assembly, c o n s i s t i n g of two l e a f d e f l e c t o m e t e r s mounted on
a rod w i t h t h e c e n t e r b o r e and supported on bushings screwed i n t o t h e end
p l a t e s , i s shown on F i g u r e 6-17. Leadwires f o r t h e i n t e r n a l instrumenta-
t i o n were passed through t h e end p l a t e and t h e high p r e s s u r e p i p i n g , and
f i n a l l y out of t h e p r e s s u r i z e d volume through a p o t t e d n i p p l e . This
leadwire system of n e c e s s i t y occupies p a r t of t h e f l u i d piping volume
and i s exposed t o t h e f o r c e s a s s o c i a t e d w i t h t h e movement of t h e pres-
surizing fluid.

Due t o t h e v a r i e d d e s i g n s f o r p a r t i a l motor a n a l o g s , no p a r t i -
c u l a r r u l e s f o r i n s t r u m e n t a t i o n a r e o f f e r e d . However, t h e p a r t i a l motor
analog a r t i c l e s a r e u s u a l l y simple d e v i c e s , and no s p e c i a l i n s t r u m e n t a t i o n
beyond t h a t t o measure loads and d e f l e c t i o n s i n a conventional t e s t machine
i s required. I n some i n s t a n c e s i t may be necessary t o o b t a i n more
d e t a i l e d s t r a i n r e s o l u t i o n , i n which c a s e , o p t i c a l methods may be employed.
Following t h e movement of g r i d l i n e s s c r i b e d on t h e t e s t sample, v i s u a l l y
o r p h o t o g r a p h i c a l l y , during t h e t e s t i s one way of g e t t i n g s t r a i n measure-
ments. A more p r e c i s e method i s t h e Moire f r i n g e experimental s t r a i n
a n a l y s i s technique. 1
 3. Test Operations

The h i g h - r a t e p r e s s u r i z a t i o n w e r t e s t was performed on subscale

motor analogs t o study g r a i n cracking i n t h e Minuteman 11, s t a g e I11
motor. Test procedures generated i n t h a t program a r e provided here as an
a i d i n planning s i m i l a r o v e r t e s t s r e l a t i v e t o o t h e r motors. No attempt
i s made i n t h i s r e p o r t t o d e f i n e methods a p p l i c a b l e t o o t h e r o v e r t e s t
approaches o r types of loading which may be e q u a l l y a s u s e f u l i n p a r t i -
c u l a r a p p l i c a t i o n s . The subscale u n i t t e s t s on t h e ICBM o v e r t e s t program
a r e reported i n Reference 6.

Figure 6-18 shows t h e assembled test arrangement f o r t h e ICBM

a v e r t e s t program subscale models, and Figure 6-19 g i v e s a c l o s e r view of
t h e model i t s e l f . This system i s capable of applying t e s t pressures up
t o 2500 p s i a t very high r a t e s . The arrangement i s comprised of a gas
accumulator, h i g h - r a t e v a l v e , t h r o t t l i n g valve, and high-pressure hose
connected t o both ends of t h e t e s t model. I n performing t h e h i g h - r a t e
t e s t , t h e model and piping i n f r o n t of t h e h i g h - r a t e valve a r e f i l l e d w i t h
nonconductive mineral o i l . The accumulator i s charged w i t h n i t r o g e n gas.
The high-rate valve s e p a r a t e s t h e p r e s s u r i z e d g a s and t h e ambient-pressure
o i l u n t i l s t a r t of t h e t e s t . A s the high-rate v a l v e i s opened, i t r a p i d l y
admits t h e pressurized g a s , thus p r e s s u r i z i n g t h e o i l and model t o t h e
p r e s e t pressure determined by e q u i l i b r i u m of t h e t o t a l system volume.

This two-phase p r e s s u r i z a t i o n system incorporates many of the

e s s e n t i a l f e a t u r e s of t h e motor high-rate h y d r o t e s t system. Testing of
t h e model s e r v e s a d d i t i o n a l l y a s a small-scale checkout f o r t h e motor
o v e r t e s t system. Maxirmun t e s t p r e s s u r e i s c o n t r o l l e d by t h e p r e s s u r e t o
which t h e accumulator i s charged, and t e s t p r e s s u r i z a t i o n r a t e i s con-
t r o l l e d by t h e t h r o t t l e valve s e t t i n g . The t h r o t t l e valve s e t t i n g s a r e
e s t a b l i s h e d by checkout runs i n which a piece of pipe, having t h e same
volume a s t h e model centerbore c a v i t y , i s s u b s t i t u t e d f o r t h e model.
However, i f the pipe i s much s t i f f e r than t h e model, t h i s must be accounted
f o r o r t h e checkout runs w i l l g i v e misleading r e s u l t s .

Standard procedures must be prepared and followed during pre-

p a r a t i o n , t e s t i n g , and i n s p e c t ion of subscale u n i t s .
Appendix A includes
procedures t h a t a r e a p p l i c a b l e t o p r e s s u r e t e s t i n g of subscale p a r t i a l -
motor analogs. Additional d e t a i l s concerning t e s t equipment and t e s t
s e t u p a r e given i n Reference 6, which i s t h e t e c h n i c a l r e p o r t on t h e
analog t e s t phase of t h e ICEPl Overtest Technology Program.

J. FULL-SCALE MQTOR TESTS

F u l l - s c a l e motors a r e o v e r t e s t e d t o o b t a i n information t h a t cannot

be con£i d e n t l y obtained otherwise. A l l questions regarding properties,
a n a l y s i s , f a i l u r e c r i t e r i a , e t c , a r e eliminated i n d e f i n i n g minimum
s t r u c t u r a l c a p a b i l i t y of a p a r t i c u l a r motor by a s u c c e s s f u l o v e r t e s t , As
previously noted, t h e primary disadvantage of the f u l l - s c a l e t e s t i s i t s
expense. Also, much planning and c a r e i s involved i n achieving a success-
f u l and a p p l i c a b l e o v e r t e s t . Relating r e s u l t s from a few t e s t s t o a l a r g e
motor population i s a key problem of i n t e r p r e t a t i o n .

The major r e s u l t s t o be obtained from f u l l - s c a l e motor w e r t e s t s

a r e : (1) Confirmation of c r i t i c a l f a i l u r e modes, (2) v e r i f i c a t i o n of
a n a l y s i s , and (3) confirmation and/or understanding of analog devices.
Results from an individual t e s t c o n t r i b u t e t o t h e d a t a t o be used f o r
s t r u c t u r a l r e l i a b i l i t y p r e d i c t i o n s , but due t o t h e l i m i t e d number per-
formed, t h i s i s not s u f f i c i e n t j u s t i f i c a t i o n f o r t h e t e s t .

The p r i n c i p a l elements of the f u l l - s c a l e o v e r t e s t a r e :

(1) Motor s e l e c t i o n s

(2) Analysis

(3) Instrumentation

(4) Test planning and execution

(5) Inspec t i o n

These elements a r e presented, g e n e r a l l y , i n o t h e r paragraphs of t h i s

r e p o r t , v i z , D , E , F, and G. The i n t e n t i n t h i s paragraph i s t o r e l a t e
them more s p e c i f i c a l l y t o t h e f u l l - s c a l e o v e r t e s t program.

