Beruflich Dokumente
Kultur Dokumente
AIAA 98-3911
Post-Fire Short Circuit Phenomena
Of "NSI Equivalents"
Lien C. Yang
TRW Strategic Systems Division
San Bernardino, CA 92402-1310
34th AIAA/ASME/SAE/ASEE
Joint Propulsion Conference & Exhibit
July 13-15,1998 / Cleveland, OH
For permission to copy or republish, contact the American Institute of Aeronautics and Astronautics
1801 Alexander Bell Drive, Suite 500, Reston, VA 20191
POST-FIRE SHORT CIRCUIT PHENOMENA
OF
"NSI EQUIVALENTS"
Lien C. Yang
TRW Strategic Systems Division
San Bernardino, CA 92402-1310
ABSTRACT much as 2 seconds. The cross sectional view of the
NSI in Figure 1 shows the path of the electrical firing
Recent post-fire electrical short circuiting of initiators signal. The current enters one electrical pin, passes
in NASA Standard Initiator (NSI) "equivalents" in two through the bridgewire (a 0.002-inch diameter stain-
launch vehicles, has highlighted a potential problem less steel wire), and out the second electrical pin. A
area for all users of electrically initiated pyrotechnic 5-ampere direct-current input to the NSI typically
devices. A high-level firing current continues to flow ignites the propellant adjacent to the bridgewire within
during the entire firing command (45 ms to 2 sec), one millisecond. The bridgewire burns within that
long after the initiator has functioned and the time period and the current soon decreases to zero.
bridgeware has burned out. This phenomena may However, post-fire short circuiting allows this
introduce several undesirable side effects and failure 5-ampere current draw to be sustained, which can
modes. A preliminary assessment has identified a introduce several deleterious side effects:
number of parameters that can affect post-fire short
circuiting: (1) conductivity of the burning propellant (1) The time frame for initiating multiple initiators in
and gases; (2) conductive, unbumed fuel and residue; parallel electrical circuits can be increased. If the
(3) the presence of a slurry mix on the bridgewire; (4) current draw remains high in one initiator after
the presence of a Viton binder in the propellant; (5) functioning, that current cannot be transferred to
higher voltage levels in firing circuits; and (6) small parallel initiators to accomplish more rapid
initial volumes in mechanisms into which initiators are initiation of the remaining units.
fired. This paper presents a compilation of the data (2) The electrical batteries can be depleted more than
collected on this phenomena and recommends necessary. The greatest influence occurs with
approaches to accommodate post-fire short circuiting batteries that are shared in a common bus with
and to conduct additional diagnostic testing for other subsequent usages.
possible corrective actions. (3) The electrical pins through the initiator body can
melt and allow internal hot gases to vent, which
INTRODUCTION could lead to failure of rocket motors and
mechanisms.
Post-fire short circuiting of direct-current, electrically (4) A number of electrical system failure modes can
actuated initiators has long been recognized as a be introduced. High-current draws on electrical
potential problem area in launch vehicle and circuits can damage resistors and batteries, as well
spacecraft applications. Specifications have been as overload and weld mechanical contacts or
generated for both electrical initiators and firing stress solid-state relays.
