an update on structural seal development at nasa grc
TRANSCRIPT
AN UPDATE ON STRUCTURAL SEAL DEVELOPMENT AT NASA GRC
Pat Dunlap, Bruce Steinetz, and Josh Finkbeiner National Aeronautics and Space Administration
Glenn Research Center Cleveland, Ohio
Jeff DeMange and Shawn Taylor
University of Toledo Toledo, Ohio
Chris Daniels
University of Akron Akron, Ohio
Jay Oswald
J&J Technical Solutions, Inc. Cleveland, Ohio
National Aeronautics and Space Administration
www.nasa.govNASA Glenn Research Center
An Update on Structural Seal Development at NASA GRC
Pat Dunlap, Dr. Bruce Steinetz, Josh FinkbeinerNASA Glenn Research Center, Cleveland, OH
Jeff DeMange, Shawn TaylorUniversity of Toledo, Toledo, OH
Dr. Chris DanielsUniversity of Akron, Akron, OH
Jay OswaldJ&J Technical Solutions, Inc., Cleveland, OH
2005 NASA Seal/Secondary Air System WorkshopNovember 8-9, 2005
Pat Dunlap, Dr. Bruce Steinetz, Josh FinkbeinerNASA Glenn Research Center, Cleveland, OH
Jeff DeMange, Shawn TaylorUniversity of Toledo, Toledo, OH
Dr. Chris DanielsUniversity of Akron, Akron, OH
Jay OswaldJ&J Technical Solutions, Inc., Cleveland, OH
2005 NASA Seal/Secondary Air System WorkshopNovember 8-9, 2005
NASA/CP—2006-214383/VOL1 411
Nat
iona
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Intr
oduc
tion
& B
ackg
roun
d
•A
dvan
ced
stru
ctur
al s
eals
are
re
quire
d on
futu
re h
yper
soni
c ve
hicl
es a
nd o
n ve
hicl
es a
nd
syst
ems
for
NA
SA
’s E
xplo
ratio
n In
itiat
ive
–D
ynam
ic s
eals
:•
Con
trol
sur
face
s•
Land
ing
gear
doo
rs
•A
cces
s pa
nels
and
doo
rs
•H
yper
soni
c en
gine
ram
ps a
nd
pane
ls
–S
tatic
sea
ls:
•D
ocki
ng/b
erth
ing
syst
em s
eals
•
Lead
ing
edge
pan
el jo
ints
•A
crea
ge th
erm
al p
rote
ctio
n sy
stem
(T
PS
) jo
ints
•H
eats
hiel
d jo
ints
and
inte
rfac
es
Hype
rson
ic e
ngin
e se
alsSe
al
loca
tion
Heat
shie
ld s
eals
NASA/CP—2006-214383/VOL1 412
Nat
iona
l Aer
onau
tics
and
Spa
ce A
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istr
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n
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GR
C S
truc
tura
l Sea
ls T
eam
Res
earc
h A
reas
•G
RC
Str
uctu
ral S
eals
Tea
m d
evel
opin
g se
als
for
NA
SA
’s
Exp
lora
tion
Initi
ativ
e:–
Adv
ance
d D
ocki
ng/B
erth
ing
Sys
tem
(A
DB
S)
for
CE
V (
JSC
)–
CE
V T
PS
Adv
ance
d D
evel
opm
ent (
LaR
C, A
mes
) –
Aer
ocap
ture
Tec
hnol
ogy
Dev
elop
men
t (M
SF
C)
–D
eplo
yabl
e S
kirt
Sys
tem
(N
orth
rop
Gru
mm
an)
Trai
ling
ballu
te fo
r ae
roca
ptur
eCr
ew E
xplo
ratio
n Ve
hicl
e (C
EV)
Adva
nced
Doc
king
/Ber
thin
g Sy
stemSe
alin
g in
terf
ace
NASA/CP—2006-214383/VOL1 413
Nat
iona
l Aer
onau
tics
and
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ce A
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istr
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n
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Res
earc
h A
reas
& O
bjec
tive
•G
RC
Str
uctu
ral S
eals
T
eam
als
o de
velo
ping
se
als
for
hype
rson
ics
