# PHOENIX, ARIZONA

(NASA-CR-161703) DEVELOPPIENT, UUALIFTCATION, AH.D DELIVERY OF A H Y D R C G E N BUQNOFP I G N I T E R F i n a l f e p n r t (Unidynamics/Phoenix) 37 p NC A03/MF A 0 1 Unclas

CSCL 218 63/25 42066

P I I I 1 I= u.. ,..".T.,... ,.,. A SUBSIDIARY OF

https://ntrs.nasa.gov/search.jsp?R=19810012615 2020-02-22T16:07:39+00:00Z

24 March 1981

phoenix, arizane

UN.IDYNAMICS DOCUMENT NO. DTR-149

FINAL REPORT ON DEVELOPMENT, QUALIFICATIONI AND

DELIVERS OF A HYDROGEN BURNOFF IGNITER

(NASA Contract No. NASO-34195)

[Unidynamics Account No. C35-780)

Prepared For: e

National Aeronautics and Space Administration George C. Marshall Space F l i g h t C e n t e r

Marshall Space Flight Center, Alabama 35822

. . A t t e n t i o n : Donald W, 5,2ax * ~ i u s Cont r ac t i ng Officexs' Rekiesentative

Prepared by:

Approved by: w. Cox / *

Project Manager

TABLE OF CONTENTS

SECTION

INTRODUCTION

PAGE NUMBER

PHASE I - MATERIAL STUDY 3

POTASSIUM NITRATE COEIPOSITIONS EVALUATED IN PHASE I 10

AMMDNIUM PERCEILORnTE COMPOSITIONS EVALUATED XN PHASE I 16

PIIASE 31 - PROTOTYPE FABRICATION AND DEVELOPMENT TESTING, AND FINAL D E S I G N 23

. PHASE 111 - FABRXCATION AND QUALIFICATION TESTING 32

CONCLUSIONS

XNTRODUCTION

Under Marshall Space F l i g h t Center Contract NAS8-34195, Unidynamics/

Phoen ix , Inc, desiged, fabricated, and q u a l i f i e d the hydrogen burn-

off i g n i t e r illustrated on t h e next page to MSFC-SPEC-541. This

item iS a pyrotechnic device used to burn off excess hydrogen

gas near the Space Shuttle Main Engine (SSME) nozzle.

As set forth in the-statement of work, .the pro$ram was ko be

completed i n four phases:

n Phase I - Material Study and Prototype Design

a Phase I1 - P r o t o t y p e Fabricztion, Development

T e s t i n g , and F i n a l Design

s Phase I11 - Fabricat ion

m Phase IV - Qualification Tes t ing

MSFC-SPEC-541 specified that the burnoff i g n i t e r was t o have .a

func t ion t i m e of 8 - + 2 seconds, a minimum three-foot flame

l ength at maximum o u t p u t , and hot part icles projected 15 feet

when fired directly i n t o o r perpendicular t o a 34.5-knot wind.

The three-foot flame requirement was considered to be of

q u e s t i o n a b l e importance, s i n c e the hot particles are t h e media

for i g n i t i n g the hydrogen. Flame temperature was t o be greater

than 1500°F. As shown by the q u a l i f i c a t i o n repor t* , all of

these specifications were m e t .

Additional de ta i l s are provided in subsequent s e c t i o n s .

*Unidynamics Document No. 51-1151-QTR-03.

TOTAL LENGTH - 5,91 DIAMETER - 2.00 !3

LEGEND

I - NSI 8 - PAD 2 - ADAPTER 9 - NOZZLE HOUSING 3 - ALUMINUM FOIL 10 - NOZZLE 4 - 107-PPR-02 11 - WELDED CLOSURE DISK

(LOOSE LOAD) 12 - PAPER DISK 5 - T R A N S F E R P E L L E T 13-GRAIN 6 - FITCO 14 - INHIBITOR 7 - CASE 15 - ALUMINUM FOIL

51-1151 H'fDROGEN BURMOFF IGNITER

PHASE I - blATERIAL STUDY

Sincc it was deemed desi~able to eliminate all corrosive halides

from the conibustion products of the hydrogen burnoff igniter,

the most promising propellant conrposition was a composite of

po*tassiurn n i t r a t e , a hydrocarbon fuel-binder, a high-combustion-

temperature metal powder of appropriate particle s i z e , and necessary ballistic additives t o enhance i g n i t i o n o r modify - burn ra tes .

Potassium nitrate was selected as t h e best cand ida t e because

of i t s relatively non-hygroscopic nature and established history of use in halogen-free propellants and ignition materials.

It was f e l t , however, t h a t the most widely used solid propellant

oxidizers, such as aminonium p e r c h l o r a t e , should not be eliminated

from this program even though t h e y do produce small amounts of

corrosive halides in the combustion process. Therefore, the

potassium nitrate forrnclations and the anunqnium perchlorate

formulations were evaluated simultaneously.

The oxidizer/fuel binder/ballistic additive combination functions

as a propellant base to generate a contxolled mass flow of hot

gases to form a high ve loc i ty jet in the exit plume of the nozzle.

This flow of high temperature, high velocity gases con ta ins a

flux of e n t r a i n e d burning par t ic les of t h e metal fuel additive.

These par t ic les are e j e c t e d into the plume w h i l e still burning

and continue on their respective flight paths f o r distances which

are determined principally by their i n i t i a l v e l o c i t y , p a r t i c l e

sizes, burning rates in air and the effects of wind v e l o c i t i e s .

The NASA requirements of 8.0 - -+ 2 seconds burn time, spark pro- jection of 15 feet minimum when fired directly into o r pe rpend icu la r

t o a 34.5-knot wind, and particle temperature of 3500°F were a31

met under this program. Total cartridge burn time was c o n t r o l l e d

by grain web thickness, length of grain and nozzle opening.

Several nozzle openim~g diameters and shapes were evaluated

d u r i n g t h e program i n an effort to conkrol the p a r t i c l s plume.

The nozzle shaping configurations proved to be i ne f f ec t ive due

primarily to the fact that the resulting n o z z l e opening was

r e l a t i v e l y small. Two of the t e s t e d nozzle configurations are

illustrated an the next page.