systems to help reduce the occurrence of this
phenomena. However, data collected on past NSI MIL-STD-1512, the specification applied in the
qualifications, an NSI-derived cartridge, and NSI 1960's, required the initiator to exhibit a post-fire open
"equivalents" on two recent launch vehicles indicate circuit (less than 50 mA at 28 Vdc). However this
that post-fire short circuiting remains an important standard has been superseded by MIL-STD-1576,
issue. DoD-E-83578A, and APR 127-1, which eliminate this
requirement and allow relays, fuses, or current-
Post-fire electrical short circuiting occurs in direct limiting resistors to protect the firing systems. The
current firing systems, when the level of current NSI specification1 still contains a requirement for a
remains constant or increases after the propellant post-fire 50 mA electrical current limitation. Although
within an initiator has ignited and burned. This level some manufacturers strictly adhere to NSI manu-
of current is sustained throughout the duration of the facturing procedures for NSI equivalents, others have
electronically timed firing pulse, which has been set in made changes based on customer requests, the
launch vehicles from as little as 45 milliseconds to as
EPOXY
ELECTRICAL PIN
CUP, CLOSURE
DISK, INSULATING
DISK, INSULATING
DISK, SEALING -
BRIDGEWIRE
EPOXY SEAL BOTH PINS-//
BODY ASSY
Zr/KC104 /
PROPELLANT./
114-4MG
(2 INCREMENTS)
.586-396REF
relaxation of post-fire electrical inspections, and the functional requirement; without this certification and
interest of economy. Also, since drawings and rigorous quality assurance documentation, no other
assembly procedures are usually not part of pro- initiator can be an NSI. NASA policy restricts the sale
curement packages, much of this information is or transfer of Government property for private use or
considered proprietary. exposure of the Government to a shared liability for
the success of a commercial project. Therefore,
NSIs and NSI equivalents were created to provide the commercial launch vehicle managers requested NSI
electrical ignition interface for a wide variety of equivalents, which were subsequently accepted for
pyrotechnic applications. Prior to the Apollo program, U.S. Air Force-sponsored programs. The intent was
NASA, recognizing the myriad problems being that the NSI equivalents met the same form, fit, and
encountered with initiators, decided to create and function, including the same output charge, as the NSI,
utilize a NASA Standard Initiator. The NSI was and were thus interchangeable. However, a number of
derived from the dual bridgewire Apollo Standard post-fire short circuits have occurred with the use of
Initiator (ASI) and the Single Bridgewire Apollo NSI equivalents in several recent launches. Because
Standard Initiator (SBASI). NASA Johnson Space the initiator firing circuits in these vehicles were
Center has the management responsibility for designed with current-limiting resistors or could
production and distribution of the NSI to all accommodate heavy current loads, the phenomena did
government agencies and their contractors. Each not cause electrical system failures.
manufacturing lot of NSIs is certified to meet a -420F
Two major launch vehicle programs, both managed by Functional data on the available post-fire short circuit
Lockheed Martin, use standard initiators which are phenomena for the NSI, the NGGC, and each of the
based primarily on the NSI. The two NSI equivalents NSI equivalents in each respective application were
in this study were manufactured by Hi Shear collected and reviewed. The potential causes for the
Technology. Hi-Shear uses a company-standard observed short circuit phenomena then were analyzed,
housing, the PC23, which is modified to meet based on each particular configuration.
customer requirements and given a "dash number" for
each configuration. For example, the unit that most RESULTS
closely matches the NSI (without the NASA
certification process) is the PC23-23. The Hi Shear The results of this effort are presented hi the above
part numbers for each unit, along with the differences order: the NSI, the NGGC, and the NSI equivalents.
from the NSI, are described below.
NSI
PC23 used on MSLS Direct current, closed bomb, lot acceptance data on
This initiator was purchased as "any PC23." No over 1,000 firings of Apollo Standard Initiators and
detailed requirements were made on the electrical Single Bridgewire Apollo Standard Initiators (prede-
initiation interface or the zirconium/potassium cessors to the NSI), references 5 and 6, indicated a
perchlorate propellant formulation. Therefore, since difference in post-functioning decay of current
any PC23 type was acceptable, 4 or 5 different between firings hi 10 and 0.5 cc closed bombs. It
available lots, including different "dash numbers," should be noted that the firing system used hi these
were provided. Two PC23 initiators are used in each tests was a solid-state system, which maintained the
of four 3/8-inch and eight 1/2-inch separation nuts and preset current level, as the resistance at the bridgewire
one isolation valve for the MSLS. Also used were interface changed, until the 50-volt limit voltage was
separation thrusters that employ PC 178-1 cartridges, exceeded. As shown hi Figure 2, the 10 cc firings, the
containing dual, one-ohm bridgewires. The applica- current at 3.5-amperes decreased exponentially to zero
tions hi the mission require 3, 4 and 6 initiators to be hi 2 milliseconds after bridgewire burnout. The
fired in parallel. The working volume within the 1/2- current in the 22-ampere firings dropped to zero hi 0.3
inch nut is 70% greater than that of the 3/8-inch nut. millisecond after bridgewire burnout. However, hi the
Each electrical firing circuit employs a 28 +/- 4 volt 0.5 cc bomb (Figure 3), the current decays were 12 ms
battery with current limiting resistors to provide for 3.5 amperes, 13 ms for 5 amperes; the 22-ampere
5.5 amperes, 45-millisecond gated pulse for each firing trace indicated an 8-ampere current draw at 0.43
bridgewire. The current drawn in each of the ms, at which time it exceeded the recorder's time
redundant firing systems on the MSLS were measured limit.
during flight and transmitted to ground recorders.
