Joshua R. Finkbeiner

Characteristics of Elastomer Seals Exposed to Space Environments

Abstract A universal docking and berthing system is being developed by the National Aeronautics and Space Administration (NASA) to support all future space exploration missions to low-Earth orbit (LEO), to the Moon, and to Mars. The Low Impact Docking System (LIDS) is being designed to operate using a seal-on-seal configuration in numerous space environments, each having unique exposures to temperature, solar radiation, reactive elements, debris, and mission duration. As the LIDS seal is likely to be manufactured from an elastomeric material, performance evaluation of elastomers after exposure to atomic oxygen (AO) and ultraviolet radiation (UV) was conducted, of which the work presented herein was a part. Each of th e three candidate silicone elastomer compounds investigated, including Esterline ELA-SA-401, and Parker Hannifin S0383-70 and S0899-50, was characterized as a low outgassing compound, per ASTM E595, having percent total mass loss (TML) less than 1.0% and collected volatile condensable materials (CVCM) less than 0.1%. Each compound was compatible with the LIDS operating environment of –50 to 50 °C. The seal characteristics presented include compression set, elastomer-to-elastomer adhesion, and o-ring leakage rate. The ELA-SA-401 compound had the lowest variation in compression set with temperature. The S0383-70 compound exhibited the lowest compression set after exposure to AO and UV. The adhesion for all of the compounds was significantly reduced after exposure to AO and was further decreased after exposure to AO and UV. The leakage rates of o-ring specimens showed modest increases after exposure to AO. The leakage rates after exposure to AO and UV were increased by factors of up to 600 when compared to specimens in the as-received condition.

Optimized Shapes of Oscillating Resonators for Generating High-Amplitude Pressure Waves

Several studies have proved that the geometry of an oscillating acoustic resonator strongly influences its resonance frequencies and the nonlinear standing pressure waveform generated within the cavity. The research presented herein uses a quasi-one-dimensional numerical model to solve the acoustic field and is validated by comparing with experimental results. A quasi-Newton type numerical scheme is used to optimize the axisymmetric cavity contour by maximizing the pressure compression ratio, defined as the ratio of maximum to minimum gas pressure at one end of the oscillating resonator. Cone, horn-cone, and cosine resonator contours are each optimized for a fixed amplitude of the periodic external force oscillating the cavity. Different optimized shapes are found when starting with different initial guesses, indicating multiple local extrema. The maximum pressure compression ratio value of 48 is found in an optimized horn-cone shape. This represents a 241% increase in the compression ratio over any previ...

Apollo Seals: A Basis for the Crew Exploration Vehicle Seals

The National Aeronautics and Space Administration is currently designing the Crew Exploration Vehicle (CEV) as a replacement for the Space Shuttle for manned missions to the International Space Station, as a command module for returning astronauts to the moon, and as an earth reentry vehicle for the final leg of manned missions to the moon and Mars. The CEV resembles a scaled-up version of the heritage Apollo vehicle; however, the CEV seal requirements are different than those from Apollo because of its different mission requirements. A review is presented of some of the seals used on the Apollo spacecraft for the gap between the heat shield and backshell and for penetrations through the heat shield, docking hatches, windows, and the capsule pressure hull.

Nonlinear Resonant Oscillations of Gas in Optimized Acoustical Resonators and the Effect of Central Blockage

Optimizing resonator shapes for maximizing the ratio of maximum to minimum gas pressure at an end of the resonator is investigated numerically. It is well known that the resonant frequencies and the nonlinear standing waveform in an acoustical resonator strongly depend on the resonator geometry. A quasi-Newton type scheme was used to find optimized axisymmetric resonator shapes achieving the maximum pressure compression ratio with an acceleration of constant amplitude. The acoustical field was solved using a one-dimensional model, and the resonance frequency shift and hysteresis effects were obtained through an automation scheme based on continuation method. Results are presented for optimizing three types of geometry: a cone, a horn-cone and a half cosine-shape. For each type, different optimized shapes were found when starting with different initial guesses. Further, the one-dimensional model was modified to study the effect of an axisymmetric central blockage on the nonlinear standing wave.

Investigations of Shuttle Main Landing Gear Door Environmental Seals

The environmental seals for the main landing gear doors of the Shuttle Orbiters were raised by the Columbia Accident Investigation Board as a potential safety concern. Inspections of seals installed on the Shuttle Discovery revealed that they were permanently deformed and no longer met certified seal compression requirements. Replacement of the seals led to the inability to fully close the main landing gear doors. Johnson Space Center requested that Glenn Research Center conduct tests on the main landing gear door environmental seals to assist in installing the seals in a manner to allow the main landing gear doors to fully close. Further testing was conducted to fill out the seal performance database. Results from the testing indicated that the method of bonding the seals was important in reducing seal loads on the main landing gear doors. Also, the replacement seals installed in Shuttle Discovery were found to have leakage performance sufficient to meet the certification requirements.