prog
ram
s:–
Fal
con
prog
ram
(Lo
ckhe
ed
Mar
tin, D
AR
PA
, JS
C)
–X
-43C
Dire
ct C
onne
ct
Com
bust
or R
ig (
AT
K G
AS
L,
LaR
C)
Obj
ectiv
e: D
evel
op s
ealin
g sy
stem
s th
at m
eet v
ehic
le/s
yste
m
requ
irem
ents
and
dem
onst
rate
per
form
ance
in r
elev
ant e
nviro
nmen
ts
Falc
on v
ehic
leCont
rol
surf
ace
seal
s
Lead
ing
edge
sea
ls
Acre
age
TPS
seal
s
NASA/CP—2006-214383/VOL1 414
Nat
iona
l Aer
onau
tics
and
Spa
ce A
dmin
istr
atio
n
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Pre
sent
atio
n O
utlin
e
•W
afer
sea
ls•
Spr
ing
tube
sea
ls•
Hig
h te
mpe
ratu
re s
eal p
relo
ader
s: T
ZM
can
ted
coil
sprin
gs•
Arc
jet t
est r
ig
NASA/CP—2006-214383/VOL1 415
Nat
iona
l Aer
onau
tics
and
Spa
ce A
dmin
istr
atio
n
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Waf
er S
eal G
eom
etry
/Flo
w In
vest
igat
ions
•P
revi
ous
test
s re
veal
ed th
at w
afer
sea
l ins
talla
tion
fact
ors
influ
ence
d flo
w r
ates
•O
bjec
tive:
Impr
ove
unde
rsta
ndin
g of
waf
er s
ealin
g sy
stem
•A
ppro
ach:
Par
amet
ric s
tudi
es o
f per
form
ance
(flo
w te
sts)
–D
esig
n of
exp
erim
ents
(D
OE
) st
udy
to e
valu
ate
varia
bles
that
affe
ct
seal
inst
alla
tion
–W
afer
sea
l geo
met
ry s
tudy
Bri
dg
e el
emen
t
Sea
l pre
load
ers
0.12
5 in
. gap
Tes
t se
al
Sea
l ca
rtri
dg
e
Co
ver
pla
te
Ple
nu
m
cham
ber
Met
ered
air
su
pp
ly
Line
ar fl
ow fi
xtur
e
NASA/CP—2006-214383/VOL1 416
Nat
iona
l Aer
onau
tics
and
Spa
ce A
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istr
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n
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Waf
er S
eal I
nsta
llatio
n D
OE
Stu
dy
•W
afer
geo
met
ry: 0
.5 in
. wid
e x
0.92
in. l
ong
x 0.
125
in. t
hick
•F
ive
fact
ors
eval
uate
d at
two
leve
ls–
Waf
er h
eigh
t tol
eran
ce: 0
.000
3 an
d 0.
0020
in.
–P
relo
ad: 1
.8 a
nd 4
.3 lb
f per
inch
of
seal
–B
ridge
ele
men
t thi
ckne
ss: 0
.015
an
d 0.
060
in.
–G
roov
e w
idth
cle
aran
ce: 0
.001
an
d 0.
007
in.
–G
roov
e le
ngth
cle
aran
ce: 0
.001
an
d 0.
005
in.
•T
est m
atrix
:–
16 tr
ials
–F
ract
iona
l fac
toria
l des
ign
(Res
olut
ion
V)
–T
ests
per
form
ed in
ran
dom
ord
er
to m
inim
ize
bias
es
Stac
k Le
ngth
Heig
ht
Wid
th
Thic
knes
s
Bri
dg
e el
emen
t
NASA/CP—2006-214383/VOL1 417
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iona
l Aer
onau
tics
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ce A
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istr
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Res
ults
of W
afer
Sea
l Ins
talla
tion
DO
E S
tudy
Mean of 0-100 psi leakage metric, SCFM-psi/in
0.00
200.
0003
108 96 84 72 60
4.3
1.8
0.06
00.
015
0.00
70.
001
108 96 84 72 60
0.00
50.
001
WH
TP
relo
adB
ET
GW
CG
LC
WH
T =
Waf
er h
eigh
t tol
eran
ce, i
n.
Pre
load
= P
relo
ad p
er in
ch o
f sea
l, lb
f/in.
BE
T =
Brid
ge e
lem
ent t
hick
ness
, in.
GW
C =
Gro
ove
wid
th c
lear
ance
, in.
GLC
= G
roov
e le
ngth
cle
aran
ce, i
n.
Leak
age
met
ric =
Are
a un
der
flow
vs.
