The Development of Improved Normal Stress Transducers for Propellant Grains. Volume II. Appendices.

摘要

This report details the CSD effort in the design, analysis, manufacturing, calibration, and embedded use of improved normal stress transducers. Prototype transducers from two different contractors were manufactured and tested as well as final production transducer models. Finite element analysis techniques used for transducer analysis are extensively covered and were used for design optimization and gage interpretation. Results covering gaseous nitrogen calibrations, long term stability, self-heating, diode effects, embedded thermal and pressurization loadings, and mechanical tests are presented and compared with design goals. Detailed manufacturing specifications are presented along with recommended calibration and installation techniques. The final transducer design is 0.130-in. high with an external prewired compensation package. Stability of the metal and epoxy bond has been optimized by special processing techniques which are presented. Several significant achievements were obtained during the program. The first computerized design tradeoff curves were generated for stress transducers. Successful electron beam welding of critical components on stress transducers were demonstrated. Transducer measured stress in propellant was verified independently in the tension-compression-shear and TM-1 devices. Transducer response under high rate loading conditions was demonstrated. Agreement between predicted and measured stresses for a thermal loaded solid propellant motor using the thermal-mechanical interaction factor was achieved. (Author)