Since it was still cdcsirable to be able to redice or eliminate

errant sparks which traveled above the 28-inch height as measured

from the cent :ar l inc of the unit, a spark defleckor which could

easily be attached to the nozzle was designed. This deflector

effectively controlled the e r r a n t sparks.

A series of small 1abora.tory-size batches of propellants using

various metals for the sparks were blended as a means of quickly

evaluating spark characteristics. ~irconium, aluminum, iron

and magnesium were e v a l u a t e d . zirconium proved t o be t h e bes t candidate. E s s e n t i a l l y two p a r t i c l e - s i z e z i rconiums were evalu8,tzd;

the f i n e r particles produced undesirable a n o m a l i e s , Coarser

grade z i rcon ium, approximately 400-micron, produced good spark

characteristics and was selected for the final design.

The computer a n a l y s i s reproduced on the following pages was

conducted for t h e f i n a l p r o p e l l a n t system. The potassium nitrate

and the anmonium p e r c h l o r a t e compositions evaluated d u r i n g

Phase I are discussed more thoroughly in t h e f o l l o w i n g s e c t i o n s .

SHAPED

STRAIGHT

NOZZLE CONFIGURATIONS

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POTASSIUM NITRATE COMPSITIONS EVALUATED IN PHASE I

Table I summarizes this series of evaluations, and the i n d i v i d u a l

compositions are discussed below.

rest No. 1 involved tho following composition:

6 4 . 0 % Potassium Sitrate

11.49 Hydroxyl-Terminated Polybutadiene . (HTPB) C

* 14.0% Zirconicm (30-44 ~ i c r o n )

6.0% Boron

* 2.5'1, Dimethy.Z Diisocyanate (UBI-1410)

2.06 Ferric Oxide

0.1% Antioxidant {CAO-14)

T h i s composition was ~ x e s s c d i n t o a p e l l ~ t at 1500 p s i . The

pe l l e t was t h z n i n h i b i t e d w i th a rnixkure of Epon 8 2 8 (50 percent)

and versamid 140 (50 p e r c e n t ) . Whcn f i r ed , the prope l lan t

overpressurized i n rhe t e s t unit using a nozzle diameter of 0.200-inch (Kn49). The nozzle asssernbly was e:cpelled.

Test No. 2 used the following composition:

+ 56.0% Potassium Nit ra te

a 20.08 Powdered Sugar , commercial grade

16.0% Zirconium (-200/+325)

6.03 Polyes ter Resin

2.08 Ferric Oxide

This composition was pressed i n t o a pellet at 10,000 p s i and

i n h i b i t e d w i t h a m i x t u r e of 50 percent Epon 8 2 8 and SO percent

Versamid 140, Overpressurisation occurred in the test u n i t f

using a nozzle diameter of 0.200-inch ( l (n49) . The nozzle u2s

expelled.

TABLE I - POTASSIUM NITRATE PROPELLANT TESTS t

( S.40843 1.030 1 . 3 C C

10 \ f U B D L 3 1.032 1:344

27 ' S O D S 7 1.170 1.20

50 n; I 9 0.189

0 mg 400 mg 0,250

41 EM0861 1.951 1.336

12 EL18861 1.950 1.344

4 3 n C B o 6 1 l - ( 50 1-345 25 ( 400 p q 3.230 12) 32 ) 0.0~1 0.055 1 10.60 bunker* St&le--!-r& sa*{kc, ! QS (cL:LCAR~L 1.4W l * a 4 2 25 mg ' 400 ng 0.150 t2) - 1 29 ( 0.001. 0,055 1 10.30 15-21)' 1-2' I24 nsh vind--6-14 spark &€1==io~

f

46 5LbBQ61 ( 1.401 25 m~ 403 pg ! 0.250 ( 2 ) 29 1 O . O O i 0.055 1 10.36 15-20' 1-2' i 42 pph uind-6-lA .park &ficctlcd 30 r l X B 8 6 1 1 1.447 It344 25 $3 4 ~ 0 ng 0.250 I21 29 1 0.001 0.055 1 10.60 15-25' 1-2' 38 m;..h u/+.-6-10

52 EL40811 1 lmcOa 1.342 25 mg 400 Dp Ou2SD (21 29 0.WI 0.055 ( 10.00 20-25' 2 ' 20 mph wbnd--2-6']bpart

5 I L . ~ B S G ~ I 1.coo 1.JG2 25 mg COO ag 0.250 (21 29 0.001 10.055 ( 10.90 20-25' 1-2' 20 nph --2-61 =pack ,$fleetion (2) 1

4 5 4 E ~ C B U G L 1.100 1.350 25 aq 900 0.221 2? ,-,OD1 0.055 7.57 bunker*! I

1 I I I I I I 1 I ! I

KsrZ5r I. 0 51Wm PUZZLe OPEHIHG- L

f I -- 2. 0 r W D MUZZLE O Y M I M ; . - 1.

A= CPAIID VEFE INHIBITED VI?H 50 PERCM EPOX 828, SO PERCU~P YersamiddO. - I 4. AU. XGHITIW Y A l T R l U WAS 107-PPR-02-

*BO?r'KEa - UNRIDERGROtJrID TEST BAY, 1 t I I 1 I 1 - I I I I

I I I I t I I t I 1

I -

I I 1 I 1 I I I 1 -

Tests 8 and 10 cnrployed the following composition:

5 4 . 0 2 Potassium it rate (15.4-micron)

2 4 .08 Powdered Sugar, cammcrcial grade

e 14.08 Zirconium (Type I, Class 1) (approximately 100 micron)

8.02 E'luorel.

T e s t Unit No. 8 was fabricated using a 0.200-inch diameter

nozzle, (Kn45) , a n h it burned for 23.35 seconds. The burn

was stable, but spark output and projection were poor.

Nunher 10 also had a 0.200-inch diameter nazzlc (Xn45). This

unit also pro2uced poor sparks. Burn time was 22.78 seconds.

