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APPENDIX B: I LLUSTRATIONS 77
APPENDIX B: ILLUSTRATIONS Designs , Solid Rocket Booster Configuration Redesigned Solid Rocket Motor Configuration Case Field Joint: Comparison of Challenger and ~ ~ Case Field Joint Seals Challenger ~ ~ Discoverv cnaracterlstlcs ot the Redesigned Case Factory Joint: Comparison of ~ ~ ~ - `~ ~ _ _ r ~ _ ~ of Challenger and Discovery Case-to-Nozzle Joint: Comparison Ignition System: Discovery Igniter Adapter: Discovery Nozzle Assembly Aft Struts to the External External Tank Attach Ring: External Tank Attach Ring: Aft Skirt Test Program Tank 270° Design 360° Design ana Discovery (Challenger) (Discovery) Diagram of Testing Program Configuration of the Joint Environment Simulator Configuration of the Nozzle Joint Environment Simulator Configuration of the Transient Pressure Test Article Configuration of the T-24 and T-97 Test Stands Layout of the T-97 Test Facility Configuration of the Structural Test Article Simulation of a J-Seal Wave Defect Simulation of a J-Seal Channel Defect and Separation Simulation of a Blowhole in Insulation Edge the Case-to-Nozzle Joint Adhesive Selected Design Alternatives An Inset (Nonrotating) Case Field Joint Interlocking Insulation for a Vented Case Field Joint "Rat-Trap" Baffle for a Case Field Joint Joints with "Thermalock" Metal Seals 78 Vented
Designs 79
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- c c o . - - > ~ a, n OWL a, lo 1 a, _ ~ _ N _ O 7 ~ _ CO I _ ~ - ~ a' On An ~ - ~ Nt ~ \ hi' \ \:/ \ ~~ ~ ~ ,::' ~ _ a, y O U' 1 as rat ~ _ O _ 7\\~ \ ~ 1 ~ L / / - o ~ ~ 0 _ o ~ . ~ . CtS _ _ ~ I ~ 1 ·_ t - ._ ~ 1 m Z ! it' \ JO ~ ~ ~ ~ ~ In · ~ ~ ~ _ ~ tID _ 0 - , ~ me .~ ~ ~ ~ - - y - - - ~ - ~ 4< - ,` >~ as ~ _ __ ~ ~n ~n ~ c a, tn - - - a) Q ,0 0 I - c - a O ~ ns a' ~n o . _ -N \N . 1 E _ ~' \ \ / _ a, Y tn ._ _ C c ~ a, o ,~ - a y U. m 86 - o ~D . ,~ - - _ _ ~ ' y O tn Q _ ~ a~ a~ ~ ~ Y C) a, _e a C~ ~n o y ~n C~ o 1 _ a, ~ O - - - - o m v H U U] . - o X . O ·. E~ O U] ~ u] o o .-l ·- ~ u H O U) o C~ - -
Leak Check Port Plug Outer Bolts ~ \ Outer Gaske7~ Environmental Seal Forward Dome \ ~ , ~ . ~ . \ T R ~ ~ 1~_ , ,~ ,, =- ~ , _ 1 1 1 i// Leak Check Port Plug O-ring r Leak Check Ports / Packing With Retainers Inner Bolts Kit 1 Igniter Adapter: Discovery Source: Morton Thiokol, Inc. 87 ~ Igniter Adapter Inner Gasket
Nose Inlet Assembly / in) Throat Inlet Assembly '~ it Bearing Assembly / ~ - ~ it) Cowl Assembly /< Fixed Housing / Assembly ill '/~/~. ~ //7 b'.~ Exit Cone Assembly / ~ / it, /'7~ art Aft Exit Cone Assembly (forward part) \ \ , Hi A_ Nozzle Assembly Source: Morton Thiokol, Inc. 88
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1 ,~' Fir '.~_ /' /, \\ it. - ~C'. ..J // _~ ~ ~ _ _ ~ I .~ Or :~--id .~\ q External Tank Attach Ring: 270° Design (Challenger) Source: United Space Boosters, Inc. 91
i/~_~1 \ //// 1 - - -~/~^ l - ~~,~-,~ \ Aft Skirt Source: United Space Boosters, Inc. 92
Testing Program 93
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~ J - ~ ~ - ~ - , o 0 1 1y co ~ 1 '71 in · - ~ o A LD ~ N o o o o o o ~5 o - A: at_ =~` \ i\ an, my,' 101 V (Lit - V H o X o . ~ . - a U] CQ In m o - o o ~- ~ O .,'
/ - ~'~l. I\ ~ -in ~0.050 in. / 0.125 in. 10.0 in 1.7 in. //- it--_ / \ ~ -a ~ ~jr-: ~ ~ Edge Separation a. ............ - . . . . .. .. ... ...\ .......... ~ .: .. .. . .:.:.1 . . .... .. ..... ....... . . .... .................. ,,6 . . . .2. :: :.2 2 - 1 .... ... - .. , ............. .. . . . . ... . .. .... - . . . .. . -- ~ _ -.... . .. . _ , .............. ~ ~ / ~ - Propellant ._ ~ . ~ ~ ~ .. - - .. 1 ::::::::.: :: :::::::::::::::::::~: - : -:: l -. ~ ~ - ,, - . I ~ .. : , hi- . . - A, . . .. . ~ - NOR ~ -I--- Insulation me-- Clevis Simulation of a J-Seal Channel Defect and Insulation Edge Separation Source: Morton Thiokol, Inc. 102
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Selected Design Alternatives 104
Radial inset dimension determined to eliminate joint rotation Motor Exterior ~ _ Design inside radius Motor Interior /, / An Inset (Nonrotating) Case Field Joint 105
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