. 24/7 Space News .
ROCKET SCIENCE
Foam and cork insulation protects deep space rocket from fire and ice
by Staff Writers
Huntsville AL (SPX) Jun 26, 2018

NASA technicians have completed application of spray-on foam thermal insulation on the Launch Vehicle Stage Adapter. It is being outfitted for Exploration Mission-1, the first flight of NASA's new rocket, the Space launch System and the Orion spacecraft. The adapter, which connects the rockets 212-foot-tall core stage to the upper in-space stage of the rocket, is the largest piece of hardware that has ever had insulation applied by hand at NASA's Marshall Space Flight Center in Huntsville, Alabama.

Extreme temperatures - ranging from minus 423 degrees Fahrenheit to more than 200 degrees Fahrenheit - call for novel thermal protection systems on NASA's new heavy-lift rocket, the Space Launch System (SLS). NASA is advancing state-of-the-art technology for thermal protection with more environmentally friendly materials and 3D printed molds for smaller parts. With the power and precision needed for sending humans to deep space, SLS will launch astronauts in NASA's Orion spacecraft to distant destinations such as the Moon and Mars.

Spray-on foam insulation, along with other traditional insulation materials such as cork, will provide thermal protection for every rocket part, large and small. The insulation is flexible enough to move with the rocket but rigid enough to take the aerodynamic pressures as SLS accelerates from 0 to 17,400 miles per hour and soars to more than 100 miles above Earth in just 8 minutes. The cryogenic fuel, made up of liquid hydrogen and liquid oxygen, that powers the rocket has to stay extremely cold to remain liquid. Hydrogen has to remain at minus 423 degrees Fahrenheit and oxygen at minus 298 degrees Fahrenheit. If temperatures rise too high, the fuel would become a gas.

"As the Space Launch System flies, it builds up tremendous heat. Without insulation, heat from launch would affect the stability of the cryogenic propellants and the rocket's structural integrity would be compromised," said Michael Alldredge, who leads the thermal protection system team for the SLS core stage at NASA's Marshall Space Flight Center in Huntsville, Alabama.

"NASA is asking this unique foam material to do the incredible job of protecting critical rocket systems, which vary from large structures to electronics and fuel lines, in an unforgiving launch environment with extreme temperatures and pressures."

Materials engineers qualified the third-generation, orange-colored spray-on foam insulation to meet the harsh environments that the SLS will experience. At the same time, they made the foam more environmentally friendly. The foam insulation is composed of two liquids - isocyanate and a special polyol blend - that stay separate in the pumping system and mix in the spray gun before releasing and rising into foam - similar to hair mousse. When the foam is applied, it gives the rocket a light-yellow color that the Sun's ultraviolet rays eventually "tan," giving the SLS core stage its signature orange color.

Spray the Big Stuff
Foam will protect the larger of the hardware, including the entire SLS core stage that is the 212-foot-tall backbone of the rocket. The foam is applied with robotic or hand-held spray guns, and, much like painting walls in a home, hardware has to be primed and taped off before spraying begins. Primer serves as corrosion protection from the environment and enhances the bond between the insulation and the rocket.

Engineers will use a robotic system to apply both primer and foam to the cryotanks at NASA's Michoud Assembly Facility in New Orleans where the core stage is being built. Manually-sprayed foam will cover the domes, or bottoms, of both cryotanks. The largest piece of SLS hardware built at Marshall, the launch vehicle stage adapter, which serves as a connector between the core stage and the interim cryogenic propulsion stage will have manually-sprayed foam.

The original plan was to use cork for the SLS launch vehicle stage adapter, according to Amy Buck, Marshall's launch vehicle stage adapter thermal protection systems lead, but the team determined that foam would be more efficient. "The foam is lighter," she said. "And since we have the resources to spray it by hand at Marshall, we are saving time and money because we don't have to ship it to Michoud. We spray on the foam at Marshall at the same time the core stage pieces for the first SLS mission get their foam applied at Michoud."

"It takes about three months for the entire foam application process," Buck explained. "The prep work takes longer than the actual spraying. The hand-spraying only takes about 30 minutes for each 4-foot-wide section."

3-D Printed Molds Help Protect Smaller Stuff
Insulation protects many small parts of the rocket that play big roles. The avionics, the "brains" of the rocket, are located throughout the vehicle. Other small parts like the intertank's exterior pockets, the engine section's internal ducts and close-out areas of hardware - where two major pieces connect - require manually-sprayed foam or foam cast with 3-D printed molds.

"NASA is using a novel 3-D printing process to make customized molds for certain parts," said Alldredge. "Some parts have unique geometries or are in locations in the rocket where it is difficult to cover them with spray foam. The 3-D printed molds allow us to shape insulation to protect specific parts."

Small hardware like internal fuel systems and brackets on the feedline that run along the outside of the core stage and connect it to the engine section need pour foam. The foam is mixed and poured into a mold before it expands to fill the shape it enters.

Put Some Cork on It
Cork is heavier than foam but provides even stronger protection for certain applications. Cork comes in sheets and is applied to areas that have high predicted heat loads, like the core stage engine section, which houses four RS-25 engines that produce 2 million pounds of thrust. Cork is applied under the solid rocket boosters that provide 75 percent of thrust at liftoff and on the fairings, the areas where feedlines come out of the intertank and run down the rocket to connect the intertank to the other hardware.