Tests 27 and 30 used t h e following com~-qition:

e 41.39% Potassium Nitrate (15.4 Micron)

* 31.03% Zircollium (Type I, Class I)(approximateZy 400 micron)

8.62% Magnesium *

0 8.62% Powdered Sugar, comercia1 grade

.m 8.623 Fluorel (10% soiutiol.1 in MEK)

1.. 726 Boron

The 2 r o p e l l a n t was pressed at 10,000 psi and then inhibited

using a mixture of 5 0 percent Epon 828 and 50 parcent Vcrsarnid

140. Test u n i t No. 2 7 had a 0.200-inch diam~ter nozzle ( ~ ~ 4 9 ) .

A stable bsrn with good spark output was sustained f o r G.89

seconds. T e s t Unit No. 30 had a 0.150-inch diameter nozzle

(Kn87). A 3.45-second stable burn produced good spark output.

A to t31 of 14 t e s t s ware conducted us ing the fol lowing propellant

composition:

41.0% Potassium itr rate 30.0% Zirconium (Typo I, Class 1) (approximately 4 00 micron)

9 . 0 2 Magnesium

9.0% Potvdcred Sugar, commercial grade, w i t h 3.0% cornstarch

9.05 Fluorel

2.06 Boron

A 1 1 propellants i l l this series were i n h i b i t e d us ing a mixture

of 50 percent: Epon 828 and SO percent Versamid 140. T e s t No.

33 had a 0.1.50-inch diameter n o z z l e , (Kn87), and t h e nozzle

assembly was expelled d u r i n g f u n c t i o n i n g .

T e s t U n i t s 3 4 and 35 had 0,183-inch diameter nozzles. T e s t

No, 34 had a 7.2-second burn w i t h good spark output. The

nozzle cxpelled on U n i t 35 d u r i n g f u n c t i o n i n g . As a r e s u l t

of the e x p u l s i o n of nozzles, a brief analysis of the cause

was conducted. LC was felt that the reuse of hardware Inore

than twice r e s u l t e d in t h r e a d fatique, thus causing the nozzle

housing to blow opt. This problem was eliminated when new

hardware was used axclusively for t e s t i n g .

T e s t s 3 8 , 4 0 , 41, 45, 4 6 , SO, 52, and 53 were conducted as

above but with 0.250-inch diameter nozzles. All units produced

good sparks with stable b u r n s f o r the d u r a t i o n s as listed below:

Burn Time Unit No, (seconds)

36 10.6 4 0 10.6 41 10.6 4 5 10.3

Burn T ime U n i t No. (seconds)

4 6 10.3 50 10. G 52 10.0 53 10.9

On October 24, 1980, Unidynamics conducted a series of t e s t s

fo r MSPC and Rockwell I n t e r n a t i o n a l . The t e s t s were conducted in crass winds of 40 miles per hour and 20 miles p ~ r hour tb

evaluate the effects of the wind upon the sparks. Bas ica l ly ,

the units performed very well under t h e effects of the wind.

Units 45, 46, 50, 52 and 53 of t h e above group werc f i r e d i n t o

a cross wind with the following results:

. Unit No. cross wind velocity Spark Deflection

4 0 nlpll

42 mph

38 rnph

20 mph

20 lnp11

6 to 10 feet

6 to 12 f e e t

8 to 20 feet

2 to 6 fcek

2 to 10 feet

Although the cross wind did deflect the sparks , a s i g n i f i c a n t

number passcd through a target placed seven f c c t away. Spar" 4

projection was in excess of 15 foct.

T e s t L k i t s 1 2 and 13 u s i n g the sama propel lant composition had

0.238-inch d i a m e t e r nozzJ,es and produced stable burns with good

spark outpu t . T e s t Uni t . No. 42 had a b u r n time of 10.5 seconds,

and U n i t No. 4 3 burned for 10.6 seconds.

Test Unit No. 54 u s i n g the same propellant composition had a 0.221-inch diameter nozz l e . It produced good spark o u t p u t and

burned fo r 7.57 seconds.

Although t h ~ potassium n i t r a t e units performed well under thc

wind condi t ions , Unidynamics a l s o t e s t e d t h e ammonium perchlorate

composi.tions under t h e same conditions. Both compositions per- - formed w e l l . w i t h t h e potassium nitrate producj-ng more smoke.

S i n c e i t was felt t h a t t h e s n m l l anlount oE corrosive hal ides given off by the ammonium parchlorate compositions were

insignificant, a decision was made to concen t ra t e on the more

widely used ammonium perchlorate system. In addi t ion to kha

potassiuin n i t r a t e compositions, one unit was fabricated (Test

No. 28) us ing the following co~npclsition:

GO. 0% 47-PPR-01

42.0% Magnesium Powder

21.0% Halon

6.5% Fluorel

3.58 Red Lead Oxide

27.0% Tetranitrocarbazole

4 0 . 0 % Zirconium (Type I, Class 1)

T h i s u n i t had a 0.125-inch diameter nozzle ( 1 1 . 2 5 Burn time

was 3.31 seconds. Thc burn was stable but with poor spark o u t p u t .

AMEONXUM PERCIILOIV\TE COEIPOSITfONS EVAItURTED IN PHASE 1

Table II summsrizcs this series of evalnakions, and t h e i n d i v i d u a l

composikior~s are discussed below.

~ i ~ c ammonium, perchlorate compositions evaluated were formulated

.us ing a hi-modal particle diskribution of anunonium pcrchloratc,

and a ground ammonium perchlorate system. Nozzle diameter var ia-

t i o n s were also ev31uated. Test No. 3 had th& following composition:'

+ 32.0: Anunonium Parchlorate

3 2 . 0 2 Anu~~onium Perchlorate (ap~roximately 11 micron)

r 13.1.8 R-45M

19.0% zirconium 1-200/325 mesh)

a 2.8% DDX-1410

1.02 Ferric Qxidc

e 0.1% CHO-14

T h i s mixture was r e a d i l y castabla and burned v igorous ly ~ i t h - ~ o o d

sparks , Howcver, Unit No. 3 with a 0.200-inch n o z z l e ( ~ ~ 4 9 )

expelled t h e n o z z l e . T h i s phcnome~-ln was attrlbutad to tsllc multiple uses of the hardware causing s t r u c t u r a l f a t i g u e .