The f u l l - s c a l e w e r t e s t methodology i n the ICBM o v e r t e s t program

was l i m i t e d t o motors t h a t were a v a i l a b l e from f i e l d use. Consequently,
t h e technology discuseion i n t h i s s e c t i o n i s l i m i t e d . Also, t h e d i s -
cussion i s primarily d i r e c t e d t o i g n i t i o n - r a t e p r e s s u r i z a t i o n o v e r t e s t s .
Although t h i s i s very probably a c r i t i c a l load, o t h e r c r i t i c a l loading
conditions (Paragraph C) should be recognized a 1so.

The following subparagraphs a r e devoted t o considerations p r i o r t o

t h e t e s t , t e s t instrumentation, and t e s t performance. These subpara-
graphs should be considered along with o t h e r major paragraphs of t h i s
r e p o r t i n d e f i n i n g a n o v e r t e s t program.

1. Preliminary Considerations

The f u l l - s c a l e motor w e r t e s t i s b a s i c t o . t h e concept of

o v e r t e s t technology a p p l i c a b l e t o a p r e d i c t i v e s u r v e i l l a n c e program. By
t h e f u l l - s c a l e o v e r t e s t , confidence i s e s t a b l i s h e d f o r the more economical
a n a l y t i c a l and subscale analog t a s k s which a r e a l s o necessary i n g r e d i e n t s
of the o v e r t e s t program. S p e c i f i c o b j e c t i v e s of the f u l l - s c a l e o v e r t e s t
a r e presented i n Paragraph C.
 Unlike t h e analog a r t i c l e s , t h e f u l l - s c a l e d e s i g n i s p r e d e t e r -
mined i n t h a t it must be r e p r e s e n t a t i v e of t h e a c t u a l motor design. For
o p e r a t i o n a l motors, t h e o v e r t e s t sample is removed d i r e c t l y from t h e
o p e r a t i o n a l f o r c e . For motors i n development o r production, they can be
a s s i g n e d s p e c i f i c a l l y t o t h e o v e r t e s t program. I n some r a t e i n s t a n c e s ,
motors have been planned a s s t r u c t u r a l v e h i c l e s p r i o r t o t h e i r manufacture;
consequently, i t was p o s s i b l e t o i n c o r p o r a t e s p e c i a l i n s t r u m e n t a t i o n u s e f u l
f o r o v e r t e s t purposes.

There i s a g r e a t d e s i r e i n a l a r g e motor program t o u s e l i n e -

l o s s motors i n aging and s u r v e i l l a n c e programs. This philosophy i s
expected t o p r e v a i l i n expanding t h e u s e of o v e r t e s t technology. Funda-
mentally, t h e r e i s nothing wrong w i t h u s i n g motors t h a t have been r e j e c t e d
f o r f i e l d use i f t h e reason f o r r e j e c t i n g them does n o t a f f e c t t h e f a i l u r e
mode under i n v e s t i g a t i o n . This p o i n t r e q u i r e s c a r e f u l c o n s i d e r a t i o n i n
choosing a motor which may perhaps i n f l u e n c e t h e conduct of a long-duration
p r e d i c t i v e s u r v e i l l a n c e program.

Another c o n s i d e r a t i o n i n t h e use of l i n e - l o s s motors i s t h a t

they may n o t r e p r e s e n t p a r t i c u l a r l o t s o r motor s u b s e t s where such
d i f f e r e n c e s a r e important. D i f f e r e n c e s t h a t should be considered important
a r e p r i m a r i l y t h o s e t h a t may r e s u l t i n a change i n t h e o r d e r of f a i l u r e
mode c r i t i c a l i t y .

I n summary, f u l l - s c a l e motors used i n t h e o v e r t e s t program must

be r e p r e s e n t a t i v e of t h e d e s i g n and manufacturing procedures of t h e motor
population under i n v e s t i g a t i o n .
I d e a l l y , a f u l l - s c a l e u n i t should be t e s t e d f o r each c r i t i c a l
f a i l u r e mode. However, f a i l u r e by one mode ( t h e most c r i t i c a l ) i s l i k e l y
t o a l t e r t h e r e s u l t s p e r t a i n i n g t o o t h e r modes. I f more than one c r i t i c a l
f a i l u r e mode i s i d e n t i f i e d and t h e i r margins of s a f e t y i n d i c a t e s i m i l a r
f a i l u r e l e v e l s , p o s s i b i l i t i e s of f a i l u r e by e i t h e r mode should be recogn-
ized i n t h e program planning.

D e t a i l e d s t r u c t u r a l a n a l y s e s should be performed on s p e c i f i c
motors t o be o v e r t e s t e d . P r o p e r t i e s f o r u s e i n t h e a n a l y s i s should be
obtained by s e c t i o n i n g and t e s t i n g of p r o p e l l a n t from l a w - s t r a i n r e g i o n s
of t h e motor and/or a p p l i c a b l e p r o p e l l a n t samples taken a t t h e t i m e of
manufacture. Case growth behavior under p r e s s u r e should be defined f o r
t h e p a r t i c u l a r motor case. This i s u s u a l l y s t a n d a r d procedure a s s o c i a t e d
w i t h hydroproof p r i o r t o use. However, i n s t r u m e n t a t i o n i n a d d i t i o n t o
normal hydroproof i n s t r u m e n t a t i o n may be r e q u i r e d . Other l o a d s should be
p r e d i c t e d f o r each of t h e c r i t i c a l f a i l u r e modes and t h e e x a c t loading
program imposed on t h e t e s t motor. It i s necessary t o d e f i n e ( t o t h e e x t e n t
p o s s i b l e w i t h t h e p r e s e n t s t a t e of a n a l y s i s knowledge) t h e p r e d i c t i v e s t r u c -
t u r a l performance of t h e s p e c i f i c motor during t h e o v e r t e s t . These r e s u l t s
can then be c o r r e l a t e d w i t h t h e o v e r t e s t r e s u l t s t o e s t a b l i s h r e l a t i o n s h i p s
between f u l l - s c a l e experiment and a n a l y s i s . R e s u l t s from t h e analog t e s t s
performed on p r o p e l l a n t r e p r e s e n t a t i v e of t h e o v e r t e s t motor a r e s i m i l a r l y
c o r r e l a t e d w i t h t h e f u l l - s c a l e r e s u l t s t o d e f i n e f u l l - s c a l e motor-to-
analog r e l a t i o n s . The s u b j e c t of a n a l y s i s i s addressed i n Paragraph G of
t h i s report.
 2. Instrumentation of F u l l - S c a l e Overtest Motors

A general d i s c u s s i o n of instrumentation a p p l i c a b l e t o h i g h - r a t e
p r e s s u r i z a t i o n a v e r t e s t s was presented i n Paragraph H and, t h e r e f o r e , w i l l
not be repeated here. It cannot be overemphasized, however, t h a t i n s t r u -
mentation should be planned t o i d e n t i f y a s p r e c i s e l y a s p o s s i b l e t h e e x a c t
load and l o c a t i o n a t which f a i l u r e i s i n i t i a t e d i n a given a v e r t e s t . P a r t i -
c u l a r l y f o r f u l l - s c a l e motors, t h e f a i l u r e loads must be defined w i t h a
minimum of t e s t s . I n p r i n c i p l e , i t should be p o s s i b l e t o t e s t t o v a r i o u s
loads and examine t h e motor a f t e r w a r d , t o determine which loads d i d and
d i d not cause f a i l u r e . By p r o g r e s s i v e l y i n c r e a s i n g t h e l o a d , o r by
b r a c k e t i n g , t h e f a i l u r e l e v e l i s determined by examination, and f a i l u r e
d e t e c t i o n during t h e t e s t is n o t a problem. However, t h e expense of such
a program is p r o h i b i t i v e w i t h ICBM motors.