After thermal protection material density and adhesion are verified for both foam and cork, engineers take thickness measurements to ensure the required amount of thermal protection has been applied. Overall thermal protection systems thickness for SLS ranges from about a half-inch to 2 inches. The launch vehicle stage adapter requires 0.7 inches of foam while the hydrogen tank requires around 1.2 inches because of its extremely cold temperature. The final system level test of the insulation, prior to flight, will be when the entire core stage will be tested with all four RS-25 engines firing, and the foam and cork guarding the hardware as hot and cold collide.


Related Links
Space Launch System
Rocket Science News at Space-Travel.Com


Thanks for being there;
We need your help. The SpaceDaily news network continues to grow but revenues have never been harder to maintain.

With the rise of Ad Blockers, and Facebook - our traditional revenue sources via quality network advertising continues to decline. And unlike so many other news sites, we don't have a paywall - with those annoying usernames and passwords.

Our news coverage takes time and effort to publish 365 days a year.

If you find our news sites informative and useful then please consider becoming a regular supporter or for now make a one off contribution.
SpaceDaily Monthly Supporter
$5+ Billed Monthly


paypal only
SpaceDaily Contributor
$5 Billed Once


credit card or paypal


ROCKET SCIENCE
S7 space mulls restoring production of heavy rocket engines in Russia
Moscow (Sputnik) Jun 20, 2018
Russia's S7 Space, part of the S7 Group, plans to build a plant in Samara to produce Soviet-designed NK-33 and NK-43 rocket engines for super heavy-lift launch vehicles and intends to purchase production capacities from the state-owned United Engine Corporation (UEC) for this purpose, S7 Space General Director Sergey Sopov said in an interview. "We would like to buy from the state the well-known engines NK-33 and NK-43, produced earlier by the Samara-based Kuznetsov plant, as well as the documenta ... read more

Comment using your Disqus, Facebook, Google or Twitter login.



Share this article via these popular social media networks
del.icio.usdel.icio.us DiggDigg RedditReddit GoogleGoogle

ROCKET SCIENCE
Deep space navigation: tool tested as emergency navigation device

NASA Administrator Statement on Space Policy Directive-3

New head of 'space nation' aims for the stars

Hague, Ovchinin talk ISS mission during presser

ROCKET SCIENCE
The rockets that are pushing the boundaries of space travel

Aerojet Rocketdyne and SMC investing in engine technology

Virgin Orbit's LauncherOne to join Spaceflight's portfolio of launch vehicles

Foam and cork insulation protects deep space rocket from fire and ice

ROCKET SCIENCE
Opportunity sleeps during a planet-encircling dust storm

Martian Dust Storm Grows Global; Curiosity Captures Photos of Thickening Haze

Explosive volcanoes spawned mysterious Martian rock formation

Unique microbe could thrive on Mars, help future manned missions

ROCKET SCIENCE
China confirms reception of data from Gaofen-6 satellite

Experts Explain How China Is Opening International Space Cooperation

Beijing welcomes use of Chinese space station by all UN Nations

China upgrades spacecraft reentry and descent technology

ROCKET SCIENCE
Forget Galileo - UK space sector should look to young stars instead

A milestone in securing ESA's future role in the global exploration of space

SSL ships first of 3 ComSats slated for launch this summer

GomSpace and Aerial Maritime Ltd enter MOU for delivery and operation of a global constellation

ROCKET SCIENCE
Clearing out space junk, one step at a time

RemoveDEBRIS spacecraft launched from ISS with Airbus space debris capture removal technology

Experiments of the Russian scientists in space lead to a new way of 3D-bioprinting

Futuristic data storage

ROCKET SCIENCE
Hunting molecules to find new planets

Will we know life when we see it

Scientists developing guidebook for finding life beyond Earth

Nearly 80 exoplanet candidates identified in record time

ROCKET SCIENCE
Webb Telescope to target Jupiter's Great Red Spot

Charon at 40: four decades of discovery on Pluto's largest moon

A dark and stormy Jupiter

NASA shares more Pluto images from New Horizons









The content herein, unless otherwise known to be public domain, are Copyright 1995-2024 - Space Media Network. All websites are published in Australia and are solely subject to Australian law and governed by Fair Use principals for news reporting and research purposes. AFP, UPI and IANS news wire stories are copyright Agence France-Presse, United Press International and Indo-Asia News Service. ESA news reports are copyright European Space Agency. All NASA sourced material is public domain. Additional copyrights may apply in whole or part to other bona fide parties. All articles labeled "by Staff Writers" include reports supplied to Space Media Network by industry news wires, PR agencies, corporate press officers and the like. Such articles are individually curated and edited by Space Media Network staff on the basis of the report's information value to our industry and professional readership. Advertising does not imply endorsement, agreement or approval of any opinions, statements or information provided by Space Media Network on any Web page published or hosted by Space Media Network. General Data Protection Regulation (GDPR) Statement Our advertisers use various cookies and the like to deliver the best ad banner available at one time. All network advertising suppliers have GDPR policies (Legitimate Interest) that conform with EU regulations for data collection. By using our websites you consent to cookie based advertising. If you do not agree with this then you must stop using the websites from May 25, 2018. Privacy Statement. Additional information can be found here at About Us.