T e s k No. 4 had the f o l l o w i n g composition:

rn 32.0% Ammonium P s r c ~ ~ l o r a t e

* 32.06 Ammonium Perclllorate tapproximately 11 micron)

r 13.12 R-45M

1 2 . 0 % Aluminum ( ~ e y n o l d s N o . 4 0 - 30 + 5 micron) - 7 . 0 % ~ l u m i n u m (Heyaolds No. 1-842)

2.8% DDI-1410

1.08 Ferr ia Oxide

+ 0.1% CAO-14

t . TmLE I1 - A M i O X I U M PERCHLOKATE MIX PROPELLAN'L' TESTS

: ;o t t r f Zgnirion I. D. Emxzla Pellet (Inchcn) CnnIlrl. rn e o n r . z n ~ s

3 -8834 ' 1.31 50 rq ba!?-rc.' 0.200 ( 2 ) 4 9 I

4 p a 0 3 ~ 1 1-30 , 1.395 so m I iv,:terrj ,. o.;loa (21 49 o.ca 0.030 2.0 --- 9

19 o.?o?- 12) 44 o-col- o.am 18.41

0.001 0.039 30.0' ---- --- -- ----- EGtiEIYe 1.150 1.336 53 mq :q h~:rerc? D.ZC3 121 54 9 , C D l c-030 30.9 -- ---

3 [ trmaa;~ 1.20 1.358 50 Ixg tucterc~ 0.201 (21 46 J.CD: o-,20 18.82 - I ----, m a ~ f e d b d sparks 1

11 IrV;kae* 1.19 (21 QS 0.091 0.030 19.6 1 50' 1 1-2" ~ t a b l t - - h ~ spar\= I 12 fi1 45 O.CC1 0.030 2 1 - 2 1 1 30-35' 1 1-2' ~ t & l c - & m d nwrkr

13 111 e l 0.011 0.030 23.9 --- ----

0.031 0.055 10.46 30-35' I*-1'6- CP.uffcd

0.125 (21

0.125 (2)

0,234 (2)

0.001 0.055

1 TAELE I1 - X44ONTUL.I PZRCHLOFGiTE M I X PKOPELmiT TESTS G m s d train Xguziar i I Grain Length ~ i a = e t ~ =

hest No. C h g . . t l n c % ~ ( l ~ = h e s l . Lw.e h a 2

25 -q

1 . D . (IDC~CB~

0.201

'-ozzie

5.5 wE*M 1.1C3

:gr.i:!en ?*!IT: 4s.) y

" 7 --QsLG- ?:FC~J -

1 . 3 4 9

55 1 - 2 9 41,s rq 0.150 1 12)

!Iorzlc C m 1 S t ~ .

[a 1-350 f 1s rq 8;

rn

C 5

s64G5 ( 2,1D: 1 1.3<9 f 2s W / SCIJ y 1 0.222 ] (21 I :: 5,353 25 rq 1 LC,? q

sfak Ti..? ma. f

17 I o*gEz ] 0.555+[ e-61 2 I - f &:&lc--lcm: 5w;km I I C.221 1 12:

25 =q 1 <cs r, 1 0-121 ( t2l

25 C-3 1 453 1 a*221 1 2 I 53 i EL;eq65 1 l.rm

&* I t s a ' b s ( 1-102

r,lsa 1-352

0-:55 ( 7.33 {3%?S* 1 7-2' 1 ~ m t l e - - / - d s F 3 1 ~ s 0.055 ' - 7 4 ) 33-35' 1-2* j s u a ~ a - ~ , p s < s w i k ~

I 1

37 ( O-C31

) r ~ ~ d 6 5 ?.G52 1.351

7

0 . ~ 9 2 1 0,055 1 8 -82 (55-59' 1 1-2' ' l~t&~*-:;-& z;~{hs

1 0 . ~ ~ 2

1 . 3 4 B j :: r:;c$~s 2.361 1,353

I L5 t L L ~ 5 3 l-IS5 1.158

' ffi I ~ 3 5 : W J-IC' 1.351

2s C 4

0=C52 I t : 1 (71 1 73 K.9 q 1 6,162 f

0.655 1 a.eg 145-so# ) 1-2- ~ s ~ ~ I o ~ ; ~ s;a;&s

I 0.055 e*02 25-Ja' 1 L-2' S F E / ~ = 1 t 37

e v e p i 5 2.401 1 1.3Ce

25 rq

C C

0-532

61 I w a - t e 1 r.101 1 1 . 3 4 5 1 25 q 1 t o 7 n7 1 0.221 j 1 ~ 1

25 4

5Z9 .q 1 (21 ) 37 1 c . c : ~

42'; 1 00.161 1 12) 1 73

0 . ~ 5 5 1 7.95 I s s : ~ * ! 1-2. ' 15&:c--;?& a : ~ ji-l

37 1 C . C ~ Z / C.055 1 7-74 I 3~-35*

1 1 5+5ga 1 7-3' ' I : t : i~~t=i t:err<+ I I D.Cf9 1 7-33 133-Is* 1 1-2' ]5rabrP-!;wd s:aii.s I 1 0.055 1 7-88 13(J-35' 1 1-2. - i ~ t a b ~ ~ - - / ? ~ + .-,*jk3 1

25 s3 1 4 x 1 -7 1 G.151 (25 1 73 1 O.C=Z

25 r q 1 455 eq 1 5Az2: 1 (2) 1 37 1 C-Cc2

- 2 i5ratl-+rd *elkr I 1 I I I ! I I I I I

3-3: f. 0 5 &. '~3 -:ZazL': CBZ+i1::5, i

25 rq ( 55l? y D-zZ1 ( I21

1 1 1 1 I I

I 37 f O-C37

$ 2. 0 ?&LIT f t 2 Z l . Z Cif.*i:!.G. I

,. cif1,5 EPZ I ~ S I : D L ~ WITH 50 ?E=F~ mr e2e. p E K E ~ ' J r ~ ; , ! ~ ~ C : ~ o - I 1 1 1 4. ~'1. XC'rIflQI rATflIAL W > S 107-YPR-02-

I I ' I 1

I I 11 I I 1 I I

I I I

1 I I I I I I

1 I I 1 I

1 I I I, 1 I t I 1 I I

I I I

I I + +--- 1

! t

t 1

I I I

T h i s composition w a s readily cast-nblc, and stable burning, but:

spark o u t p u t was poor. The unit had a 0.200-inch dianleter

nozzlc and burned for 2.0 saconds. S inca t h e sparks produced

were poor, olu~ni~luln was c1irninat;cd f r o m f u r t h c r development a c t i v i t i y .

