PRELIMINARY DESIGN 

OF TWO SPACE SHUTTLE 

FLUID PHYSICS EXPERIMENTS 

NASA-CR-174649 

19840015599 
A -, 

1 l 1 RN/NASA-CR-174649 

[iISPLA"=/ 17./2/~1 

T t-o._1 Ir- A.it 

i:j~l}t. l~ CATEGORY 16 RPT#: NASA-CR-]74649 NAS 

CNT#: NAS3-23774 84/05/00 225 PAGES 

UTTL: Preliminary design of two Space Shuttle fluid physics experiments 

Al)TH= 
/~ 

PRELIMINARY DESIGN 

OF TWO SPACE SHUTTLE 

FLUID PHYSICS EXPERIMENTS 

FINAL REPORT 

NASA CR174649 

PERFORMED ON 

CONTRACT NAS 3-23774 

SUBMITTED TO 

NASA/LeRC 

BY 

TRW - S&TG 

APPLIED TECHNOLOGY DIVISION 

MAY 1984 

SIN 41763 

liBRARY COpy 

LANGLEY RFSEARr.1 1 CENTER 

LIBRARY. NASA 

HAMPTON, VIRGINIA 
1. Report No. I 2. Government Accession No. 3. Recipient', Catalog No. 

NASA CR-174649 

4. Title and Subtitle 5. Report Date 

Preliminary Design of Two Space Shuttle Fluid Physics Experiments May 1984 

Final Report 6. Performing Organization Code 

7. Author(s' 8. Performing Organization Report No. 

N. Gat and J.L. Kropp 41763-6001-UT-OO 

10. Work Unit No. 

9. Performing Organization Name and Address 

TRW Space and Technology Group 11. Contract or Grant No. One Space Park 

Redondo Beach, CA. 90278 NAS 3-23774 

13. Type of Report and Per.iod Covered 

12. Sponsoring Agency Name .nd Address Final 1-83-484 National Aeronautics and Space Administration 

Washington, D.C. 20546 14. Sponsoring Agency Code 

15. Supplementary Notes 

16. Abstract 

Concepts for the operation of two fluid experiments in the mid-deck region of the STS were developed Based upon these concepts a preliminary design for each experiment is made. The two experiments are 

the Surface Tension Induced Convection experiment and the Free Surface Phenomena experiment. The 

mid-deck lockers of the STS are described and the requirements for operating an experiment in this 

region are described. For each locker the experiment design uses a two locker volume with an experiment unique structure as a housing. For the Surface Tension Induced Convection experiment a manual mode is developed. The fluid is 

maintained in an accumulator pre-flight. To begin the experiment a pressurized gas drives the fluid 

'i nto the experiment conta i ner. The fluid is an inert silicone oil and the container material is 

selected to be compatable. A wound wire heater is located axisymmetrically above the fluid. The 

heater is designed to deliver three wattages to a spot on tne fluid surface. These wattages vary 

from 1-15 watts. The fluid flow is observed through the motion of particles in the fluid. The 

experiment container is illuminated by a 5 mw HeiNe laser. Scattered light is recorded on the film 

plane of a 35mm camera. 

The free surface phenomena experiment consists of a trapezoidal cell which is filled from the bottom 

The fluid is photographed at high speed using a 35mm camera which incorporated the entire cell 

'Iength in the field of view. The assembly can incorporate four cells in one flight. 

For each experiment an electronics block diagram is provided. A control panel concept is given also 

for the surface tension induced convection. Both experiments are within the mid-deck locker weight and c-g 1 imits. 

17. Key Words (Suggested by Author(s', 18. Distribution St.tamant mid-deck experiments Unclassified - Unlimited 'Iow gravity fluid behavior 

surface tension induced convection 

free surface phenomena low gravity research 

19. Security Clallif. (olthitreport, 120. Security elllsif. (of this Plge' 21. No. of Pages 

1

22

. 

Price· 

Unclassified Unclassified 221 

• For sale by the National Technical Information Service, Springfield, Virginia 22161 

NASA-C·l68 (Rev. 10.75) 
TABLE OF CONTENTS 

Page 

FOREWARD ••••.••.••• ••••••••••••••••••••••••••••••••••••• V 

ABSTRACT ••••••••••••••••••• " ••••••••••• 

1.0 INTRODUCTION ...•••.•••••••••••••.• 

2.0 MID-·DECK EXPERIMENT ACCOMODATIONS. 

2.1 MID-DECK LOCKER ARRANGEMENTS .. 2.1. 1 

2.1. 2 

Structural/Volume ••• 

Thermal/Environment •••••••••••••• 

2.1.3 Electrical/Power •••••••••• 

2.2 APPROACH TO FLUID EXPERIMENT DESIGN. 

3.0 SURFACE TENSION DRIVEN CONVECTION •....•. 

3.1 EXPERIMENT REQUIREMENTS, CONCEPT AND PRELIMINARY 

DESIGN •••••••••••••••••••• 

Experiment Container. ... Fl uid .......... . 

Fluid Delivery. 

Fluid Heating ••• 

3.1. 1 

3.1. 2 

3.1. 3 

3.1. 4 

3.1. 5 

3.1. 6 

3.1. 7 

Experiment Operation ••• 

Diagnostic Instrumentation •• 

Experiment Timeline •• 

3.1.8 Thermal Control •• 

3.2 SYSTEM ELECTRONICS .• 

3.3 EXPERIMENT LAYOUT .•• 

3.4 WEIGHT ESTIMATE •..•.• 

3.5 EXPERIMENT STATUS AND RECOMMENDATIONS •• 

3.6 SAFETY .••••••••••••••..•.•••••..•••••• 

· . vi 

• •• 1 

• 7 

•• 7 

· .. 13 

• • 13 · •• 13 

• •• 14 

.16 

• •• 16 . ..... . 18 

• .22 

• .22 

• •• 36 

• •• 52 

• •••••• 56 

• •• 62 

• .63 

• .. 64 

• •• 69 

• •• 72 

• ••• 74 

· .76 

4.0 FREE SURFACE PHENOMENA UNDER REDUCED GRAVITy •.•••••. .77 

4.1 EXPERIMENT REQUIREMENTS, CONCEPTS AND PRELIMINARY 

DESIGN ••••••••••••••••••• 

4.1. 1 

4.1. 2 

4.1. 3 

4.1. 4 

4.1. 5 

4.1. 6 

Experiment Container ••• 

Fl uid ................. . 

Fluid Delivery System. 

Experiment Operation. 

Diagnostics •••••••••• 

Experiment Operation. 

4.1.7 Thermal Control ••• . ..... . 4.2 SYSTEM ELECTRONICS .• 

4.3 EXPERIMENT LAYOUT ••• 

4.4 WEIGHT ESTIMATE ..•... 

4.5 EXPERIMENT STATUS AND RECOMMENDATIONS. 

4.6 SAFETY •••.•.••••••••.••••••••••••••••• 

APPENDIX A 

APPENDIX B 

APPENDIX C 

APPENDIX D 

APPENDIX E 

APPENDIX F 

Fluid Transfer In Zero 

Surface Tension Driven 

Visualization •.•••••••• 

Gravity ••.•..... 

Connection Flow 

Cameras and Films •••.••••••.•• 

Shuttle Qualified Lamp •• 

Accelerometer Data ••••• 

Surface Tension Induced Convection Safety 

Hazard Reports ••••••••••••••••••••••••• 

.77 

• ••• 77 

• .82 

.86 

· .88 

· .91 

• ••••• 94 

• •• 96 

• ••••• 96 

• •. 98 

• .•. 103 

.103 

• •••• 106 

.Al 

• • B 1 

• ••••• C 1. 

• • D 1. 

• ••• E 1. 

• ••• F 1. 

APPENDIX G Free Surface Phenomena Safety Reports •••••• ••••• G 1. 
LIST OF TABLES 

TABLE TITLE PAGE 

1.1 Reference Documents FDR Space Shuttle Fluid Physics 

Experimen ts ....••...•. 1\ ••••• •.••••••• 0 •••••••••••••••••••• 3 

1.2 Science Requirements For the Surface Tension Induced 

Convection Experiment. 11 ••••••••••••• 0 •••••••••••••••••••• 4 

1.3 Science Requirements For the Free Surface Phenomena 

Experiment ........•... II ••••••••••••• G •••••• 5 

2.1-1 Shuttle Mid-Deck Accomodations •••••• ; ••••••••••• ••••••• 9 

3.1-1 Experiment Container Requirements ••••••••••••••• 

3.1-2 Fluid Requirements For Surface Tension Induced 

..20 

3.1-3 

3.1-4 

3.1-5 

3.1-6 

3.1-7 

3.1-8 

3.1-9 

3.1-10 

3.1-11 

3.3-1 

4.1-1 

4.1-2 

4.1-3 

4.1-4 

4.1-5 

4.1-6 

4.1-7 

4.3-1 

4.4-1 

Convection Experiments ••••••.•.•••.••••••.••••• •• 23 

Candidate Fluids For the Surface Tension Induced 

Convection Experiment ••••••••••••••••••••••••••••••••• 24 

Fluid Delivery Requirements ••••••••••••••••••••••••••• 25 

Fluid Heating Requirements •••••••••••••••••••••••••••• 37 

Heater Power Requirements, Heater Resistance = 208 

OHM S •••••••••••••••• II ••• ~ ••••••••• 0 • • • • • • • • • • • • • • • 46 

Nichrome Wire Requirements For Surface Tension 

Induced Convection Experiment................ .49 

Experiment Operation Requirements ••••••••••••••••••••• 54 

Diagnostics Requirements •••••••••••••••••••••••••••• 55 

Comparison of Experimental Parameters ••••••••••••••••• 61 

Surface Tension Induced Convection Experiment 

Timeline ............ Cl •••••••••••••••••••••••••••••••• • 63 

Surface Tension Driven Convection Experiment Major 

Equipment List •••••••••••••• 

Experiment Container •••••••• 

•••••••••• 73 

• ••••••••• 79 

Fluids .............. 0 ••••••••••••• I) ••••••••••••••••••• 84 

Fluid Delivery System ••••••••••••••••••••••••••••••• 85 

Experiment Operating Conditioning ••••••••••••••••••••• 89 

Di.agnostics ......... (I ••••••••••••• 0 ••••••••••••••••••• 90 

Comparison Between Field-of-View and Depth-of-Field 

with Two Different Formats •••••••••••••••••••••••••••• 92 

Experiment Timeline..................... .94 

Equipment List .•••.• o •••••••••••••••••••••••••••••••• 102 

Free Surface Phenomena Weight Estimate ••••••••••••••• l05 

ii 
(,/"----. 

FIGURE 

lola 

1.1 b 

2.1-1a 

2.1-1b 

2.2-1 

3-1 

3.1-1 

3.1-2a 

3.1-2b 

3.1-3 

3.1-4 

3.1-5 

3.1-6 

3.1-7 

3.1-8 

3.1-9 

3.1-10 

3.1-11 

3.1-12 

3.1-13 

3.1-14 

3.2-1' 

3.2-2 

3.3-1 

3.3-2 

4-1 

4.1-1 

4.1-2 

4.1-3 

4.1-4 

/""""' 

LIST OF FIGURES 

TITLE PAGE 

Surface Tension Induced Convection Objectives and 

ME=thods ...•..••..••.•..••.•.••••.•••..••.•..•••.•••• 2 

The Surface Phenomena Experiment Objectives and 

Methods ..••.•••••.•..•..•....•.•••.......•.•..••.••• 2 

Mid-Deck Location in the Space Shuttle ••••••••••••• 8 

Mid-Deck Area Arrangement ••••••••••••••••••••••••••• 8 

Mid-Deck Development Through Preliminary Design •••• 14 

Surface Tension Driven Convection Experiment 

Func t ional Flow ......•............................. 17 

Surface Tension Induced Convection Experiment 

C()n tainer ...................... ,; ................... 18 

Typical Thermistor Insertion Into Experiment 

Container ••..•...•.••.••..••.•.•.•••.••••..••..•••• 21 

Experiment Container Showing the Position of 

Thermal Sensors .................................... 21 

Fluid Delivery Time as a Function of Flow Rate ••••• 28 

The Fluid Delivery System •••••••••••••••••••••••••• 30 

The Accumulator with the Piston Drive and the 

Attached Stirrer .•••••.••..•...••..•••.••..•.•••... 33 

The Gas Storage Tank, Volume = sOOcc ••••••••••••••• 36 

Steady State Temperature of Fluid in Cell As a 

Function of the Cell Radius for Various Powers ••••• 40 

Model of Heat Addition Procers to Experiment 

Container (Axisymmetric Modes used in Sinda Code) •• 41 

Radial Temperature Distributions at 1 Watt Energy 

Input For Different Depths ••••••••••••••••••••••••• 43 

Radial Temperature Distributions at Various Fluid 

Depths .••••.••.••...•••...•.....••..•.....•....•... 44 

Space Qualified Catalyst Bed Heater for Surface 

Tension Induced Convection Experiment •••••••••••••• s1 

The Heater Mounted on to the Experiment Container •• s3 

The Optical Train for Surface Tension Induced 

Convection Experiment •••••••••••••••••••••••••••••• s8 

Sketch for Expansion of HeNe Laser ••••••••••••••••• s9 

Surface Tension Induced Convection Electronic 

Block Diagram ....•..•...•.•.•...•..•.•••.•.•......• 65 

Typical Control Panel ••••.••••••••••••••••••••••••• 67 

Surface Tension Induced Convection Experiment 

Layou t ..................•.......................... 70 

Surface Tension Induced Convection Experiment 

Isometric Drawing ...•.•....•....•....•••..•..•..•.• 71 

Free Surface Phenomena Experiment Function Flow •••• 78 

Experiment Container Assembly •••••••••••••••••••••• 80 

Overfill Containment Vessel •••••••••••••••••••••••• 81 

Container Design ........•.......................... 83 

Fluid Delivery System Concept •••••••••••••••••••••• 87 

iii 
4.2-1 

4.2-2 

4.3-1 

4.3-2 

4.3-3 

LIST OF FIGURES (CONT.) 

Free Surface Phenomena Experiment ••.•••.••.•..•...• 95 

Free Surface Phenomena Experiment Control ••...•••.• 97 

Free Surface Experiment Layout .•••••..••...•••..... 99 

Free Surface Phenomena .....•..•.•••.•••••••.•.•..• l00 

Experiment Enclosure .•..•...•••••.•••••••.•....•.• lOl 

iv 
(~ 

FOREWARD 

This program was sponsored by NASA/Lewis Research Center. This 

study was conducted to transpose two sets of science requirements 

for fluids experiments into hardware concepts and preliminary 

design for mid-deck operation on the STS. 

The major participants in the program were: 

Liam Sarsfield NASA/LeRC Program Manager 

Jack Kropp 

Nahum Gat 

TRW Program Manager 

Experiment Analysis 

George Dosa Design 

Contributions were made by Talbot Jaeger and Chie Poom in 

electronics; Dale Waldo in Safety Analysis and James Zamel in 

Design. 

v 
ABSTRACT 

Concepts for the operation of two fluid experiments in the mid-deck region 

of the STS were developed. Based upon these concepts a preliminary design 

for each experiment is made. The two experiments are the Surface Tension 

I~duced Convection experiment and the Free Surface Phenomena Experiment. 

The mid-deck lockers of the STS are described and the requirements for 

operating an experiment in this region are described. For each locker the 

experiment design uses a two locker volume with an experiment unique structure as a housing. 

For the Surface Tension Induced Convection experiment a manual mode is 

developed. The fluid is maintained in an accumulator pre-flight. To begin 

the experiment a pressurized gas drives the fluid into the experiment container. The fluid is an inert silicone oil and the container material is 

selected to be compatable. A wound wire heater is located axisymmetrically 

above the fluid. The heater is designed to deliver three wattages to a spot 

on the fluid surface. These wattages vary from 1-15 watts. The fluid flow 

is observed through the motion of particles in the fluid. The experiment 

container is illuminated by a 5 mw HeiNe laser. Scattered light is recorded 

on the film plane of a 35mm camera. 

