AEDC-TR-65-85

A SIMULATED ALTITUDE TEST

OF A SATURN SIC RETRO DEVELOPMENT MOTOR
(TEST UNIT NO. SD-20)
J. S. Culp and B. M. Bishop
ARO, Inc.
May 1965
ROCKET TEST FACILITY
ARNOLD ENGINEERING DEVELOPMENT CENTER
AIR FORCE SYSTEMS COMMAND
ARNOLD AIR FORCE STATION, TENNESSEE
HTTP://HEROICRELICS.ORG
NOT/CBS
When U. S. Government drawings specifications, or other data are used for any purpose other than a
definitely related Government procurement operation, the Government thereby incurs no responsibility
nor any obligation whatsoever, and the fact that the Government may have formulated, furnished, or in
any way supplied the said drawings, specifications, or other data, is not to be regarded by implication
or otherwise, or in any manner licensing the holder or any other person or corporation, or conveying
any rights or permission to manufacture, use, or sell any patented invention that may in any way be
related thereto.
Qual ified users may obtain copies of this report from the Defense Documentation Center.
Hcfcrenccs to named commercial products in this report are not to be considered in any sense as an
endorsemcIlt of the product by the United States Air Force or the Government.
Defense Documentation Center release to the Clearinghouse for Federal Scientific and Technical
Information (CFSTI) and foreign announcement and distribution of this report are not authorized. The
distribution of this report is limited because significant details of U. S. altitude testing capabilities
are revealed.
A SI MULATED ALTITUDE TEST
OF A SATURN SIC RETRO DEVELOPMENT MOTOR
(TEST UNIT NO. SD-20)
J. S. Culp and B. M. Bishop
ARO. Inc.
AEDC TR6585
FOREWORD
The work reported herein was sponsored by the National Aeronautics
and Space Administration (NASA) and The Boei ng Company (TBC) for t he
Thiokol Chemical Corporation (TCC) under Progr am Area 92 1E,
Project 9115 .
The r esults of the test presented were obtained by ARO, Inc. (a
subsidiar y of Sverdrup and Parcel, Inc.), contract operator of the
A rnold Engineering Development Center (AEDC), Air Force Systems
Command (AFSC) , Arnold Air Force Station, Tennessee, under Con-
tract AF 40(600)-1000. The test was conducted on February 24, 1965,
under ARO Project No. RP1435, and the report was submitted by the
authors on April I, 1965.
ii
This technical report has been reviewed and is approved.
Ralph W. Eve rett
Major, USAF
A F Repres entative, RTF
DCS/Test
J ean A. Jack
Colonel, USA F
DCS/Test
AEDCTR 65 85
ABSTRACT
Saturn SIC retro motor TE-M-424, Test Unit Number SD-20, was
fired in Propulsion Engine Test Cell (J- 5) as part of the user
1
s ,
Thiokol Chemical Corporation, research and development program for
this motor. The primary test objectives were to determine ignition
characteristics , ballistic performance, and hardware integrity at alti-
tude conditions. The motor was ignited, as planned, by the two ignition
systems at a simulated altitude of 113, 000 ft and burned at an average
altitude of 113, 000 ft for a total of 1. 5 sec. The effective burn time was
0.626 sec, a nd the motor produced an effective vacuum impulse of
59,530 lbf-sec, which is above the specification minimum of
57,300 Ibf-sec. The ignition time of 92 ms ec i s within the specifi cation
requirements . Post-fire motor inspection revealed that the hardware
integrity was satisfactory.
iii
heroicrelics: Page iv is blank
CONTENTS
ABSTRACT .

1. INTRODUCTION.
II. APPARATUS
2. 1 Test Article
2. 2 Test Cell and Installation.
2. 3 Instrumentation .
2.4 Calibrati on.




III. PROCEDURE




I V. RESULTS AND DISCUSSION
4. 1 General



4. 2 Motor Ignition.

4. 3 Ballistic Performance.
4.4 Motor Thermal Data .

4. 5 Motor Structural Int egrity
V. SUMMARY OF RESULTS.
REFERENCES.


.
ILLUSTRATIONS
Figure
1. Saturn SIC Mockup
a. Retro Location.
b. Retros under Fairing .
2. Saturn SIC Retro Motor
a. Overall View . . . .
b. Sectioned View .. ..
c. Throat and Pyrogen Detail
3. Exploding Bridgewire Ignition System
4. Propulsion Engine Test Cell (3 - 5)
a. Spray Chamber and El evated Tank .
b. Overall Testing Complex . . . . .
c. Artist's Cutaway Vi ew .... . .
d. Schematic of Thrust Measuring System.
e. Plan Vi ew. . . . . . . . .
f. Interior Vi ew . . . . . . .
5. Saturn SIC Retro in X-Ray Inspection
6. Motor Installation . . . . . . . . .
AEDCTR6585


Page
iii
1
1
2
4
4
5
6
6
6
7
8
9
9
11
12
13
14
15
16
17
18
19
20
21
22
23
24
v
AEDC TR6585
Figure
7. Motor Ignition Detail
8. Measured Motor Ballistic Performance.
9, Comparison of SO-19, SO-20, and Predicted Motor
Vacuum Performance
a , Axial Force , , ,
b , Chamber Pressure
10. Chamber T emperatures
a . Thermocouple Location
b. Data . . . . .
11. Post- Fire Motor Condition
a . Overall View, , .. ..
b. Close-Up of Nozzle Throat.
c . Propellant Slivers
TABLES
1. Composition of TP-E-8 104 Propellant
II. Countdown Sequencer Program ..
Ill. Summary of Motor Instrumentation
IV. Summary of Motor Performance Data