The Minuteman, s t a g e I11 i s used t o t y p i f y instrumentation of

a f u l l - s c a l e I C W motor. Modifications t o t h i s p l a n w i l l be necessary
based on t h e motor design and c r i t i c a l f a i l u r e modes.

The motor e x t e r n a l instrumentation l o c a t i o n s a r e shown i n

F i g u r e 6-20. Eight s t r a i n gages were i n s t a l l e d on t h e c y l i n d r i c a l s e c t i o n
of t h e c a s e , d i r e c t l y outboard of t h e c r i t i c a l s l o t t i p c r o s s - s e c t i o n
( i n l i n e w i t h t h e expected f a i l u r e s i t e ) . The case s t r a i n gages were
o r i e n t e d i n t h e hoop d i r e c t i o n . Eight s t r a i n gages were i n s t a l l e d on t h e
a f t dome; t h e s e gages were l o c a t e d on f o u r 45O azimuths and o r i e n t e d i n
t h e hoop d i r e c t i o n . A l l 16 s t r a i n gages were intended t o respond t o
g r a i n cracking or c e n t e r p o r t debonding and t o measure c a s e s t r a i n during
motor p r e s s u r i z a t i o n . P r o p e l l a n t cracking o r p o r t debonding r e s u l t s i n
a r a p i d t r a n s f e r of t e s t p r e s s u r e load from t h e g r a i n t o t h e c a s e o r dome.
Hence, a sudden s h i f t i n measured c a s e s t r a i n i s an i n d i c a t i o n t h a t a
s t r u c t u r a l f a i l u r e has occurred. The degree t o which t h e gages respond
t o such a t r a n s f e r of load depends upon t h e p r o p e l l a n t p r o p e r t i e s and
how much load i s c a r r i e d by t h e g r a i n when i t f r a c t u r e s .

P r e s s u r e t r a n s d u c e r s were i n s t a l l e d i n nozzle p o r t s 1, 2 , and

4 and i n t h e a f t c e n t e r p o r t . I n previous high r a t e h y d r o t e s t s , p r e s s u r e
d a t a showed a h i g h frequency o s c i l l a t i o n , which was b e l i e v e d t o o r i g i n a t e
i n t h e i n s t r u m e n t a t i o n , n o t i n t h e motor. To avoid t h i s o s c i l l a t i o n ,
e x t r a precautions were taken w i t h t h e transducer i n s t a l l a t i o n . F i r s t ,
t h e tubing l e n g t h s which connected t h e p o r t c l o s u r e and t h e transducer
was made a s s h o r t a s p o s s i b l e . Second, t h e transducers were f i l l e d w i t h
o i l and s u b j e c t e d t o vacuum t o b o i l out a l l t h e a i r trapped i n t h e t r a n s -
ducer. F i n a l l y , t o ensure t h a t t h e transducer tubing would be f r e e of
a i r , t h e transducers were i n s t a l l e d a f t e r t h e motor had been f i l l e d w i t h
mineral o i l ; o i l . w a s allowed t o flow out of t h e tubing during t r a n s d u c e r
hookup t o prevent entrapping of a i r bubbles.
 F i g u r e 6-21 shows t h e l o c a t i o n s of t h e i n s t r u m e n t a t i o n i n s t a l l e d
i n t h e p r o p e l l a n t g r a i n c a v i t y . A t o t a l of 44 instruments was s p e c i f i e d .
L i n e a r p o t e n t i o m e t e r s were i n s t a l l e d i n t h r e e wing s l o t s t o measure t h e
change i n s l o t width.

F i v e event gages were i n s t a l l e d i n each wing s l o t . The forward-

most row (El through E4) was n e a r t h e s l o t - c e n t e r b o r e i n t e r s e c t i o n and
was thus a p p l i e d over one of t h e ' e x p e c t e d a r e a s of maximum s t r e s s concen-
t r a t i o n i n t h e Minuteman motor. The second row (E5 through E8) was a t a
s l o t t i p c r i t i c a l c r o s s s e c t i o n (3.7-inch r a d i u s ) . The t h i r d , f o u r t h , and
f i f t h rows were l o c a t e d 10-118, 16-3/4, and 23 inches, r e s p e c t i v e l y , from
t h e forward end of t h e s l o t s . Two event gages were i n s t a l l e d over t h e
b o o t - f l a p bonded i n t e r f a c e i n t h e a f t c e n t e r p o r t , and two were i n s t a l l e d
i n t h e s t r e s s r e l i e f groove.

Two l i n e a r p o t e n t i o m e t e r s were i n s t a l l e d i n t h e forward c e n t e r

c o r e ; one o r i e n t e d on t h e '0 t o 180' azimuth and one a t 90' t o 270'. The
potentiometer was mounted on a b r a c k e t which i n t u r n was bonded t o t h e
p r o p e l l a n t s u r f a c e . Two l i n e a r p o t e n t i o m e t e r s w i t h b r a c k e t r y were
i n s t a l l e d i n t h e a f t end of t h e c e n t e r c o r e ; o r i e n t e d a t 0' t o 180' and
90' t o 270'. One l i n e a r potentiometer was i n s t a l l e d on a diameter a c r o s s
t h e s t r e s s r e l i e f groove. Two l i n e a r potentiometers were each bonded
t o t h e s u r f a c e of t h e a f t c e n t e r c o r e j u s t forward of t h e s t r e s s r e l i e f
groove. These p o t e n t i o m e t e r s measured t h e r e l a t i v e displacement of
p l a t e s bonded t o t h e i n s i d e diameter of t h e a f t c e n t e r c o r e j u s t a f t of t h e
b o o t - f l a p bond. Thus, t h e s e potentiometers were expected t o respond t o
debonding by r e c o r d i n g an a b r u p t e x t e n s i o n of t h e potentiometer. The
s p e c i f i c i n s t r u m e n t a t i o n arrangements a r e presented i n d e t a i l i n Reference 6.

3. T e s t Operations

The o v e r t e s t o p e r a t i o n s f o r f u l l - s c a l e Minuteman 11, s t a g e I11

motors a r e d e s c r i b e d i n Reference 6. T e s t procedures generated i n t h a t
program and p r e v i o u s programs a r e summarized h e r e a s an a i d i n planning
o t h e r h i g h - r a t e - p r e s s u r e o v e r t e s t programs. Reference 6 provides a more
complete e x p l a n a t i o n of t h e t e s t s .