The free surface phenomena experiment consists of a trapezoidal cell which 

is filled from the bottom. The fluid is photographed at high speed using a 

35mm camera which incorporates the entire cell length in the field of view. 

The assembly can incorporate four cells in one flight. 

For each experiment an electronics block diagram is provided. A control 

panel concept is given also for the surface tension induced convection. 

Both-experiments are within' the mid-deck locker weight and c-g limits. 

vi 
1. INTRODUCTION 

Two experiments in Fluid Physics have been identified by 

NASA/LeRC for operation on STS. Each experiment is to be 

accommodated in the orbiter mid-deck locker region. Both 

experiments have a demonstrated potential for benefitting greatly 

from investigation at reduced gravity. During this program a 

concept of each experiment and preliminary drawings based upon 

that concept have been made. 

The two experiments are: 

1) Surface Tension Driven Convection in Reduced Gravity 

(Dr. S. Ostrach, Principal Investigator) 

2) Free Surface Phenomena Under Reduced Gravity Conditions 

(Dr. Paul Concus, Principal Investigator) 

Concepts and preliminary designs for each experiment have 

been developed specifically for mid-deck operation. In this 

development we: 

o use developed components in so far as possible. 

o utilize a simple design that will accomplish the science. 

o maintain performance compatible with mid-deck 

constraints. 

o minimize cost. 

o conform to PI requirements. 

The objectives of each of these experiments are outlined in 

Figure 1-1 a and 1-lb) together with a schematic for the 

performance of the experiment. Reference documents that 

establish experiment requirements and background are given in 

Table 1.1. Science requirements for each experiment were derived 

1 
A. Surface tensions driven convection in reduced gravity 

Dr. Simon Ostrach - CASE - Western Reserve 

CELL 

FLUID 

DELIVERY 

Exp"im.nt Obj.ctins 

• Conduct ..... riInnt •• rHuC'" .r . ..., .... wilSIIIIIy _IC • 

.. lIIiIII-IIriv .. ..... 

• O ••• rmiH .... trll sarliC. ship.; • ...,.r ... " ,,,file; nlecity 

,refile for trllllilnt ...... dy-Illtl cllllllili ... 

• T. illcr •••• lIIIII.rlllndinl .f ..... H.c. of co.'li." •• o •• try; llid 

"I' 01 Huid b.hlwior .lSOci.t.d with.UrfIC ••• nsio .... riv •• 

collYlClion 

!!!l!!!! 

• FiR I cylindricil c.n with •• ill.,. Huitl con"ininl ,.rticl •• 

• H.II'" fluid SUrfIC' .,...tricilly fr ..... 'OIl 

• R.cord Huill _liotl ~ oIIsemn. perticle IIIOIioII 

• Monitor ....... , • ..,. 

FIG. l.la) SURFACE TENSION INDUCED CONVECTION OBJECTIVES AND METHODS 

B. Free surface phenomena under reduced gravity conditions 

Dr. Paul Concus - University of California - Berkley 

FLUID 

DELIVERY 

CAMERA 

Exp"imenl ObjlCtiYlI 

• To pI!o, •• reph'" n ... ,. of 11NIui4 tr •• SUrfIC' under'" 

eomliti_ II "ducI" .rnily 

• To tnt ... fIuiII .... nior ill trl ... zoidll nlllls ............ is 

dic ...... by th.oreticl! '1II1ysis. th"I" .. lidlli", this .... " 

• T. IiIw ... fluid cOllfiI.rItiDl II • f1IIIclion of tim. II it flows ... 

........ 1 

!!!!!!!! 

• T. fiR fHr trlplzoidll ..... Is with HIIiII 

• T. pboCOgrep. the ftuitl pesition wi",", the n .... III .... elion.f fill 

time 

FIG. 1.lb) THE SURFACE PHENOMENA EXPERIMENT OBJECTIVES AND METHODS 

2 
and these are given in Tables 1.2 and 1.3. In addition to these 

requirements there are derived requirements that apply to each 

experiment subsystem. These requirements are contained in tables 

under the sub-system discussed. 

In Sections 3 and 4 of this report the concept and design 

developed for each experiment respectivel~. Drawings of the 

major subsystems together with a list of instrumentation are 

presented. 

Table 1.1 

REFERENCE DOCUMENTS FDR SPACE SHUTTLE 

FLUID PHYSICS EXPERIMENTS 

1.1 Surface Tension Driven Convection in Reduced Gravity 

Science Requirements 

(Dr. S. Ostrach, Dr. Y. Kamatoni) 

(Attachment to RFP 3-505994 

1.2 Surface Tension Gradient Induced Flows at Reduced 

Gravity 

(S. Ostrach, June 1980) 

(NASA Contractor Report 159799 with Appendices). 

1.3 Free Surface Phenomena Under Reduced Gravity Conditions 

- Science Requirements 

(Dr. P. Concus, Dr. R. Finn) 

(Attachment to RFP 3-505994) 

1.4 Free Surface Phenomena Under Low and Zero-Gravity 

Conditions 

(D. Coles, P. Concus, R. Finn, L. Hesselink, 

June, 1981). 

(Phase II entry proposal with Appendices). 

3 
Table 1.2 SCIENCE REQUIREMENTS FOR THE SURFACE 

TENSION INDUCED CONVECTION EXPERIMENT 

1. Experiment Container 

o Circular Cylinder - 10 cm inside diameter 

- 5 cm deep - sharp lip located at the top edge to 

eliminate fluid creep 

o Container made of franspa~ent mat~ria~ to facilitate observation 

2. Fluid Requirements 

o Test fluid silicon oil (kinematic viscosity = 10 cs) 

o Fill requirement - 395 ml ± 5% 

3. Fluid Heating 

o Supply heat such that a 50°F parabolic temperature distribution 

is established from center to edge 

o Heater fixed in one position axisymmetric to the experiment 

container with fluid 

o Experiment to be conducted at three heater powers; nominally heater will be on at one power for 20 minutes then switched 

to the next higher power. 

4. Experiment Operation Requirements 

o Fluid to be quiescent at start 

o Temperature - ambient 

o Pressure - ambient 

5. Diagnostics 

o Temperature of fluid - measured a mlnlmum of four places within the fluid bulk. Temperature accuracy ± O.l°C 

o Observation - visualization achieved by using particles in 

fluid 

- illumination of plane of fluid perpendicular 

to the camera 

- film time first three minutes and last three 

minutes at a given heater power 

o Timing - lapsed time for each sum from heater on-recorded 

(on film) 

4 
I~ TABLE 1. 3 SCIENCE REQUIREMENTS FOR THE FREE SURFACE . 

PHENOMENA EXPERIMENT 

1. Experiment Container 

Container Dime~sions - trapezoidal with relative dimensions as 

given 

CYLINDER a· b A 

# units) "nits ) units) AR 

1.1 2 26 4:1 

2 1.3 2 2S 11:1 

3 I.S 2 2S 4:1 

ALTITUDE, A 4 2.0 2 2S 4: 1 

AR • ASPECT RATIO. HEIGHT/ALTITUDE 

I-b-f 

- Overall height to be 100 cm 

- Interior finish to be "smooth" 

- Corners "sharp", without joints 

- Accommodate overflow 

- Container material/fluid must establish proper contact angle 

- Resolve fluid height 

2. Fl ui d Requi rements . 

- Surface contact 58° ± 3° at 25°C with the container surface 

- Low evaporation rate 

- Fluid available to fill 4 containers to ! volume each 

- Slow flow rate to fill 

- Inflow to cover bottom - hold then re-start flow 

3. Experiment Operations 

Temperature - Ambient 

- No thermal gradient along experiment container wall 

Pressure - 760 torr (Shuttle ambient) 

Experiment 

Number - Four 

4. Diagnostics 

Thermal Management - to ° O.l°C at 10, 20, 30 50, 70% of height 

- At center bottom (all thermal measurement 

requirements deleted at conceptual design) 

5. Observation 

- View experiment along entire tube length from two angles 

- View from start of inflow through fill to ! volume I 

, _____ -----1 

5 
Using this data we have developed a schedule and rough order 

of magnitude (ROM) cost for each experiment through assembly and 

delivery. As specified in the original requirements we did not 

include integration in these costs. An estimate of the 

integration support is given. 

Section 2 gives a description of the mid-deck accommodations 

for the experiments that are utilized in the present design. 

6 
2. MID-DECK EXPERIMENT ACCOMMODATIONS 

This section summarizes the interface requirements and the 

design constraints for experiments that are accommodated in middeck. The number of lockers available for experiments in any 

flight will depend upon the number not required for crew use. 

The interfaces for experiments for mid-deck .1ockers are given in 

the following references: 

2.1) Orbit Mid-Deck Payload Provisions Handbook Rev. B 

JSC-16536 (September 1982) 

2.2) Orbiter Mid-Deck/Payload Standard Intefaces 30 

Nov. '82. (JSC) 

The experiments to be performed in the mid-deck will conform 

to volume, power and in crew involvement constraints. The 

operation in the mid-deck will allow crew intervention that is 

required for fluids experiment operation. 

2.1 MID-DECK LOCKER ARRANGEMENTS 

The mid-deck area of the STS system is shown in Figure 2.1-

1a. 

The location of the lockers within the mid-deck area is shown in 

Figure 2.1-1b. There are 33 locker spaces. An experiment can use 

the lockers themselves, or can utilize the volume of one or more 

lockers with an experiment peculiar structure built around it. A 

summary of the interfaces for each experiment in the mid-deck are 

given in Table 2.1-1 (Data abstracted from ref. 2.2). The 

important design parameters are highlighted below. 

7 
STORAGE 

COMMANDER'S ,SEAT 

CREW HATCH 

(LEFT SIDE) 

fLUl!'+-~~~,-- FLIGHT DECK 

ACCESS LADDER 

._-----\---

Figure 2.1-1a MID-DECK LOCATION IN THE SPACE SHUTTLE 

AIR LOCK -iJ~===nc=l.:::3iT::c:=rt==" 

AFT ST!IINiE _.lh...,...,."7II"'I .... 1 SIDE HATCH 

(9 LOCICERS) 

AIRLOCK HATCH 

Figure 2.1-1b MID-DECK AREA ARRANGEMENT 

8 
I 

~ 

Table 2.1-1 

SHUTTLE MID-DECK ACCOMMODATIONS 

1. VOLUME 

o 

o 

o 

0 

0 

0 

0 

II. MASS 

o 

o 

o 

Standard Locker Size 

Standard Locker Volume 

Optional Stowage Tray Sizes 

o large 

o small 

Single Adapter Plate 

Double Adapter Plate 

Maximum Total Payload 

Length 

Maximum Total Payload 

Width and Breadth 

Maximum Payload Mass 

o Standard Locker 

Size 

Size 

o Single Adapter Plate 

o Double Adapter Plate 

Adapter Plate Mass 

o Single 

o Double 

Center of Mass Location 

o Light, centered 

loads 

o Off-axis or nearmaximum loads 

9 

9.950" x 17.312" x 20.320" 

internal dimensions. 

2.00 cubic feet 

9.59" x 16.95" x 20.00" 

4.64" x 16.95" x 20.00" 

10.757" x 18.125" x 0.750" 

18.125" x 21.882" x 0.875" 

21.062" Including adapter 

plates 

May not extend beyond 

adapter plate perimeters. 

60 lbs. includings trays, 

etc. 

69 lbs including plate, 

mounting hardware, etc. 

120 lbs. including 

plates, etc. 

6.2 lbs. 

12.5 lbs. 

< 14" from attachment 

face 

< 10" from attachment 

face 
Table 2.1 (cont.) 

III. STRUCTURAL 

0 Steady-State Load Factors 

0 along x-axis -3.15 to + 1.22 

0 along y-axis -0.80 to + 0.80 

0 along z-axis -1.00 to + 2.50 

0 Load Factors for Critical or Potentially Hazardous 

Components 

0 along x-axis 

0 along y-axis 

0 along z-axis 

0 Other Stresses 

IV. CABIN ENVIRONMENT 

0 Temperature 

0 Normal 

0 During ascent 

reentry 

and 

-3.3 to + 20.0 

-3.3 to + 3.3 

-4.4 to + 10.0 

Random vibrational, 

acoustic, and transient 

stresses, as outlined 

in Interface Control 

Document. 

68-80 degrees F 

< 95 F 

0 Air Pressure and Oxygen Content 

0 Normal 14.7 PSIA, 25.9 % 02 

0 During EVA 10.2 PSIA, 31.0 % 02 

0 Emergencies 8.0 PSIA, 32.0 % 02 

o Fixed Rate of Pressure Change 

o EVA Adjustment 2.0 PSIA/min 

o Emergencies 9.0 PSIA/min 

V. COOLING AND THERMAL 

o Passive Cooling Dissipate heat to middeck cabin air. 

o Preferred method of Fan or equivalent 

Active Cooling 

o Maximum Waste heat Without 

Fan 

(Standard Storage Locker) 60 watts 

(Experiment Specific Structure) 90 watts 

10 

() 
~\ 

I 

Table 2.1 (cont.) 

o Active Cooling Dissipates heat via water 

flow through connectors 

in mid-de~k floor 

o Maximum System Coolant Pressure 

o Normal 200 psig 

o Safety Factor 300 psig without leaks 

o Payload Surface Temperatures 

o Surfaces Accessible to <113 degrees F 

Crew 

o Other External Surfaces <120 degrees F 

o Maximum Total Payload Waste Heat 

o At 14.7 PSIA cabin air pressure 

o Two man crew 650 W 

o Four man crew 375 W 

o At 10.2 PSIA cabin air pressure 

o Two man crew 425 W 

o Four man crew 150 W 

VI. ELECTRICAL 

0 DC Power From Orbiter 

0 Mimimum Voltage 

0 Maximum Voltage 

0 Nominal Voltage 

o Maximum DC Continuous Power 

o Bus A 

o Bus B 

o Bus C 

o AC Power From Orbiter 

o Frequency 

o Minimum Voltage 

o Maximum Voltage 

o Nominal Voltage 

o Connections 

11 

23 VDC 

32 VDC 

28 VDC, 

amps. 

at Min. 

224 W 

215 W 

165 W 

all at 

Voltage 

400 Hz, 3 phase 

108 VAC 

120 VAC 

up to 10 

115 VAC, all up to 3 amps/ 

phase 

Done by crew. Two-wire 

cords for DC, four-wire 

cords for AC, with 

interfaces described in 

Orbiter specs 
Table 2.1 (cont.) 

o 

o 

o 

o 

o 

o 

o 

Electrical Bonding 

Requirements 

Electrostatic Discharges 

Alternating Magnetic Fields 

Electrical Interface Noise 

o DC Power from Orbiter 

o Nominal Ripple 

o During Orbiter 

Hydraulic pump StartUp (t < 300 msec) 

Transient Spikes 

AC Power From Orbiter 

o Nominal ripple 

Transient Spikes 

12 

RF circuits and electrical 

interfaces shall be 

electrically bonded to 

Orbiter structure. 

Not permitted 

< 130 dB above 1 picotesla 

(30· Hz to 2 kHz) falling 

40 dB per decade to 50 

kHz, at 1 meter away. 

< 0.9 volts peak to peak 

narrowband (30 Hz to 7 

kHz), falling to 0.28 

volts at 70 kHz, remaining 

constant to 400MHz 

Sawtooth ripple voltage, 

4.0 volts peak-to-peak, 

500 to 700 Hz, on the 28 

VDC power bus. 

< 300 x 10-6 volt-seconds 

above or below line 

voltage. Peak spikes not to 

exceed +/- 50 volts from 

nominal bus voltage; rise 

and fall times < 56 

volts/microsecond. 

<1.5 volts rms narrowband 

(30 Hz to 1.5 kHz) , 

remaining constant to 400 

MHz. Ripple shall not 

exceed 4% rms of the AC 

line voltage at inverter 

harmonic frequencies. 