Page
25
26
27
28
29
30
31
32
33
34
35
36
38
AEDCTR6585
SECTION I
INTRODUCTION
The Saturn V launch vehicle consists of three stages. SIC, S-ll, and
S- IVB, and the instrument unit. The first of the Saturn V stages, the
SIC, has two TE-M-424 solid-propellant retro motors located in each of
the four fairings. which are at the base of the s t age (Fig . 1) .
The nominal 800, OOO-ib thrust produced by these retro rockets pro-
vi des for a more rapi d separation of the SI C and S-ll stages, thus
reduc ing the time in which there i s no vect or control of the vehi cle.
Ignition of these motors i s programmed to occur during main engi ne
tailoff. After i gnition, the motors are to burn through the fairing and
decelerate the stage .
T he TE-M- 424 Saturn SIC retro motor i s built by Thiokol Chemical
Corporation (TCC), Elkton Division. Test unit number SD- 20 (Seri al
Number 5007) was test fired in Propulsi on Engine Test Cell (J-5) at the
Rocket Test Facility (RTF). This was the second and l ast firing of a
TE-M-424 in an alt itude facility as part of the research and development
program for this motor. The results of the first firing are di scussed in
Ref. 1.
Objectives of the altitude test were to determine ignition character -
i stics when two ignition systems are used, ballistic performance, and
hardware int egrity at altitude conditions.
2.1 TEST ARTICLE
SECTION II
APPARATUS
Each retro motor has an approximate gross weight of 520 Ib and is
des i gned to produce 100.000 Ibf for 0. 6 sec of its 1. 5- sec burn time.
The overall wei ght i s l ess than the 537 Ib specifi ed in Ref. 2, and the
motor fits within the phys i cal envelope specified.
The motor chamber. 15.2 in. in diameter and 79. 7 in. long, i s
constructed of l iB-in . - thick Ladish DC-6 steel with a liquid pol ymer
liner (TL-L- 300) (Figs. 2a and b). A single fixed 15-deg, half-angle
nozzle having a nominal throat diameter of 6.70 in. is submerged
12.9 in. into the chamber . The submerged portion of the nozzle is con-
structed of Ladish DC-6 steel, having a graphite throat insert backed
1
AEDC TR 65 85
by a cork and rubber compos ition gasket (Armstrong Type DK-l49) and
a cadmium plated steel retaini ng ring which is pinned to the nozzle body
(Fig. 2c). The outside diameter of the throat portion of the submerged
nozzle is insulated with a paper phenolic insulation material. whereas
the remai nder is insulated with TL- L-300. A tapered steel exit cone
(AISI 4130 heat treated per MIL-H-687S) extends the nozzle from an
area ratio of 3. 7 to 8. 7. A styrofoam nozzle closure is cement ed int o
the nozzle at an area ratio of 1. 6.
The chamber was loaded with approximately 278 lb of compos ite.
case-bonded, polysulfide propellant (TP- E-8l04) cast directly into the
chamber in an internal burning twelve-point. double-web star grai n con -
figuration. Propellant composition is presented in Table 1.
Propellant ignition is effected by a pyrogen-type igniter. which is
ignited by two exploding bridgewire (EBW) initiators firing into a cavity
containing Boron 2A pellets (Fig. 2c). The system is armed by pro-
viding 2S v to the EBW firing units that consist of a series of capacitors
which accumulate a sufficient charge so that , upon applying the firing
current to the system. a thyratron is triggered, supplying approximately
2300 v to the EBW initiators (Aerojet AGX- 200S Rev . K) (Fig . 3). This
ignites I S g of Boron 2A pellets which ignite the pyrogen grain. The
pyrogen exhaust passes th rough five 3/B- in. -diam holes and impinges
on the motor graln at a 45-deg angle. The 1. 75-lb pyrogen grain, cast
in a double -web star grain configuration, is the same composition as
the motor grain.
To determine the condition of the EBW firing units after arming
and before firing, an EBW Firing Unit Monitor (Fig . 3) was constructed.
This monitor verifi es that the system is armed pri or to fi ring. indicates
that the system has di scharged. and relays the time of di scharge to the
end recording system.
2.2 TEST CELL AND INSTALLATION
The Propulsion Engine Test Cell (J - 5) (Fig. 4) is a horizontal test
cell designed for testing solid-propellant rocket engines with a thrust
up to 100.000 lbf (with a growth potential to 200,000 lbf thrust) at alti-
tudes in excess of 100.000 ft. The cell is a cylindri cal section 16 ft in
di ameter and 50 ft long and is fabricated from a l/2-in. hot rolled steel
plate reinforced at 6-ft intervals with ring girders . It i s insulated with
2 in. of cellular glass , coated with l iS- in. vapor seal mastic. and pro -
tected by a O. 020-in. aluminum jacket .
2
A.EDC TR 6585
The single compenent thrust stand used in this test is capable .of
measuring axial ferces in excess .of 100,000 lbf. Axial thrust is
reacted by twe 33-in. I-Beams, which are anchered in the cell feunda-
tien centaining appreximately 600,000 Ibm .of rei nferced cencrete. The
stand is stabili zed in the yaw plane by a forward and aft celumn extend-
ing threugh bellews seals in the wall .of the test cell te a "seismic mass"
censisting .of appreximatel y 600,000 Ibm .of reinferced cencrete. Cali-
bratien .of the axi al lead cell i s accemplis hed, i n place, by a binary
deadweight calibrater havi ng a range frem 0 t e 127,000 lbf. With the
leaded Saturn meter and suppert hardware i nstalled, the thrust stand
had a natural frequency .of apprexi mately 55 cps i n the axial directien.
Twe tandem steam ejecters (Fig. 4c) are placed in each .of feur
auxili ary ducts which are lecated circumferent i ally areund the test c ell
at 90-deg intervals . The auxiliary pumping system is used fer impreve -
ment .of the test cell altitude .or fer remeval .of exhaust gases frem thrust
terminatien .or ether auxiliary centrol systems. Three .of the ejecter-
duct systems were used during the Saturn tests.
The test cell is equipped with a t emperature cenditiening system
designed te mai ntain the test cell and meter at the prescribed tempera-
ture frem meter i nstallatien unt il just prier te pre- fi re pumpdewn.
The recket exhaust discharged inte a 53-in. -diam, water - ceel ed
diffuser having a twe-step entrance cene (Fig. 4d). which is inserted
i n a 102 - in. - diam, water - ceeled diffuser. A center - bedy steam ejecter
installed i n the 102-in. - diam diffuser is used te fac ilit ate pre- fire pump-
down, te maintain altitude, and te reduce recirculatien .of gases inte the
test cell at meter taileff. The steam ejecter has an 8. 5 - i n. -diam threat
and an area ratio .of 10. It may be centrelled a utematically .or manually
eve r a driving-pressure range frem 0 te 500 psig.
The exhaust - steam mi xture then flews threugh a spray chamber
16 ft in diameter and 50 ft leng which centains nine spray banks. each
.of which i s capable .of delivering apprexi mately 9000 gpm at a maxi mum
pressure .of 47 psia. Water is supplied te the spray chamber frem an
elevated water tank with a usable capacity .of appreximately 250,000 gal.