pr
essu
re c
urve
from
0 to
100
psi
g
Key
Loos
er
groo
ve le
ngth
cl
eara
nce
Thic
ker b
ridge
el
emen
tHi
gher
sea
l pr
eloa
d
Tigh
ter w
afer
he
ight
tole
ranc
e
Tigh
ter g
roov
e w
idth
cle
aran
ce
NASA/CP—2006-214383/VOL1 418
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iona
l Aer
onau
tics
and
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ce A
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istr
atio
n
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Waf
er G
eom
etry
Stu
dy: T
hick
ness
Var
iatio
ns
•M
otiv
atio
n: T
hick
er w
afer
s ha
ve lo
wer
par
t cou
nt, l
ower
leak
age
rate
s?•
Com
para
ble
leak
age
rate
s fo
r 1/
8-in
. and
1/4
-in. t
hick
waf
ers:
can
re
duce
par
t cou
nt 2
X b
y us
ing
1/4-
in. t
hick
waf
ers
•H
ighe
r flo
w r
ates
for
1-in
. and
2-in
. thi
ck w
afer
s, le
ss a
ble
to c
onfo
rm to
w
afer
mis
alig
nmen
ts a
nd s
ealin
g su
rfac
e di
stor
tions
0.0
0.2
0.4
0.6
0.8
1.0
1.2
020
4060
8010
0
Pre
ssu
re d
iffe
ren
tial
acr
oss
sea
l, p
sig
Flow per inch of seal, SCFM/in
1/8-
in.
thic
k
1/4-
in.
thic
k
1-in
. th
ick
2-in
. th
ick
1/8
in.
1/4
in.
1 in
.
2 in
.
NASA/CP—2006-214383/VOL1 419
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iona
l Aer
onau
tics
and
Spa
ce A
dmin
istr
atio
n
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Waf
er G
eom
etry
Stu
dy:
Ful
l-Siz
e vs
. Hal
f-S
ize
Waf
ers
•M
otiv
atio
n: S
mal
ler
waf
ers
occu
py le
ss s
pace
, wei
gh le
ss, f
it in
tight
er
loca
tions
•F
low
rat
es fo
r ha
lf-si
ze w
afer
s ~
3X th
ose
for
full-
size
waf
ers
(1/8
-in. t
hick
)•
Can
red
uce
part
cou
nt 4
X fo
r ha
lf-si
ze w
afer
s by
usi
ng 1
/2-in
. thi
ck
waf
ers
vs. 1
/8-in
. thi
ck (
sim
ilar
flow
rat
es)
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
020
4060
8010
0
Pre
ssu
re d
iffe
ren
tial
acr
oss
sea
l, p
sig
Flow per inch of seal, SCFM/in
1/8-
in. t
hic
k, f
ull-
size
1/8-
in. t
hic
k, h
alf-
size
1/4-
in. t
hic
k, h
alf-
size
1/2-
in. t
hic
k, h
alf-
size
0.25
in.
0.5
in.
0.92
in.
0.5
in.
Full-
size
w
afer
Half-
size
w
afer
NASA/CP—2006-214383/VOL1 420
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iona
l Aer
onau
tics
and
Spa
ce A
dmin
istr
atio
n
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Spr
ing
Tub
e S
eal D
evel
opm
ent
•O
bjec
tive:
Impr
ove
resi
lienc
y of
spr
ing
tube
se
als
at h
igh
tem
pera
ture
s•
App
roac
h:S
ubst
itute
R
ene
41 a
s m
ater
ial f
or
knitt
ed s
prin
g tu
be v
s.
Inco
nel X
-750
in b
asel
ine
desi
gn
Saf
fil
core
Sp
rin
g
tub
e
Nex
tel 3
12 s
hea
th Per
man
ent s
et
Loss
of r
esili
ency
in
bas
elin
e se
al
NASA/CP—2006-214383/VOL1 421
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iona
l Aer
onau
tics
and
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ce A
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istr
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n
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Res
ilien
cy Im
prov
emen
t for
Ren
e 41
Spr
ing
Tub
e
Pre-
test
2000
°F17
50°F
1500
°F12
00°F
20%
Com
pres
sion
Tes
ts o
n IN
X-7
50 S
prin
g Tu
be
Perm
anen
t set
20%
Com
pres
sion
Tes
ts o
n Re
ne 4
1 Sp
ring
Tube
Pre-
test
1200
°F15
00°F
1750
°F20
00°F
Sign
ifica
nt p
erm
anen
t set
for I
ncon
el a
t 150
0°F
No
visi
ble
perm
anen
t set
for R
ene
until
175
0°F
NASA/CP—2006-214383/VOL1 422
Nat
iona
l Aer
onau
tics
and
Spa
ce A
dmin
istr
atio
n
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Spr
ing
Tub
e S
eals
: Go-
For
war
d P
lan
•T
estin
g to
-dat
e ha
s be
en o
n sp
ring
tube
s by
th
emse
lves
•W
ork
in p
rogr
ess:
–F
abric
atin
g se
als
with
Ren
e 41
spr
ing
tube
s fo
r ev
alua
tion
(Jac
kson
Bon
d E
nter
pris
es, L
LC)
•F
utur
e w
ork
–P
erfo
rm h
ot c
ompr
essi
on te
sts
on n
ew s
eals
to e
valu
ate
if re
silie
ncy
impr
ovem
ents
tran
slat
e to
full
seal
s–
Fab
ricat
e an
d ev
alua
te s
eals
with
Kan
thal
A1
wire
ove
rbra
id
inst
ead
of N
exte
l fab
ric (
impr
oved
dur
abili
ty)
–F
abric
ate
and
eval
uate
sea
ls w
ith e
ngin
eere
d co
res
inst
ead
of S
affil
(im
prov
ed r
esili
ency
and
low
er fl
ow r
ates
)
NASA/CP—2006-214383/VOL1 423
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iona
l Aer
onau
tics
and
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ce A
dmin
istr
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n
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Hig
h T
empe
ratu
re S
eal P
relo
ader
Dev
elop
men
t: T
ZM
Can
ted
Coi
l Spr
ing
•O
bjec
tive:
Dev
elop
pr
eloa
d de
vice
s th
at
prov
ide/
augm
ent s
eal
resi
lienc
y at
hig
h te
mpe
ratu
res
•A
ppro
ach:
Pur
suin
g hi
gh
tem
pera
ture
TZ
M c
ante
d co
il sp
rings
–U
niqu
e lo
ad v
s.