A drawing of a h i g h - r a t e p r e s s u r i z a t i o n system i s given i n

F i g u r e 6-22. The system shown i s f o r a f our-nozzle motor, b u t arrange-
ments f o r s i n g l e - n o z z l e motors w i l l g e n e r a l l y be t h e same. Components f o r
t h e system must be s i z e d i n accordance w i t h l o c a l p l a n t p o l i c i e s and t h e
p a r t i c u l a r motor load requirements. Therefore, i t i s not possible t o
s p e c i f y a t e s t arrangement t h a t i s u n i v e r s a l l y a p p l i c a b l e . This presenta-
t i o n i s intended t o s e r v e a s a g u i d e l i n e only i n t h e d e s i g n of a p r e s s u r e
o v e r t e s t system.
 Major components of t h e system, i n a d d i t i o n t o t h e motor, a r e :
Accumulator, b u r s t diaphragms, high p r e s s u r e f e e d and dump l i n e s , and
i n t h e c a s e of f o u r - n o z z l e motors, n o z z l e , and unloading p i s t o n s . Hercules
recommends nonconductive m i n e r a l o i l ( d i s c u s s e d below) a s t h e p r e s s u r i z a -
t i o n medium i n c o n t a c t w i t h t h e p r o p e l l a n t g r a i n .

Operation of t h e system i s a s follows: The motor g r a i n c a v i t y

and t h e p a r t of t h e p i p i n g system on t h e motor s i d e of t h e p r e s s u r i z i n g
b u r s t diaphragm i s i n i t i a l l y f i l l e d w i t h mineral o i l . Nitrogen gas i s
s t o r e d a t a predetermined p r e s s u r e , dependent upon motor volume and
d e f l e c t i o n c h a r a c t e r i s t i c s , i n t h e accumulator. The h i g h - r a t e p r e s s u r i z a -
t i o n of t h e motor i s accomplished by blowing t h e r u p t u r e diaphragm w i t h
a f l e x i b l e l i n e a r shaped charge (FLSC). As t h e diaphragm i s
r u p t u r e d t h e n i t r o g e n p r e s s u r e i s a p p l i e d t o t h e o i l , and t h e e n t i r e system
comes t o p r e s s u r e e q u i l i b r i u m . The p r e s s u r e r a t e i s l i m i t e d through t h e
u s e of a sharp-edged o r i f i c e i n t h e gas l i n e between t h e accumulator and
t h e motor. The r a t i n g of t h e r u p t u r e diaphragm and s i z i n g of t h e o r i f i c e
must be r e l a t e d t o t h e p a r t i c u l a r t e s t requirement, and t h e system opera-
t i o n should be confirmed p r i o r t o t h e t e s t program.

I n some s i t u a t i o n s i t w i l l be d e s i r e d t o hold t h e p r e s s u r e on
t h e motor f o r a chosen p e r i o d of time. The arrangement i n F i g u r e 6-22
a l l o w s f o r t h i s p o s s i b i l i t y by t h e u s e of dump l i n e s . Rapid r e l i e f i s
achieved by b u r s t i n g a diaphragm i n much t h e same way a s i s done t o
p r e s s u r i z e t h e motor.

A p r e t e s t photograph of t h e motor and t e s t arrangement i s given

i n F i g u r e 6-23. The motor was mounted i n a modified f i r i n g h a r n e s s and
i n s t a l l e d i n t h e h o r i z o n t a l p o s i t i o n on a f i r i n g s t a n d . The f i r i n g
h a r n e s s was a t t a c h e d t o a f i r i n g pylon, b u t no t h r u s t gage was i n s t a l l e d .
Nozzle p o r t s were p o s i t i o n e d a t t h e same l o c a t i o n s a s i n a s t a t i c f i r i n g .
Nozzle p o r t No. 3 was c l o s e d w i t h a n a d a p t e r t o which a 3-inch p i p e ,
running from t h e n i t r o g e n p r e s s u r e v e s s e l , was a t t a c h e d . The o t h e r t h r e e
p o r t s were c l o s e d w i t h h y d r o t e s t c l o s u r e s . Hydrotest c l o s u r e s each
i n c o r p o r a t e a n unloading p i s t o n , of t h e same d i a m e t e r a s t h e n o z z l e
t h r o a t , which i s supported by a c r o s s framework and t i e b o l t s a t t a c h e d
t o t h e a f t harness r i n g . The unloading p i s t o n s s i m u l a t e t h e unloading
e f f e c t of t h e motor n o z z l e i n reducing t h e t o t a l p r e s s u r e load on t h e
a f t dome. The i g n i t e r p o r t was s e a l e d w i t h a s o l i d c l o s u r e . The c l o s u r e s
were p i e r c e d , a s n e c e s s a r y , t o admit i n s t r u m e n t a t i o n c a b l e s t o t h e motor
and t o a t t a c h p r e s s u r e t r a n s d u c e r p i p i n g .

The t e s t arrangement a l s o included a d e p r e s s u r i z a t i o n system.

The motor was vented through t h r e e 3-inch i i n e s , two of which were connected
t o t h e p r e s s u r e p i p i n g immediately a d j a c e n t t o n o z z l e p o r t No. 3 , and one
which was connected t o t h e p i p i n g between t h e p r e s s u r e v e s s e l and t h e b u r s t
diaphragm. Each v e n t l i n e was s e a l e d w i t h a 1250 p s i b u r s t diaphragm,
equipped w i t h a FLSC. The v e n t c h a r g e s were f i r e d by a p r e s s u r e - a c t u a t e d
s w i t c h , s e t t o o p e r a t e a t 540 p s i , t h e d e s i r e d p r e s s u r e l e v e l .
 The c h o i c e of a nonconductive o i l a s t h e p r e s s u r i z a t i o n f l u i d
needs some e x p l a n a t i o n . A l i q u i d , such a s mineral o i l , i s p r e f e r r e d i n
d i r e c t c o n t a c t w i t h t h e p r o p e l l a n t i n s t e a d of gas. S a f e t y c o n s i d e r a t i o n s
predominate i n t h i s p r e f e r e n c e f o r a l i q u i d . This i s p a r t i c u l a r l y s i g n i -
f i c a n t i f a b u r s t diaphragm i s used t o admit p r e s s u r e t o t h e motor. A s
t h e diaphragm b u r s t s , small metal p a r t t c l e s a r e t o r n from t h e diaphragm
even i f i t i s s c r i b e d t o cause f a i l u r e a l o n g predetermined l i n e s . A
l i q u i d slows dawn and c o o l s t h e p a r t i c l e s more t h a n does a g a s , t h u s
minimizing t h e impact energy and t h e p o s s i b i l i t y of i n a d v e r t e n t i g n i t i o n
of t h e motor. Use of a l i q u i d i s e s p e c i a l l y i n d i c a t e d when a pyrotechnic
d e v i c e i s used t o break t h e b u r s t diaphragm. Small f i r e s have been
experienced i n u s i n g t h e pyrotechnic d e v i c e s i n t h i s way.

The second s a f e t y f e a t u r e t h a ~f a - ~ o r st h e u s e of a l i q u i d con-

c e r n s t h e p o s s i b i l i t y t h a t h i g h - r a t e t e s t i n g b i l l 1 proceed beyond t h e
d e s i r e d l i m i t s and s p l i t t h e motor c a s e . By u s i n g a l i q u i d i n t h e g r a i n
c a v i t y , t h e r e q u i r e d accumulator p r e s s u r e and volume a r e minimized, thus
s i m p l i f y i n g t h e system d e s i g n . Minimizing t h e accumulator p r e s s u r e and
volume a l s o minimizes t h e s t o r e d energy and w i l l thus reduce the p o s s i -
b i l i t y of damage by chamber r u p t u r e a n d / o r o t h e r a c c i d e n t a l sudden r e l e a s e
of t h e work s t o r e d i n t h e gas.

