Refractory Materials for Flame Deflector Protection System Corrosion Control: Similar Industries And/or Launch Facilities Survey

Publisher Marketing: During the Technology Prioritization Panel held in December 2007, the Constellation Program (CxP) Ground Operations Project (GOP) identified corrosion control technologies as their #2 technology need for initial capability to meet Draft Stretch/Operability requirements for reduced ground processing complexity, streamlined integrated testing, and operations phase affordability. The Refractory Materials for Flame Deflector Protection System Corrosion Control task under the Supportability project will develop refractory technologies that will provide support at Kennedy Space Center (KSC) launch facilities and ground systems through increased operational life cycles. As a result of the constant deterioration from launch heat/blast effects and aggressive environmental exposure, the refractory materials currently used as a part of the launch pad flame deflectors have become very susceptible to failure, resulting in large pieces of refractory materials breaking away from the steel base structure. These pieces are projected at high speed during launch, and jeopardize the launch complex, vehicle, and safety of the crew. Replacement refractory systems must be developed to withstand the extremely corrosive environment at the launch pads, and the highly corrosive hydrochloric acid and heat/blast effects that are generated by the solid rocket boosters during a launch. Advanced technologies for the corrosion protection of launch pad flame deflectors are necessary to address these problems and significantly impact ground processing and launch safety. The objective of the ETDP project, Refractory Materials for Flame Deflector Protection System Corrosion Control is to develop replacement refractory materials that exhibit long-term resistance to degradation. This degradation results from the extremely corrosive Florida coastal environment and aggressive launch conditions. The highly corrosive solid rocket booster (SRB) exhaust, extreme temperature fluctuations between SRB heat impingement and noise suppression water deluge, and SRB blast vibrations, in combination, have a pronounced detrimental influence on the degradation of refractory materials. The flame deflector must safely divert flames, exhaust, and small items that are loosened during a launch. In essence, the system must prevent debris from bouncing back and hitting the launch complex and vehicle. Performance in this regard is dependent upon integrity of the refractory materials used on the flame deflectors. The development process for the ETDP Refractory Materials for Flame Deflector Protection System Corrosion Control project has four primary elements: Capability to develop a refractory protection system for the launch pad flame deflectors, Capability to develop advanced refractory materials, Capability to develop material requirements, system specifications, and qualification standards for the refractory material protection system, Capability to incorporate the refractory material formulation onto the flame deflector base structure, and evaluate the in-situ performance in an integrated demonstration on a scaled, simulated flame deflector.