Frem the spray chamber, the exhaust gases flew threugh appreximat ely
2000 ft .of 13 - ft-diam duct t.o the RTF exhauster machines and are
pumped te atmosphere as shewn schematically i n Fig. 4e.
Te previde additienal light fer the high-speed (2000 fps) .optical data
systems, the test cell was paint ed white, and a light heed was fabricated
(Fig. 4f) . The hoed censists .of 48 reflect ers, each having twe leng dura-
tion (1.75 sec) flash bulbs. In .order to previde the light required fer three
3
AEDC TR65 85
seconds, the reflectors were divided into three groups arranged to pro-
vide equal light intensity over the motor area. Ignition times are given
as part of Table II.
2.3 INSTRUMENTATION
Axial thrust was measured using a nominal 100, OOO-lbf, fourfo1d-
output , bonded strain- gage-type load cell . Universal flexures were used
to isolate the load cell from any force not directed through the load cell
axis . Strain-gage-type transducers were used to measure pyrogen,
chamber, steam, water, exhaust system, and auxiliary pumping system
pressures. Motor case and nozzle temperatures were sensed with iron-
constantan thermocouples bonded to the motor chamber and nozzle.
Steam, water, exhaust system, and auxiliary pumping system tempera-
tures we re measured with iron-constantan thermocouples.
The output signal of each measuring device was recorded on re-
dundant end recorders . The types of data acquisition and recording sys-
tems used during this test were a multiple-input digital data acquisition
system scanning each parameter at a rate of 45 or 225 samples per
second and recording on magnetic tape, single input analog continuous
magnetic tape. FM systems recording on magnetic tape, photographi cally
recording galvanometer-type oscillographs recording at paper speeds of
16 in. /sec or 80 in./sec, and direct-inking null-balance potentiometer-
type strip charts . Vi sual observation of the firing was provi ded by a
closed-circuit televis i on monitor. High-speed (2000 fps) optical data
were obtained to provide a permanent visual record of the firing . Table III
presents instrument ranges , recording methods , and system accuracies
for all measured parameters.
2.4 CALIBRATION
The axial thrust i nstrumentation systems were calibrat ed at alti-
tude conditions before and after the motor firing by using a remotely
controlled, hydraulically activated deadweight binary calibrator . The
a xial thrust calibrator wei ghts are secondary standard weights certified
by the National Bureau of Standards (NBS) to be in error by less than
0.01 percent. By using a standard load cell system, accurate to 0.05 per -
cent, the entire axial thrust calibrator was in-place calibrated from the
4000 to the 100,000 Ibf level.
All transducers used in this test were laboratory calibrated before
installation. The strain-gage-type pressure transducers were in-place
4
AE DC-TDR-65-85
calibrated with an electrical calibration system. A voltage substitution-
type of in-place calibration was used on the thermocouples . They had
a 15(fF reference junction, and the NBS (Ref. 3) iron- constantan tabl es
were used to reduce the data to engineering units. All in-place calibra-
tions were performed at altitude before and after the firing.
SECTION III
PROCEDURE
The motor arrived at AEDC January 29, 1965, and was transported
to the AEDC Radiographic I nspection Laboratory and subjected to an
inspection with the Betatron X-ray machine (Fig. 5). On February 17,
1965, it was transported to the Rocket Preparation Area where the pres-
sure transducers and chamber thermocouples were install ed. A pres-
sure check was performed following TCC Procedure OCL-T-2198.
Revision 2.
Prior to fir i ng the first motor, an impul se test and linearity check
were p2rformed on the thrust stand with the mass simulated motor in-
stalled to determine basic thrust stand characteristics. In addition, an
EBW initiator was fired by each ignition system, verifying the system's
performance.
On February 19, 1965, the motor was transported to the test cell,
install ed in the thrust stand (Fig. 6), aligned, and prepared for firi ng.
This included connecting, checking, and insulating the instrumentation
cables with asbestos cloth, al uminum foil , glass tape, and RTV-88
silicone rubber as well as positioning the diffuser entrance cone and
checking the ignition and camera systems .
The temperature conditioning system was started on February 19,
and the test cell temperature was maintained between 62 and 75F until
12 hr prior to air-on. During the 12-hr period, the motor case temper-
ature was maintained between 66 and 69F. This is within the limits of
70 5F specified by TCC.
On February 24, sea-level calibrations were performed followed by
a sequence run, which verified that all transducers and end recording
systems were operating properly and were acceptable for firing. Final
test cell pre-fire operational procedures were compl eted; the test cell
was sealed and evacuated by the RTF exhaust machinery to 0. 34 psia
(apprOXimately 84 , 000 ft) (Ref. 4). Altit ude calibrations were then
performed.
5
AE DC- TR65 85
Approximately 65 sec prior to ignition, the automatic sequencer
was s tarted, act ivating the steam, water, light, camera, instrumenta-
tion, and ignition systems at the times shown in Table II. Starting at
T + 10 sec, the sequencer began the post-fire shutdown.
After post-fire altitude calibrations were performed, the cell was
returned to sea-level pressure. The motor was removed from the test
cell February 25, 1965, and returned to the Rocket Preparation Area
for post-fire inspection. On March 2, 1965, the spent motor was re-
turned to TCC by truck.
4. 1 GENERAL
SECTION IV
RESULTS AND DISCUSSION
The results reported herein are those obtained from t he firing of the
Saturn SIC Retro Motor SD-20 in Propulsion Engine Test Cell (J - 5) on
February 24 , 1965. In addition to ballistic performance, the objectives
of this test were to verify hardware integrity and ignition characteristics
at altitude conditions. The results , with the corresponding data from t he
test of motor SD-1 9, are summari zed in Table IV.
4.2 MOTOR IGNITION
Propellant combustion was initiated by one of the two exploding bridge -
wire ignition systems at an altitude of 11 3,000 ft (Ref. 4). The second
EBW initiator apparently fired 9 msec later. The nozzle closure, which
sealed the chamber and ignit er at atmospheric pressure, was ejected
without damage to the nozzle or nozzl e extension.
Ignition delay, defined as the time from receipt of ignition current by
the EBW Firing Unit until chamber pressure reaches 100 psia, was
58 msec. The ignition rise time , which is the time required for chamber
pressure to change from 100 psi a to 75 percent of its maximum value, was
34 msec. Ignition time, the sum of ignition delay and ignition rise t ime,
was 92 msec. This was less than the 130 msec required by Ref. 2. An