Test N~imbers 5, 12, 13, and 1G fcnturcd thc following composi t ion:

p 29.03 Anlrnoniunl Perchlorate

29 .0% A~nrirol~ium Pcrclllorstc (approsimatcly 11 mj.cro11)

CJ 2 4 . 0 1 Zirconium (Typc I, Class 1)

14.8% R-45M

3 . 2 2 DDI-1410

T h i s calnposition was readily castable. Unit No. 5 had a 0.200-

inch diometcr nozzle (K1144) and producod a stable burn and good

sparks f o r 18.41 scconds, Test U n i t No, 1 2 a lso had a 0.200-

inch diameter nozzle (Xl,45) , and i ts burn t i m e was 21.27 scconds

w i t h good s t a b i l i t y and output. Test ~ n i ; 13 had a 0.150-inch

d i a l l l e t e r nozz lc (Kn81), and its burn time vos 13.9 scconds.

T e s t U n i t 1G had a 0.150-inch diamctcr nozzle (Xn79) and a burn

tirnc of 12.9 scconds. Both units produced good sparks w i t h a

s t ab l e burn.

Tests G and 7 cvaluatcd the following composition:

58.0% Anlnloniun~ Pcrchloratc, *ground approxi~natcly 11 m i c r o n )

2 4 . 0 % zirconium (-200/+325 mesh)

r 14.8% R-45bl

e 3.2% DDI-1410

B o t h units had 0.200-inch diainetcr nozzles 4 , and both +

had b u r n timcs of 30 scconds plus. JJowever, the u n i k s chuffed

d u r i n g burn, and few sparks were produced.

Tests 9, 11, 14, and 15 were conducted w i t 1 1 u n i t s incorporating

thc following propellant composition:

32.0% Ai~~manium Percl~lornte e 32.01 ~mmonium Perchlorate (11 micron)

r 20 .0% Zirconium (Type I, Class 1)

o 13.2% R-Q5M

o 2.8% DBI-1410

d

U n i t No. 9 , with a 0.200-inch diameter nozzle ( ~ , 4 6 ) , had a

burn time of 18.82 seconds. It chuffad during burn, but spark

o u t p u t w a s good. Unit No. 11 a l so had a 0.200-inch diameter

nozzle (Kn45), and it: burnod for 19.6 seconds. The spark output

was good and the burn was stable.

Test Units 14 and 15 had 0.150-inch diameter nozzles (K1179).

U n i t N o . 14 had a burn t i m e of 7.30 seconds, and U n i t No, 15 had a burn time of 2.99 seco~ljls. Both u n i t s burned s t a b l y with

good spark ou tpu t .

The follawir-tg propellant mix was used in Tests 17, 1 8 , 1 9 and

20:

r 24.08 Anunonium Pcrchlora te

4 0 . 0 % Ammonium Perchlorate (11 micron)

20.0% Zirconium (Typo I, Class I)

e 1 3 . 2 % R-45M

s 2 . 8 % DDI-141.0

u n i t s 1 7 and 1 9 bad 0.200-inch diameter nozzles (Xn46) and

produced burn times of 19.90 and 19.35 seconds, respectively. Both units had stable burns w i t h good spark output. U n i t No. 18

had a 0.150-inch diameter nozzle (Kn 81) and burned s t a b l y - for

11.76 seconds with good spark output.

U n i t No. 19 had a 0.150-inch diamotcr nozzle (Kn81) and

produced a burn time of 9.5 0 seconds. T h i s unit chuf fed, but

spark output was good.

TI-la following p r o p c l l a n t composition was used for Tests 21, 22,

23, 2 4 , and 25:

2 9.0% A m m c ~ i u m P e r c h l o r a t & . 29.08 ~rnmo~iun i Perchlorate (11 micron)

e 21.08 Zirconium (Type I, Class 1) (,qpproxin~ately 400 micron) 8 14.7%. R-45M

3 .28 DDI-1410

0 . 1 2 CAO-14

A l l f i v e u n i t s had 0.150-inch dj.ametcr n o z z l e s (Kn81). N i k h

tlie except ion of Test No. 25, all units clluffed f o r appnoxiinatcly

two secailds a f t e r i g n i t i o n and the11 b u r n e d s t a b l y f o r t h e

remainder of function. This i n d i c a t e d s l i g h t nozz l e plugging.

u n i t No, 25 had 2 sta13l.c bur11 ~ A I ~ o u ~ ~ I o u ~ . All u n i t s had good

spark , o u t p u t , and burn tirncs were 1 0 . GG, 1 1 . 4 0 , 10 .30 , 10.46,

and 9.90 scconds, respectively,

U n i t s 21 and 22 incorporated a four-inch l o n g d e f l e c t o r s h i e l d

made from 0.010-inch thick stainless steal. T h i s produced no

s i g n i f i c a n t d c f l c c t i o n in t h e spark p a t t e r n , because the 0.010-

inch thick stainless steel shield would not withstand t h e heat.

U n i t 25 had a one-inch long deflector shield made from 0.090-

inch stainless steel, It also proved ineffective. A thicker

1 ~ a l 3 c d deflector was later fabricated ivllich did signiflcontly

rcaluce the e r r a n t sparks.

A t this p o i n t i n t h e program, t h e bi-modal particle size

distribution of amoniurn p e r c h l o r a t e was discontir lued i n

favor of the grouna perchlorate for burn rate enhancement .

