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NASA/TM-2012-217348NESC-RP-09-00529International Space Station (ISS)Heat Rejection Subsystem (HRS)Radiator Face Sheet DamageHenry A. Rotter/NESCLangley Research Center, Hampton, VirginiaDistribution limited to NASA Contractors and U.S. Government OnlyMarch 2012
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NASA/TM-2012-217348NESC-RP-09-00529International Space Station (ISS)Heat Rejection Subsystem (HRS)Radiator Face Sheet DamageHenry A. Rotter/NESCLangley Research Center, Hampton, VirginiaDistribution limited to NASA Contractors and U.S. Government OnlyNational Aeronautics andSpace AdministrationLangley Research CenterHampton, Virginia 23681-2199March 2012
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NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage1 of 83International Space Station (ISS) Heat Rejection Subsystem (HRS)Radiator Face Sheet DamageFebruary 9, 2012Distribution Limited to NASA Contractors and U.S. Government OnlyNESC Request No.: TI-09-00529
NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage2 of 83Approval and Document Revision HistoryNOTE: This document was approved at the February 9, 2012, NRB. This document wassubmitted to the NESC Director on February 29, 2012, for configuration control.Approved:Original Signature on File3/1/12NESC DirectorVersion1.0Description of RevisionInitial ReleaseDateAuthorMr. Henry Rotter,NASA TechnicalFellow for LifeSupport/ActiveThermal, JohnsonSpace CenterNESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government OnlyEffective Date2/9/12
NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage3 of 83Table of ContentsTechnical Assessment Report1.0Notification and Authorization . 72.0Signature Page . 83.0Team List . 93.1Acknowledgements . 93.2NESC Involvement . 104.0Executive Summary . 115.0Problem Description . 165.1ISS HRSR Description . 165.1.1 Hydraulic Rupture Analysis . 215.2HRSR Design, Flight and Assembly Data . 215.3Review of MMOD Test Coupons and Data . 245.4IR Thermography . 255.4.1 NDE Imagery Analysis . 28Form Factor Analysis . 335.56.0LS-DYNA Analysis. 366.1Background . 366.1.1 LS-DYNA Overview . 366.1.2 Material Definition. 366.1.3 Model Evolution . 366.2Model 1.0 . 376.2.1 Model 1.0 Results Discussion . 406.3Models 2.0 and 3.0 . 416.3.1 Models 2.0 and 3.0 Results Discussion . 42Model 4.0 . 476.46.4.1 Model 4.0 Results Discussion . 486.4.2 Peer Review . 516.5Model 5.0 . 516.5.1 Model 5.0 Features. 536.5.2 Model 5.0 Results Discussion . 546.6LS-DYNA Analysis Conclusions . 587.0NESC Supported Radiator Testing . 597.1Radiator Tests . 597.1.1 Test 3.1 -- Panel NDE . 607.1.2 Test 3.3 -- Tube Damage/Proof Test. 60NESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government Only
NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage7.1.37.1.47.27.34 of 83Test 3.8 -- Permeation/Leakage Through Silver-Filled Epoxy From FlowTube . 62Test 3.11 --Panel Segment Pressure Tests . 63General Discussion of Test Results . 70Concluding Remarks . 718.0Findings, Observation, and NESC Recommendations . 718.1Findings. 718.2Observation . 73NESC Recommendations. 738.39.0Alternate Viewpoints . 7310.0Other Deliverables . 7311.0Lessons Learned . 7312.0Definition of Terms . 7313.0Acronyms List . 7414.0References . 7515.0Appendices . 76List of FiguresFigure 4.0-1.Figure 4.0-2.Figure 4.0-3.Figure 4.0-4.Figure 5.1-1.Figure 5.1-2.Figure 5.1-3.Figure 5.1-4.Figure 5.1-5.Figure 5.1-6.Figure 5.1-7.Figure 5.2-1.Figure 5.3-1.Figure 5.3-2.Figure 5.4-1.Figure 5.4-2.HRSR S1-3 Panel 7 Damage . 11Initial Damage Assessment of HRSR S1-3 Panel 7 Survey . 12S1-3 Panel 7 Back Side Face Sheet . 13Panel Test Segment with Face Sheet Peeled Back . 15EATCS Loop A and B Schematic . 16PM including FCV . 17EATCS HRSR Array showing the Dual Flow Paths. 18PVR Deployment. 18HRSR Panel Face Sheets View from Nadir Side . 19Radiator Panel Design Overview . 20Radiator Panel Construction Details . 20S1-3 Array Loop 1 and 2 N2 Pressures . 23Panel 7 MMOD Impact Exit Hole 5/16 Inch (Note ring around hole). 24Impact Test #9; Exit Side and Exit Hole Size ( 0.31-inch-diameter) for a 6.35mm Projectile [ref. 1] . 25Raw Temperature Data Showing Normal Radiator Panel (Center) TemperatureGradients . 26Enhanced IR Imagery of a Thermal-Vacuum Ground Test of a Radiator Panelwith Temperature Range . 26NESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government Only
NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet DamageFigure 5.4-3.Figure 5.4-4.Figure 5.4-5.Figure 5.4-6.Figure 5.4-7.Figure 5.4-8.Figure 5.4-9.5 of 83Normal Radiator Temperature Contour Plot Showing Flow Paths . 27Possible Frozen Flow Path on S1-2 Panel 7 (Center Array) . 27IR Imagery Processing Results . 28Registration of Images Based on Affine Transform. 30Transformation of ISS HRSR Panel from Camera to Normal Views . 30(a) Temperature Image of HRSR Panel (b) Laplacian Image . 31(a) Laplacian Image of a Damaged Panel (b) Laplacian Image of anUndamaged Panel . 31Figure 5.4-10. Temperature Profiles for Analogous Cooling Tubes Compared for EachRadiator . 32Figure 5.5-1. Thermal Desktop Geometric Model of ISS (with Starboard HRSRNodalization shown) . 34Figure 5.5-2. IR Imagery Depicting Panel-to-Panel Temperature Trends . 35Figure 5.5-3. Form Factor to Space Results for Case 1 . 35Figure 6.2-1. (Top) State of Face Sheet Prior to Failure Initiation, (Bottom) Face SheetFailure Propagation . 38Figure 6.2-2. Face Sheet Lifting. 39Figure 6.2-3. Face Sheet Fold Over . 40Figure 6.2-4. Side View of Figure 6.2-2 Depicting Incorrect Penetration of the Face Sheetinto the Honeycomb Volume . 41Figure 6.3-1. Radiator Features (Models 2.0 and 3.0) . 42Figure 6.3-2. Pressure Ramp Down Study for Models 2.0 and 3.0 . 43Figure 6.3-3. Failure Propagation in Model 2.0, Front and Side Views . 44Figure 6.3-4. Failure Propagation in Model 3.0, Front and Side Views . 45Figure 6.3-5. On-orbit Image of Radiator Panel showing Face Sheet Displacement . 46Figure 6.3-6. Face Sheet Tearing Along the Bolt Holes . 46Figure 6.3-7. Comparison of Wrinkling Features to On-orbit Images . 47Figure 6.4-1. Peel Test Configuration . 48Figure 6.4-2. Model 4.0 at Impact State . 49Figure 6.4-3. Marking on Panel 7 Neighboring Panel . 50Figure 6.4-4. Simple Paper Model shows the Folded Face Sheet Lines up with the Markingon the Neighboring Panel. 50Figure 6.5-1. Calculated Pressure Unloading Time History . 52Figure 6.5-2. A Comparison of Bolted Constraint Definitions . 53Figure 6.5-3. Zoomed View of the Failure Progression as the Face Sheet Pulls from theBolts . 55Figure 6.5-4. Comparison of Bolt Pullout Near Failure Initiation and Tearing Along BoltHoles . 56Figure 6.5-5. Comparison of the Location of the Contact Edge in the LS-DYNA Model tothe Paper Model . 57Figure 7.1-1. Subset of Overall Test Plan Presented to MVCB and SSPCB . 59NESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government Only
NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet DamageFigure 7.1-2.Figure 7.1-3.Figure 7.1-4.Figure 7.1-5.Figure 7.1-6.Figure 7.1-7.Figure 7.1-8.Figure 7.1-9.Figure 7.1-10.Figure 7.1-11.Figure 7.1-12.Figure 7.1-13.Figure 7.1-14.6 of 83Parent Material Defect Detected During Inspection . 61Silver-Filled Epoxy Testing with Ammonia . 62Panel Test Segment 6-7 . 64Panel Test Segment 8-8 . 64Panel Test Segment 6-3 . 65Panel Test Segment 6-2 . 65Panel Segment 6-7, Post Leak Test Condition . 66Delaminated Face Sheet . 67Delaminated Face Sheet . 67X-Ray View Depicting Lagoons . 68HOBE Lagoons Revealed After Removal of Face Sheet . 69HOBE Bond Failures from the Face Sheet . 69Comparison Between Test Failure and Panel 7 Images Showing RipplesPerpendicular to the Flow Tube Orientation . 70List of TablesTable 5.5-1.Table 6.5-1.Table 7.1-1.Form Factor Analysis Case Summary with Joint Rotation Angles (Degrees) . 33Feature Comparison Between Model Predictions and On-orbit Images . 58Comparison of Test Article Environments to HRSR Environment [ref. 14] . 60NESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government Only
NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage7 of 83Technical Assessment Report1.0Notification and AuthorizationThe starboard side International Space Station (ISS) heat rejection subsystem radiator (HRSR)was launched on October 2002, and deployed and serviced in November 2007. A survey ofprevious ISS images and videos verified this radiator was in the normal configuration onAugust 29, 2008. However, on September 1, 2008, a video survey of ISS indicated a face sheethad debonded and peeled up on HRSR S1-3 panel 7 with no apparent source for the damage.This radiator damage consisted of a large section of the face sheet peeled up, sheared face sheetmetal, and debonded from the adjoining face sheet. The face sheet showed considerablewrinkling and evidence of one micrometeoroid orbital debris (MMOD) penetration. The facesheet on the panel’s back side showed a smaller wrinkled area with suspected debonding. Sincebeing discovered, S1-3 panel 7 has showed no observable signs of increasing damage.Additionally, multiple dockings of Soyuz, Progress, and Space Shuttle Orbiter, and vibrationinduced during ISS reboost have resulted in no detectable changes.Mr. Henry Rotter, NASA Technical Fellow for Life Support/Active Thermal, was selected tolead this assessment. An Initial Evaluation was approved by the NASA Engineering and SafetyCenter (NESC) Review Board (NRB) on March 12, 2009. The assessment objective was todetermine the most probable cause for the ISS HRSR S1-3 panel 7 face sheet damage and anygeneric risks for the other ISS radiator panels.NESC’s initial recommended plan of action, formed with the ISS Program input, included:requests for previously performed MMOD test data from ISS radiator coupon testing; a requestfor infrared (IR) imagery of radiator panels for the port and starboard sides (planned for a 15A/STS-119 extravehicular activity (EVA)); a recommendation for an over pressure test;consideration of additional tests to perform on a subset of the nine panels located at the JohnsonSpace Center (JSC); conducting a face sheet strength test to determine what pressure can initiateface sheet debonding; and an investigation of how to pressurize the internal panel withoutweakening the panel structure.Subsequent investigation resulted in changes to this initial plan. The work performed in supportof this assessment is summarized in Section 3.2 and documented throughout this report.NESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government Only
NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage2.08 of 83Signature PageSubmitted by:Team Signature Page on File – 3/8/12Mr. Henry A. RotterDateSignificant Contributors:Mr. Steven L. RickmanDateMs. Patricia A. HowellDateMr. Marshall D. NeipertDateSignatories declare the findings, observations, and NESC recommendations compiled in thereport are factually based from data extracted from Program/Project documents, contractorreports, and open literature, and/or generated from independently conducted tests, analysis, andinspections.NESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government Only
NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage3.0Team ListNameCore TeamHank RotterSteven RickmanGary RankinRichard MortonBruce HarknessMarshall NeipertDave WrightJohn RaetzAjay KoshtiGary ReynoldsWalter WilsonCharles AntillPatricia HowellWilliam WinfreePamela ThrockmortonConsultantsDisciplineNASA Technical Fellow for LifeSupport/Active ThermalNASA Technical Fellow for PassiveThermalCrew and Thermal Systems DivisionCrew and Thermal Systems DivisionActive ThermalLS-DYNA Radiator TestingISS ATCSStructural EngineeringActive Thermal SystemsAvionic Systems DivisionSystems EngineeringNDENDEMTSONASA Technical Fellow for Loads andCurtis LarsenDynamicsRobert PiascikNASA Technical Fellow for MaterialsBill ProsserNASA Technical Fellow for NDELS-DYNA Analysis Peer ReviewersScott FordLS-DYNA Babu MekaLS-DYNA Jeremie AlbertLS-DYNA Nika McManusLS-DYNA Jon GabrysLS-DYNA Siamak GhofranianLS-DYNA Administrative SupportChristina WilliamsTechnical Writer3.19 of BoeingJacobs TechnologyJacobs TechnologyJacobs oeingBoeingBoeingBoeingLaRC, ATKAcknowledgementsThe investigation team acknowledges Mr. Steven Gentz (NESC), Mr. Timothy Brady (NESC),and Dr. Eugene Ungar (JSC) for their peer review of the final report draft.NESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government Only
NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage3.210 of 83NESC InvolvementThe NESC involvement augmented the original ISS Program support with the following:a. Review of design, flight, and assembly data to determine whether problems observedduring construction;b. Review of MMOD test coupons and reports;c. Review of IR imagery from the 15A flight;d. Form factor analysis for HRSR surfaces to assist with the interpretation of temperaturetrends observed in the IR imagery;e. Development of an LS-DYNA model to understand the physics of the radiator facesheet failure;f. Sponsorship of radiator component testing in support of fault tree investigations;g. Participation in team technical interchange meetings (TIMs) in July 2009, and March2010; andh. Engaging support from JSC and Langley Research Center (LaRC) for the IR softwareanalyses.NESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government Only
NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage4.011 of 83Executive SummaryOn September 1, 2008, a planned external image survey of the International Space Station (ISS)found the heat rejection subsystem radiator (HRSR) S1-3 panel 7 thin (0.010 inch) aluminumface sheet was peeled up (Figure 4.0-1). A survey of previous ISS images and videos verifiedthat this radiator was in the normal configuration on August 29, 2008. A survey of ISSaccelerometers and events during this time period found no evidence to determine when thisevent specifically occurred and offered no clues to its origin.Figure 4.0-1. HRSR S1-3 Panel 7 DamageNESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government Only
NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage12 of 83A detailed image survey showed that approximately half of the panel face sheet had peeled up,but was stable (i.e., not liberating debris) and not increasing in size (Figure 4.0-1). The largesection of the peeled up face sheet contained perimeter bolt shearing and tearing, sheared facesheet material, and debonding from one of the adjoining face sheets. The peeled up sheet hadsignificant wrinkles, was debonded from the internal materials, and contained onemicrometeoroid orbital debris (MMOD) impact penetration exit (Figure 4.0-2). The back sheethad a small area of wrinkles and some debonding on the outer edge (Figure 4.0-3).Figure 4.0-2. Initial Damage Assessment of HRSR S1-3 Panel 7 SurveyNESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government Only
NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage13 of 83Figure 4.0-3. S1-3 Panel 7 Back Side Face SheetOn February 18, 2009, the ISS Program Manager, Mr. Michael Suffredini, requested the NASAEngineering and Safety Center (NESC) to support the NASA and Boeing External ActiveThermal Control System (EATCS) ISS system teams to determine the possible causes of theHRSR face sheet damage.The NESC supported the team by providing nondestructive evaluation (NDE) expertise to helpanalyze the ISS infrared (IR) imagery. The analysis found no clues as to why the face sheetpeeled up. The joint team identified the remaining panels had no identifiable face sheetanomalies, but identified one panel with a suspected frozen ammonia flow tube.The NESC sponsored development of a LS-DYNA model to assess the plausibility of aninternal pressure type root cause for the radiator face sheet failure. The radiator face sheetgeometry was modeled using basic physics and refined through iterations, which includedprogressively higher fidelity representations of the radiator face sheet and its attachment to theradiator panel. The analysis showed that low pressure in a large void beneath the face sheetcould induce face sheet peeling similar to that observed in the ISS imagery.The NESC funded the Boeing EATCS ISS system team and the radiator vendor, LockheedMartin Missiles and Fire Control (LMMFC), to conduct limited testing of eight qualificationradiator panels and flight tubing stock. The panels were rechecked for flaws with samplesNESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government Only
NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage14 of 83extracted from suspect areas. The checks found no detectable voids or anomalies. A surfaceflaw was found in the tubing stock, which would have been dispositioned to use “as is.”A small ( 10-inch 10-inch) and a large (15-inch 20-inch) panel section was sealed at theedges with a pressure feed port installed in the manifold. Each test was to reach 150 pounds persquare inch gauge (psig) pressure, but both test articles exhibited internal void volume growth atabout 20-40 psig during the helium leak test with audible popping sounds. The face sheet on thesmall panel was removed and void areas (measuring 0.5-inch width) obs
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