analog trace of thrust, chamber pressure, and pyrogen pressure for the
first 160 msec is presented in Fig. 7.
4.3 BALLISTIC PERFORMANCE
A measured thrust-time curve i s
chamber pressure and cell pressure.
6
presented in Fig. 8 along with
Motor - diffuser pumping was
AEDCTR6585
maintained throughout motor tail off. The average altitude during the firing
was 113,000 ft.
Motor operation time. defined as beginning at the first perceptible
of thrust and ending when the thrust falls to zero, was approxi-
mately 1. 5 sec. The effective burn time, defined as the elapsed time
from the point where chamber pressure rises to 75 percent of its maxi-
mum value and ends when it returns to this value, was 0.626 sec.
The average effective measured impulse based on motor effective burn
time as determined by five high accuracy magnetic tape systems was
59,510lbf-sec. One standard deviation was O. 105 percent. Effective im-
pulse, corrected to vacuum conditions by adding the product of the cell
pressure integral and pre-fire nozzle exit area. was 59,530 lbf-sec. Thi s
is greater than the required 57,300 lbf-sec stated in Ref. 2. This correc-
tion amounted to 0.033 percent of measured effect ive impulse. The aver -
age effective vacuum thrust was 95.100 lbf, whi ch is within the required
limits of 81,500 and 100,140 lb specified in Ref. 2 for a 70F motor.
Measured motor operation, or total impulse, was 66,000 lbf-sec.
The vacuum corrected total impulse including the correction to vacuum con-
ditions was 66,050 lbf-sec for a specific impul se of 234.6 sec based on the
user's stated propellant weight.
The maximum c hamber pressure was 1700 psia. Average chamber
pressure based on motor effective burn time was 1679 psia . Figure 9
provides a compa rison between the results predicted in Ref. 5, the results
of the first t est (SD-19), and those obtained in this test. The predicted dat a
started at 100-psia chamber pressure. This time was correlated with the
ignition del ay experienced on both firings and the composite plot made. The
SD-20 effective burn time was longer (0.626 versus 0.610 sec) and at a
lower chamber pressure (1700 versus 1760 psia max) than SD-19. Both
motors had substantially the same throat area .
4.4 MOTOR THERMAL DATA
Fourteen iron- constant an the rmocouples were installed on the motor
as s hown in Fig. lOa . Figure lOb presents a series of plots of chamber,
nozzle. and cell temperatures versus time from T - 0 to T + 320 sec. It
is noted that the disagreement between two corresponding thermocouples
located at different web sections 30 deg apart is less than 25F.
AEDCTR 6585
Although cell temperature remained relatively constant during the
peak period. all of the chamber temperatures continued to rise. indicat -
ing that they were insulated sufficiently to prevent the cell temperature
from affecting the data significantly. The data indicate that there was
no significant case temperature rise during the firing even though post -
fire temperatures reached 280F at T + 320 sec when data acqui sition
ended.
The nozzle exit cone thermocouples were bonded to the nozzle with
epoxy cement in accordance with the userls request. Optical data sys-
tems indicated that thermocouples T - 12 and T - 14 came completely un-
bonded at T + 1. 5 sec. Data analysis indicated that during post-fire
heat soak these parameters approximated cell temperature.
Thermocouples T-ll and T - 13 exhibited 6 and 16F temperature
rise, respectively, during the 1. 5 - sec motor burn time. It is believed
that these data are invalid because the optical data recorders indicated
that the nozzle paint blistered during this same time period. The post -
fire heat soak resulted in maximum indicated exit cone temperatures of
190F (Fig. l Ob ).
4.5 MOTOR STRUCTURAL INTEGRITY
Post-fire inspection (Fig. 11) revealed that all components of the
motor were in satisfactory condition. The paint on the nozzl e exit cone
started to burn at approximately 0.7 sec, and a portion of it was blown
off at the end of motor operation (T + 1. 5 sec) . There was a consider -
able amount of bluing on the exit cone with the hot spots corresponding to
the valleys in the propellant grain configuration.
The nozzle throat remained in place and showed no sign of major
erosion. Twelve propellant slivers, approximately 5/8 in. wide and
3/8 in. high, remained in the chamber. Tee estimated the remaining
propellant at 3 to 4 lb. With the exception of the propellant sliver s and
the heating of the exit cone, the condition of the vi sible part of the motor
was excellent.
8
A EDC TR 6585
SECTION V
SUMMARY OF RESULTS
The results of the firing of Saturn SIC Retro devel opment motor SD-20
at a simulated altitude of 11 3,000 ft in Propulsion Engine T est Cell (J - 5)
are summarized as follows:
1. Structural integrity of the chamber, nozzle, nozzle
extension, i gnit er, and t hroat was sati sfactory.
2. With the pyrogen and chamber sealed at atmospheric
pressure, t he motor was successfully ignited by one
ignition system as planned. The i gnition time was
92 msec.
3. The motor produced an effective vacuum i mpulse of
59,530 lbf - sec which is greater t han the 57,300 lbf - sec
specified in Ref. 2.
4. Average effective vacuum thrust of 95, 100 lbf i s within
the specification limits of 81 ,500 to 100,140 lbr for a
70F motor.
5. Twelve s livers 5/8 in. wide and 3/8 in. high remained
in the chamber after firing. TCC estimates that they
contain 3 to 4 lb of propellant.
REFERENCES
1. Culp, J. S. ItA Simulated Alt itude Test of a Saturn SIC Retro Devel-
opment Motor (Test Unit No. SD-1 9). " AEDC-TR- 65 -76,
April 1965.
2. Retro Rocket Motor Design Procurement Drawing 60B47001
Originated by George C. Marshall Space Flight Center, NASA,
Huntsville, Alabama, 5-17- 63. Last Revision F ebruary 14, 1964 .
3 , National Bureau of Standards Circul ar 56 1, 1955.
4. Minzner, R. A., Champion, K. S. W., and Pond, H. L. li The
ARDC Model Atmosphere. !! AFCRC- TR- 59-267, August 1959.
5. Bl ack, R. E., Jr. " Internal Ballistics Report TE-424 Rocket
Motor. I. Thiokol Chemical Corporation RE-350, J anuary 3D,
1964 .
9
heroicrelics: Page 10 is blank
a. Retro Location
Fig. 1 Saturn SIC Mockup
AEDCTR6585
11
AEDCTR6585
12
b. Retros under Fairing
Fig. 1 Concluded
a. Overall View
Fig.2 Saturn SIC Retro Motor
AEDCTR6585
13
~
tJ::>.
A
A
View AA
Pyrogen Grain
a I 15. 2
Propellant
(TP-E-8104)
View BB
12-Point Sta r Grain
Config uration
B
I. ." .1
b. Sectioned View
Fig. 2 Continued
>
m
o
()
.
-I
;:0
.
0-
If'
OJ
111
Paper Phenolic Insula1ion
3.34 in.
j
11---------- 8. 4in.
Pyrogen Grain
c. Throat and Pyrogen Detai I
Fig.2 Concluded
AEDC TR6S8S
TL -L -300 Insulation
Nozzle
Graphite Throat
Motor Ii
'I
Five, 3/8-in. -Diam Exit Ports
Plug
o
15
A E DC T R6585
28 V D-C
Arming
Power ~
Supply
Control
28 V D-C ..... Firing EBW
Power
Firing
Unit Firing Squib
Supply
Control
Monitor Unit
Block Diagram
VoJtage
C _ Monitor
ii!l!!