Design Study of Wafer Seals for Future Hypersonic Vehicles

Future hypersonic vehicles require high temperature, dynamic seals in advanced hypersonic engines and on the vehicle airframe to seal the perimeters of movable panels, flaps, and doors. Current seals do not meet the demanding requirements of these applications, so NASA Glenn Research Center is developing improved designs to overcome these shortfalls. An advanced ceramic wafer seal design has shown promise in meeting these needs. Results from a design of experiments study performed on this seal revealed that several installation variables played a role in determining the amount of leakage past the seals. Lower leakage rates were achieved by using a tighter groove width around the seals, a higher seal preload, a tighter wafer height tolerance, and a looser groove length. During flow testing, a seal activating pressure acting behind the wafers combined with simulated vibrations to seat the seals more effectively against the sealing surface and produce lower leakage rates. A seal geometry study revealed comparable leakage for full-scale wafers with 0.125 and 0.25 in. thicknesses. For applications in which lower part counts are desired, fewer 0.25-in.-thick wafers may be able to be used in place of 0.125-in.-thick wafers while achieving similar performance. Tests performed on wafers with a rounded edge (0.5 in. radius) in contact with the sealing surface resulted in flow rates twice as high as those for wafers with a flat edge. Half-size wafers had leakage rates approximately three times higher than those for full-size wafers.

NONLINEAR OSCILLATIONS AND FLOW OF GAS WITHIN CLOSED AND OPEN CONICAL RESONATORS

A dissonant acoustic resonator with a conical shaped cavity was tested in four configurations: (A) baseline resonator with closed ends and no blockage, (B) closed resonator with internal blockage, (C) ventilated resonator with no blockage, and (D) ventilated resonator with an applied pressure differential. These tests were conducted to investigate the effects of blockage and ventilation holes on dynamic pressurization. Additionally, the investigation was to determine the ability of acoustic pressurization to impede flow through the resonator. In each of the configurations studied, the entire resonator was oscillated at the gas resonant frequency while dynamic pressure, static pressure, and temperature of the fluid were measured. In the final configuration, flow through the resonator was recorded for three oscillation conditions. Ambient condition air was used as the working fluid. The baseline results showed a marked reduction in the amplitude of the dynamic pressure waveforms over previously published studies due to the use of air instead of refrigerant as the working fluid. A change in the resonant frequency was recorded when blockages of differing geometries were used in the closed resonator, while acoustic pressure amplitudes were reduced from baseline measurements. A sharp reduction in the amplitude of the acoustic pressure

Determination of dimensionless attenuation coefficient in shaped resonators

The value of the dimensionless attenuation coefficient is an important factor when numerically predicting high‐amplitude acoustic waves in shaped resonators. Both the magnitude of the pressure waveform and the quality factor rely heavily on this dimensionless parameter. Previous authors have stated the values used, but have not completely explained their methods of determination. This work fully describes the methodology used to establish this important parameter. Over a range of frequencies encompassing the fundamental resonance, the pressure waves were experimentally measured at each end of the shaped resonators. At the corresponding dimensionless acceleration, the numerical code modeled the acoustic waveforms generated in the resonator using various dimensionless attenuation coefficients. The dimensionless attenuation coefficient that most closely matched the pressure amplitudes and quality factors of the experimental and numerical results was determined and will be used in subsequent studies.

Effect of forcing function on nonlinear acoustic standing waves

Nonlinear acoustic standing waves of high amplitude have been demonstrated by utilizing the effects of resonator shape to prevent the pressure waves from entering saturation. Experimentally, nonlinear acoustic standing waves have been generated by shaking an entire resonating cavity. While this promotes more efficient energy transfer than a piston‐driven resonator, it also introduces complicated structural dynamics into the system. Experiments have shown that these dynamics result in resonator forcing functions comprised of a sum of several Fourier modes. However, previous numerical studies of the acoustics generated within the resonator assumed simple sinusoidal waves as the driving force. Using a previously developed numerical code, this paper demonstrates the effects of using a forcing function constructed with a series of harmonic sinusoidal waves on resonating cavities. From these results, a method will be demonstrated which allows the direct numerical analysis of experimentally generated nonlinear a...

Experimental and numerical investigation of flow through an oscillated acoustic resonator

An acoustic resonator was oscillated experimentally at the fundamental gas resonant frequency to develop standing pressure waves. The conical shaped resonator contained openings that provided an air passage from a pressurized cavity through the resonator to the ambient environment. For several pressure differentials applied across the resonator, the rate of air flow is reported for no resonator oscillation, and for on‐resonant and near‐resonant frequency oscillations. When compared to no oscillation and near‐resonant frequency oscillation at all pressure differentials, the standing waves within the resonator reduced the flow of air through the system when oscillated on‐resonance. A two‐dimensional numerical model was developed using a commercial CFD package to simulate the gas flow within the system. The mass flow of air through the oscillating resonator was matched using the numerical simulations. For a low value of differential pressure, the simulations showed the reversal of gas flow into the high pres...