Space Systems 

Southwest Research Institute® (SwRI®) supports the government and the commercial space industry with a variety of testing and analysis capabilities. In the area of experimental testing, SwRI developed—under NASA sponsorship—the Inhibited Shaped Charge Launcher (ISCL), a unique facility that launches aluminum projectiles with masses between 0.3 and 1.5 grams to velocities over 11 km/s. This system simulates orbital debris impact conditions on the Space Station, and has been used to test and qualify numerous shield designs. A two-stage light-gas gun is available for simulating micrometeoroid or small orbital debris impacts.

Finite element and hydrocode computer codes are used to simulate low-velocity through hypervelocity impacts for design and analysis purposes. Fracture analysis of pressurized modules has been conducted and supplemented by high strain rate materials testing. SwRI is internationally recognized for experimental and analytical impact studies against the Space Shuttle’s thermal protection systems and wing leading edge.

Simulated ISCL projectile (hollow cylinder positioned on rod) and the resulting damage to a 38-mm-thick plate of 3003 aluminum

Computational fluid dynamics (CFD) codes are used to simulate fuel release and mixing under failure (on-pad and in-flight) scenarios. Hydrocodes are used to simulate detonation of fuel plumes, resulting over-pressure, and fragment formation in support of crew escape studies.

Capabilities

• Ballistics and explosives testing
• Materials testing, including high strain rate testing
• High-speed digital video of impacts up to 100,000,000 frames per second
• Nicolet Multipro^© high-speed data acquisition up to 200 MHz
• Test fixture fabrication, machining, and welding
• Institute ISO-compliant QA
• Computer simulation of impact and structural response
• Projectile and sabot design

Foam impact test on Space Shuttle wing

Experience

• NASA Space Station orbital debris shield impact testing
• Hypervelocity impacts on a wide variety of space components and materials
• Simulated hailstone impacts on Space Shuttle thermal protection tiles
• External tank foam impacts on Space Shuttle components including thermal protection tiles, reinforced carbon-carbon (RCC) panels on the wing leading edge, and carrier panels
• Scale modeling analyses of ballistic missile defense impact scenarios
• Hypervelocity impact modeling of spacecraft shields, lightweight armors
• Development of velocity scaling concepts for DOD and NASA to extrapolate design curves
• Characterization of impact damage to Space Shuttle windows
• Detailed damage assessments
• Development of damage maps
• Orbital Space Shuttle explosive hazard

ISCL facility during a test

Facilities

• Ballistics and explosives test ranges
• Materials test laboratories
• Inhibited shaped charge launcher facility, 0.3 to 1.5 grams of aluminum to 11+ km/s
• Two-stage light-gas gun
• Portable instrumentation trailer
• Flash X-ray systems with film processing capability
• Machine shops, fabrication facilities, materials laboratories
• Compressed gas gun systems for low-velocity impact (hailstones, foam, etc.)

Computer simulation of foam impact on RCC panel leading edge

Typical hypervelocity impact crater in a Space Shuttle windshield panel, showing central crater and circumferentially located microcrack ensembles

This flyer was published in April 2009. For more information about Space Systems, contact Donald J. Grosch, (210) 522-3176, or Scott A. Mullin, (210) 522-2340, Mechanical Engineering Division, Southwest Research Institute, P.O. Drawer 28510, San Antonio, Texas 78228-0510.

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