EBW Firing Unit Monitor
Fig.3 Exploding Bridgewire Ignition System
16
~
-J
a. Spray Chamber and Elevated Tank
Fig.4 Propulsion Engine Test Cell (J5)
>
m
o
()
.
-t
;:u
.
0-
'1'
<XI
VI
A E 0 C T R 6585
b. Overall Testing Complex
Fig. 4 Continued
18
':._. -, ...... 1
Js<i.:. ,-
E D C
:64-1502-U
.. : ..... -
.....
CD
Auxiliary Duct
Ej ector System
(Typical)
Tandem Steam
Ejectors
(Typical)
Second Stage
First Stage
53-in .' -diam
Insert with
Cone
I02-in.-diam Water
Cooled Diffuser
Seismic Mass
Thrust Butt
Load Cell
Axial
Calibrator
Air-Conditioning Ducts v
c. Artist's Cutaway View
Fig." Continued

m
o
Q
-i
;:0
.
0-
If
ex>
f.I1
t'-'
o
127, OOQ-Ib Binary
Deadweight Thrust
Calibrator
53- in. Diffuser
Entra nce Cone
~
~ ~ ~ r : ;
~ ~ . ~
" ~ ~ ~ - -
- - ~ - - - - : : : . - - - - - ~ - - ~
~ ~ 200
~ ~ .""-Ib,Thrust Butt
d. Schematic of Thrust Meas uring System
Fig.4 Continued
Motor
53-in. Diffuser Entrance Cone
>
m
o
()
.
-l
;0
.
0-
'f
Ol
(J1
t\:)
f-O
Test Cell
Auxiliary Duct (l of 4)
\water-Cooled Diffuser
-1-
IH IH iH I
. l --------.e--Diffuser Water
Thrust CalIbrator Diffuser Exit Spray Ring
Seismic Mass
53-in. -diam Diffuser Insert
o 10 20 30
I I I I
Scale, It
e. Plan View
Fig ... Continued
Spray Cooling Water
Spray Chamber
>
m
o
()
.
-t
;0
0-
U1
Co
VI
r-:>
r-:>
f. Interior View
Fig .4 Concluded