Peak spikes not to exceed 

+/- 600 volts from nominal 

bus voltage; rise and fall 

times < 2.5 volts/ microsecond. 
"r-, 

2.1.1 Structural/Volume 

The payloads that utilize their own structure must mount to 

the wire of the mid-deck locker region using a single 

adapter 

through 

18.125 

trays 

plate 18.125 inches wide by 10.757 inches high; or 

two 

inches 

single adapter plates to a double 

wide by 21.882 inches high~ All 

adapter 

hardware 

plate 

must 

extend no further than 20.32 inches from the wire trays including 

the adapter plates. Experiments usually occupy the space of one 

or two lockers. They must conform to the defined locker volume. 

The c.g. of the system is as defined in the Table 2.1-1. 

2.1.2 Thermal/Environment 

The thermal and the environmental interfaces in the mid-deck 

are given in Table 2.1-1. Pressure is as low as 10.2 PSIA during 

EVA activity. The oxygen partial pressure at 14.7 psi can be as 

high as 25.9%. Both factors will affect oxygen solubility in 

exposed liquids. The heat rejection by an experiment must be 

accommodated through coupling to the galley location fluid heat 

exchanger or through exchange to the cabin air. The fluid heat 

exchanger is available at the galley location and its use is 

not considered for the fluid experiments. The heat loss must be 

positively moved to the cabin air if it will be greater than 90W 

when an experiment specific structure is used. 

2.1.3 Electrical/Power 

The total power 

location other than 

available to an experiment 

the galley is 250 watts. 

13 

at 

If 

a locker 

the power 
requirements are greater than this the galley location must be 

used. The variation in DC power level is 23-32 volts which may 

require power supplies for equipment power stabilization. 

2.2 APPROACH TO FLUID EXPERIMENT DESIGN 

The approach used in developing the Fluid experiments in 

this study is diagrammed in Figure 2.2-1. For each experiment, the 

form and operation of the components within mid-deck were 

considered. In the presentation we have grouped the 

requirements, the concept and the preliminary design. These are 

discussed together in the appropriate section. 

Identify . 

Mid-Deck f-t 

Interfaces 

Volume 

Structure 

Safety 

Power 

Crew Time 

Etc, 

I...t Mid-Deck 

Concept 

Develop Operation 

Concept 

Component 

Development 

Fit and Form to 

Mid-Deck 

Figure 2.2-1 

Relate Subsystem Parameters f-t Requirements to Operation 

Size Expts Material 

Time Size 

Compartment No, Interfaces 

Constraints Crew Intervention 

.. Preliminary 

Design 

Component Design 

Mid-Deck Layout 

Instrument Identification 

Establish 

f-t " Mid-Deck ~ 

Compatability ,: 

Meets Guidelines 

Within Operating 

Parameters 

Accomplishes Experiment 

Objectives , . 

MID-DECK DEVELOPMENT THROUGH PRELIMINARY DESIGN 

14 
The experiment concepts were devised to be consistent 

with maintaining STS safety and achieving scientific objectives. 

The weight requirements and the e.g. requirements were estimated 

to insure that each of the experiments met these criteria. Each 

experiment was developed for two locker volumes using the 

standard double adapter plate. After completing the design we 

were made aware of a lighter weight plate and a method of 

attaching to them that will result in weight saving. This is 

discussed in Section 3.4 and 4.4. 

I 

~ 

15 
3. SURFACE TENSION DRIVEN CONVECTION 

The experiment concept meets the objectives shown in Figure 

I-la, and the science requirements of Table 1.2. The equipment 

function flow diagram for the experiment is described in Figure 

3-1. This figure defines subsystems that must be addressed to 

accommodate experiment operation. The experiment description is 

grouped as follows. Section 3.1 describes the requirements, 

their conceptual implementation and the preliminary design 

drawings. The electronics requirements are contained in Seetion 

3.2 while Section 3.3 describes experiment layout based upon this 

approach. The weight estimate is given in Section 3.4. 

The nature of this effort was such that not all design 

issues could be resolved during the present effort. Section 3.6 

gives design issues and lists some steps to accomplish their 

solution. 

3.1 EXPERIMENT REQUIREMENTS, CONCEPT AND PRELIMINARY DESIGN 

This section discusses the experiment requirements, and 

describes the implementation and the preliminary design of the 

experiment, its subsystems and components. The experiment can be 

described by the following subsystems: 

a) experiment container 

b) fluid storage and delivery 

c) fluid heater 

d) diagnostics; including temperature sensors, timing; 

illumination; flow visualization and data recording. 

16 
...... 

....... 

-) 

k 

DC 

Middec 

28V 

10 AMPS 

Cabin 

air 

Niddec k 

-j 

~9~1~~~~!_f~~f!lQ~_fhQ~ 

~- -- ,--1 I r-----------------, 

Experiment I t 

,... I I 

Contro 1 r----- I 

I 

I Thermal I 

tool Thermal --! Conditioni ng I 

H Data Measurement 1-1 Acquisition _______ 1 

~ Heater fPower 

I- Conditioning ~ Experiment Opticsj ~ f-to Container 111 umi nati on 

Thermal rt Camera IH Conditioning 

'- 4 Fluid ~ Fluid 

Drive Delivery 

Electronics Experiment Enclosure 

-----

Figure 3-1 SURFACE TENSION DRIVEN CONVECTION EXPERIMENT FUNCTIONAL FLO~J 

Cabin - -- air 
e) thermal control (heat rejection) 

f) electronics 

The following functions are also considered in the analysis: 

a) fluid type, including compatibility with STS 

environments. 

b) experiment operations 

3.1.1 Experiment Container 

Table 3.1-1 details the requirements derived for the 

experiment container and their implementation. Figures 3.1-1 

shows the design details of the container including 

containment construction. 

3.9 OIA 

r 1.9 DIA l 

bJ!1 "- I~ 

r;::;; -- i-J l 

1 --c:: 

2.0 

" 

5.3 OVERALL l< 

ID C 

I I 

the spill 

HEAT ER OPENING 

OV ERFLOW CONTAINMENT 

SHARP EDGE 

FLUID VOLUME 

TYPICAL THERMISTER 

Fig. 3.1-1 SURFACE TENSION INDUCED CONVECTION EXPERIMENT 

CONTAINER 

18 
/~ { . 

This consists of a trough on the container top with roof type 

protection cover. The fluid is fed to the container via a single 

port using 1/4" (O.635cm) line. This cross section is optimized 

compared to other cell dimensions to minimize influence on 

experiment operations. The fluid flow velocity is discussed in 

Section 3.1.2. The inner lip on the cell is a "sharp edge", 

designed to contain the fluid within the experiment volume and to 

establish the proper fluid surface characteristics. The overflow 

construction provides protection to contain liquid in the event 

of a spill from the container volume. The opening at the top of 

the vessel is designed to mate with the heater body. For this 

design embodiment, the experiment can be run only once. However, 

a growth option is to operate the experiment more than one time. 

(\ Therefore, there is provision to remove the heater and replace it 

with a stopper. The stopper will contain the test fluid within 

the experiment container during reentry and landing. The 

provision for a stopper will also allow heater removal if it will 

be degraded by contact with the test fluid. Figure 3.1-2a shows 

atypical thermistor insertion method. 

Figure 3.1-2b shows the PI's sketch of the container indicating 

the position of the thermistors. Four positions will be chosen 

for inclusion in the final design. 

19 
N 

o 

TABLE 3.1-1 EXPERIMENT CONTAINER REQUIREMENTS 

REQUIREMENT SOURCE/COMMENTS 

1-1 DIMENSIONS: • PI REQUIREMENT IN RFP 

CIRCULAR CYLINDER 

10 CM 10 

5 CM DEEP 

LIP ON TOP FOR CONTAINMENT 

1-2 t1ATERIAL • PI REQUIREMENT IN RFP 

TRANSPARENT TO OBSERVATION 

ILLUMINATION 

1-3 FOUR TH1PERATURE SENSORS • PI REQUIREMENT IN RFP 

1-4 FILL EXPERIMENT CONTAINER • LOW "G" ENVIRONMENT 

WITH 395 CM3 FLUID 

1-5 SPILL CONTAINMENT • AVOID SPILLING ANY FLUID INTO THE EXPERIr~ENT ENCLOSURE (DERIVED 

REQU I REMENT) 

C--.. 

J J 

I MPLH1EtHATION 

•. CYLItWER OF MATERIAL THAT MEETS 

STS REQUIREMENTS 

• PREFERABLY CLEAR POLYMER 

• COMPATIBLE WITH FLUID 

• POLYCARBONATE OR 

ACRYLIC 

• SEE 3.1.6 

• USE 1 cm2 ORIFICE 

• FLUID WILL CONTAIN PARTICLES 

• ENCLOSE EXPERIMENT CONTAINER 

TO TRAP ANY OVER-FLOW 

~ 
WALL---. ...... 

CEMENT 

\ 

PROTRUDING THERMISTER 

~ 'WALL MOUNTED 

THERMISTER 

Figure 3.1-2a TYPICAL THERMISTOR INSERTION INTO EXPERI~lENT CONTAINER 

~ iliT 

10 

LlOUID 

SURFACE 

Figure 3.1-2b EXPERIMENT CONTAINER SHOWING THE 

POSITION OF THERMAL SENSORS 

21 
3.1.2 Fluid 

Table 3.1-2 summarizes the requirements for the 

experiment fluid. The selection of a fluid is based upon the 

fluid properties and its compatability with the test cell 

material. Several fluids are appropriate for the experiment 

requirement and are compatible with the Shuttle environment. 

These fluids fall into two general categories; fluorocarbons such 

as Fluorinert (3M Company Electronic Liquids) and Silicone 

Fluids (Dow Corning Corporation or GE). The final selection can 

be made on a basis of a development evaluation in which the 

surface tension and the wetting angle of the liquids (with the 

selected test cell material) is measured for fluids of acceptable 

viscosities. Table 3.1-3 lists properties of several potential 

fluids. Particles are required for flow visualization and will 

be mixed with the fluid prior to loading into the experiment 

during pre-flight integration. A discussion of the methods used 

for particle dispersal and analysis of test fluids is contained 

in Appendix B. Appendix B also discusses the fluid properties 

further. The polydimethylgiloxane fluids have the required 

properties. There properties are listed under the Dow Coming 200 

Series in Table 3.1-3. 

3.1.3· Fluid Delivery 

The fluid delivery requirements are given in Table 3.1-4. 

The critical requirement is to fill the experiment container to 

the sharp edge containment rim with fluid without voids. The 

fluid flow rate must be such that the integrity of the fluid mass 

is maintained during the filling process without bubbles or 

separation of parts of the fluid. 

.r') I 

22 
N 

W 

'\ 

) 

.. " 

) 

TABLE 3.1-2 FLUID REQUIREMENTS FOR SURFACE TENSION INDUCED CONVECTION EXPERIMENT 

REQUIREMENT SOURCE/COMMENTS IKPLEMENTA TI ON 

II-l SILICON OIL I PI SPECIFIED IN RFP I AS REQUIREMENT STATES 

KINEMATIC VISCOSITY = 

10 CPo I LIST POTENTIAL FLUIDS 

II-2 SUSPEND PARTICLES IN I TO VIEW FLUID MOTION I NUMBER DENSITY SIZE AND TYPE 

FLUID AND ACTUAL FLUID - SEE 3.1.6 

II-3 INERT WITH LOW VAPOR I SATISFY NASA-STS SAFETY REQUIRE- I SILICON OIL SHOULD MEET 

PRESSURE t~ENTS REQUI REt-1ENTS 

II-4 COMPATIBLE WITH CONTAINER I, TEST FOR Cm4PATABILITY • 

MATERIAL 

11-5 SPECTRAL ABSORPTIVITY I DERIVED REQUIRH1ENT FOR RADIATIV£ I PART OF FLUID SELECTION HIGH IN THE IR, LOW HEATING AND FLOW VISUALIZATION PROCESS BY TEST & ANALYSIS 

IN THE VISIBLE 

I 

-; 

I 

1 

I 
I'V 

-t::> 

-) 

FLUID 

SPECIFIC GRAVITY 

(@ 25°C) 

KINEMATIC VISCOSITY 

IN CST 

AT 99°C 

38°C 

25°C 

SURFACE TENSION 

DYNE/CM (25°C) 

SPECIFIC HEAT 

CAL/GM/DEG. C 

FLASH POINT (OC) 

IGNITION TEMP (OC) 

VOLUME EXPANSION 

@ 100°F 

COMMENTS 

Table 3.1-3 CANDIDATE FLUIDS FOR THE SURFACE TENSION INDUCED 

CONVECTION EXPERIMENT 

DOW CORNING 510 FLUID 550 FLUID 710 FLUID DOW CORNING 200 

PHENYL-METHYl PHENYL-METHYL SILICONE FLUID 

-50 -100 -500 SILICONE OIL POLYSILOXANE 10 cst. 20 cst. 

0.985 0.992 0.992 1.07 1.11 0.935 0.949 

14 26 180 20 30 ----- -----

38 77 380 75 250 ----- -----

50 100 500 125 500 10 20 

25 24.1 24.6 24.5 28.5 20.1 20.6 

-- 0.372 0.372 0.368 0.363 0.360 -----

-- -- -- 308 302 210 246 

482 482 482 --- 487 ----- -----

0.41993xlO-3 0.43x10-3 ----- -----

1) BLENDING IS 1) COLORLESS 1) COLORLESS 1) BLENDING IS 

POSSIBLE TO OBTAIN 2) VAPOR PRESSURE 2) VAPOR POSSIBLE TO 

ANY DESIRED 0.08 TORR AT PRESSURE ACHIEVE 

VISCOSITY 443°F 1.5 TORR DESIRED 

2) CLEAR FLUID @ 450°F VISCOSITY 

2) CLEAR FLUID 

-

J 

FLUORINERT (3M FLUID): 

FC-43 FC-70 

1.88 1.94 

----- -----

----- ----- 2.6 13.4 

16 18 j 

! 

0.25 0.25 

BP 174°C BP215°C 

NON-COM- NON-COM- i 

BUSTIBLE BUSTIBLE I 

1.2x10-3 1.0x10-3 

1) VAPOR 1) VAPOR 

PRESSURE PRES1.3 TORR SURE 

@ 25°C 0.1 

2) CAN BE TORR 

BLENDED AT 

WITH 25°C 

FC-70 

---

J 
N 

U'1 

~ .-

) --) 

Table 3.1-4 FLUID DELIVERY REQUIREMENTS 

REQUIREMENT SOURCE/COMMENTS 

I II-l FLUID VOLUME - DELIVERED • THIS FILLS THE CONTAINER TO 90% 

VOLUME 395 CM3 ± 5% OF VOLUME 

(TO EXPERIMENT 

CONTAINER,PER EXPERIMENT 

111-2 FILL TIME TBD MINUTES • NO PI REQUIREMENT 

I II-3 FLOW RATE TBD CC/~HN • FLOW AT FIXED RATE 

• ~~INTAIN FLUID ADHERENCE TO 

SURFACE 

• DEVELOP FILL APPROACH 

) 

IKPLH1ENTATION 

• DESIGN TO 1900. CM 3 CAPACITY 

• CAPABILITY TO FILL.AT LEAST 

3 CONTAINERS 

• CYLINDER WITH POSITIVE~' 

DISPLACEMENT'FEED 

• USE PNEUMATIC DRIVE 

FOR 1900 CC CYLINDER, THE REQUIRED DIMENSIONS IN CENTIMETER ARE: ) 

OPTION DIAMETER LENGTH 

1 10.0 24.0 I 

2 15.0 10.75 I 

3 20.0 6.0 
The initial operating scenario for this experiment is that 

the cell be filled once for each STS flight. The filling method 

was selected to be manual using crew operation and involvement. 

