Challenges of Cold Conditioning and Static Testing the Second Ares Demonstration Motor (DM-2)

On August 31, 2010, a five-segment demonstration motor (DM) for the Ares program was successfully tested. A series of demonstration motors (DMs) will be tested in different conditioned environments to confirm they meet their design specifications. The second demonstration motor (DM-2) was the first cold motor. The motor needed to be subjected to sub-freezing temperatures for two months so that its internal propellant mean bulk temperature (PMBT) was approximately 40 F. Several challenges had to be overcome to make this a successful test. One challenge was to condition four field joints to get the O-rings approximately 32 F. This would be done by applying conditioning shrouds to externally cool each field joint after the test bay was pulled off. The purpose of this conditioning was to validate the new O-ring design and allow joint heaters to be eliminated. Another challenge was maintaining temperature requirements for components in the nozzle vectoring system. A separate heating system was used to warm these components during cold conditioning. There were 53 test objectives that required 764 channels of data to be recorded; 460 were specific to DM-2. This instrumentation had to be installed prior to conditioning, which meant the baseline process and timeline had to be modified to meet this time critical schedule.