Collsiderable effort was exgendcd in selection of the proper

propellant colnposition, i nh ib i to r mater ia l , nozzle conf igura t j .on and the a d d i t i o n of a small amount of f e r r i c oxide te a c t as

a burn r a t e c a t a l y s t . The final propellant composition developed f o r this program was designated CH3 MOD I and has t h e fo l lowing

ingredients :

58.0% Ammonium Perchlorate, (ground approximately 12 micron) C

a 23.5% zirconium, Type I, Class L

14.88 ~ydroxy- terminated Polybutadiene . 3 . 2 % DDI-1410 C a t a l y s t

0.58 Ferric Oxide

WN? f i n a l nozzlc dianleter was 0.221-inch, (K,37) . A l l t e S t s

produced stable bur~ls and good sparlc pt-ejection. Additional

discussion of burn characteristics is provided in the n e x t

section.

A t o t a l of 10 u n i t s were fabricated and shippocl to Santa

Susana Field Laboratory and NSTL.

PHASE I1 - PROTOTYPE FAI3RICATION.AND DEVELOPMENT TESTING, AND

FINAL DESIGN -

This phase encofipassed prcparakj.011 of f i n a l drawings, the

acceptance t e s t procedure, RIOS , and rnanufact-.~~ring process

proccdurcs. The documents were presented to MSPC in a design

rcvicrv mcetiilg on November 10 and 13, 1980. Rccommcnded changes

were incorporated and these documents welo submitted for f i n a l - approval on Novcm~er 19, 1980. Final. approval was granted. on

November 24, 1980.

As specified i n MSFC-SPEC-541, the N3I i g n i t e r cartridge fifty-

percent Eire poj i l t tests were cor~duct.ed on November li. Ttvcnty u n i t s

functioned a t a d i s t a n c e of 2 . 2 3 inches, ~ ~ h l c h is an increase

of one inch above normal. N o f u r t h e r tests were conduckcd,

s ince a l l units functioned.

K, motor t e s t i n g was conducted on November 25. Intcrnal/externol burni ,ng centrally garforntcd grains with both e n d s inhibited were

tested in the 30-3738 Kll motor. Results are tabulated helow and shown graphically on t h e n e x t page.

Grain 14ax. c o n Burn Test OD s SD x Leng th Prossure P T i m e R a kc NO - ( i n c h e s ) - ( p s i g L (psig) (set) (in/sec)

Strand burn ing rate tests were a l s o conducted on November 19.

The propellant; strands w e s t ; i n h i b i t e d w i t h two coats of 50/50

Epon 828/Versamid 3.10 with two percent carbon black added.

PROPELLAYT CONPOSlTlON - CH3 MOD 4

PROPELLtlNT LOT NO. - EL48868

Mean Prcssure (ps i )

K VERSUS MEAN PRESSURE n

Pressure -

224 583 963

Plean Prrssul-e ( p s i ) BURN RATE VERSUS PRESSUPE

50 psi - 0.25 in/sec 250 p s i - 0.40 i n / s e c 500 p s i - 0.51 in /scc 1000 psi - O . G ? i n / sec

Strands were burned under nitrogen in the low pressure bomb.

R e s u l t s are tabulated below and shown graphically on the previous

Page

Pressure Length Time Rate ( P S ~ (in) (SCC) (in/second)

1,000 1.90 3.157 0*602 20.61 1,000 1.90 3 ,094 0.614

One lot of 28 igniter cartridges were fabricated in December 1980

u s i n g accepted process procedures. Before pre-qualification

t e s t i n g the l o t was subjected to the LOO-percent acceptance

t e s t s described below an2 outlined by the table on the next page. 4

Visual Mechanical. - Each NST igniter ca r t r i dge was inspected f o r

conformance to workmanship, dimensional, and marking require-

m e n t s of Drawing 51-2151, R e v i a i o n A. Five units (S/N 111, 112,

114, 125, and 129) fa i led t h i s t e s t . u n i t s 111 and 114 had a small

crack i n the adapter. Uni t s 112, 125, and 129 had a small crack

in the nozzle housing. These cracks would cause t h e units to fail

the leak t e s t s . MSPC gave approval to use these units in test.

Six a d d i t i o n a i u n i t s had vo ids or blow holes in the weld area

which could n o t be sealed. These u n i t s were also approved for

t e s t by MSPC s i n c e the leaks would n o t affect performance.-

Visunl/ Mcchanicn?

P

P

(21

h'SL F l i g h t Cerc.

X

X

;Y

X

X

X

$

Unit S/S

109 XSZ 1864

Grain SIN

212 ::Sf 1869 - 112

" 3 "1 1870 1 K: 114 :IS1 1871

115 NSI 1372 115

S/3

NSI StaPLag Verif .

110 SSI 1867 110

111 NSI 1e68 111

116 11SZ 1873

109 ' 1 1864

Gross Lcak Tcs t (1 )

*-

1367

1868 -

-1869 1 (3)

1870 I P

1871-1 (2)

. 116 x 2

1872

1873 P :(A

117 :;ST la75

1 118 NSI I876

118 XSI 1895

C.928

Hcllvn Leak Test

x f F F

X F ?

X I F " ' -

?

P I X X I: ? X

, ~ 5 2 ~ itesiscac;e

X-?ay

P X A

X

X

--- x I X I

117 1 187s

x I FA

d3) -- X

1 x I Y I

129 XSI 1878

0.993 j P (41

118

119

t""~I"'i0 . DIS?CSIPIOW

P -- I P x

x I ? - - I P I T P

1876

1895

C e s i s t a n ~ ~ 50MC

X P

P P

P

P 1 X 10.490

X

X

0.997

SA

x

S A 1 P - F

x

x I

P

P

Qua1

0,992 P . F F

F P

X

X

x LZO :C

1881

1882

1883

121 SSi 1379 1 121

122 N 5 i 1880 1 122 123 X I 1881 LZ3

1.24 !;ST la82 1 124

Shipnen

x- x

::A I X

- c

P

f Nd

P :&I

X

x

l679

1880

X XA f

125 NSf 1833

0.089

0.994 X

X

10.999

F P i P 1878

::A

Xd

iJ I x 1 -Y I P -- I P 1 X 10,995 1 P

125

126 W S I 1886

127 NSt 1887 ,

128 --- --- 129 351 1889

130 NSI 1899

10.975

S'i

SII

P

X 10.973 f P f SA

': ? -- 1 P 1 /0.991

P

P

, P

(3)

x

126 '

127

128

129

130

P - P

Y I i p - - I x (1.~05 I P

-

:< 1o.sao

x X F

1 (61 -

--- N A

--

132 N S f 1892

133 KSI L893

131 XfI 1886

- 135 NSI 1895

141

X

ss;2,

I.OC0

0.946

I.G04

0.963

1,002

x I F ( 6 ) P

F

136 SS1 1896

1866 ] P I x I x 1 P P 1 T 1 y.

