Age Life Evaluation of Space Shuttle Crew Escape System Pyrotechnic Components Loaded with Hexanitrostilbene (HNS)

Determining deterioration characteristics of the Space Shuttle crew escape system pyrotechnic components loaded with hexanitrostilbene would enable us to establish a hardware life-limit for these items, so we could better plan our equipment use and, possibly, extend the useful life of the hardware. We subjected components to accelerated-age environments to determine degradation characteristics and established a hardware life-limit based upon observed and calculated trends. We extracted samples using manufacturing lots currently installed in the Space Shuttle crew escape system and from other NASA programs. Hardware included in the study consisted of various forms and ages of mild detonating fuse, linear shaped charge, and flexible confined detonating cord. The hardware types were segregated into 5 groups. One was subjected to detonation velocity testing for a baseline. Two were first subjected to prolonged 155 F heat exposure, and the other two were first subjected to 255 F, before undergoing detonation velocity testing and/or chromatography analysis. Test results showed no measurable changes in performance to allow a prediction of an end of life given the storage and elevated temperature environments the hardware experiences. Given the lack of a definitive performance trend, coupled with previous tests on post-flight Space Shuttle hardware showing no significant changes in chemical purity or detonation velocity, we recommend a safe increase in the useful life of the hardware to 20 years, from the current maximum limits of 10 and 15 years, depending on the hardware.