During the design phase it was determined through discussions 

with NASA-JSC that there was a possibility of human error in the 

fill procedure. There is also the probability that in future 

missions the experiment may be run several times on a given 

missions. To enable several experiments to be run we determined 

the maximum size fluid storage container that could be 

incorporated into the mid deck arrangement. There is an existing 

1900cc storage container that is available and that is flight 

qualified. This volume provides four fills of the current 

experiment container with approximately 20% excess. This storage 

vessel and the driver fit conveniently into the two locker middeck volume. Our concepts and designs are based upon the 1900cc 

volume. This does not compromise operation in any way and adds 

growth potential to the design. 

The elements of the fluid delivery are: 

(a) flow rate at low gravity 

(b) fluid delivery device 

(c) fluid flow driver 

Flow Rate ~ Low Gravity 

The appropriate fluid feed rate in low gravity is one which 

maintains a continuous stream without bubble and droplet 

formation. The maximum rate is determined by the force balance 

between fluid momentum and surface tension forces. 

26 
,.~ 

! 

~. 

( 

Figure 3.1-3 shows time required to fill a container as a 

function of entrance flow rate. At lower flow rates, the fluid 

will be less susceptible to flow breakup. Experiments are being 

performed at LeRC that will test fluid flow rates under reduced 

gravity. These tests will utilize a Lear Jet. When results are 

available they can be used to assist in evaluate final fluid 

flow values. 

Several minutes will be required to fill the container. Lower 

flow rates will assure the appropriate fill characteristics. 

Fluid Deliv~ry Design 

Two types of fluid delivery systems were evaluated. 

1 • A fluid storage vessel with the fluid moved by a 

piston driven by a dc motor drive or a stepper 

motor drive. The flow rate and total volume is 

controlled through the motor by elapsed time or the 

number of steps. 

2. An accumulator method in which the fluid is driven by 

the expansion of compressed gas, either behind a piston 

or into bag which expands to drive the fluid out. 

Fluid flow rate is controlled by line sizing and 

the volume delivered is controlled by the on time of 

the driver gas. 

27 
The latter force maintains fluid cohesion and adherence to a 

surface of the test cell. A modified Weber number is derived in 

Appendix A which defines the criterion for meeting this 

condition. The modified We number must be less than four. If 

the We number <4 is maintained for the flow, the entrance 

velocity for silicon oil into the test cell is: 

v < J40 '" 12cm/sec pd 

Coupled with the 0.63cm diameter entrance port this determines a 

maximum feed rate into the cell of about 3.8 cm /sec. (less than 

230 cm /min). Significantly Lower flow rates will be required 

to achieve the required fill properties. Therefore, capability to 

control the fluid flow rate rate is included in the design 

allowing for margins. 

; __ MINIMUM TIME FOR SILICON OIL 

I 

\ ~NCREASING 

\SAFETY 

10 

8 

o 

w 

f!? 

6 ~ 

~. 

C3 

4 g 

2 

w 

> 

o 2 4 6 8 12 

CONTAINER FILL TIME, MINUTES 

Fig. 3.1-3 FLUID DELIVERY TIME AS A FUNCTION 

OF FLOW RATE 

28 

· .fj 

!") J 
Either method is suitable for this experiment. The 

accumulator concept is simpler and is adequate for the degree of 

control required. The stepper motor approach gives a more 

precise control of the fluid flow but it is more expensive. The 

precision stepper motor control is not required for this 

experiment. Space qualified accumulators with cylinder and 

piston arrangement are commercially available. The use of a 

shaped piston drive was compared to use of an expandable bag. 

Shaped piston drives are more reliable than an expandable bag. 

Therefore, a shaped piston drive was chosen. 

Figure 3.1-4 shows the fluid delivery system design in the 

double locker structure. The fluid is stored in the accumulator. 

~ The large accumulator with a capacity to hold 1900 cc of fluid I 

provides the capability to fill 3 to 4 experiment containers. 

As discussed above, this volume is oversized for initial 

experiment operating concept. However, as figure 3.1-4 

illustrates, the storage volume is readily accommodated. This 

will result in built-in added experiment flexibility without 

increase in complexity or significant cost impact. A lesser 

fluid 'storage capacity cannot reduce the number of locker spaces 

required. The two locker volume is controlled by the laser 

length (see section 3.1.6). 

The accumulator is driven by pressurized gas. A stirrer with 

a motor is incorporated into the fluid end of the accumulator. 

29 
ACTIVATOR 

SWITCHES 

w 

o 

,J 

GAS FIll 

VALVE 

GAS SOlENOI 

VALVE 

IQUID FILL 

VALVE 

TEST CELL IQUID METERING VALVE 

SOLENOID VALVE 

FIGURE 3.1-4: THE FLUID DELIVERY SYSTEM 

J 

GAS STORAGE 

TANK 

LUID ACCUMULATOR 

IXER MOTOR 

) 
, 

/~ 

(~ 

The fluid from the accumulator is moved to the experiment 

container through standard lines fitted with a liquid metering 

valve. The driver gas interfaces to the piston end of the 

accumulator through a regulator which maintains constant pressure 

at the piston. There are two solenoid valves, one in the 

pressure line and the other in the liquid flow line. The two 

valves are used to give redundancy and to insure safe operation 

in STS environment. Provision is made to load the gas into the 

storage tank and the working fluid into the accumulator from 

outside the locker after experiment assembly. The same valve 

openings can be used to check the system during the integration 

cycle. The arrangement permits late filling if required. 

The pressure regulator and the metering valve are preset at 

the operating values. They will not require adjustment during 

the experiment unless an inflight anomaly develops. The valves 

do have the capability for adjustment by a crewman if the initial 

flow rate requires correction. Such adjustment will allow for 

change in the flow rate if the flow levels determined pre-launch 

are not realized or are inappropriate. 

The stirrer is used to mix the fluid containing particles for 

flow visualization. This insures uniform concentration. 

particles will probably not be uniformly distributed 

The 

at 

experiment initiation and the stirrer operation may require 5 to 

10 minutes to insure the proper mixing. Particles so mixed will 

remain suspended at the low gravity levels expected. 

31 
The fluid flow will be initiated when stirrer operation ceases 

(or can begin with the stirrer still operating). When the 

solenoid values are opened, the compressed air drives the piston 

which in turn pushes the fluid into the experiment container. 

The flow rate is controlled by the metering valve. 

Figure 3.1-5 shows the accumulator fitted with a stirrer 

assembly. A commercially available space-qualified accumulator 

with a fluid capacity of 1900cc is chosen. The stirrer assembly 

consists of a small propeller that is driven by a motor that is 

also commercially available. The stirrer and the motor unit are 

designed in such a way that will be retractable if it is 

contacted by the piston. 

Fluid Flow Driver 

Compressed gas is used to drive the fluid from the 

accumulator to the experiment container. The fluid flow rate 

must be controlled to meet the criteria set out above. 

The pressure drop required to drive fluid from the 

accumulator to the experiment container is small because of the 

low flow velocities and is given by 

L V2 

=f-p- o 9C 

where 

f = friction coefficient = 64/Re for laminar flow 

L/D = length to diameter ratio 

V velocity 

Re = Reynolds number 

32 
-j 

/ ) 

"., "E"" 'E"" :1 

14.0 ---------------1 

Working 

S S S S 

Fluid 

s r' , , S s~ ~I w ~_ ....f\.,~ ~ 1\'\.'.[--1 Nitrogen w nfl-----1'I1\. " ,,'- ~rr Il n liill Il Ii 1111 or 

Air / lUI. 

\ 

Slirrer Gas Inlet 

I.. 4.6 -----I 

Fig. 3.1-5 THE ACCUMULATOR WITH THE PISTON DRIVE AND THE ATTACHED STIRRER. 
(\ 

I 

A typical calculation of P is made using 

f 

V = 10 cm/s 

D = 0.635 cm (for 1/4" flow line) 

L = 23 cm 

With the velocity and tube diameter and length chosen and with 

silicon oil as the fluid, the Reynolds number calculated is 

Re = 15.9 

which yields 

f = 64/Re = 4.025 

The pressure drop is 

= 9.1 torr = 0.175 psi 

The required pressure differential across the piston in the 

accumulator will be defined by the specifications supplied with 

the accumulator or can be obtained by component tests. For 

sizing the gas storage tank, this pressure differential is 

3 2 

assumed to be 3.5x10 N/M (26 torr or 0.5 psi). Summing the 

pressure losses in the piping and values, and the pressure 

differential at the piston, the pressure of the gas (nitrogen or 

3 2 

air) at the piston is around 6.9x10 N/M (51 torr or 1 psi) 

higher than ambient pressure. 

In determining the appropriate gas storage bottle volume we 

defined a volume, pressure and stored energy that would not 

require the qualification of the container as a pressure vessel. 

34 
I 

~ 

A pressure vessel as defined in NHB 1700.7A is one in which 

1) the stored energy is greater than 19 kj, or 

2) has a pressure of greater than 100 psi, or 

3) contains toxic or flammable gas. 

Requirement 3 is met by using an inert ga~ nitrogen or air. A 

gas storage volume of 500cc was selected (Figure 3.1-6). The 

5 2 

pressurant gas is stored at 6.8x10 N/M (98 psi). This pressure 

is chosen to be below the design pressure which defines a 

pressure vessel (100 psi) for 8T8. The internal energy is given 

by: 

At 20 C: 

Internal energy, 

where 

E = _1_ RT 

Y - 1 

E internal energy per unit mass 

R gas constant 

T absolute temperature 

y = c /C = 1.4 

p v 

5 

E 2.14 X 10 joule/kg 

The mass of 500cc of nitrogen at 98 psi is 0.0038 Kg. Thus, 

the total stored energy is only 0.814 K joules. The gas storage 

container of 500 cc need not be treated as a pressure vessel in 

the design and will accomplish experiment objectives. 

35 
1-____________ '7 •• OVERALL LENGTH ------------1 

f-----------' •. 0 -------------1 

a"",nlll • us "', I*COI ~. 181- OUl ~ 12"un IIIII! • ID.~I sc.u. \I.~I;I(IO 

Fig. 3.1-6 THE GAS STORAGE TANK, VOLUME = 500cc 

The operating requirement on the gas storage is that the 

final pressure remain greater than 7 psi above atmospheric when 

3 2 

1900 cc of nitrogen at 7x10 N/M (1 psi) (.00232 Kg of nitrogen) 

is removed from it to drive the 1900 cc of fluid. In the present 

conditions, when 1900 cc of nitrogen is removed from the storaga 

tank, the pressure falls from 98 psi to 39 psi. This pressure 

gives a satisfactory margin for performance. The regulator is 

selected to operate in this range of upstream pressures. 

3.1.4 Fluid Heating 

The requirements for the fluid heating are given in Table 

3.1-5. Original requirements specified heater powers of 30, 60 

and 100 watts. This was later amended to specify the desired 

temperature differential at the fluid surface (see Table 1.2). 

We have performed transient and steady state heat transfer 

analysis of heating of the experimental fluid in the container to 

determine the initial power requirements at the fluid surface. 

The model used gives the initial heat inputs at the fluid 

surface allowing the heat deposition to be determined. This 

initial heat disposition is important in the determination of 

heater sizing. In this analysis, the heat deposition was 

determined in the absence of fluid convection. 

36 
w 

......, 

'\ 

) ) 

Table 3.1-5 FLUID HEATING REQUIREMENTS 

REQUIREMENT SOURCE/COMMENTS 

IV-1 SUPPLY HEAT SUCH THAT • 'REQUIREMENT IN RFP 

A 50°C PARABOLIC 

TEMPERATURE DISTRIBUTION 

IS ESTABLISHED FROM 

CENTER TO EDGE 

IV-2 HEATER FIXED IN ONE • REQUIREMENT IN RFP 

POSITION AXISYMMETRIC 

TO EXPERIMENT CONTAINER 

WITH FLUID 

IV-3 HEATER TO BE ADJUSTABLE • REQUIREMENT IN RFP 

WITH AT LEAST THREE 

POWERS AVAILABLE 

IMPLH1ENTATION 

• TRANSIENT HEAT TRANSFER ANALYSIS 

INDICATE HEATER 'POWERREQUIREMENTS OF ONLY 3 TO 15 WATTS 

• EXPERIMENTS AT CASE WESTERN 

SHOW SIMILAR RESULTS 

• EVALUATE HEATER SOURCES 

• SELECT COMMERCIALLY AVAILABLE 

RESISTANCE WIRE 

HEATERS (CATALYST BED HEATERS) 

, 

• ANALYSIS SHOWS HEATER STARTUP TRANSIENT TIME TO BE VERY 

SMALL. FEW SECONDS FOR A WIRE 

ONLY. WITHIN A MINUTE FOR 

CATALYST BED HEATERS. 

• .NO NEED TO BLOCK THE HEATER 

FROM FLUID DURING START-UP 

• MANUAL ADJUSTMENT TO 

THREE HEATER POWERS 

• FINAL POWER LEVELS TO 

BE BETWEEN 1-15 WATT 

i 

I 

I 
Such convection will of course be set up at the free surface and 

the flow measured as a part of he experimental observations. Two 

methods of heating the fluid were investigated. 

were by lamp and by wire wound resistance heaters. 

strong 

These methods 

Lamps with a 

IR component can be readily directed and focussed, therefore they 

are attractive. However, radiant coupling to the fluid may be 

poor since in most cases a significant portion of the lamp's 

output is at shorter wavelengths. 

made of a resistance wire seems 

Heating with a heater element 

most promising. We have 

identified a space qualified catalyst bed heater that will 

satisfy the experiment requirements. The following sections 

detail these analyses. 

3.1.4.1 Power Requirements 

Analyses were performed to determine 

1) the amount of heat that must be incident upon the surface 

to achieve the required temperature gradient. 

2) the steady-state temperatures to be expected in the 

experiment container. 

The time to achieve steady-state was not calculated. The initial 

analysis was made to determine the steady-state temperature 

conditions reached by the fluid in the cell. These conditions 

were calculated in the absence of heat loss at the cell wall. 

38 
This condition will be approximated at low gravity in the absence 

of convective cell wall cooling. The results of these 

calculations are given in figure 3.1-7 for three container radii. 

These results show that under these conditions energies of only 

a few watts (1-2 watts) was sufficient to raise fluid 

temperatures by 100 K or more at steady-st~te. The fourth graph 

illustrates that if the container interface has heat removed by 

convective cooling, 5-10 watts of heat at the center are 

adequate to develop the required thermal gradient. 

These steady-state results show that the heat reaching the 

heater should be of the order of a few watts. The time required 

to reach steady-state temperature can be of the order of one or 

more hours. 

The application of ten's of watts to a surface spot will 

initially overheat the heated area of fluid and boil it at the 

point of contact. Heat of a few watts at the surface is 

indicated. Work done at Case Western Reserve by Dr. Y. Kamotani 

and his student Tom Kessage show unshaped heater power of 

several watts is effective in initiating convective motion at 

earth gravity (Appendix B). 

The transient temperature distributions are significant for 

this experiment especially the initial phases. Therefore we 

utilized a transient numerical model to determine the initial 

heat energy input requirements. The model inputs heat into 

given nodes and monitors the heat flow. 

modelled by conduction only. 

39 

The heat flow is 
rb=6cm 

1000 ---....;;-----... 

900 

800 

5W 

2W 

1W 

300 C::C:::::c=:c::::c:~ 300 ""---'----'L..o-.~~-~ o 23450 2 5 

RADIUS, em RADIUS, em 

1000 

900 i800 ~ 

700 I600 -

500 ~ 

400 

I 

300 

o 

P-5W 

2W 

1W 

.1 W 

2 3 

RADIUS,cnt 

4 

FORCED 

CONVECTION 1000 ..... --;;.;.;..;.;..:;,;;.;.;~--., 

900 

800 

700 

F ,. 30 W; V ,. 80 ft/sec 

20 80 

5 1 

10 80 

5 80 600 

500 

400 

RADIUS,cm 

Figure 3.1-7 STEADY STATE TEMPERATURE OF FLUID IN CELL AS A 

FUNCTION OF THE CELL RADIUS FOR VARIOUS POWER LEVELS 

(rb refers to the boundary radius at which 

boundary conditions at infinity are imposed) 

40 
,~ 

Convection which will occur due to the free surface will moderate 

this flow" However, modelling below will give the initial heat 

input. 

