An automated inspection system has been developed to inspect the o-ring sealing surfaces on the Space Shuttle reusable solid rocket motor (RSRM) case segment joints. A laser digitizing system is used to create a three dimensional map of the o-ring sealing surfaces. This data is analyzed for any irregularities, which are noted for further inspection and disposition. This paper describes both the hardware and the software used to gather data as well as the methods developed to analyze the data.The RSRM is assembled from four casting segments.Each of the field joints between these segments is sealed with three o-rings.
Subscale test motors are often used for the evaluation of solid rocket motor component materials such as internal insulation. These motors are useful for characterizing insulation performance behavior, screening insulation material candidates and obtaining material thermal and ablative property design data. One of the primary challenges associated with using subscale motors however, is the uncertainty involved when extrapolating the results to full-scale motor conditions. These uncertainties are related to differences in such phenomena as turbulent flow behavior and boundary layer development, propellant particle interactions with the wall, insulation off-gas mixing and thermochemial reactions with the bulk flow, radiation levels, material response to the local environment, and other anomalous flow conditions.In addition to the need for better understanding of physical mechanisms, there is also a need to better understand how to best simulate these phenomena using numerical modeling approaches such as computational fluid dynamics (CFD).
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