I n s p e c i a l s i t u a t i o n s i n which gas i s s a f e t o u s e a l o n e a s t h e
p r e s s u r i z i n g medium, i t does o f f e r two s i g n i f i c a n t advantages. F i r s t ,
s i n c e gas i s much l e s s dense t h a n l i q u i d , t h e impact f o r c e s a g a i n s t t h e
i n s t r u m e n t a t i o n and w i r i n g w i l l be lower and l e s s l i k e l y t o t e a r i n s t r u -
mentation o u t of p o s i t i o n . Second, u n p r o t e c t e d e l a s t o m e r i c event gages
may be p e n e t r a t e d by l i q u i d s and rendered nonconduc t i v e , whereas gas w i l l
have no such e f f e c t .

The primary c o n s i d e r a t i o n i n s e l e c t i n g a l i q u i d t o be used i n

h i g h - r a t e t e s t i n g i s t h a t it be nonconductive. I n s t r u m e n t a t i o n , such a s
l i n e a r p o t e n t i o m e t e r s , s,lould b e immediately s h o r t e d out i f exposed t o a
conductive f l u i d , such a s water. Although event gages and e l a s t o m e r i c
s t r a i n gages could perhaps be p r o t e c t e d by t h e same technique a s used t o
waterproof w i r e s t r a i n g a g e s , t h e s e techniques have n o t been proven f o r
use on a s u b s t r a t e capable of high e l o n g a t i o n , such a s p r o p e l l a n t .

F i v e motors were s u c c e s s f u l l y high r a t e t e s t e d by Hercules from

1963 through 1.965 u s i n g nonconductive m i n e r a l o i l . The s u i t a b i l i t y of
mineral o i l was f u r t h e r demonstrated by a d d i t i o n a l c h a r a c t e r i z a t i o n i n
t h e LRSLA and o v e r t e s t programs. C o m p a t i b i l i t y w i t h p r o p e l l a n t was checked,
and it was found t h a t t h e o i l d i d not chemically r e a c t w i t h p r o p e l l a n t .
The a b s o r p t i o n of n i t r o g l y c e r i n from p r o p e l l a n t i n t o mineral o i l was found
t o be l e s s t h a n one p a r t p e r thousand i n 24 hours. This was judged t o be
a s a f e l e v e l f o r h i g h - r a t e t e s t i n g b u t a l s o i n d i c a t e d t h a t used mineral
o i l should be disposed of i n accordance w i t h procedures f o r contaminated
materials.
 T e n s i l e t e s t samples t h a t were soaked i n o i l were t e s t e d t o
determine t h e e f f e c t of o i l immersion on p r o p e l l a n t s t r a i n c a p a b i l i t y . O i l
immersion was found t o s l i g h t l y lower t h e f a i l u r e p r o p e r t i e s of CYH pro-
p e l l a n t , b u t t h e e f f e c t was s o small t h a t motor f a i l u r e p r e d i c t i o n s would
not be d i s t o r t e d .

A t e s t plan o u t l i n i n g t h e t e s t and r e l a t e d o p e r a t i o n s should

be prepared f o r each o v e r t e s t o p e r a t i o n . Any d e v i a t i o n s t o t h e p r e s c r i b e d
plan should be noted i n a log of t h e motor h i s t o r y . A t y p i c a l t e s t plan
is outlined i n Appendix B.
 LIST OF REFERENCES

JANNAF S o l i d P r o p e l l a n t S t r u c t u r a l I n t e g r i t y Handbook, SMBWG, St r u c -

t u r a l I n t e g r i t y Committee, S. C. Browning, Chairman, CPIA P u b l i c a t i o n
230; UTEC CE 72-160, September 1972.

Case Bond S t r e s s C a l c u l a t i o n s f o r Flapped C y l i n d r i c a l Analogs of

S o l i d P r o p e l l a n t Rocket Motors, Bondline Parametric S t u d i e s , Task I ,
I n t e r i m Technical Report, AFRPL-TR-72-77, Hercules I n c o r p o r a t e d ,
Magna, Utah, May 1972.

L. D. Webb, R. W. H a r r i s , E. T. Cook, Study and L i t e r a t u r e Survey

of S t r e s s S t a t e Transducer Development, F i n a l Report, Volume 11,
Bibliography, Texas A & M U n i v e r s i t y , AFRPL-TR-69-74, Volume 11,
R-4532-11, March 1969.

H. Leeming, Techniques f o r Measuring S t r e s s , S t r a i n and Temperature

i n S o l i d P r o p e l l a n t Motors, Lockheed Propulsion Company, Redlands,
C a l i f , AFRPL-TR-71-131, November 1971.

L. D. Webb, "Development of a n I n S i t u T r a n s m i t t e r f o r S o l i d Rocket

P r o p e l l a n t S u r v e i l l a n c e , ' ' Task I , F e a s i b i l i t y Study, P a r t 11, L i t e r a -
t u r e Survey on I n s t r u m e n t a t i o n and Measurement Techniques, Texas A & M
U n i v e r s i t y , Report No. 1 & 26-26F, November 1972.

A. S. D a n i e l s , ICBM O v e r t e s t techno lo?^. Motor O v e r t e s t (Task IV) and

P o s t t e s t Examination, Hercules I n c o r p o r a t e d , Magna, Utah, Report
No. AFRPL-TR- ( i n review) , February 1975.

" S t r a i n Gage Comes Through i n t h e S t r e t c h , " Machine D e s i ~ n ,12 J u l y

1973.

Edward E. Herceg, Handbook of Measurement and C o n t r o l , Schaevitz

Engineering , Pennsauken, Pa, 1972.

J. M. Anderson, T. D. Pavelka, and P. S. Bruno, Techniques f o r

Assessing Case Liner-Bond I n t e g r i t y i n S o l i d P r o p e l l a n t Rocket Motors,
Hercules I n c o r p o r a t e d , Magna, Utah, AFRPL-TR-73-75, September 1973.

S. R. Swanson, Subscale Motor V e r i f i c a t i o n Program, Report No.

-544/6/40-168, Hercules I n c o r p o r a t e d , Magna, Utah, 10 February 1967.
 APPENDIX A

S P E C I F I C TEST PLAN

FOR

PRESSURIZATION TESTING O F
SUBSCALE CENTERBORE CRACICING CYLINDER
FAILURE MODE MODEL

THE RPL ICBM OVERTEST

TECHNOLOGY PROGRAM
I. INTRODUCTION

This t e s t p l a n d e s c r i b e s t h e requirements and procedures a p p l i c a b l e

t o t h e High Rate Hydrotest of a Centerbore Cracking Cylinder F a i l u r e Mode
Subscale Model.

Any change t o t h i s t e s t plan i s t o be documented on a QA Testing

Event Record (Form BW-6000/769) and approved by QA T e s t Engineering,
Product Engineering and Test Area Supervision.

11. TEST OBJECTIVES

(a) To v e r i f y t h a t t h e h i g h r a t e h y d r o t e s t i s a v a l i d o v e r t e s t
f o r t h e wing-slot-cracking f a i l u r e mode.

(b) To measure t h e p r e s s u r e l s t r a i n a t which c e n t e r b o r e crack-

ing occurs i n t h e c i r c u l a r c e n t e r b o r e model.