The transient heat transfer analysis of the fluid heat 

distribution by conduction is performed using the computer code 

SINDA (Systems Improved Numerical Differential Analyzer). This 

code can also solve heat transfer problems with multiple 

media. The experiment geometry is modeled using separate sets of 

nodes for the three involved regions, namely test liquid, 

container walls and surrounding air. The axisymmetric nodes used 

in solving the heat transfer problem are shown in Figure 3.1-8. 

100 BOUNDARY. T ... 

100 B2 61 

Fig. 3.1-8 

7B 

77 ADIABATIC J WALL 

72 

iIII 71 

I • 

70 

8 5 4 ~--=~ 3 q~- .2 - - - - - - - .. 

60 50 :lB~ .::ts: ':'14: ':'13:" ~ l' - - - - - - - - - - - - --- - - -- - - - - - - - -:za- -26- -24- -23 22"21 - - - - - - - - - - - - ---- - - -

-- - - - - - - - - - -36 35- 34 33- 32- 31 - - - -- - - - - - - - - - -48 1- 45- 44- 42 Il' -- - - - - - 43_ _. - - - - - - 51 

80 

81 I 

82 ! ENERGY ADDITION 100 

MODEL OF HEAT ADDITION PROCERS TO EXPERIMENT 

CONTAINER (AXISYMMETRIC MODES USED IN SINDA 

CODE) 

41 
Using this model, energy addition can be made at any node. The 

heater is located axisymmetrically above the fluid and we 

simulated energy input from the heater to the experiment fluid by 

distributing the energy over the two top layers of the liquid in 

the proportion of 70% for the top lay~r (nodes 1-6) and 30% for 

the next layer (nodes 11-16) (see Figure 3.1-8). The energy is 

added only at the three inner nodes (1-3 and 11-13) to simulate 

the heater diameter. The distribution of the incident energy 

over these nodes is varied as part of the parametric analysis. 

In this way the initial energy distribution is approximated and 

the energy level that is required can be defined. This 

information used to size the heater. 

Figures 3.1-9 and 3.1-10 show the radial temperature 

distributions at the liquid interface and at other axial depths 

as a function of the fluid radii. Figure 3.1-9 shows the radial 

temperature distributions at 20 and 40 minutes after energy 

addition of 1 watt. Since 70% of the energy in this case is 

added to the small inner most node, its temperature increases 

sharply as seen in the figure. This heating pattern is 

relatively independent of time especially at the center. The 

diffusion of heat energy in radial and axial direction from 

conduction is low. The variations in radial temperature 

distributions over an interval of 20 minutes is small. The 

temperature difference from center to edge of the liquid 

o 

interface is around 80 C. 

(See Table 1.2). 

This exceeds the requirement of 50 C 

42 
,f', 

0 

0 

W 

a: 

::> 

le( 

a: 

w 

a.. 

::E 

w 

I1~-----------------------------------------' 

120 

110 

90 

80 

70 

60 

QTOTAL '" 1 W; 

70%,20% AND 10% IN INNER MIDDLE 

AND OUTER NODES RESPECTIVELY 

___ HEATING TIME'" 20 MIN 

--- HEATING TIME'" 40 MIN 

2OL-----L---::2~~=s3~~~4----~5----~----~7 

RADIUS,em 

Figure 3.1-9 RADIAL TEr~PERATURE DISTRIBUTIONS AT 1 WATT 

ENERGY INPUT FOR DIFFERENT DEPTHS 

43 
u 

o 

w' 

a: 

a: 

~ w 

a.. 

:E 

w 

t1~~--------------------------------------~ 

60 

50 

40 

30 

clTOTAL =3W; 

20%,50% AND 30% RESPECTIVELY IN 

INNER MIDDLE AND OUTER NODES 

RESPECTIVELY 

HEATING TIME" 20 MIN 

--- HEATINGTIME=60MIN 

2OL-----L-~:J2c:==~§;~~4 .. ~-L5----~6----~7 

RADIUS,em 

Fig. 3. 1-10 RADIAL TEMPERATURE DISTRIBUTIONS AT VARIOUS 

FLU ID DEPTHS. 

44 
Figure 3.1-10 shows the radial temperature distributions at 20 

and 60 minutes during energy addition of 3 watts. Here the 

energy added was modelled to be more evenly spread out over the 

three inner nodes. This gives the wider peak in the temperature 

distribution. In this case the temperature difference from 

o 

center to edge at the liquid interface is around 90 C. The 

initial energy is concentrated near the center and develops the 

required temperature difference. The initial heater deposition 

at the center is required to be only one watt in a one cm 

o 

diameter circle to generate at least a 50 c differential from 

center to edge. 

The temperature distributions shown in Figures 3.1-9 and 

3.1-10 indicate that energy additions at a rate of 1 to 3 watts 

is sufficient to obtain the required temperature difference of 20 

o 

to 50 C between the center and the edges. The calculations used 

water as a model fluid but the heat absorption characteristics of 

silicone oil or fluorinert are expected to be similar. In an 

efficiently designed heater about 30 to 40% of incident radiation 

will be absorbed. In addition, there will be other losses at the 

heater so that not all the radiation emitted by the heater is 

incident on the liquid. The overall efficiency will be 20-30% 

and a heater of 3 to 15 watts power output is required. Table 

3.1-6 summarizes the heater power requirements using a heater 

with 208 ohms resistance. 

45 
Power Dissipation at 

3 Watts 6 W 10 W 15 W 

the heater resistance 

Voltage drop required 

across the 208 f2 25 Volts 35 V 46 V 56 V 

resistor 

Radiant energy incident 

on liquid per second 2.4 Watts 4.8 W 8.0 W 12.0 W 

(power) 

Energy absorbed by 

liquid (water) per 0.82 Watts 1.63 W 2.7 W 4.1 W 

second (power) 

Table 3.1-6. HEATER POWER REQUIREMENTS, HEATER 

RESISTANCE = 208 OHMS 

3.1.4.2 Review of Heat Sources 

The analysis above translates in a requirement for a heat 

source capable of delivering from 1 to 20 watts. The source must 

meet the safety and flight qualifications required for STS 

operation. Another requirement is that the energy be transferred 

to the fluid and that a variable energy output of known power be 

available. The heater levels that were determined using the 

modelling techniques above are similar to those that were 

determined to be effective experimentally by Dr. Kamotani 

(Appendix B). In his work heater powers of 6-20 watts were used 

to obtain flow data under terrestrial conditions. 

46 
These heaters were simple wire coils without reflectors and 

therefore ly inefficient. These results do verify that a heater 

power range of up to 20 watts by analysis has to be verified 

through initial experiments. 

3.1.4.3 Heat Coupling to Test Liquid 

Flow visualization requirements dictate that the fluid be 

transparent in the visible range. The spectral absorptivity of 

the liquid or the spectral extinction must be known in order to 

determine whether the heat is deposited near the surface. The 

heat source spectrum must match this spectral absorptivity. 

We considered both lamps (radiant) and wound wire heaters. The 

following is a brief summary of lamps available as heat sources. 

3.1.4.4 Lamps as a Heat Source 

We discussed the use of lamps as heat sources with 

several potential manufacturers. The following is a summary of 

our contacts. 

o Medtherm Corp., Huntsville, AL. (205)837-2000 

manufactures IR heaters, quartze lamps enclosed 

within an elliptical reflector. The lamps are in a 

linear array; up to 500 watts with an efficiency of 

60-75%. Water cooling is sometimes required. No 

flight qualified lamps available or circular 

symmetric lamps are available. 

o Oriel Corporation, Stanford, Conn., (203)357-

1600 produce quartz-halogen (tungsten) lamps and 

mercury, up to 1000 watts in power. The tungsten 

filament lmap has a gray body type radiant 

spectrum, all other lamps produce output in the 

visible and UV. None of these lamps are suitable 

for the experiment. 

47 
o Optical Radiation Corp., Azusa, Ca., (213)969-

3344 makes compact xenon and mercury-xenon arc 

lamps, which come in various rating and packed in 

a reflector which focuses the beam to a small spot. 

A typical xenon lamp has output as follows: 4.4% 

from 0.2 to 0.38 The lamps have the same 

problems as those of Oriel. 

o ILC Technology, Sunnyvale, CA., (408)745-7900. 

produce compact xenon illuminators (33 mm diameter, 

40.4 mm long - 300 watt device) which are very 

efficient. They produce the flood lights (800 

watts short arc lamp) used in the Shuttle's payload bay. They do have the experience for space 

flight and are the most promising contact. (They 

also mentioned a substitute for a fluorescent 

lamp for the Shuttle crew compartment). 

o Other sources that can be considered are: 

Radiant spot heaters for desoldering 

Sources in vaporization spectrophotometers 

3.1.4.5 Resistance Wire Heating 

A wound wire heater is formed by wrapping wire about a 

central core or by a large coiled loop. The electrical power (P) 

dissipated by the wire alone is related to the voltage (V) and 

resistance (R) by 

2 

P = V IR 3.2 

where 

R = P (LiS) 

p = resistivity or specific resistance 

L = length of wire 

S = cross section 

48 
The heat dissipated by radiation is 

4 

p = E 6 T At 

where: 

A is 11' DL 

L 

E is the emissivity 

6 is the Stefan - Boltzman constant 

T is the absolute temperature. 

3.3 

A typical wire heater uses nichrome wire. For this wire the 

properties are: 

P = 650 ohm - circ mil/ft. 

EO.6 

-6 2 4 

5.73 x 10 watt/in K 

Table 3.1 - 7 

NICHROME WIRE REQUIREMENTS FOR SURFACE TENSION 

INDUCED CONVECTION EXPERIMENT 

WIRE VOLTAGE REQUIRED FOR 

GAGE # DIAMETER LENGTH RESISTANCE POWER = 3W POWER = 15W 

(em) (em) (ohm) T = 1l00oK T = 1645°K 

24 5.1x10 -2 3.74 0.227 0.83 volts ! 1. 84 volts 

30 2.6xlO-2 7.3 1. 79 2.3 V 5.26 V 

34 1. 6x10 -2 12.0 7.4 4.7 V 10.5 V 

49 
Table 3.1-7 gives the required length of wire and the required 

voltages for power dissipation of 15 watts and 3 watts. The 

o 

nichrome wire length is chosen such that temperature of 1100 K 

o 

at 3 watts power and 1645 K at 15 watts power, are maintained. 

The analysis above considers the heater requirements with 

reference only to a suspended coiled wire and was derived to 

determine the wire wound heater design parameters. These 

indicate that a wire wound heater can be designed that allows the 

heater conditions to be met. The wire wound heater is a 

preferred approach and will satisfy the experiment requirements. 

The heater design will require development into a structural 

unit. 

We have identified an available space qualified heater which 

meets the requirement to supply up to 20 watts of power. This is 

a catalyst bed heater that is used in TRW satellite programs and 

is well tested and space qualified. Figure 3.1-11 shows the 

design of the heater that can be modified to meet our 

requirements. The heater is available at resistances 208, 257 

and 273 ohms, and operates on both 110 Vac or 28V DC voltages. 

With the 208 ohms resistance heater, the heater power dissipation 

of 3 to 15 watts can be obtained with voltage drops across the 

heater of 25 to 56 volts. This heater will satisfy all 

requirements when used with an efficiently designed reflector. 

50 
A critical parameter is the time for the heater to reach 

steady-state temperature. The transient analysis of the wire 

heater shows that the heat-up time for a suspended wire is 6-7 

seconds. An actual heater has other support structures which 

increase the thermal mass of the heater system. For the catalyst 

bed heater chosen in this design the support structure consisting 

of insulation, inconel housing and lead wires increases the 

thermal mass of the heater by an order of magnitude. This in 

turn increases the time to reach a steady temperature to one 

minute. The duration of the surface tension experiment is 40 

minutes and longer. The heater start-up transient is 

small compared to experiment time and it is not expected to 

appreciably effect fluid motion measurements. 

3.1.4.6 Heater Design 

The catalyst bed heater chosen for the surface 

tension experiment (Figure 3.1-11) is 1.25 inches long and 0.125 

inch in diameter. 

INCONEL eoo END DISC 

PLASMA ARC WELD -

INCDNELeoo 

HOUSING 

ELEMENT WIRE NICHIIOME Y 

(0.0028-0.003 DIAl 

2~ES ~~;~~~~~~~~~~~~~~~~~ ~ a:;~~~~~~~~~O.125" 

INCONELeoo 

END PLUG 

IttSULATION MID 

1. 25" 

Figure 3.1-11. SPACE QUALIFIED CATALYST BED HEATER 

FOR SURFACE TENSION INDUCED CONVECTION 

EXPERIMENT 

51 
The heater must radiate symmetrically on a small surface area, 

use a minimum of power, and maximize radial temperature gradient 

across the liquid surface. To shape the heat at the fluid 

surface, a parabolic reflector is required. The reflector must 

be designefd to conform to required heat distribution as defined 

for the experiment practical. 

Figure 

figure 

3.1-12 shows the experiment container with the heater 

3.1-11 mounted vertically over the liquid surface. 

of 

The 

heater is mounted rigidly to the reflector and isolated from the 

reflector structure. The parabolic reflector is placed around the 

heater to concentrate the reflected radiation to an area at the 

center of the liquid surface. The design of the reflector will 

determine the initial heat distribution across the cell. The 

modelling considered 70% of the heat to be put into a O.scm 

diameter area at the center of the fluid surface. The reflector 

design 

Further 

will be dependent upon the required heat distribution. 

analysis must be performed during the detailed design 

phase to finalize the reflector configuration. 

3.1.5 Experiment Operation 

The requirements that must be maintained during experiment 

operation· are listed in Table 3.1-8. The experiment operation 

requires the gravity be maintained at a low steady level with no 

perturbations during the experiment. The experiment fluid must 

be within a temperataure range that maintains vapor pressure 

compatable with the STS atmosphere purity. 

52 
I .8 

2.0 12>----j 

+ 

I .25 

. , ! 1"""------------...::::::::..., r : 

I 

I! 

I ! 

! ! 

