Prefabricated Refractory Panels for Use in KSC's Flame Deflectors: A Feasibility Study

[摘要] The launch complexes at the John F. Kennedy Space Center (KSC) have been used to launch space vehicles for the Apollo and Space Shuttle programs. NASA is currently designing and developing a new space vehicle. The launch complexes have been in service for a significant duration and the aggressive conditions of the Florida coast and the launches have resulted in failures within the launch complexes. Of particular interests is the performance of the refractory lining that covers the steel base structure for the diversion of the exhaust from the launched vehicles (i.e., the flame deflectors). An unprotected steel base structure would likely experience loss of strength and possible failure when subjected to the high temperatures during launches. The refractory lining is critical for successful launches. The refractory material currently used in the flame trenches was developed in 1959 and is the only refractory material approved for use in these facilities. Significant effort and costs are expended in repairing the lining system after each launch. NASA is currently performing a comprehensive research program to assess and develop refractory materials for improved performance in the flame trenches. However, one challenge associated with the use of refractory materials in the flame trench is that the materials should be cured, dried, and fired to maximize their properties and characteristics. Because of the large size of the deflectors and trenches, drying and firing of the lining system is difficult, if not impossible. Most refractory materials are dried and fired before use. Because the refractory materials used for the deflector lining cannot be dried and fired, the full potential of the materials are not being realized. A system that could use refractory materials that could be cured, dried, and sintered in a controlled environment would likely improve the performance of the lining system. This report evaluates the feasibility of fabricating and placing prefabricated refractory panels on the deflector. Panels could be fabricated and processed off-site in a controlled environment to maximize performance. These panels could then be transported to KSC and installed on the flame deflector. The findings of this report indicate that conventionally reinforced, prefabricated refractory panels can likely be designed, fabricated, and placed on the deflector. Post-tensioning of the panels will reduce the amount of "open' joints, which can be susceptible to accelerated erosion and abrasion. The panels, produced with newer, better performing refractory materials, should exhibit lower deterioration, providing a more economical system. A method for placing the panels has been provided. The findings of this research indicate that post-tensioned, prefabricated refractory panels can be placed on the flame deflectors and should exhibit improved performance when compared with the current method of gunning the refractories on the deflector. Further evaluation will be needed to confirm these findings. Specific focus should be placed on the performance of the joints transverse to the exhaust flow, erosion/abrasion rates of "closed" joints, uplift forces at joints transverse to the exhaust flow, development of composite action between the steel base and the refractory panels, and refractory material resistance to the launch and Florida coast environment.

[发布日期] 2010-05-01

[学科分类] 复合材料