disp
lace
men
t cur
ve
prov
ides
nea
rly c
onst
ant
forc
e ov
er la
rge
rang
e
–La
rge
wor
king
def
lect
ion
Larg
e w
orki
ng d
efle
ctio
n of
can
ted
coil
sprin
g
5%35
%
Can
ted
Coi
l S
prin
g
NASA/CP—2006-214383/VOL1 424
Nat
iona
l Aer
onau
tics
and
Spa
ce A
dmin
istr
atio
n
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TZ
M C
ante
d C
oil S
prin
g D
evel
opm
ent
•R
ecen
t acc
ompl
ishm
ents
–S
ucce
ssfu
lly fa
bric
ated
spl
it-fr
ee
0.02
5-in
. dia
met
er T
ZM
wire
with
be
tter
than
exp
ecte
d st
reng
th a
nd
duct
ility
(R
heni
um A
lloys
, Inc
.)–
Suc
cess
fully
col
d-co
iled
TZ
M w
ire
into
rep
rese
ntat
ive
sprin
g ge
omet
ries
•W
ork
in p
rogr
ess
–W
ire c
oatin
g tr
ails
usi
ng p
latin
um–
Wire
tens
ile te
sts
at r
oom
te
mpe
ratu
re a
nd 2
300°
F
•F
utur
e w
ork
–A
sses
s pl
atin
um c
oatin
g du
rabi
lity
via
bend
test
s at
230
0°F
in a
ir –
Coi
l TZ
M w
ire in
to c
ante
d co
il co
nfig
urat
ion
and
perf
orm
co
mpr
essi
on te
sts
to e
valu
ate
resi
lienc
y
Succ
essf
ul c
oilin
g tri
als
of T
ZM w
ire
Split
-free
TZM
wire
NASA/CP—2006-214383/VOL1 425
Nat
iona
l Aer
onau
tics
and
Spa
ce A
dmin
istr
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Arc
Jet
Tes
t Rig
Dev
elop
men
t
•O
bjec
tive
–E
valu
ate
seal
s un
der
sim
ulat
ed
reen
try
heat
ing
cond
ition
s in
JS
C
arc
jet u
sing
GR
C-d
evel
oped
test
fix
ture
•F
eatu
res
–U
niqu
e G
RC
des
ign
perm
its
test
ing
of d
iffer
ent s
eal a
nd fl
ap
desi
gns/
mat
eria
ls–
Mod
ular
sea
l car
trid
ges
enab
le
rapi
d ex
chan
ge o
f sea
l spe
cim
ens
–M
otor
-driv
en fl
ap m
oves
dur
ing
test
ing
to s
imul
ate
fligh
t–
Adj
usta
ble
angl
e-of
-atta
ck a
nd
yaw
ang
le p
erm
it in
vest
igat
ion
of
diffe
rent
flow
con
ditio
ns–
Inst
rum
enta
tion
reco
rds
tem
pera
ture
s an
d pr
essu
res
arou
nd s
eal a
nd fl
ap–
Coo
led
suba
ssem
bly
perm
its ti
me-
at-t
empe
ratu
re te
sts
Insu
latin
g til
e
Mov
able
C/
SiC
flap
(MR&
D/G
E)
Seal
loca
tion
Cool
ed
inst
rum
enta
tion
tray
and
tube Ty
pica
l arc
jet t
est a
t JSC
NASA/CP—2006-214383/VOL1 426
Nat
iona
l Aer
onau
tics
and
Spa
ce A
dmin
istr
atio
n
ww
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NASA/CP—2006-214383/VOL1 428