Thermal Expansion of Three Closed Cell Polymeric Foams at Cryogenic Temperatures

The Space Shuttle External Tank (ET) contains the liquid H2 fuel and liquid oxygen oxidizer and supplies them under pressure to the three space shuttle main engines (SSME) in the orbiter during lift-off and ascent. The ET thermal protection system consists of sprayed-on foam insulation and pre-molded ablator materials. The closed-cell foams are the external coating on the ET and are responsible for minimizing the amount of moisture that condenses out and freezes on the tank from the humid air in Florida while it is on the pad with cryogenic propellant awaiting launch. This effort was part of the overall drive to understand the behavior of these materials under use-conditions. There are four specially-engineered closed-cell foams used on the tank. The thermal expansion (contraction) of three of the polyurethane and polyisocyanurate foams were measured from -423 F (the temperature of liquid hydrogen) to 125 F under atmospheric conditions and under vacuum. One of them, NCFI 24-124, is a mechanically-applied material and covers the main acreage of the tank, accounting for 77 percent of the total foam used. Another, BX-265, is also a mechanically-applied and hand-sprayed material used on the tank's "closeout" areas. PDL 1034 is a hand-poured foam used for filling odd-shaped cavities in the tank, Measurements were made in triplicate in the three primary material directions in the case of the first two materials and the two primary material directions in the case of the last. Task 1 was developing the techniques for getting a uniform heating rate and minimizing axial and radial thermal gradients in the specimens. Temperature measurements were made at four locations in the specimens during this initial development phase of testing. Major challenges that were overcome include developing techniques for transferring the coolant, liquid helium (-452 F), from its storage container to the test facility with a minimal transfer of heat to the coolant and control of the heating rate at the lowest temperatures.