X lit Fb' --

X l o . ? ~ ~ I P

x 1 ::A

1 . C C G

0,9?0

--

1)1-1 X X

P

P

P

--

X I X

I

XA I --

* F P P -I-

P

P

P

P

--

P

0.586

X

-- X

--- rsss

1687

---

P I x P 1 x

!:A

:JA

XA

X

---

X 132 1692

x I0.95a 1 p - 1 I 2

I

,IG) F 1 F 1 i[

- I- t --I 1 ---

3 I x x -

i?

--- d 3 ) - F

were :

P X

133 1 1893

134 1888

tlA

0.997 . 1 F I X ,Cbl 1690

x

--

peurnd t i : ; e

- TZST CIWfN A CEPTMCE 136

:U

? X X

I ---

135 1 1895 j G ~ I N A~CEFT~Q~CE

P

P

X ' 2

I 1895

X 11

p f X -

P

F

X

X X

1 I 1 - -

1

--- ---

7 ~ d ~ x ~ f - ~ c k

3 Sozrte b u - K c i a o k

1.003 1 P

::A

X

x F ... TEST

ihen ;eccstbd. Unit1 that fakled rhb

- I --- 10.985

I ;ross lea. CesE che they verr 1 I£ Imics E;

I 4 Unic 2sssej a11 cesc

5 Inhiblce: l lrsckcd Grr - - -- 6. Weld Lee i-

- - 4 -- ,

f irst rire rec;elded i l e d t h e

used in Xini-C/ sl T e s t ng

I

--- --- - --- --

2 carries over intr

-ink nachlninq --I-. . . . A

n e x t lot1

- -

I --

- . . -- - 1 . -t-r - . -

NSI P l i g h t Certification. Vaxification tvas made that each

car t r idge was Iiskead by ser ia l nunlbcr and lot number i n t h e NASA

FLigh t C e r t i f i c a t i o n Dacurnenk (P/N SEB 261-0000-1).

NSJ: S t a k i n g V e r i f i c a t i o n . Verification was made t h a t al,l units

were tlrclded to the i n i t i a t o r adapter for h e r m e t i c scaling par

NASA/JSC Drawing SED 261-0000-1.

- Leak Tests. Maximum al lowLibla leakage was 1 x i u v 6 cc per second of hc l iu rn rncasu1:ed at one atmospl'lcrc d i f f e r e n t i a l pressure and at

ambient tempcraturc. Twenty-five igniter carkr idges were subjected

to the gross leak check per Paragraph 4.1.4.2 of Unidynamics'

,Docuincntr 51-1151-ATP-01. Eleven units f a i l e d . These u n i t s were

used as t h e e lcvcn test i ~ n i t s in ~ I I C p r e - q u a l i f i c a t i o n sarias.

The same group of 25 u n i t s was a l s o subjcctcd to the l ~ e l i u m 1-enk

t c s k pe r Paragraph 4.1.4.3. o f Unidynamics' Documcnt 52-1151-hTP-01.

The e l c v c n u n i t s t h d t faailcd the yross leak a lso f a i l e d the llcliurn

leak. (Sce ~isuul/MccI~anicaL paragraph. ) ,

Radioqraph Inspection. Each i g n i t e r cartridge was X-rayed for

cvj dcnce of visual defects, m i s s i n g co~tlponcnts, cracks, and

vo ids . None ware found.

Bridgewire Resistance. A l l u n i t s were within tlie speci f i s d

resistance of 0.95 k a 1.15 ohms.

I n s u l a t i o n Rcsistancc. - A 1 1 u n i t s pnsscd a n i n s u l a t i o n rcsistnncc

test luaasured betwee11 the shorted bridgewire circuit and t h o

i g i l i t e r body. Resistance was greater than t w o mcgohms (25 nlicro-

amperes) at 5 0 VUC. Tl~c eleven units d c s i g n a Ccd fo r p r e q u a l i f i c a t i o n

testing passed t h e 1 2 5 n~icroarnpercs ( 2 nlegohms minimu~n) at 250 VDC

except far S/N 123 (NSI S/N 1887) and 129 (NSI S/N 1883) which - failed.

MSFC au t l lo r i zed use of the u n i t s for t e s t i n g .

P r e q u n l i f i c a t i o n Testing, Twv, S / N 135 and 1 3 6 , of the o r i g i n a l

lot of 28 u n i t s were used by Unidyllainics in grain acceptance t e s t s .

Recorded b u r n times wcre 9.20 and 8.00 seconds, rcspcclively.

As outlined in the flow chart and t a b l e of results on t h e next

two' pages, four u n i t s (S/N 114, 123, 125, and 1 2 9 ) were E u r ~ c t i a n c d

a t ambient temperature w i t h no wind. R e s u l t s were satisfactory a s o u t l i n c d below:

Burn T i m e (seconds)

7.96

Spaxk P r i : ~ c t i o n was in excess of 15 feet.

Three u n i t s (S/N 111, 1 1 2 , a n d 1 2 4 ) were f u n c t i o n e d a t h i g h

temperature (+150 OF) w i t h a 4 ~ - r n i l ~ - ~ e r - h o u ; cross wind. Results

wcre s a t i s f a c t o r y as o u t l i n e d below:

Burn Time (seconds)

7.39

7.17

7.17

Spark projection was in excess of 15 feet.