m
o
o
-t
;:0
.
0-
'f
00
(,n
"" CAl Fig- 5 Saturn SIC Retro in X-Ray Inspection
>
m
o
n
.
--t
;u
.
0-
'f
0>
c.n
AEDCTR6585
24
c
o
..
...2
f
III
C
..
o
'0
~
~
c.n
V'l
......
o
>
100, 000
.i!J 80,000
_ 60,000
......,
V'l
2 40,000
.r::
t- 20,000
ro
V'l
0..
0)-
10-
~
V'l
V'l
0)
10-
CL
ro
V'l
0..
0)-
10-
~
V'l
V'l
0)
10-
CL
o
2000
1500
1000
500
o
2500
2000
1500
1000
500
o
o 0
I Ignition Voltage (Squib 1)
I I I I I I I
ilgnition, Voltage (Squib 2)
I I I
Thrust, FY-l I
I
I
i
~ I I
--
Chamber pressure, P C - ~
I
=Vi
I
20 40 60 80 100
Time, msec
Fig. 7 Motor Ignition Detail
I I I I I
I
1
-
120 140 160

m
o
(')
-I
;0

'"
c.n

QO
c.n
tv
m
100,000
2000 _
0.50
90,000 1800 0.45
80,000 1600 0. 40
70,000 1400 0.35
'" Vi
0.30 oC 60,000
0.1200
- ..,- 0.
-:;;-
...
..,-

VI ...
50,000 E 1000 0.25
..... e..
..,
c;; ...
...
x
.., e..
oC
< E
0. 20
40,000
u
30,000 600 o. 15
20,000 400 0. 10
10,000 200 0.05
0 0 0
I-

I-
o
I I I I I I I I I I I I I I I I
1-- . - - 1- --I-
I
J 1 1 -11_ ._._._.-.
, ........ . ;/ - I I I I \
- - -
J.1 . l-
I I I Axial Thrust I
, I I I II -' i
; -t-/, I I I I i\ .
;
1 I 1 1 1 I 1 1
Chamber Pressure
;
;
j
I
i
I
!
\
lBcell Pressure
-
I I I I
-

'[
-
I I I II I I I I I ._.--... . ......
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0. 8 0. 9 1.0 1.1 l.2 1.3 1.4 1.5
Time, sec
Fig.8 Measured Motor Ballistic Performance
>
m
o
n
,
-l
;::0
.
0-
If
co
111
AEDC-TR-6S-SS
'" ..;
,
,

..;
,
.....
-:-
I
I I
..;
.-
+
f-
i-
I

T
r
... -
- -- -
..
- -
.- . f-- .. - . - .. . .
+
-+-
.. . .. - .
r
f-+ ... - f -
. .
I
r- r - - -r r -
I
.j-
-It
..