I 

i 

Figure 3.1-12. THE HEATER MOUNTED ON TO THE 

EXPERIMENT CONTAINER 

53 
U1 

~ 

Table 3.1-8 EXPERH1ENT OPERATION REQUIREt4ENTS 

REQUIREMENT SOURCE/COMMENTS -----

V-l TEMPERATURE - At1BIENT • PI REQUIREMENT IN RFP 

PRESSURE - AMBIENT 

V-2 FLUID STORAGE TEMPERATURE • DERIVED REQUIREMENT 

25 ± 5°C 

V-3. G - LEVEL < 10- 5 • PI REQUIREMENT IN RFP 

• AC FLUCTUATIONS IN G-LEVEL • BOND NUMBER IS 

DURING EXPERIMENT B 0-- = pGR2 < 0.8 

cr 

THUS ACTUAL G LEVEL DEPENDS ON 

FLUID PROPERTIES 

V-4 INITIAL CONTAINER 

TEMPERATURE AMBIENT 

V-5 MAXIMUM ALLOWABLE FLUID • SAFETY REQUIREMENT TO NEGATE 

TEMPERATURE < TSD ANY BOIL-OFF 

V-6 TOTAL EXPERIMENT VOLUME 

INCLUDING HARDWARE AND A MINIMUM CAt4ERA-TO-OBJECT 

DIAGNOSTICS - IN TWO DISTANCE DETERMINES EXPERIMENT 

LOCKERS VOLUME 

-

J 'J 

I KPLH1EtHATION 

• NO ACTIVE CONTROL 

• NO SENSOR 

• NO ACTIVE CONTROL OF FLUID 

TEMPERATURE 

• ESTABLISHED BY STS ORBITS AND 

ACTIVITfES 

• , 

• UNCONTROLLED 

• INTERLOCK FLUID TEMPERATURE AND 

HEATER OPERATION TO SHUT-OFF 

HEATER AT TBD = T (FLUID) 

• ANALYZE WEIGHT AND VOLUME FOR 

COt4PATASILITY 

~ J-------
U1 

U1 

.~ 

) " ) 

TABLE 3.1-9. DIAGNOSTICS REQUIREMENTS 

REQUIREMENT SOURCE/COMMENTS 

VI-l THERt·10COUPLES - • PI REQUIREMENT IN RFP 

4 REQUIRED • RECORD DURING EXPERIMENT 

VI-3 POWER TO HEATER 

VI-4 I LLUMI NAT! ON • SHEET OF LIGHT IN A MERIDIONAL PLANE OF CYLINDER 

• CONSIDER INTERNAL LASER COOLING 

REQUIREMENTS 

VI-5 VISUAL DATA • PI REQUIREMENTS IN RFP 

VIEWING TIME - 15 • FRA[11E RATE: 1 FPS 

MINUTES. with 1 HOUR 

CAPABILITY 

VI-6 DATA RATE O.l/SEC • SINCE TEMPERATURE AND HEATER POWER 

ARE TO BE MONITORED THE TEST. THE 

OPTIONS FOR DATA ACQUISITION ARE 

(a) DUAL IMAGE SPLIT FILM. AND 

(b) TAPE RECORDER 

VI-7 TIMING ± 1 SEC 

IMPLH1ENTATIOti 

• RANGE 10°C - 100°C CALIB/ 

PRECISION/ACCURACY EACH 0.5°C 

• MONITOR TO ± 10% 

.0 He/Ne LASER (5 MW) 

• CINE CAMERA I 

• 200 FT CASSETTE REQUIRED 

• TAPE RECORDER REQUIRED TO 

ACCEPT ACCELEROMETER DATA 

• TAGGED TO CAMERA OPERATION 
In the event of heater overvoltage an automatic shut-off can be 

coupled to a thermistor to power down the experiment to prevent a 

runaway situation. 

3.1.6 Diagnostic Instrumentation 

Table 3.1-9 gives requirements for experiment diagnostics. 

The specific diagnostics required are: 

1. Thermal sensors. 

2. Flow visualization and data recording 

3. Timing 

The implementation of these diagnostics, and data rates required 

are discussed in the following sections. 

3.1.6.1 Flow Visualization 

The experiment requires that the surface tension induced 

flow be visually determined and recorded. The objective can be 

met by mixing particles in the fluid and illuminating them with a 

laser and photographically recording the light scattered by the 

particles at 90 degrees from the beam. 

The suspended particles must have the following properties: 

o They should be small enough that they are carried 

with the fluid flow and do not suffer drag nor 

distort the flow. 

o On the other hand, they should be as large as 

possible to enhance observation. 

56 
~, 

( 

o The specific gravity of particle should be such 

that it will not settle in the selected fluid at 

the gravity levels expected. 

The number density of the particles must be low enough to allow 

observation of discrete events on film and to minimize secondary 

scattering. But, the number density must be high enough to 

produce sufficient scattered light intensity for recording. A 

study of particle and fluid properties relevant to the 

visualization of surface tension driven convective flow was 

conducted by Y. Kamotani and T. Kerslake at Case Western Reserve 

University (1983). Results of tests by these authors indicate 

that 1# alpha alumina particles in a concentration range of 3.0-

7.0 mg per liter give adequate flow visualization (see Appendix 

B) • 

3.1.6.2 Optical Recording 

Optical Train. The optical train is shown in figure 3.1-13. 

The light source chosen is a 5 mW HeNe laser, which is the 

highest power laser that can be accommodated within the 

experiment volume of a double locker. A 20 mW HeNe laser of 

similar design is already qualified for Spacelab use. The laser 

chosen can probably be qualified by similarity to the larger 

laser. The HeNe laser emits at 633nm, in the red. The light 

intensity should be maximized since the following analysis 

suggests the system may be intensity limited. 

57 
).·833 nm 

OBJECT 

PLANE 

FILM 

PLANE 

I j.... .._--340mm ---"~I 

~~=:.!.....::::.:..&='.,!,"'T,.g. 10 em 

r-fTI35mm - -----~CAMERA 

86mm LENS 

90° VIEWING ANGLE 

FIELD OF VIEW" 10.2 em x 7.8 em 

Fi gure 3.1-13. THE OPTICAL TRAIN FOR SURFACE 

TENSION INDUCED CONVECTION EXPERIMENT 

A cylindrical telescope expands the laser beam in one 

direction and transforms the laser output into a sheet of light 

that illuminates a narrow corridor through the center of the 

experiment container The beam expanding telescope is shown in 

Figure 3.1-14. It consists of a cylindrical concave lens (focal 

length = - 5 mm) and a cylindrical convex lens (focal length 

137 mm) separated by a distance of 132 mm. In the vertical (Y) 

direction, the 2 mm input HeNe beam diameter is expanded to 55 

mm, which fills the test cell height (50mm) and includes a 10% 

overfill. 

In the horizontal (X) direction the beam remains unchanged with 

an output beam width of 2 mm. The diameter of the concave lens 

is 10 mm. The diameter of the convex lens is large enough to 

accommodate the expanded beam of 55 mm and a mechanical lens 

mount (65 mm), The laser beam is shielded from its emission port 

through the telescope to eliminate any potential eye damage to 

the crew. 

58 
V-AXIS 

X-AXIS 

f.I.III-l!imm f.I.-137 mm 

2mml 

-, 

T 

55mm 

I----L 

2mmJ 

1 

r--- 132 mm ---"f 

:D~[}= T2mm 

f.I."'" 

f.l . .,; 00 

Figure 3.1-14. SKETCH FOR EXPANSION OF HeNe 

LASER BEAM 

The sheet of light passes through the cell and illuminates 

the entire 10 cm cell diameter with 2 mm thick plane. A 35 mm 

movie camera with a 65 mm f/3.5 lens views the scattered light at 

90 degrees from the plane. 

The Camera. The surface tension induced convection exper-

-4 

iment requires operation at 10 g or less for one hour, to 

maintain this low g level requires that film not be changed. The 

experiment dynamics require only a framing rate of l/sec or less. 

The camera selected is a special modification (4 - S) of the 

Photo-sonics 35 mm 4ML which has a frame rate of one frame per 

second (fps) and a maximum allowable exposure time of .4 

seconds. The camera must be capable of recording information on 

ft. cassette if thin-based film is used. The camera also has a 

built-in data recording system allowing digitized data 

(temperature and time) to be displayed in a 7 segment format on 

individual frames. The camera runs on 28 V and requires 56 W to 

start and 13 W to run. The Photo-sonics 35 mm 4ML camera has 

been used in space applications previously. 

59 
The rate of film exposure will be a critical factor to this 

experiment. The exposure rate should be such that only one film 

cassette is used during an entire experiment. Optical alignment 

simplicity is achieved through a small camera-experiment distance 

with both hard-mounted and aligned preflight. In this 

configuration, changing the film in flight will induce 

significant fig" jitter into the fluid cell and induce extraneous 

flow. A frame rate of 1 per second is consistent with the 

analysis of flow rates and will not degrade the experiment data. 

Imaging Considerations. The distance between the object 

plane and the film plane of the camera has been set at 340mm or 

less by constraints of available space. This distance is the 

least acceptable that will give a field-of-view of the entire 

test volume and still minimizes wide angle distortion 

characteristics of short focal length lenses. The film format 

for a 35 mm movie camera film is 24 mm x 18 mm and to image an 

object 340 mm away, a 65 mm focal length lens is required. The 

0 0 

angle of view is 20 x 16 and the field of view is 10.2cm x 7.6 

cm which covers the test cell • 

• 24 .. 

Film and Exposure Time. 

The magnification is 24 mm/102mm 

Y. Kamotani and T. Kerslake (K&K) 

(Appendix B) obtained photographs of particle movements induced 

by surface tension driven convective flows. A comparison of 

their experimental parameters with the parameters recommended in 

the proposed design are listed in Table 3.1-10. 

60 
Table 3.1-10 COMPARISON OF EXPERIMENTAL PARAMETERS 

ASA Rating Shutter Speed Aperture Laser I 

Power 

Density 

K&K Test 3000 3 sec f/8 IX 

Proposed Design 250 1/2 sec f/2.8 6X 

500 " f/4 " 

1000 " f/5.6 " 

2000 " f/8 " 

Their light source in the laboratory was a diverging 5 mW HeNe 

laser beam which we estimate used approximately 1/6 of the 

available wave front. The power densi ty a vaila'b I e in an 

efficiently designed system gives a collimated beam that is at 

least 6 times the laboratory power density. This is an advantage 

of 3 camera f-stops. However, their exposure times (3 sec) are 

longer than the exposure times ( 1/2 sec) allowed by the Photosonics camera, a disadvantage of 2-1/2 f-stops. The design has 

an overall 1/2 f-stop advantage. Acceptable values of film speed 

and aperture settings are listed. The ASA-rated film required is 

commonly available. Note however that there is little intensity 

margin in the 5mw HeNe laser. The highest power laser that can be 

accomodated should be used to maximize light intensity. 

Background Considerations. The fluid must be free of 

contaminants, which can serve as unwanted scattering centers that 

can overwhelm the image and destroy the contrast. Also the 

particle number density must be kept low enough to prevent 

multiple scattering. 

61 
.1) 

Film Format Choice. Use of a 35 mm I 

camera has 

advantages over the use of a 16 mm camera. The 35 mm film format 

(24 mm x 18 mm) has 4 times the area of the 16 mm format (12 mm x 

9 mm) allowing better resolution because the information is not 

as compressed. The fast films and fast lenses are required for 

the experiment due to low light levels and a greater variety of 

high speed film and lenses are available for 35 mm cameras. 

Likewise, a greater number of black and white film types with 

extended red sensitivity are on the market for 35 mm and these 

are more sensitive to the red light specified. 

3.1.6.3 Thermal Sensing 

Thermistors with a temperature range of 0-100 Care 

specified. Thermistors are chosen since they simplify the 

electronics and are conveniently designed into the system. 

Thermistor insertion is shown in Figure 3.1-2a. The temperature 

from each thermistor will be sensed a rate of once every four 

seconds. 

3.1.7 Experiment Timeline 

The experiment timeline is divided into three steps. The 

first is a preparation step, during which the experiment is 

activated and the system placed in a test-ready position. Upon 

verification of the experimental conditions, the test is 

initiated in the second step. The sequence of events which takes 

place during this step is designed to meet the science 

requirements. 

62 
Thus the power to the heater is controlled, at predetermined 

times relative to the heater. The third step is the termination 

step in which all systems are secured for stowage and return. 

The list of operations in each one of the steps is given in 

the experiment timeline in Table 3.1-11. 

Table 3.1-11. SURFACE TENSION INDUCED CONVECTION 

EXPERIMENT TIMELINE 

Experiment Preparation I 

Power On 

- Instruments On 

o Power Meter 

o Temperatures/ 

Pressure 

- Illumination On 

- Camera Ready 

- Activate Liquid Solenoid Valves 

- Fill Cell to Required Level 

- Heater Activated 

- Verify Experiment Conditions 

o Fluid Quiescent 

o Illumination Constant 

3.1.8 Thermal Control 

I Initiate and operate Experiment I 

- Start Camera 

o Time On 

- Activated Heater to TBD Watts 

- Operate Camera Continuously 

at 1 FPS for 15 Minutes 

- Heater to TBD Watts 

- Camera Operate for 15 Minutes 

- Change Heater to TBD Watts 

- Camera Operate for 15 Minutes 

- Heater Off 

- Stop Camera 

I Stop Experiment I 

- Instruments Off 

- Lights Off 

- Power off 

- Heater Raised 

- Plug Liquid Container 

Secure Experiment and 

Container for Landing 

For the container no active thermal control is required. 

Subsystems requiring heat rejection include: 

o Power supplies 

o Camera power 

o Heater casing 

63 
Specified method of heat rejection is a muffin fan of the 

Rotran Spartan Series installed on the structure wall. This fan 

will circulate cabin air through the experiment volume. The 

heater air will exit through vents in the structure door, or, if 

available the backside. Ducting to the component surfaces may be 

required. Adequacy of the specified uni~ should be verified by 

additional development tests. 

3.2 SYSTEM ELECTRONICS 

The design for system electronics for the Surface Tension 

Induced Convection Experiment is based upon operating procedures 

developed in Section 3.1.7. 

An electronics block diagram for the experiment is shown in 

figure 3.2-1. The electronic approach features the following: 

o Manual control of the experiment process. 

manual on/off 

o Switches wherever feasible. 

manual operations of valves for fluid flow 

o Temperature sensor readout on film out of scene area and 

utilizing internal camera functions. 

o Timing control on the camera out of the scene area. 

o DC heater selection of four powers; nominally 2 w, 5 w, 10 

w, 15 w. 

In operation the master on/off switch activates all units. This 

switch turns on the fan and laser which operate continuously. 

.~ ! 

64 
(' 

\ 

FRONT PANEL 

SOLENOID 

ON/OFF 

b 

1 

NO.2 NO.1 

HEATER SELECT 

5_W I "'---~1Q.!~W~ 0 2 W 

--~~ ~W c OFF 

CAMERA 

ONIOFF 

6 

c) 

,. ~r -. "'1 CAMERA I"'" 

HEAT~ER~+-__ ~_~~-J 

R SISTOR 

I 

I 

r-----n 

,J, I -;:[ :t,MERA I- ~I ~ 

I Lr TIMER r 

r I ANALOG ~"'~ 1 ... I-+---I 

I -SIGNAL I 

PROCESSOR 

- -,-

I-'- L

I : MUL TI;LEXER I ____ J 

FAN -. 

I~ 

LASER -. 

I 

+5V DC I 

SUPPLY ~ 

±15 VDC 1 

SUPPLY 1 

+56VOC 

HEATER ....- SUPPLY 

MASTER t}- ON/OFF 28VPRIMARY 

r- FROM 

6, SlL 

'--

~ +5V 

~I-' 

~f­

...i.fSENSORS SOLENOID 11----1-[7,-0"'1-' 0--1----... 

NO.1 r I~ 

SOLENOID 11-_-+-_I--lY1 n-...... ---.... 

NO.2 I I ~v 

~------------------.... 

Fig. 3.2-1 SURFACE TENSION INDUCED CONVECTION ELECTRONIC BLOCK DIAGRAM 

65 
The particle mixer is activated and mixes 

defined period. Once the master switch 

continuously for a 

is activated the 

experiment can be sequenced manually 

operations. 

through control panel 

A typical control panel is shown in Figure 3.2-2. The fluid 

fill is activated by two solenoid valves. It is planned that 

the pressure will be preadjusted and no inflight change will be 

necessary. However, If the fill rate is inappropriate the drive 

pressure can be adjusted at the panel. 

When the cell is filled with fluid the solenoids are shut off. 

The heater power is set to position 1, and the camera and heater 

are activated manually. After the appropriate heating time the 

heater and camera are turned off. Then a second heater power is 

selected, and the experiment operated. This cycle occurs until 

all heater powers required are activated. During camera 

operation it receives one thermistor datum or a time marker per 

frame. This results in each sensor being recorded every five 

seconds during the heating process. The' temperature sensors 

produce analog data. This data is mUltiplexed and is then 

channeled through the camera interface unit. From there it is 

sent to the camera where it is recorded as part of the film 

record. The use of the camera for data recording eliminates the 

need for a data recorder. 

66 
MASTER 

ON 

FLUID FILL 

STOP 

FLUID 

0 

PRESSURE 

CELL 

GAS 

NO. t 

HEATER POWER 

15MIN. 