111. TEST ITEM DESCRIPTION

The c e n t e r b o r e cracking c y l i n d e r f a i l u r e mode model i s a s shown i n

F i g u r e A-1. It i s a machined g r a i n of CYH p r o p e l l a n t bonded i n t o a hoop-
wound c a s e of Herculon-nylon f i b e r and C7/W r e s i n . The g r a i n i s 6 inches
OD by 1 inch I D by 7.35 inches long. A f l a p subassembly i s bonded t o
each end of t h e g r a i n . The f l a p subassembly i s made of two each 0.16-inch
SBR s i l i c a f i l l e d rubber pieces bonded t o g e t h e r . The ends of t h e motor
a r e s e a l e d with aluminum end p l a t e s bonded t o t h e f l a p subassembly and
a x i a l l y r e s t r a i n e d by f o u r each t i e rods b o l t e d between the end p l a t e s .

The model i s i n t e r n a l l y instrumented w i t h two l e a f deflectomkte&

and a conductive RTV event gage. The model i s e x t e r n a l l y instrumented
with e i g h t case-mounted s t r a i n gages and one g i r t h band.

IV. TEST LOADS, ENVIRONMENTS, AND CONDITIONS

(a) The motor w i l l be maintained and t h e t e s t conducted a t

a temperature of 70' 2' F. +
(b) The c e n t e r b o r e c r a c k i n g c y l i n d e r f a i l u r e mode model w i l l
be p r e s s u r i z e d t o 1250 p s i a t a r a t e of 10,000 p s i / s e c
using mineral o i l a s t h e c a v i t y p r e s s u r i z i n g f l u i d .

(c) The mineral o i l w i l l be maintained a t a temperature of

70° t 2' F.

(d) The t e s t w i l l be conducted a t t h e P l a n t 1 Range F a c i l i t y .

V. TEST PROCEDURE

(a) Instrument t h e motor and a s s o c i a t e d t e s t equipment w i t h

s t r a i n g r i d s , g i r t h band, l e a f d e f l e c t o m e t e r s , and p r e s s u r e
t r a n s d u c e r s i n accordance with the Data Acquisition
Instruction. (See Table A-1.)

(b) Assemble t h e p r e s s u r i z a t i o n system i n accordance w i t h

Figure A-2 and a s d i r e c t e d per HD 2-1-3127 (Subscale
P r e s s u r i z a t i o n T e s t s ) . The system must be capable of
handling a minimum expected p r e s s u r e of 1250 p s i a t a
maximum r a t e of 10,000 p s i / s e c .
(c) I n s t a l l t h e t e s t c y l i n d e r and remaining instrumentation
i n accordance w i t h Data Acquisition I n s t r u c t i o n . (See
Table A-1 and Figure A-1.)

(d) P r e s s u r i z e t h e t e s t c y l i n d e r per HD-2-1-3127 t o 1250 p s i g

a t a r a t e of 10,000 p s i / s e c .

VI . DATA REQUIREMENTS

A. Instrumentation

The m o t o r / t e s t f i x t u r e s w i l l be instrumented and t h e d a t a w i l l

be recorded i n accordance w i t h t h e Data Acquisition I n s t r u c t i o n . (See
Table A-1.) Two l e a f deflectometers a r e mounted a t 180' on a 1/4-inch
rod held c o a x i a l t o the model c e n t e r l i n e . Each deflectometer measures t h e
r a d i a l displacement of t h e c e n t e r b o r e wall. The sum of both r a d i a l
d e f l e c t i o n s i s the d i a m e t r i c a l d e f l e c t i o n of the centerbore, a s t h e
extraneous motions of t h e support rod cancel out. One end of t h e support
rod passes through a f l a t - s i d e d h o l e i n one support bushing s o it i s f r e e
t o s l i d e a x i a l l y , b u t prevented from r o t a t i n g . The o t h e r end of t h e rod
passes through a h o l e i n t h e o t h e r support bushing and i s clamped t o it
by a nut. The flow a r e a through support bushings i s reduced by 35 percent
by the p l a t e s which support the rod. The deflectometers a r e t o be com-
pressed during i n s t a l l a t i o n enough t o g e t p a s t t h e event gages and t o keep
from dragging on t h e p r o p e l l a n t u n t i l they a r e i n place.

B. Data Reduction

Engineering u n i t l i n e p l o t s of a l l d a t a channels a t 1 m s sampl-

ing r a t e f o r t h e f i r s t 1000 ms a r e required.

Additional information w i l l be reduced a s requested by the

Product Engineering p r o j e c t engineer.
 TEST NO. SHEET
DATA ACQUISITION INSTRUCTIONS - TABLE A-1
B'N.~OGO'~IS 19.631 MEASUREMENT PRIORITIES
CODES : i OF i
FM Frequency Modulation ( i n . / s e c
- I/C - I r o n Constantan 1. H o l d test until instrument i s
operoti ve. MOTOR INSTRUMENT L I S T S N
magnetic t a p e speed) CIA - Chromel/Alumel
RO - Recordillg O s c i l l o g r a p h ( i n . / s e c ) PIPlUXR - Platinurn/Platinum 2. These measurements be M 1 17SD006
10% Rhodium deleted only upon direction of the A,,,,v,o .. - '
MV - Millivolts cognizant H P C test conductor.

I
UEASUREMEIdT TYPE LOCATION AND/OR EXPECTED
INSTALLATION PRIORIV PURPOSE O F M E A S U R E M E N T R E C O R D I N G MODES
NUMBER RANGE
MEASUREMENT I TRANSDUCER DRAWING
I
*P-1 I Pressure Taber 2000 Figure 2 I I 1 Chamber P r e s s u r e 1 1500 p s i g / 0-250 FM-60 RO-16
*P-2 psig or
Equivalent
II I1
P-3 I Pressure 1 Taber 2000 1 Figure 2 I 1 ( Nitrogen Pressure 1 2000 p s i g I D-250 FM-60 RO-16

I Equivalent I 1
o\ R1 I Deflection I / Figure 1 I 1 I Change i n C e n t e r 1 0.5 I n c h I D-250 FM-60 RO-16
4
C
R2 1 Diameter
SG-1 Strain BLH PA-3 A0 128-020 1 2 i Circumferential 5 3% D-250 FM-60 RO-16
Through I o r Equiv. Figure 1 I I Growth
I
SG-8 I I I
"T-1 I Valve I Breakwire I 1 D-250 FM-60 RO-16
(Time "0")
E-1 Event Conductive Figure 1 1 Time o f Centerbore . 2 9 to D-250 FM-60 ~0-16
RTV Gage Cracking 1 meg R
D-1 Deflection ElectroTek Figure 2 2 Circumferential .5 Inch D-250 FM-60 RO-16
.25 Inch Growth
 1

. .

B r i e f Description of Operation .
The system i s f i l l e d . v i t h mineral o i l on t h e motor s i d e of
v a l v e 11. T h i s i s done by f i l l i n g a t 9 and bleeding a t 6.
P r e s s u r e v e s s e l 18 i s then pressurized v i t h n i t r o g e n t o
the d e s i r e d d r i v i n g pressure by a c t u a t i n g valve 16 remotely
and monitoring the pressure r i s e on 15. When 1 8 reaches . .
t h e pressure d e s i r e d , 16 i s closed and motor p r e s s u r i z a t i o n
is accomplished by a c t u a t i n g the r a p i d opening valve, 11.
The system i s then exhausted by opening d a l v e 10. .
I
i
-
Figure A-2. Subscale Pressurization System
VII. PHOTOGRAPHIC COVElZAGE

Black and white s t i l l photographs of t h e m o t o r / t e s t arrangement a r e

required.