20
Figure 2. Typical ASI/SBASI Firing Current Figure 3. Typical ASI/SBASI Firing Current
Traces in 10 Cubic Centimeter Bomb Tests. Traces in 0.5 Cubic Centimeter Bomb Tests.
Electrical conductivity between the electrical pins density (zirconium is 6.5 g/cm3 and potassium
occurs during the combustion of the zirconium/ perchlorate is 2.52 g/cm3). The presence of unreacted
potassium perchlorate propellant. The following zirconium is virtually inevitable. The addition of 5%
observations have been made. The burning of the Viton and 1% carbon slows the burn rate and enhances
zirconium/potassium perchlorate produces a highly the opportunity for more complete combustion.
conductive plasma and creates a temporary short-
circuit between the pins and between the pins and the Ignition, burn rate, and combustion efficiency are
initiator body. The level of voltage available in the dramatically affected3 by the size and shape of the
firing system has a significant effect; when the volume into which the NSI is fired. The ZPP
bridgewire burns away, the full voltage of the firing formulation is very sensitive to ambient pressure and
source appears across the pins to drive an electrical the thermal conductivity of the housing materials. The
current through the plasma. Conductivity is further higher the pressure and the lower the thermal losses
enhanced when two cartridges are fired simultaneously (as provided by small initial free volumes), the faster
in redundant devices. As long as the gases remain hot, and more completely it burnsan avalanching effect.
conductivity continues. Firing into smaller volumes, Large volumes induce lower ignition and combustion
as described in the previous paragraph, produces efficiencies, but do allow the burning material to be
higher pressures and requires longer times for the expelled from the NSI to reduce the opportunity of
gases to cool. The products of combustion of a zirconium deposits on its electrical pins.
stoichiometric zirconium/potassium perchlorate (ZPP)
composition are non-conductive solids, ZrO2 and KC1, The presence of a bridgewire slurry mix could have an
and gaseous CO2 (due to the 5% Viton and 1% affect on post-fire short circuiting. The slurry, being
graphite additives). The ZrO2 and KC1 can only be the first to ignite, could assist in the expulsion of the
"gases" in the vapor state at thousands of degrees hi mam portion of the propellant load and the reduction
temperature; they quickly condense on the cool walls of combustion residue from the electrical pins,
of the containment volume. However, since the particularly in large initial free volumes.
composition is formulated to be fuel (zirconium) rich,
the unburned zirconium is highly conductive. NSI-derived Gas Generating Cartridge
As described in reference 4, the NGGC exactly
Fuel-rich mixtures were selected to achieve a fast burn duplicated the electrical ignition characteristics of the
rate. The dissimilarity in particle size (zirconium 1 to NSI. At higher current levels (15 and 20 amperes),
8 microns, versus potassium perchlorate 15 to 20 however, a number of post-fire short circuits were
microns) increases the opportunity for heterogeneity, observed. These short circuits can be attributed to the
reduces physical fuel-to-oxidizer contact, and high voltages applied (up to 200 volts) and to firing
ultimately yields fuel-rich residue. Heterogeneity is into devices with small initial free volumes.
further exacerbated by the differences in material
10 -
8-
: 6-
j-
10 20 30 40 50 I * -
Tim*, milllMConds 3
2-
Figure 4. Current Drawn in Firing 3 PC23's in \
0 2 4 6 8
Parallel in MSLS, Flight 1, System A: 2 PC23's Tlnw, milliseconds
in 3/8-inch Nuts and 1 in an Isovalve.
Figure 7. Typical GDSI 5-ampere Firing
Current Trace in a 10 cc Closed Bomb.
8
American Institute of Aeronautics and Astronautics