0 

HEATER 

WARNING 

Figure 3.2-2. TYPICAL CONTROL PANEL 

67 
The estimated power consumption has been estimated based 

upon the above design. 

experiment are: 

The power for two cell fill and 

I. Cell Fill Operation 

Fan 

Motor (Stirrer) 

Valve Operation 

II. Experiment Operation 

Camera 

Heater 

Motor 

Fan 

Electronics 

34 watts 

15 watts 

5 watts 

56 watts 

20 watts 

15 watts 

34 watts 

20 watts 

-54 watts 

-145 watts 

Mid-deck power available to the experiment will range from 165 

watts to 224 watts dependent upon the bus used. A secondary 

consideration is that the current to all sources be less than 5 

amps -if possible. The current design of the Surface Tension 

Induced Convection Experiment is within these constraints. 

68 
(~ 

I 

3.3 EXPERIMENT LAYOUT 

A layout of the experiment is shown in Figure 3.3-1. A 

corresponding isometric view of the experiment including major 

components is shown in Figure 3.3-2. The experiment is packaged 

into the volume of two adjacent lockers which contain both the 

experiment hardware as well as the control electronics and the 

data acquisition system. The specific layout provides: 

o A full field of view of the cell plane at the camera. 

o Access to the cell through the window (or door in the 

front poanel). 

o A window to view the cell. 

o Shielding of laser light from the crew. 

o Mechanism to fill the gas pressure bottle and the 

accumulator after assembly with the front panel off. 

o Pressure control at the front panel. 

o A fully enclosed system under operating conditions. 

The window will be removable so that the crew can gain entrance 

to the experiment interior. This will accommodate any in-flight 

adjustments that may be required. A door can be provided if 

desired to have greater access. Under manual operating minimal 

access is antipicated. Should multiple cells be indicated in the 

future cell units can be interchanged using a quick disconnect. 

Additional storage must be provided. 

69 
-..J 

C> 

H 

G 

F 

E 

lEn 

CELL 

... IT._---..... 

'0' TAM 

,C 

8 

'.ER ~ONER SU~PL Y 

~ II ......... _.S£. lUll EX~.IIO£R 

LECT.DHICS ~KG 

_011£ ~L""'I. IENDWED rllll CLARITY 

~n 

fRONT VIEII nOIT ~'NEL RENDYED FOR CLA.ITY 

.. T.OI. "'II[L 

FRONT PANEL DETAIL 

DOLING AIR EXIT 

UER MOTOR 

SIDE VIEW '-LIQUID NETERING VALVE 

C'NERA. LASER. POWER SUPPLIES. 'NO TURNING FLU REMOVED FOR CLARITY 

H 

G 

F 

E 

o 

,c 

8 

~I-I'" 

. - ~tDN 

r~lf~~j I ~:;;m~!b. __ 1'1 ImEl-I.I. * _. _ _ __ 

¥ _~. __ 8 1 6 5 , 4 I ~ 

Fig. 3.3-1 SURFACE TENSION INDUCED CONVECTION EXPERIMENT LAYOUT 

,) J -) 
'-I 

..... 

-') 

FLUID 

ACCUMULATOR 

PRESSURIZED 

GAS 

ADAPTER 

PLATE 

SOLENOID 

VALVES 

TEST CELL 

~) 

LASER 

LASER POWER 

SUPPLY 

" > < ELECTRONICS 

FAN 

'< \ 'b&~ IF'>" ~ II OPTICS 

~>? ~ FILL PORTS 

Figure 3.3-2 Surface Tension Induced Convection 

Experiment Isometric Drawing 

) 
The current design uses a 35mm camera. The reasons for this 

are detailed in 3.1.6. The camera is a design driver in both 

dimension, volume and mass. The camera is accommodated in this 

design only by fitting it diagonally in the two locker volume. 

Due to the predicted exposures of up to seconds the camera must 

be stabilized and vibrations of the test container relative to 

the camera must be eliminated in the design. 

A list of major subsystem and parts are given in Table 

3.3-1. 

3.4 WEIGHT ESTIMATE 

The weight is estimated based upon the experiment design. 

The weight of identified components are given in Table 3.3-1. 

Weights for items reqiring detailed design such as 

0 optical assembly including the laser 

0 fluid storage 

0 cell 

0 fluid drive assembly 

0 power supplies 

0 optics 

0 enclosure and door 

are estimates based upon current design philosophy. Therefore 

the total weight given below is only a preliminary estimate. 

72 
(~ 

Table 3.3-1 Surface Tension Driven Convection Experiment Major Equipment List 

COMPONENT DIMENSION 

Experiment 

Container 12cm x 12cm x Bcm 

Fluid Accumulator 

(Fluid Storage) 6.7B(d) x 39cm 

Gas Storage 35.6 x 5.0B(d)cm 

Camera (35mm) 13.7 x 31.1 x 14.9cm 

Illumination 

Laser 5 mw 4cm x 4.42cm dia. 

Optics 73.2 x 7(dia)cm 

Heater 1.0(d) x 4.50 

Power Supplies 15cm x 26cm x12cm 

Fan 7.6cm(dia) x 3.B 

Mixer Motor Small 

Cylinder Valve Small 

Solendoid Valve Small 

Regulator Small 

Fill 'Va 1 ves Small 

Air Filter Small 

Metering Valve Small 

Flex Hose Small 

VOLUME 

1. x 10-3M3 

0.019M3 

7 x 10-3M3 

.6 x 10-3M3 

.6 x 10-3M3 

0.3 x 10-3M3 

Small 

4.7 x 10 -3 

2 x 10-3M3 

73 

TYPICAL 

SUPPLIER 

Fabricated 

Parker Hannifi n 

MAOl16B 

Whitey 

304-HDF4-500 

Photo-Sonies 

Spectra Physics 

TBD 

Fabricate 

Watco 

Special design 

Fabrication 

Roton 

Pittman Corp. 

Whitey 

SS-16DKM4-F4-A-RD 

Marotta Sc. 

MV100-206003 

TBD 

Whitey SS-l K54 

Nupro 

SS-41F2-15 

Nupro SS-4LA 

Crawford 

Upper SS-4HO-6-5 4 

Lower SS-4HO-1-54 
The adaptor plate weights used are those currently given in 

Reference 2.2. It is our understanding that two lightweight 

single adaptor plates weighing 3.5 lbs. each can b-eused instead 

of those specified. The double adaptor plate is not required if 

the appropriate structure is used. We estimate a saving up to 15 

lbs. using the lightweight adaptor plates and atachments to them. 

The weight as currently derived is about 105 lbs. The 

weight is within the 120 limit even using the heavier adaptor 

plates. In this design, the c.g. is within 10" of the attachment 

points as required. 

3.5 EXPERIMENT STATUS AND RECOMMENDATIONS 

The design of the Surface Tension Induced Convection 

Experiment reported here reflects the requirements as given in 

Reference 1.1 and Table 1.2 as modified at the Conceptual Design 

Review and incorporating later requirements changes. The 

experiment volume and weight are compatible with incorporation 

into a double locker in the STS mid-deck. Critical design 

drivers in the volume are: 

o Field-of-view (FOV) at the observation plane. Currently 

the whole cell diameter and the cell height are in the 

FOV. This 

Maintainence 

is accomplished using a 35 mm camera. 

-4 

of a 10 "g" level requires that the film 

not be changed during an experiment. This mandates a 

1fps rate for continuous experiment coverage. 

74 
o Maximize the laser power. The required exposure time will 

be dependent upon the light scattered by the suspended 

particles. This increases with the intensity of 

the laser. Thus the higher power the laser the more 

favorable the observation a five milliwatt HeNe laser is 

the largest unit that can be contained in two vertical 

lockers in any dimension. Results of the analysis and 

tests at CWRU indicate that 5 mw of laser power scatters 

sufficient light from a 3pm particie to sensitize the 

film. 

o Containment of all fluid within the experiment container. 

This is achieved by the close coupling of the heater 

housing to the container and plugging the container at 

the experiment conclusion if required. 

o Environmental Control. This is achieved through the use 

of a fan placed in the experiment structure. The fan may 

require ducting to heat sources such as the camera; the 

power supplies and the heater. Further analysis is 

required to determine the exact size and the weight of 

the fan. 

o Optical Alignment. Structural integrity must be provided 

between the film plane and cell to accommodate the 

anticipated exposure times. The detailed design must 

provide further vibrational analysis. 

75 
The power constraints for the mid-deck are met by this 

experiment. 

The areas of design that require further definition of 

requirements follow. 

Temperature Measurement. Four tempe!ature sensors can be 

accommodated by the camera. The position of these sensor must be 

specified to maximize experiment data • 

.3.6 SAFETY 

The Hazard Reports and the Safety Matrix are included as 

Appendix E. The major safety features that must be designed into 

the experiment are: 

o Protection from heater r~naway 

o Direction of laser beam 

o Fluid containment and use of non-flammable fluid. 

None of these is considered a major design driver. This is 

especially true at the reduced heater power. The heater will be 

protected against runaway by an automatic turn-off activated when 

a maximum power level is reached. 

The fluid selected must be compatible with STS operation. 

In particular, tests of fluorocarbon by-products must be made if 

this fluid is used. 

The laser beam is totally shielded from the crew through its 

expansion into a plane sheath. The laser light viewed at the 

container is below the threshold for eye damage. Further 

analyses must be made using final design parameters to verify 

this. 

76 
4. FREE SURFACE PHENOMENA UNDER REDUCED GRAVITY 

The concept and preliminary design of this experiment meets 

the science requirements as given in Reference 1.3 in so far as 

possible in the mid-deck arrangement. The arrangement of 

material in this report is the same as that in the sections 

concerning the Surface Tension Induced Convection Experiment 

(Section 3). 

The equipment functions are laid out in Figure 4-1. We 

follow the subsystem development as given in this figure. 

4.1 EXPERIMENT REQUIREMENTS, CONCEPTS AND PRELIMINARY DESIGN 

This section discusses the experiment requirements, 

describes the conceptual development and gives preliminary 

drawings of the subsystems and components. 

divided up into the following subsystems. 

The experiment is 

a) Experiment container 

b) Fluid 

c) Fluid Delivery 

d) Experiment operation 

e) Diagnostics 

f) Thermal control 

g) Storage 

4.1.1 ~eriment Container 

Table 4.1-1 gives the requirements and their implementation. 

A conceptual design and assembly technique for a container which 

meets the experiment requirements is shown in Figure 4.1-1. The 

container body (3) is made of a clear polymer material such as 

77 
'-J 

00 

~ 

Middeck 

28V 

10 AM 

Cabi 

air 

C 

PS 

.. , ..... Experiment 

Control 

Power 

Conditioning 

Lt Thermal 

Control 

Storage 

Electronics 

FUNCTION FLOW -------------

.... Thennal .. Measurement .... - J 

.. Optics 

I ..... ~ Optical 

Measurement 

Fluid 

Del ivery .... 

T ...., Fluid 

Control 

~·I E C ~ X I 0 

I P .N 

I E T 

-;. R I 

I I N 

f M E 

.... ' E R 

H N 

T 

~ 

Experiment 

Enclosure 

Fi gure 4-1 FREE SURFACE PHENOt·1ENA EXPERIMENT FUNCTION FLOW 

'JI 

. 

-

) 
........ 

\.0 

--) ~) 

TABLE 4.1-1 EXPERIMENT CONTAINER (CONT.) 

REQUIREMENT SOURCE/COMMENTS 

1-6 SURFACE MATERIAL COMPAT- I MATERIAL MUST BE APPROPRIATE FOR 

IBLE WITH CONTACT ANGLE CONTACT ANGLE 

I SHUTTLE CONSTRAINTS WILL LIMIT 

AVAILABLE MATERIALS 

• DEVELOPMENT TESTS INDICATED 

1-7 FLUID HEIGHT RESOLUTION • MEASUREMENT OF FLUID DISTRIBUTION 

± TBD CM. AS A FUNCTION OF TIME 

1-8 EVEN FLUID OVER ENTIRE • FLUID MUST ENTER ENTIRE FILL AREA 

BOTTOM SURFACE UNDER LOW GRAVITY 

1-9 MEASUREMENTS OF FLUID I FLUID SHOULD BE AT AMBIENT AND 

TEMPERATURE TEMPERATURE CHANGES ARE NOT 

EXPECTED 

1-10 FLUID CONTAINMENT I SHUTTLE IMPOSED CONTAINMENT OF 

ACCIDENTAL SPILL 

-

~) 

IMPLH1ENTATION 

• MATERIAL - TBD 

I PLEXIGLASS IS TO BE £ONSIDERED 

I INSCRIBE MESH PATTERN ON THE 

OUTER SURFACE 

I USE A POROUS FLOW PLUG, e. g. , 

DYNALLOY FILTER MEDIA , , 

• EXPERIMENT BEGINNING - END ONLY 

• OUT OF LIMIT TEMPERATURE ALERT 

• USE OF DOUBLE WALL VESSEL TO I 

I 

CONTAIN FLUID 

I 
/ 

I 

/ 

/ 

I 

/ 

/ 

... 

80 

...... , 

o::J-

<lJ 

s... 

:::s 

en 

.... 

u... 
~ .. I 

,~ 

I 

polycarbonate or acrylic. The material must be transparent to 

the illumination and transmit the fluid image to the camera. The 

cell length is determined by the maximum dimension that is 

accommodated by the experiment volume. This determined the 45 cm 

length. The container body (3) is fabricated is made by 

injection molding or by cementing the two halves (1) and (2) to 

form the body (3). The accuracy and sharpness of the interior 

angles of the container and the interior smoothness of the 

container walls are critical to the experiment operation. The 

accuracy and the smoothness criteria have not been defined. The 

top cover (4) is used to contain the fluid with the cell but 

includes a 1mm breathing part to allow for the displacement of 

air as fluid flows into the test cell. The bottom (5) consists 

of a porous metal frit which will allow even flow of liquid over 

the bottom. A container base (6) contains the interface between 

the vessel and the feed system to be shown later and space below 

the frit. 

r*;.j~ • ., 

- T ,.., 

A • 

1 

1 

1=::: :::::::J 

Fi gure 4.1-2 OVERFILL 'CONTAINMENT VESSEL 

81 
An overfill volume for the experiment container is 

the 

the 

schematically 

test cell so 

shown in figure 4.1-2. This is placed over 

that liquid that does penetrate through 

breathing part is contained. This volume does not accommodate 

the total· cell volume since there should be minimal overflow 

through the 1 mm hole. 

The container design is shown in Figure 4.1-3. The features 

on the cell not previously discussed include 1) a 1 mm breathing 

port to the STS environment that will be plugged with glass wool 

and 2) the quick disconnect to .the fluid feed. 

4.1.2 Fluid 

Table 4.1-2 summarizes the test liquid requirements and 

implementation. The contact angle between the liquid and the 

container is a key parameter in the experiment, and the selection 

of the fluid is dependent upon the test cell material. In 

addition, the liquid has to satisfy all the safety requirements 

imposed by the shuttle environment. The most promising candidate 

liquids are, Fluorocarbons or sicicon oils. A partial list of 

fluorinert (TM) and silicon oil fluids is given in Table 3.1-4. 

The fluids in that table were selected for their high boiling 

temperature. Liquids in this experiment see only ambient 

temperatures. However, a low vapor pressure is a requirement and 

these fluids satisfy that requirement. The fluid selection must 

be made in combination with the selection of the experiment 

container material. 

82 
[F I, 

I :z , <!I 

S ....... 

V'l 

at Z l.LJ 

uX Cl r! a:: 

l.LJ 

:z 

- ~ 

, -lHI.1a- . ....... 

- c:( 

f- ... Z 

~ 0 

u :; 

E M 

I 

.-I 

'<T 

I IF H~ Ol 

.~ 

LL. 

I 

/-'""" I 

I '.'~- ...,. 

I . , .. 83 
00 

+::> 

Table 4.1-2 FLUIDS 

REQUIREMENT 

II-l CONTACT ANGLE 58 0 ± 30 

II-2 4 EXP - VOLUME - 562 CM3 

(1/4 TUBE VOLUME PER 

EXPERIMENT) 

11-3 LIQUID LEVELS MUST BE 

RECORDED DURING 

EXPERIMENT 

11-4 SHUTTLE COMPATIBLE FLUID 

" 

,.) 