The q u a n t i t y and views of photographs t o be taken s h a l l b e a t t h e

d i s c r e t i o n of t h e Test Engineer.
 APPENDIX B

SPECIFIC TEST PLAN

FOR

HIGH RATE HYDROTEST OF M57-A1 MOTOR

SIN 0033348
FOR

THE RPL ICBM OVERTEST TECHNOLOGY PROGRAM

I. INTRODUCTION

These requirements o u t l i n e t h e h i g h - r a t e h y d r o t e s t of a 6-year old

M57A1 rocket motor, which comprises a p o r t i o n of Task IV of t h e ICBM
Overtest Technology Program. The o b j e c t i v e of t h e program i s t o e s t a b l i s h
and v e r i f y methodology f o r s t r u c t u r a l o v e r t e s t t o be used f o r s e r v i c e l i f e
assessment of s o l i d f u e l rocket motors. A secondary o b j e c t i v e i s t o
determine t h e c u r r e n t margin of s a f e t y f o r t h e M57A1 motor.
This w i l l be t h e second, and l a s t , h i g h - r a t e motor h y d r o t e s t per-
formed f o r t h e ICBM Overtest Technology Program. A d i s c u s s i o n of t h e
program background was given i n t h e Test Plan d e s c r i b i n g t h e f i r s t motor
t e s t (Report No. A0128-016). The second h y d r o t e s t i s t o be conducted
l i k e t h e f i r s t t e s t s o a s t o produce comparable d a t a f o r both motors.
Some d i f f e r e n c e s i n t e s t operat ions and instrumentation w i l l be r e q u i r e d
because of t h e design d i f f e r e n c e s between t h e two motors. The same hydro-
t e s t arrangement w i l l be used i n an attempt t o d u p l i c a t e t h e p r e s s u r e
r a t e s of t h e f i r s t t e s t .

Instrumentation l o c a t i o n s s p e c i f i e d f o r t h i s t e s t a l s o d u p l i c a t e
those used i n t h e f i r s t t e s t . Some changes have been made, e i t h e r because
the t e s t p r e s s u r e i s higher or t o accommodate t h e design d i f f e r e n c e s t h a t
e x i s t between t h e f i r s t and second t e s t motors. Higher p r e s s u r e s imply
higher g r a i n d e f l e c t i o n s , s o wing s l o t potentiometer assemblies capable
of s u f f i c i e n t s t r o k e a r e s p e c i f i e d h e r e i n , where space permits mounting
them. These pot assemblies a r e capable of recording r e l i a b l e d a t a only
while t h e wing s l o t width i s i n c r e a s i n g ; s o assembly has demonstrated a
tendency t o buckle during p r e s s u r e blowdmn when the wing s l o t r e l a x e s .
F a i l u r e of t h e vulcanized a f t c e n t e r p o r t bond of t h i s t e s t motor configura-
t i o n i s n o t considered a p o t e n t i a l f a i l u r e mode. Hence, t h i s a r e a , r e q u i r e s
l e s s instrumentation than was used on t h e preceding t e s t . Four event
gages a r e l o c a t e d t o d e t e c t cracking i n t h e a f t end web; e x t e n s i v e crack-
ing occurred i n t h i s a r e a i n t h e previous t e s t .

11. TEST DESCRIPTION

A. Test Item

Third s t a g e Minuteman I1 motor S/N 0033348 has been s e l e c t e d

a s t h e second motor t o be subjected t o o v e r t e s t i n t h e ICBM o v e r t e s t
program. The motor c o n f i g u r a t i o n i s i n accordance with 01A00063-027,
and includes t h e OPRI design changes. The g r a i n was made from CYH pro-
p e l l a n t powder l o t number RAD 1-16-67, which exhibited a modulus a t
acceptance of 802 p s i and t e n s i l e s t r e n g t h of 295 p s i . The motor c a s e
i s from production l o t number 44B, which demonstrated a minimum hydro-
b u r s t pressure of 724 p s i .
 This motor i s now known t o have been subjected t o extremes of
temperature o r humidity while i n t h e a c t i v e f o r c e inventory. It was
involved i n a t r a n s p o r t a t i o n a c c i d e n t and s u f f e r e d damage t o t h e forward
s k i r t ; however, t h i s darnage is n o t judged t o be d e t r i m e n t a l t o t h e t e s t
objectives .
B. Test Loads and Arrangement

The p r e s s u r i z a t i o n system i s i n accordance with Drawing

12S00910, and i s s h a m i n Figure B-1. Three-charge-equipped b u r s t d i s c s
a r e t o be used f o r blowdown. The o r i f i c e s i z e i s t o be 1.25 inches. The
shaped charge on t h e p r e s s u r i z a t i o n b u r s t d i s c i s t o be i n t e r r u p t e d f o r
1 inch s o t h a t t h e d i s c c e n t e r w i l l be r e t a i n e d a t t h e f l a n g e assembly.
The accumulator p r e s s u r e i s t o be 700 p s i . The motor w i l l be automati-
c a l l y vented when the p r e s s u r e reached 640 p s i by blowing t h r e e r u p t u r e
discs.
0 0
The temperature of t h e motor and systems s h a l l be 70 t 2 F.
The motor s h a l l be conditioned f o r a minimum of 108 hours before t e s t i n g .

C. Data Requirements

Motor instrumentation l o c a t i o n s a r e shown i n Figures B-2

through B-4 and d a t a a c q u i s i t i o n requirements a r e given i n Table B-1.

Deflectometers required a t l o c a t i o n s D l , D2, and D3 a r e t o be

i n s t a l l e d using spacers between t h e instrument body and t h e g r a i n t o
r e t r a c t the pot a s much a s p o s s i b l e . Leadwires a r e t o be brought o u t
through t h e nozzle p o r t o r c e n t e r p o r t a d j a c e n t t o t h e instrument l o c a - .
t i o n , except f o r P o r t 3. This i s intended t o minimize t h e movement of
leadwires t h a t occurred during t h e previous t e s t . ,

Developed o s c i l l o g r a p h t r a c e s , complete w i t h c a l i b r a t i o n
f a c t o r s , s h a l l be d e l i v e r e d t o Product Engineering a f t e r t h e t e s t .
D i g i t a l p l o t s a t 4 m s s h a l l be made of a l l d a t a channels f o r t h e period
of t h e pressure r i s e . D i g i t a l p l o t s a t 40 ms s h a l l be made f o r t h e f u l l
t e s t duration. A l l channels showing evidence of f a i l u r e , t o be s e l e c t e d
by Product Engineering, s h a l l be played from FM tapes onto o s c i l l o g r a p h
c h a r t s a t a speed of 80 in./sec. Cross p l o t s of s e l e c t e d channels may
be requested by Product Engineering i f considered necessary t o d e f i n e
failure .
D. Photographic Coverage

Photographs w i l l be taken of t h e i n t e r i o r of t h e motor a f t e r

a l l instrumentation i s i n s t a l l e d . S t i l l black and white photographs of
the assembled t e s t arrangement a r e required.
 1s e c

L R

-----___
---- - - - - - - - - - - -
SC-6, 7 , 8 NOT SHOWN

26 1/2

S G - 1 THROllGH 8 TO B E LOCATED A R O W CIRCUMFERt.NCE OF MOTOR AT 450

INTERVALS S T m T I N G A'r O0 (N. P. 4 1 ) . ROllT CORK AND REMOVI: T.T.
CONDUIT A S NECESSARY TO MOUNT S T R A I N CAGE ON GLASS.