-
/-r-r-
0

r-c.r
f-I
.... _/
f-'
--
N
..;
U
U
c:
..;
0
E
..
J!
..
0 u
..;
E
;)
;)
....
u
ci 0
>
..
0
00
..
0
ci

-0
U
f-
. 4- . ..
.... u
";.7
f-II
,

I
'r-/I

/ I
\ .
'r-o
""",p
rV'l
"
I
pr
'r- 'r- t:i
r
r 'i
f-H

2" f-\,

I

r
. . .. ...
r r
- f-.-
-_ .. . - ... ..
-
. .. .. . . ,....
ci II!
u
-0
<II U
U

..
.,j


II.
-0

.!:!
c:
0
)(


'"
N

ci 0 0
cI)

....


ci
0
cI)
-
0
.....
c:
ci 0
1/1
.-
..
0
N
Q.
ci
E
0
U
. f- - -
.. .
-r
1- -- -- ... . - -_ .. . ..
f-I- . .
-------=--::=-- -
- - -;:-.e-'r- -
--
':--..:-
,
0-
ci
cit
II.
0
I
,
. ...
-
1 1
r r ..
!
:
ci

i
N

09
"
g-
tS
0"
ii"
s"
....
'"
Iql I"IXY
27
N
co
1800
1600
1400
1200
"'
j j jj j j
JJ J J
j j 4 j j4 4J 4 41 4 j
-'J 1: -' -,:I: : J:t -' -1 :l :l:l j -+ -,
[J J-,-, J -'-'-' . H-\1 -1 U J J J J J
J -' - llif::f u-,-' 1+ \ -1 U J -'-,
-1 rjiW pi':' .. ,a I J
'/.[' ..., ,., I -'
. - . il -' . , , .... S .. 20 -'
" -+n.' U i -L ' :t -1 ,- -SD-j;-i -' . -' r
-' . -iI:llr -' -' J i -'
J , ' .
1000
!- J \ :
Or ,_ . .
- r\
. -' -'
' -' . J
U i .- r
Q)
....
:::l
V>
V>
'"
....
Q..
BOO
600
400
200
.\
1 \ '
J . ,
J, It:: 1 -'
' f
4 -+ t .
' -' -'-'-' I
-' -' -' , .' -'
' -' -'H j
..,.. , .- ..!- J
I 1i r
1 ,-,-, 1 t- _ _
+.L!>i
o ,-
-' tt.1ITB
'
!U, ' 1. . ,
r ,- -'Uj'..ti U:uD"----
-0.2 -0.1 o 0.1 0.2 0.3 0.4 0.5 0.6 0.7
Time, sec
b. Chamber Pressure
Fig. 9 Continued
O.B 0. 9 1.0 l.l 1.2 1.3 1.4 1.5
-
m
o
()
-I
;0

0-
1I1
00
1I1
t\:)
co
I.
Cell Temperature
I
@
80 in
a. Thermocouple Locatian
Fig. 10 Chamber Temperatures
CDCD
>
m
o
Q
-t
;0
.
...
't'
Q)
.."
AEDCTR6585
30
~ . l l l l l l l l l l l l l l l l l l l l m l l l l l l l l l l l l l l l l l l l l l l l l l
::lllllllllllllllllllllllllllllllltIlllllllllllllllllllII1I1
~ 11111111111111 j'"lllllllt,lllllll i IIIII111111111111
~ I I I I I I I I I I I I I i'llllill 1 l'lilllllll i i III1 i I1IIII11111
:!
i ::IUIIIIIII'tllll i i 1111"11 III i 1III11111111111111111
300
IIiH
II' III
~ H
100
H
o
300
11
__
i:: TI H:lffi:H:
100
~ "
H3
~ HI
o
10011.111 ...
H1 Thermocouples came loose at T + 1.5 sec l-H-l-f1-
11
100
~
Tj
1
1 H4
o
o 50 100 150 100 150 300
Time, sec
b. Data
Fig. 10 Concluded
AEDC-TR-65-85
a. Overall View
Fig. 11 Post-Fire Motor Condition
31
w

Photograph supplied by Thiokol Chemical Corporation
"9'".. ..:..: ....
;- 4-;' 'f
AFT- vA.t::::
_ AclH .. SO..to
.,.3Y .. .. JIZ3.,lf
r
ro!;.,- TE'::.,
b. Close-Up of Nozzle Throat
Fig. 11 Continued
Retaining Ring
>
m
o
n
.
-I
;u
.
0-
'f
ex>
I.n
w
w
Photograph supplied by Thiokol Chemical Corporat i on
I
,
c. Prope Ilant Slivers
Fig. 11 Concluded

m
o
n
.
-I
;0
.
0-
'{'
00
I.n
AEDCTR6s.as
TABLE I
COMPOSITION OF TP-E-8104 PROPELLANT
Percent
by
Material Purpose Weight
Ammonium Perchlorate Oxi di zer 72.0
Ethyl Formal, Sulfide,
Type LP-33 Fuel and Binder 18.8
Dibutyl Carbitol Formal Plasticizer 2. 1
Sulfur }
Diphenylquanidine Curing Agents 2.1
p- quinonedioxime
Aluminum Powder Fuel 2.0
Fe rric Oxide Burning Rate
Accelerator 2. 0
Magnesium Oxide Stabilizer 1.0
34
T 65
T 50
T 40
T 38
T - 10
T - 5
T - 2
T 1
T 0
T + 1
T+ 10
T+ 15
T + 30
T + 40
T + 320
TABLE II
COUNTDOWN SEQUENCER PROGRAM
Start s t eam system
Start water syst ems
Start digital data acquisition system
Arm EBW ignition systems
AEDC-TR-65- 85
St art strip charts, oscillographs Band C. and
magnetic tape recorders
Start oscillographs A and D
Start cameras
Fire first seri es of photo flood bulbs
Motor ignition
Fire second seri es of photo flood bulbs
Fire third seri es of photo flood bulbs
Stop oscillographs A and D
Initiate shutdown of water and steam systems
St op strip charts and magnetic tape recorders
Stop cameras
Stop oscillographs B a nd C and digital data
acquisition system
Time i n seconds
35
w TABLE III
'"

