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NASA/TM-2012-217348NESC-RP-09-00529International Space Station (ISS)Heat Rejection Subsystem (HRS)Radiator Face Sheet DamageHenry A. Rotter/NESCLangley Research Center, Hampton, VirginiaDistribution limited to NASA Contractors and U.S. Government OnlyMarch 2012

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NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage1 of 83International Space Station (ISS) Heat Rejection Subsystem (HRS)Radiator Face Sheet DamageFebruary 9, 2012Distribution Limited to NASA Contractors and U.S. Government OnlyNESC Request No.: TI-09-00529

NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage2 of 83Approval and Document Revision HistoryNOTE: This document was approved at the February 9, 2012, NRB. This document wassubmitted to the NESC Director on February 29, 2012, for configuration control.Approved:Original Signature on File3/1/12NESC DirectorVersion1.0Description of RevisionInitial ReleaseDateAuthorMr. Henry Rotter,NASA TechnicalFellow for LifeSupport/ActiveThermal, JohnsonSpace CenterNESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government OnlyEffective Date2/9/12

NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage3 of 83Table of ContentsTechnical Assessment Report1.0Notification and Authorization . 72.0Signature Page . 83.0Team List . 93.1Acknowledgements . 93.2NESC Involvement . 104.0Executive Summary . 115.0Problem Description . 165.1ISS HRSR Description . 165.1.1 Hydraulic Rupture Analysis . 215.2HRSR Design, Flight and Assembly Data . 215.3Review of MMOD Test Coupons and Data . 245.4IR Thermography . 255.4.1 NDE Imagery Analysis . 28Form Factor Analysis . 335.56.0LS-DYNA Analysis. 366.1Background . 366.1.1 LS-DYNA Overview . 366.1.2 Material Definition. 366.1.3 Model Evolution . 366.2Model 1.0 . 376.2.1 Model 1.0 Results Discussion . 406.3Models 2.0 and 3.0 . 416.3.1 Models 2.0 and 3.0 Results Discussion . 42Model 4.0 . 476.46.4.1 Model 4.0 Results Discussion . 486.4.2 Peer Review . 516.5Model 5.0 . 516.5.1 Model 5.0 Features. 536.5.2 Model 5.0 Results Discussion . 546.6LS-DYNA Analysis Conclusions . 587.0NESC Supported Radiator Testing . 597.1Radiator Tests . 597.1.1 Test 3.1 -- Panel NDE . 607.1.2 Test 3.3 -- Tube Damage/Proof Test. 60NESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government Only

NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet Damage7.1.37.1.47.27.34 of 83Test 3.8 -- Permeation/Leakage Through Silver-Filled Epoxy From FlowTube . 62Test 3.11 --Panel Segment Pressure Tests . 63General Discussion of Test Results . 70Concluding Remarks . 718.0Findings, Observation, and NESC Recommendations . 718.1Findings. 718.2Observation . 73NESC Recommendations. 738.39.0Alternate Viewpoints . 7310.0Other Deliverables . 7311.0Lessons Learned . 7312.0Definition of Terms . 7313.0Acronyms List . 7414.0References . 7515.0Appendices . 76List of FiguresFigure 4.0-1.Figure 4.0-2.Figure 4.0-3.Figure 4.0-4.Figure 5.1-1.Figure 5.1-2.Figure 5.1-3.Figure 5.1-4.Figure 5.1-5.Figure 5.1-6.Figure 5.1-7.Figure 5.2-1.Figure 5.3-1.Figure 5.3-2.Figure 5.4-1.Figure 5.4-2.HRSR S1-3 Panel 7 Damage . 11Initial Damage Assessment of HRSR S1-3 Panel 7 Survey . 12S1-3 Panel 7 Back Side Face Sheet . 13Panel Test Segment with Face Sheet Peeled Back . 15EATCS Loop A and B Schematic . 16PM including FCV . 17EATCS HRSR Array showing the Dual Flow Paths. 18PVR Deployment. 18HRSR Panel Face Sheets View from Nadir Side . 19Radiator Panel Design Overview . 20Radiator Panel Construction Details . 20S1-3 Array Loop 1 and 2 N2 Pressures . 23Panel 7 MMOD Impact Exit Hole 5/16 Inch (Note ring around hole). 24Impact Test #9; Exit Side and Exit Hole Size ( 0.31-inch-diameter) for a 6.35mm Projectile [ref. 1] . 25Raw Temperature Data Showing Normal Radiator Panel (Center) TemperatureGradients . 26Enhanced IR Imagery of a Thermal-Vacuum Ground Test of a Radiator Panelwith Temperature Range . 26NESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government Only

NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet DamageFigure 5.4-3.Figure 5.4-4.Figure 5.4-5.Figure 5.4-6.Figure 5.4-7.Figure 5.4-8.Figure 5.4-9.5 of 83Normal Radiator Temperature Contour Plot Showing Flow Paths . 27Possible Frozen Flow Path on S1-2 Panel 7 (Center Array) . 27IR Imagery Processing Results . 28Registration of Images Based on Affine Transform. 30Transformation of ISS HRSR Panel from Camera to Normal Views . 30(a) Temperature Image of HRSR Panel (b) Laplacian Image . 31(a) Laplacian Image of a Damaged Panel (b) Laplacian Image of anUndamaged Panel . 31Figure 5.4-10. Temperature Profiles for Analogous Cooling Tubes Compared for EachRadiator . 32Figure 5.5-1. Thermal Desktop Geometric Model of ISS (with Starboard HRSRNodalization shown) . 34Figure 5.5-2. IR Imagery Depicting Panel-to-Panel Temperature Trends . 35Figure 5.5-3. Form Factor to Space Results for Case 1 . 35Figure 6.2-1. (Top) State of Face Sheet Prior to Failure Initiation, (Bottom) Face SheetFailure Propagation . 38Figure 6.2-2. Face Sheet Lifting. 39Figure 6.2-3. Face Sheet Fold Over . 40Figure 6.2-4. Side View of Figure 6.2-2 Depicting Incorrect Penetration of the Face Sheetinto the Honeycomb Volume . 41Figure 6.3-1. Radiator Features (Models 2.0 and 3.0) . 42Figure 6.3-2. Pressure Ramp Down Study for Models 2.0 and 3.0 . 43Figure 6.3-3. Failure Propagation in Model 2.0, Front and Side Views . 44Figure 6.3-4. Failure Propagation in Model 3.0, Front and Side Views . 45Figure 6.3-5. On-orbit Image of Radiator Panel showing Face Sheet Displacement . 46Figure 6.3-6. Face Sheet Tearing Along the Bolt Holes . 46Figure 6.3-7. Comparison of Wrinkling Features to On-orbit Images . 47Figure 6.4-1. Peel Test Configuration . 48Figure 6.4-2. Model 4.0 at Impact State . 49Figure 6.4-3. Marking on Panel 7 Neighboring Panel . 50Figure 6.4-4. Simple Paper Model shows the Folded Face Sheet Lines up with the Markingon the Neighboring Panel. 50Figure 6.5-1. Calculated Pressure Unloading Time History . 52Figure 6.5-2. A Comparison of Bolted Constraint Definitions . 53Figure 6.5-3. Zoomed View of the Failure Progression as the Face Sheet Pulls from theBolts . 55Figure 6.5-4. Comparison of Bolt Pullout Near Failure Initiation and Tearing Along BoltHoles . 56Figure 6.5-5. Comparison of the Location of the Contact Edge in the LS-DYNA Model tothe Paper Model . 57Figure 7.1-1. Subset of Overall Test Plan Presented to MVCB and SSPCB . 59NESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government Only

NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291.0Page #:Title:ISS HRS Radiator Face Sheet DamageFigure 7.1-2.Figure 7.1-3.Figure 7.1-4.Figure 7.1-5.Figure 7.1-6.Figure 7.1-7.Figure 7.1-8.Figure 7.1-9.Figure 7.1-10.Figure 7.1-11.Figure 7.1-12.Figure 7.1-13.Figure 7.1-14.6 of 83Parent Material Defect Detected During Inspection . 61Silver-Filled Epoxy Testing with Ammonia . 62Panel Test Segment 6-7 . 64Panel Test Segment 8-8 . 64Panel Test Segment 6-3 . 65Panel Test Segment 6-2 . 65Panel Segment 6-7, Post Leak Test Condition . 66Delaminated Face Sheet . 67Delaminated Face Sheet . 67X-Ray View Depicting Lagoons . 68HOBE Lagoons Revealed After Removal of Face Sheet . 69HOBE Bond Failures from the Face Sheet . 69Comparison Between Test Failure and Panel 7 Images Showing RipplesPerpendicular to the Flow Tube Orientation . 70List of TablesTable 5.5-1.Table 6.5-1.Table 7.1-1.Form Factor Analysis Case Summary with Joint Rotation Angles (Degrees) . 33Feature Comparison Between Model Predictions and On-orbit Images . 58Comparison of Test Article Environments to HRSR Environment [ref. 14] . 60NESC Request No.: TI-09-00529Distribution Limited to NASA Contractors and U.S. Government Only

NASA Engineering and Safety CenterTechnical ReportDocument #:Version:NESC-RP09-005291

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