Figure B-3 External Strain Gage Location (Cylindrical S e c t i o n ) ,

6-82
 '0 REF

ALL DIMFNSIONS _+ 1/4 INCHES

ROUTE EXTERNAL INSULATION AS NECESSARY
TO MOUNT STRAIN GAGE ON GLASS

Figure B-4 External Instrumentation, Aft Dome

6 -83
 T E S T NO. SrECT
DATA ACQUISITION INSTRUCTIONS - TABLE B-1
BW.tGoO'435 19.631 MEASUREMENT PRIORITIES
CODES : S/N 0033348 1 OK 2
FM - Frequency Modulation ( i n . / s e c I/C - I r o n Constantan 1. H o l d test u n t i l instrument i s
magnetic t a p e speed) c /P - Chrornel/.Alurnel operoti ve. MOTOR INsTRUklENT LIST s N
RO - Recording O s c i l l o g r a p h ( i n . / s e c ) P/PlU%R - Platinum/Platinurn 2, These measurements be M1 01AE003
l a Rhodium d e l e t e d only upon d i r e c t i o n o f t h e ,,,,
- ,,,, .. -
MV - Millivolts cognizont H P C t e s t conductor.

- I
MEASUREMENT
TYPE LOCATION A N D OR EXPECTED
INSTALLATION p~lo~l PURPOSE OF M E A S U R E M E N T R E C O R D I N G MODES
NUMBER MEASUREMENT I TRANSDUCER DRAWING
RANGE

I
P1 Pressure Pressure See F i g u r e 4 1 Monitor Motor P r e s s u r e 0-700 p s i D-250
P2 Transducer a t Nozzle P o r t s FM-60
P4 0-1000 p s i RO-40

P3 Pressure Pressure See F i g u r e 4 Monitor Motor P r e s s u r e 0-700 p s i D-250

Transducer a t A f t Center P o r t FM-60
' 0-1000 p s i RO -40
0\

do P5 Pressure Pressure See F i g u r e 1 I 1 Monitor Line P r e s s u r e 0-1000 p s i D-250

c. Transducer ! RO-40
I / 0-1000 p s i I i I
- - - - - -
T - -
El thru Even ' CONIRTV-1 See F i g u r e 2 Monitor Wing S l o t I 0-10 MW D-250
El8 1 Event Gage 1 Cracking Event 1 D(-60
E24* RO-40 (El t h r u El2 Only)
Event Monitor S t r e s s R e l i e f 1 0-10 MW
I ;X):L'y;ie 1 See F i g u r e 2 l2 1 Groove Cracking Event I
Event 1 ;~~;TVl~e 1 See F i g u r e 2 Monitor A f t Center P o r t 0-10 MW D-250
Boot-Flap Debonding 1 FM-60
-
l2 1
h I vent 1 &N/RN-1 See F i g u r e 2
( 1 1 2 Monitor A f t Web D-250
Event Gage P r o p e l l a n t Cracking

D l t h r u D3 Displace- Deflec- See F i g u r e 2 1 Monitor Expansion of 0.6" D-250

ment tome t e r Humphrey Wing S l o t FM-60
RP 101-0101-1 RO-40
D4 t h r u D9 Displace- 2 1 1 Monitor Expansion of 0.8" D-250
men t Wing S l o t FM-60
Assembly
 TEST NO.
DATA ACQUISITION
'aW...tS
,>.o 417
INSTRUCTIONS - TABLE B,1 (Cont) MEASUREMENT PRIORITIES
CODES : s/m 0033348
FM Frequency Modulation ( i n . / s e c
- I/C - Iron Constantan 1. H o l d test until instrument i s
operative. MOTOR INSTRUMENT LIST S N
magnetic t a p e speed) C 1.3 - Ch romel/Al ..me 1
RO - Recording O s c i l l o g r a p h ( i n . I s e c ) PIPlOZR - I'lat inumIPlat inum 2, These measurements may be
10?. Rhodium de!eted only upon direction of the
MV - Yillivnlts cognizant HPC test conductor.

MEASUREMENT TYPE LOCATION ANC OR EXPECTED

INSTALLATION PR,OR~ PURFOSE O F MEASUREMENT R E C O R D I N G MODES
DRC~IXS RANGE
NUMBER MEASUREMENT I TRANSDUCFR
I
Displace- Linear P o t See F i g u r e 2 1 2. Measure E x p a n s i o n o f 0.6" D-250
D-11
D-10 ! ment and 12S00911 C e n t e r Core T i p FM-60

D-12 Displace- Deflec- See F i g u r e 2 2 Measure Expansion o f ' 0.6" D-250

D-13 men t tome t e r and 12S00911 ] C e n t e r Core FM-60
D-14 I Displace- (Deflec-- rSee Figure 2 1 1 Measure Expansion o f 1 0.5" 1 D-250
m I ment tometer and 12300912 1 I Stress Relief Groove FM-60
D-15 Displace- Linear Pot See F i g u r e 2 / 2 1 Measure Axial Displace- 0.5" D-250
ment ! f ment o f A f t C e n t e r P o r t FM-60
P-6* Pressure , Kistler See F i g u r e 4 / 2 1 M o n i t o r Motor P r e s s u r e 0-700 p s i FM-60
I ! Transducer I I I a t Center P o r t
0-1000 p s i
P-7* Pressure Kistler See F i g u r e 4 2 Monitor Motor P r e s s u r e 0-700 p s i FM-60
Transducer a t Nozzle P o r t No. 2
0-1000 p s i
D-17 t h r u Displace- Linear Pot See F i g u r e 2 2 Measure R a d i a l D i s - 0.5" D-250
D-19 men t and 12S00912 p l a c e m e n t o f Nozzle P o r t DM-60 (Dl7 and 1 8 Only)

SG-1 t h r u Strain S t r a i n Gage See F i g u r e 3 2 M o n i t o r F x t e r n a l Case 1.5% D-2 5 0

SG-8 Strain FM-60

SG-9 t h r u Strain S t r a i n Gage S e e F i g u r e 4 2 A f t Dome S t r a i n 1.5% D-250

SG 16- FM-60

Time Z e r o A l l Systems

Dump Time A l l Sys terns

Zer OM

-- -.- - -
- - -- -
 Color movies s h a l l be taken of t h e motor a f t dome and unloading
p i s t o n arrangement for f u l l duration of t h e t e s t (1 sec) a t a f i l m speed
of 400 frames/sec. Film w i l l not be developed unless a chamber f a i l u r e
occurs during t e s t .

E. Test Changes

Any changes t o t h e t e s t plan w i l l be documented on an Event

Record (WJ-6000/769)and approved by QA Test Engineering, Product
Engineering, and Test Area Supervision.