SUMMARY OF MOTOR IHSTRUMEHT"TIQH
m
c
Parameter Oseillo-
"
Strip High Digital Dat a System, ~
Symbol Parameter Range Chart graph 1 Accuracy FM Sampl es per Second
~
.;.
Analog
~
..
S,x:stem
~
F'Y- l Axial Force- D to 150K I bf x A,B 225
FY2 Axial Force o to 150K l hf C,D x
FY-3 Axi al Force o to 150K l hf A,B x 225
FY-4 Axial Fo rce o to 150K lb
f
C,D x
FY-5 Axial Force o to 150K l bf x
PC- } Chamber o to 2000 psia x A,B x 225
Pressure
PC-2 Chamber o to 2000 psia C,D x
Pressure
PP-l Pyrogen o to 2500 pSia x A,B 225
Pressure
PP-2 Pyrogen o to 2500 ps is C,D x
Pressure
P A-3 Cell Pressure o to 0.5 psia C,D 22 5
P A- 4 Cell Pressure o to O. 5 psia x A,B x
PA-5 Cell P ressure o to 15 pSia A,B 22 5
T- ! Nozzle o to lOOQoF x B 45
Temperature
T-2 Case o to lOOOF B 45
Temperature
T -3 Case o to lOOO F B 45
Temperat ure
T -4 Forward Dome o to lOOOF B 45
Temperature
TABLE III (Condud. d)
Parameter Strip Oscillo- High Digital Data System,
Symbol Parameter Range Chart graph
l
Accuracy FM Samples per Se co nd
Analog
~ s t e m
T -5 Case o to lOOQoF
B 45
Temperature
T-6 Nozzle o to lOOOF C 45
Temperature
T-7 Case o to lOOOF C 45
Tempe rature
T-8 Case o to l OOOF C 45
Temperature
T- 9 Case o to 100QoF
C 45
Temperatur e
T- IO For ward Dome o to lOOO F C 45
Temperature
T - ll Nozzle o to lOOO F C
45
Temperature
T- 12 Nozzle o to l OOOF C 45
Temperature
T -1 3 Nozzle o t o l OOQo F D 45
Temperature
T -1 4 Nozzle o to lOOQoF D 45
Temperature
E- l , 2 EBW Charge 10 v A, B, C,D
Monitor
1-1, 2 Ignition A, B, C.D 45
Current
>
m
V-I , 2 Ignition A.B. C,O 45
0
n
Voltage
,
-I
~
,
~
l Oscillographs A and D were operat ed at 80 i n. Isec during the firing . Oscillographs B
~
~
ON
and C were operated at 16 in./sec during the fi ring .
~
...,
AEDC TR 6S 85
38
TABLE IV
SUMMARY OF MOTOR PERFORMANCE DATA
( SATURN SIC RETRO MOTOR TEST)
Motor Number
AEOC Test Number
Test Date
Motor Environment du ring the 12 hou r s
Prior t o Cell Pump Down, OF
Ignition Altitude, ft
Average Altitude, ft
P ropellant Mass, lb
m
* ...
Pre- Fire T hroat Area, in.
2
P ost Fire Throat Area, in.
2
Pre Fire Exit Area, in.
2
Post -Fire Exit Area, in .
2
Motor Weight, lb.
Mass Ratio.
Ignition Delay, msec
Ignition T ime, msec
Effective Burn Time , msec
Total Burn Time. sec
Maximum Chamber Pressure, psia
Total Chamber Pressure Integral, psia-sec
Effective Chamber Pressure Integral, psia-sec
Average Effective Chamber Press ure, psia
Total Impulse, lbrsec
Measured
Vacuum
Percent Vacuum Correction
Effe c tive Impulse, lbf-sec
Measured
Vacuum
Percent Vacuum Correction
Average Effective Thrust, lbf
Measured
Vacuum
Spec ific Impulse, sec
Thrust Coefficient, vacuum
*Motor manufactu r er's data
5019
RP1435-01
2 / 18/65
68 to 71
114, 000
113,000
280.25
35 . 10
35. 10
306.35
307. 16
521. 25
0.54
60
93
610
1. 5
1765
1171
1047
1716
66, 090
1
66,140
0.076
59,210
2
59,230
O. 034
97,060
97,100
236.0
1. 61
1 Five data recordi ng system readings were averaged to obtain
this value.
2Three data recording system readings were averaged to obtain
this value . Di g it al sys tems not used because of response
characteristics .
8 0-20
RP1435 - 02
2 / 24/65
66 to 69
113.000
113,000
281. 5
35.08
35.06
306.26
306.85
527.00
0.53
58
92
626
1.5
1700
1171
1051
1679
66,000
1
66,050
0.076
59, 510
1
59, 530
0.033
95, 060
95,100
234.6
1. 62
UNCLASSIFIED
Security Classification
DOCUMENT CONTROL OAT A R&D
(Sec".;,y d ilic.'I .... of lill a , body of . " afteCI end Indeal", ..,nol., ion ,"ual b nl .... d ...ft.n ,h ..... ,a/l .aport i . c l lllad)
L O"II GI NA TIN G AC TI VI '!" V ( Co ",",,,. , " tho , ) Za. IOI1<POIT '''CU R / TV e ~ " " " ~ I C A TIOH
Arnold Engineer ing Development Center UNCLASS IF lED
ARO, Inc . , Operating Contractor Z II GROUP
Arnold Air Force Station, Tennessee N/ A
1. REPORT TI TLE
A SI MULATED ALTITUDE TEST OF A SATURN SlC RETRO
DEVELOPMENT MOTOR (Test Unit No . SD- 20)
( DESCIOIIPT IVE NOTES ( T)'pe ot .. pot land I ndu e/ ". da' .. )
N/ A
5. AUTHOR(S) ( L , " ...... ,. .. , ".m., InlflaO
Cu lp, J. S. and Bi shop , B. M. , ARO, Inc.
, . REPO AT DATE 7. 1'OTAL NO. 01'" PACOl':'
1
7
1>. 5'
0" 1It1l:'"
May 1965 45
e . CONT R "'CT OR G ..... NT NO. , . O'UGINATOlil'. REPORT NU"'.IER($)
AF40(600) -1000
AEDC-TR-65-85
to. Program Area 921E
,. 'b. OTHIUII "'JPOI'IT ",0($) (Any oth " ..... b. .. 11'1., .... ,. b , .. .-1
11'11 ... pot
, N/ A
10. A V AI L A8 1L.ITY / L. IMI TATI ON NOTICES
Qualified requesters may obtain copies of this r eport from DDC.
DOC release to CFSTI and foreign announcement and distribution
not authorized.
" . SUPPL.I!MENTARY NOTES 12. SPONSORING MIL.ITARY ACTIVITY
N/ A
National Aeronautics and Space
Administration
Mi c houd Operat i ons New Orleans La .
13 ABSTRACT
Saturn SlC retro motor TE-M-424, Test Unit Number SO-2O, was fired
as part of t he Thi okol Chemical Corporation research and development
program for t h is motor. Primary test objectives were to determine
ignition c haracterist i cs, ballistic performance, and hardware integ-
rity at altitude conditions. The motor was ignited by the two i gni-
tion systems at a s imulated altitude of 113,000 ft and burned at an
ave rage altitude of 113 , 000 ft for a total of 1. 5 sec . The effective
burn time was 0.626 sec, and the motor produced an effective vacuum
impulse of 59 , 530 lbf-sec, whi c h is above the specificat i on minimum .
The ignition time of 92 msec is within the specification require-
ments . Post-fire motor inspection revealed that the hardware integ-
rity was satisfactory.
DD
FORM
, J AN 1473 UNCLASSIFIED
Securi ty Classification
"
UNCLASSIFIED
Security Classification
KEY III' OR05
Saturn SIC
Rocket Engine
Altitude Testing
Retrograde Engine
L.INK A L.I NK B L.IN I( C
11101.1: 11101.1:
INSTRUCTIONS
1. ORIGINATI NG ACTIVITY: Enter the name and addr ua
of ,h .. contractor, aubconttactor, II:rantee, Department of
fens e activity Or o ther otl!:ani z ll tion (corporale /luthor) i .. ulnlt
the report.
18. REPORT CLASSIFICATION: Enter Ike OVeT-
all secur ity classification of the report. I ndicate whether
"RestrH;, ... d Oa,." is includerl. Markina; is to be in
ance with appropriat e securit y r eaulationa.
2b. GROUP; Automatic downgradlntr; is specified in DoD Di-
r .. ctivl' 5200.10 and Armed Forces Indus trial Manual. Enter
thto g roup number. Also, wnen applicable, show thaI optional
markIng! h.lVe been used for Group 3 and Gr oup 4 as aut hor-
Iz"d.
3. REPORT TITLE: Enter complete report title in aU
capital Titl es in all cases should unclassified.
If a m<'aningfu\ title cannot be without cLal'! si h c"
li o n, show classification in all capit"ls in
Im" .... Jiately foll owinli: the
4. DF.5CRIPTIVE NOTES: If of
e.g .. nte"m. progress , summary, annaal , Or final,
G,ve the inclusive d ates when a s pec ific ,,'porting period is
c,wered.
5. AUTHOIS): Enter name( s) of author(s) aa ahown on
01 in the rcport. Enle! last name, first name. middle init i i< l,
If :-r.llita,y, show rank .>n.::! branch o f s ervice, The name of
the principal is an absolute minimum r equi rement.
6. REPORT DATI:.: Enter the dat e of the report as day.
mo nth, year: or mont h, year. If more than one date appellrs
on the report . use date of publicat, on.
7D. TOTAL NUMBER OF PAGES: The l otal page count
should foll o w nonnal pag'"ation procedures, Le., enter the
number of pages containing information.
7b. NUMUER OF REFERENCES: Enter the total number of
c ited in the report.
Sa. CONTRACT OR GRANT NUMBER: If appropriate, enl
Ihe appl icat: l e number o f the contra. I or gr ant which
Ihe report was WTitten.
8b, &., & 8d. PROJECT NUMBER: Enle. the appropr iate
mi litar y department i dent ification. such as project number,
subproject number, system numbers, 'as k numher, etc.
9a. ORIGI NATOR'S REPORT NUMBER(S): Enter the offi-
ci al report number by which the document will be identiOed
and co ntrdled by the originating activity. "fhi s nun:ber must
be unique to this report.
9b. OTHER REPORT NUMbER(S): If the .. ' port h .. s bt<en
ass 'gned any othpr repo.t number l'l (either by th .. oris,n%.
or by Ihe spon"or). al so enter this numberCs).
10. AVAILABILITY/ L IMI TATION NOTICES: Enter any lim-
.tations on fur ther dissemination of the report, other tha n those
imposed by security classification, using standa rd atatementa
such as:
(I) "Qualified requesters may obtLILin cop iell of this
report from DOC."
(2) "Forei,!:n announcement and dissemination of this
report by DOC is not author ize<1 "
(3) "u. S. Government agenciell may obtain cop ies o f
thill report directly from DOC, Other qU8l1fled DOC
use.s shaLL request through
(4) "U. S. military agencies may obtain copies of this
report directly from DOC. Other quali fied u ser.
II hall request through
"
(5) "All distribution of this report ill controlled. Qual
i fied DOC users shall request through
"
If the .epol1 has been furnished t<' the Office o f Technic al
Services, Department of Commerce, for sa le to th .. public, indi-
cate this fac:t and enter the p rice, if know'"
II. SUPPLEMENTARY NOT ES: Use for additional explan"
tory not es.
12. SPONSORI NG MILITARY ACTIVITY: Enter the name o f
the departmental project o ffi -:e Or laboratory spon30rinli: (pay-
i ns fo r) the research and devel opment, Include address.
13. ABSTRACT: Enter an abstract giving g brief and fa c tual
lIummary of the document indicative of the report, even thouah
it .nay a lso gppear elseWhere in the body of the teChnical re-
port. If additional space i s requiretl. s continuation sheet shall
be attached.
I t is highly desirable that the abstract of classified repOrU
be unclassified. Each parggraph of the abst ract shall end with
a n indicati on of the military security clusifica ti on of the in
fomr.Lllion i n the parali:raph. as ( r5). (5). (e). or (UJ
There is no Iimitalion on the length of the abstract. How
ever, the suggested length is from 150 t? 225 words.
14. KEY WORDS: Key wor<.ls are technically meaninli:ful terms
Or short phrases that characterize" report and may be used al
entTies for catalolJ:ing the repotl. Key words must be
selected so that nO security c lassification is required. Identi.
fiers. s uch 'as equipmenl model designstion, trade name. milit .. y
project code name, geographi c location, may be used as key
words but w;1l be followed by an indication of technical can.
texl . The assignment of links. rul es . and weili:hts is optionsl.
UNCLASSIF I ED
Secll ritv Cla!'l!'lifirRtinn