I 7

POST- F i RE LEAK .

ALL' UNITS

NON-DESTRUCTIVE TESTS

PRE-QUALI F I CAT1 ON TESTS

12 SHIP AFTER PRE-QUAL .

i 23 UXITS 1 b TESTS

i

11.

4 [ 13 13 I I - FUpiCT I ONAL

M"13 1 El iT 80 !AI:lD

S/N 114, 123, '125, & 129

r

E5 PE!?CEI';T FbHCTI El ' TEST

ti I Gf-! T E N P E 9 f i i U R E

LOW iEMPERF\TURE FUMCT T CI:l

F U K T i Or4

S/N 111, 112 AND 124 A

40 MPii GIIPID

5/N 109, '130 r AlfD i 3 4

s/a 127.

Three units (S/N 109, 130, and 134) wcre func t ioned at low tempera' ure (4-20°F) wit11 a 90-mile-per-hour cross wind. Results wcre satisfactory as outlined below:

S/N - Burn 'Time (seconds) - 109 8.23

130 8.37

134 ' 8 . 3 3

Spark projection was i n excess of 15 feet.

Eighty-five Percent Load T e s t . One u n i t , SIN 327, was manufactured

with an 85 percent nominal o u t p u t charge to v e r i f y that it

would still perform w i t h i n spec i f ica t ions . Burn t i m e was 5.67

seconcls, and spark projection was i n excess of 15 feet. T h i s

u n i t passed t11e post - f i re l eak k c s t . 1

A l l pra-qualification u n i t s func t ioned properly, producing high

d e n s i t y sparks. I n units tested under 40-mile-per-hour winds,

s p a r k s d r i f t ed approxima,tely LO feet; however, a s i g n i f i c a n t

number of sparks were not affected by the wind and traveled " .

through the center of the target area placed 15 feet from the

u n i t .

D u r i n g these t e s t s a deflector w a s i n s t a l l e d on the nozzle of

the i g n i t e r in an attempt to a l i ~ n i n a t e the errant sparks which

t raveled above the 28-inch height desired at the 15-foot distance,

The dcf lcc tor was successful in elirrlina ting t h e s e sparks. On

December 15 approval was given to proceed with d e s i g n , f a b r i c a t i o n ,

and s h i p m e n t of s i x def lec tors ,

A f t e r pre -qua l i f i ca t ion was .completed, twelve u n i t s were shipped.

PIIASE I11 - FABRICATION AND QUALIFICATION TESTING --

A t o t a l of 4 6 u n i t s ware fabricated in accordance w i t h Unidynamics'

Drawing 51-1151 and Urlidynamics' Manufactur ing Procedures

(51.-1151, Revision B) . Of these, 21 ~ l c x e to go into l o t qualifi-

chtion and 20 u n i t s weye for shipment. The q u a l i f i c a t i o n report

is Unidynamics ' Docun1er1.t: Number 55-llS1-OTR-03. Twenty-four

u n i t s were shipped af te r q u a l i f i c a t i o n t e s t i n g . - For c o n v e n i e n t reference, qualification r e s u l t s are o u t l i n e d on

the next page,

TABLE V QUALIFICATION TEST RESULTS

i

Cnir Grain K51 ~ 3 ~ 0 njlbrstion fhcmsl s/n so: sflc Pog I g 3 : t l o " ZbW* - I --- 1 L 3 FZI 1943. 1 6 3 ' 1903 1 -'-

I & & 5SI 190:l I & & 190A I --- --- i r: I --- X --- i x X 3 4PS --- 7 . 9 3

1 ?SR --- --- X )I

x - - i I&'? X5L l?!N! 1 b 9 + :gOs ! --- --- --- ! 6 . 9 0 1 X

x --- --- I r - r . --- --- i --- I --"

.--- --- --a ---

j C 5 %?I 19261 l b S I a - 1 ..-- --- --- 1 . 165 1 5 1 l g ~ g l 1 6 6 ! lg?? t % 1 --- I ---

1 6 7 1 5 1 ? 9 3 0 ( 1 6 7 1 --- I X X - 171 351 19341 171 1 --- 1 --- 1 --- -- - : i 3 ssz 19371 133 1937 - I x ! X I / --- --- ..-- --- I B . D P I x !--A!-,, t

1 1439 X I --- X X --- pars 1 ?ass 1 ~ n e s X . . --- i 7 . 7 ; 1 x i p,. 19Lg --- --- . . . . . - -

. X .i61* [ --- --- -- - -- .

1 7 7 YS2 1 9 6 1 ! :I7 l g ~ l I --- I --- x I --- --- --- ! 6 .93 1 I: 3 . . ! - - ! --- I 1 2 I 1 --- I --- ,,P " C ? . G . . / 1 7 8 --_ t - - i --- --- ! POSS 1 -,- I J: io . , , f - - - I - - - I

136 ?:ST l ~ o b l 1 3 b I

I F 5 6 7 --- Z 1 r: --- a m = 1 P ~ s 3 1 P U 3 --- I x --- I 7.13 1 7 1 ? > L ? / Pass I P , T . ~ 1 s l [ P a s - I P o ? ? x ! --- - - 1 . 3 i 7 a * - - i - 1

I.=& I v --- ?ena & --- I r - - - ! 7.2.4 1 X

I i t I I I i I 1 I I 1 i I I I t 1 I I 1 I I I I

- -- - - - L 1 . J I I I d I i I - 1. Actolqnltion test uniks ucrc fired for Rockwcll on 1-8-81. Autoianit ics :~qu i r rncn tn were f u l f i l l r ? r i ,by ~:escfl-=ion of data- ,

- 2. Eight-foot drop tes: unit. - 3. Fsrty-foot drop cost uni t .

- 4. GFX f a i l e d -- continued w i T h qual. - 5. BSC load test.

* 6. Extra uni t i n q u a l .

' #*

CONCLUSIONS

The P/N 51-1151 NSI Igniter C a r t r i d g e has met a l l of the

raquirernents of MSFC-SPEC-541.