SOURCE/COMMENTS IMPLEMENTATION 

• RFP AND PREVIOUS PI ANALYSIS • STUDY USE OF FLUOROCARBONS 

• CONTACT ANGLE IS FLUID - MATERIAL AND/OR SILICON OILS 

DETERMINED 

• ANY ADDITIVES MUST BE INCORPORATED 

INTO CONTACT ANGLE EVALUATION 

• WATER - ETHANOL USED PREVIOUSLY 

• 4 X CYLINDER VOLUME • DESIGN 700-750 CM 3 VOLUME 

• NO FEED LINES INCLUDED 

• LIQUID SHOULD HAVE COLOR OR • DISSOLVE SMALL AMOUNT OF DYE IN 

SIGNIFICANTLY DIFFERENT INDEX THE FLUID TO GIVE DARK COLOR 

OF REFRACTION 

• FLUID MUST NOT BE ADMITTED AT • USE INERT - NON-TOXIC FLUID 

HIGH CONCENTRATIONS OR AT TOXIC WITH A LOW VAPOR PRESSURE 

LEVELS IN MID-DECK 

J J 
co 

()'1 

-~, 

) -j 

TABLE 4.1-3 FLUID DELIVERY SYSTEM 

REQUIREMENT SOURCE/COMMENTS 

111-1 DELIVERY RATE RANGE - • CONSTRAINED BY TWO FACTORS 

TBD CC/MM - TBD CC/MIN - INSURING THAT FLUID COVERS 

TOTAL PLATE - FLUID SHOULD NOT LAG SURFACE 

CLIMB RATE AND BREAK THE SINGLE 

LIQUID VOLUME 

III-2 FLUID DELIVERY ACCURACY • NOT REGARDED AS CRITICAL ISSUE 

± TBD CC/MIN 

111-3 FLUID VOLUME 750 CM3 

• SEE 11-2 

• TRADE PACKAGING SHAPE AND STROKE 

VS ACCURACY IN FLUID DELIVERY RATE 

.' 

-) 

IMPLH1ENTATION 

• PISTON AND CYLINDER FORCED FEED 

SYSTEM 

• MOTORIZED DRIVE WITH ON/OFF 

SWITCH 

• PRE-DETERMINED TIMING 

• BASELINE SINGLE FEED RATE FOR 

ALL EXPERIMENTS 

FEED CYLINDER DIMENSIONS IN 

CENTIMETER 

DDt 1 on I011lReter LenGtJI 

1 5 H.G 

2 10 7.2-

3 15 3.2 
The fluid for the experiment can have a small amount of a dye 

dissolved to enhance contrast between the fluid and the container 

walls. 

4.1.3 Fluid Delivery System 

Table 4.1-3 gives the fluid delivery system requirements and 

implementation. The delivery system des~gn for this experiment 

is the same system described in the surface tension driven 

convection experiment. An alternate system is the use of a 

stepper motor drive. A conceptual delivery system as applied to 

the Free Surface Experiment is shown in Figure 4.1-4. 

The fluid drive mechanism is connected to the experiment 

container via a quick disconnect. The Free Surface Experiment 

has a porous plate to given even flow over the entire experiment 

bottom. The analyses in Appendix A applies and the Weber Number 

must be less than four. The pore size also determines the 

pressure required to drive the liquid. The smallest pore size 

conistent with the pressure that can be applied will result in 

the highest velocity. Typical pore sizes of 20 ~m will result in 

3 

a velocity of 35 cm /sec. The limiting flow rate will be of this 

order of magnitude. 

The flow rate required to perform this experiment has not 

been determined. If the fluid climbs the walls there must be a 

kinetic rate asociated with this phenomena. A very fast fluid 

rise time is indicated in drop tower tests which may not be 

consistent with the limited flow rate. 

86 
(~ 

/"-" 

a:: 

(5 

> a:: 

w 

U) 

w 

a: 

-' -' ;: 

a:: 

w 

Q 

Z .::; 

> u 

ti 

~ 

87 

l3 ~w u Z 

-z =»0 

o~ 

is 

a:: 

0 

b 

:& 

8 

a: 

w 

Q 

! 

-' 

> U 

Q 

3 

S! 

-' 

I0... 

LLJ 

U 

Z 

0 

u 

::E: 

LLJ 

lV') 

>-

V') 

>-

c:: 

LLJ 

> 

..... 

....J 

LLJ 

Cl 

Cl 

..... 

::l 

....J 

IJ... 

oo:!" I 

roo:!" 

<lJ 

s... 

:::l 

C'l 

.,... 

IJ... 
Further analysis and tests must be performed to determine the 

appropriate velocity and its method for achievement. 

A further parameter requiring determination is the minimum 

depth between the porous plate and the bottom. (Fill resorvior 

Figure 4.1-4). This distance should be such that it minimizes 

bubble formation and maintains flow conditions. Bubbles are 

undersireable but need not be rigidly excluded. The fluid drive 

system specified is the same as for the Surface Tension Induced 

Convection Experiment. 

4.1.4 Experiment Operation 

The experiment operation requirements and implementation are 

summarized in Table 4.1-4. The orientation of the test cell 

within the experiment structure, affects the g levels that seen 

by the fluid~ The acceleration forces acting on the Shuttle 

during orbit can be broken down into forces due to drag (parallel 

to the direction of motion), earth gravity and vibrations. The 

magnitude of all of these forces depends on the specific activity 

and the orientation and flight maneuver of the Shuttle. The test 

cell should be oriented such that the highest g-level will be 

aligned parallel with the long axis of the cell during the test. 

-5 

It is also required that the g level be 10 during the 

experiment. This may not be achieved in mid-deck on all flights. 

88 
00 

~ 

-) 

TABLE 4.1-4 EXPERIMENT OPERATING CONDITIONING 

REQUIREMENT SOURCE/COMMENTS 

IV-1 a) TEMPERATURE, • PI ANALYSIS 

AMBIENT 

• PI ANALYSIS 

b) PRESSURE, AMBIENT 

IV-2 6, LEVEL < 10-5 

• PI REQUIREMENT 

B = pgL2 = 10- 3 

0 (J 

(p = DENSITY; 9 = GRAVITY LEVEL; 

. L = CHARACTERISTIC LENGTH; (J = 

SURFACE TENSION) 

IV-3 USE NO MORE THAN TWO • RFP MID-DECK LOCKERS 

• MAINTAIN SIMPLICITY 

• OVERALL VOLUME 

H X L X 0 = 27.3 X 43.5 X 51.6 

IV-4 VIEW EXPERIMENT CON- • PI ANALYSIS 

TAINER WITH FLUID FROM 

TWO DIRECTIONS DURING 

FLUID FILL ' .. 

--'----- ----- -------

IMPLEMENTATION 

• NO THERMAL CONTROL OR CHAMBER 

SENSOR 

• NO PRESSURE SENSOR 

• ESTABLISH BY STS STABILITY 

• ACCELERATOR REQUIREMENT TBD 

• USE ONE LOCKER FOR EXPERIMENT 

EQUIPMENT 

• USE SECOND LOCKER FOR ELECTRONICS AND CONTAINER STORAGE 

• FOV TO BE WIDE AS POSSIBLE BUT 

LH1ITED BY OVERALL PACKAGE 

DIMENSIONS 

• USE MIRRORS TO VIEW 2 ANGLE '0' 

• BACKLIGHT CONTAINER USING TBo 

LIGHT SOURCE 

L-_ - -----~-~-~ ----- --- --
~ 

o 

TABLE 4.1-5 DIAGNOSTICS ' 

REQUIREMENT 

. TEMPERATURE MEASUREMENT 

AT START OF TEST 

VIEW EXPERIMENT FROM TWO 

ANGLES DURING 

EXPERIMENT TIME 

ACCELERATION 

J 

SOURCE/COMMENTS 

• PI REQUIREMENT 

• MAKE SURE THAT NO THERMAL GRADIENTS EXIST WITHIN THE TEST CELL 

(USE "COLD" BADKCGOUND ILLUMINATION) 

• LIQUID CLIMB REQUIRES .1 SEC 

ACCURACY 

• AFTER COVERING BOTTOM HOLD ONE 

MINUTES 

• FILM THE EVENT AT MAXmUM POSSIBLE 

FRAME RATE FOR A SHORT PERIOD 

OF TIME 

• TBD 

• HEASURE ACCELERATION IN 3 AXIS 

'J 

" 

IMPLH1ENTATIOH 

• SINGLE THERMOCOUPLE RANGE 

10-50oC 

• USE FLUORESCENT LAMP SOURCE 

• PHOTOGRAPHY METHOD OF CHOICE 

• TRADE 16 MM VS 35 MM CAMERA 

• CAMERA FIXED POSITION 

• FILM FOR FOUR EXPS PREFERABLY 

CONTAINED IN SINGLE MAGAZINE/ 

CASSETTE 

• ALWAYS RECORDS TWO VIEW SPLIT 

FIELD OF VIEW 

• CAMERA S.YNC TIME 

• PROVIDE A 3-AXIS ACCELERATION 

DATA TO BE RECORDED DURING 

TEST RUN 

J 
~, 

( 

4.1.5 Diagnostics 

The summary of the diagnostics requirements and 

implementat~on is given in Table 4.1-5 

4.1.5.1 Temperature 

No thermal gradients can be induced along the long axis of 

the test cell. Only one temperature reading is required that of 

the ambient air. A "cool" light source can be used. Appendix D 

describes qualified florescent lamp system which meets the 

requirements. The ILC lamp 

temperature of 45 C or less. 

experiment requirements. 

4.1.5.2 Photgraphy 

is space-qualified and has a touch 

This lamp can be built to meet the 

The entire length of the test cell must be viewed during the 

experiment. This means that the cell length may be contained by 

the field -of-view. In the two lockers arrangement the camerato-cell distance is optimized at about 18" (45.7 cm) and analyze 

the field-of-view (FOV). FOV and the depth-of-field (DOF) are 

calculated for two formats, using 16mm or a 35mm camera. The 

film area is 1.02 cm x 0.742 cm for a 16 mm camera and 2.4 cm x 

3.6 cm for a 35 mm camera. Since the experiment does not require 

special close-up capabilities, the standard circle of confusion 

of c=O.OOl" is assumed. Comparison between the two formats is 

given in Table 4.1-6. 

The results indicate that the 35 mm camera is preferred 

since it has larger FOV (due to larger format). A 16 mm camera 

91 
Table 4.1-6 

COMPARISON BETWEEN FIELD-OF-VIEW 

AND DEPTH-OF-FIELD WITH TWO DIFFERENT 

FORMATS* 

16 nun camera 35 nun camera 

lens FOV lens FOV 

focal length (nun) in em focal length (mm) in em 

(magnification) Depth-of-Field (magnification) Depth-of-Field in em in em 

10 30 x 40.6 18.5 85.7 x 57.1 

(0.0224) 22.8 to info (f/22) 

41.8 to 50 (f/2) (0.042) 29.6 to 100 (f/22) 

43.5 to 48.1 (f/2) 

12.5 25.4 x 38.1 25 62.2 x 41.4 

(0.0281) 25 to info (f/22) 

42.6 to 49.3 (f/2) (0.0579) 32.6 to 76.4 (f/22) 

44.1 to 47.4 (f/2) 

16 11.1 x 8.0 28 55.1 x 36.8 

(0.0363) 28.1 to 123. (f/22) 

43.2 to 48.5 (f/2) (0.0653) 33.6 to 71.3 (f/22) 

44.2 to 47.2 (f/2) 

35 43.4 x 28.9 

(0.O829) 35.5 to 64.1 (f/22) 

44.5 to 46.9 (f/2) 

* All cases lens focused to 18" (45.7 cm) and circle of confusion on film 

is 1/1000". 

92 
r~ I ' i 

I 

~ 

with a wide angle (10 mm) lens has as wide·a FOV, but the demagnification is worse. The DOF is usually better for a 16 mm 

camera because of the smaller format. When a print is magified, 

the 35 mm format gives a sharper image. 

The conclusion is that a 35 mm format should be used 

provided the physical size can be accomodated and the frame rate 

is sufficient. The Photo-Sonics 4 ML high speed camera is a 

potential unit. It has frame rate from 10 to 200 fps,; film 

capacity of 200 ft., 400 ft. or 1000 ft. using magazines, 

dimensions are 12.3" x 5.4" x 6" with 200' magazine, and 15.4" x 

7.6" x 6" with a 400' magazine). A 90 lens adapter is available. 

This camera is accommodated in our design. 

The optical arrangement utilizes a mirror to allow 

simultaneous observation of the test cell for two directions. It 

also leaves enough space to place four digital readouts within 

the FOV. These are the 3 axis accelerometer and the temperature 

sensor. The fluid behavior as well as the supporting data are 

recorded on film. 

The film rate and total footage available limit the viewing 

time. The viewing time is divided into four for the four 

experiments. To best utilize the available footage, the 

test should be filmed during the liquid fill at a high frame 

rate. The strategy will allow observation of liquid climbing the 

wall or free surface phenomena, but will not leave much film to 

photograph the final steady state. 

93 
EXPERIMENT 

PREPARATION 

- INSTALL CYLINDER '1, CONNECT QUICK - DISCONNECT LINE, 

CONNECT TIC WIRE 

- POWER ON 

- VERI FY TEST CONDITIONS 

9 LEVEL, TEMPERATURE 

- CHECK CAMERA READY 

SPEED SET, LIGHTS ON 

- OPEN FEED VALVES, 

FILL FEED LINES WITH 

LIQUID 

- VERIFY TEMPERATURE 

AND 9 DISPLAY-ON 

TABLE 4.1-7 

EXPERIMENT TIME LINE 

EXPERIMENT RUN 

- START CAMERA AND 

LIQUID FEED 

- AUTO~~TIC SHUT-OFF 

EXPERUIENT 

TERMINATION 

- CLOSE FEED VALVES 

- DISCONNECT TEST CELL 

AND REMOVE 

- INSTALL NEXT TEST 

CELL 

- REPEAT AS BEFORE 

4.1.6 Experiment Operation 

EXPERIMENT 

COMPLETED 

- STORE ALL FOUR TEST 

CELLS rNSIDE EXPERIMENT STRUCTURE 

- SECURE 

- POWER OFF 

The experiment time-line is shown in Table 4.1-7. The 

experiment consists of four steps. The first is a preparation 

step in which the equipment is prepared for a test, the second is 

the actual test run which is initiated and carried out 

automatically. 

94 
( 

MASTER ~ 

POWER ~ 

I 

I 

I 

I 

CONTROL UNIT 

I .... I EXPT ,-----O ............... o--L.....f--I-ta.l 

START 1 I .... • 

-- FRONT PANEL I 

I .................. I 

5 SPEED 0"-- ·7" ... I 

MOTOR 41.. ~ ~ I 

SPEED ~ ~ • 

CONTROL ~ I '--C)oiII~I---o ... «~I _________ J 

POWER 

CONDITiONING 

UNIT 

555 I 

RUN 

I MOTOR 

r RELAY ... ON/OFF 1 ..... _ ..... 1 ... 

* r: - - - - _-t.: - , MOTOR 

IVARIABLE DC I 

POWER SUPPLY 

I (OR STEPPER MOTOR DRIVE) I 

~---------~ 

MOTOR 

POWER 

~, 

DC MOTOR 

(OR STEPPER MOTOR) 

LIGHT 

POWER 

SUPPLY 

LIGHT 

POWER 

" 

LIGHT 

I

FLIPoFLOPI 

GATES I ....J 28V I ........ ""1 FAN 

A~ 

... 

.. 

~~~ .. ~ RELAY 

CAMERA II'" 1 ..... _ ....... 

ON/OFF. 

CAMERA 

POWER SUPPLY 

CAMERA 

RUN POWER 

~, H 

CAMERA 

Figure 4.2-1 FREE SURFACE PHENOMENA EXPERIMENT ELECTRONIC LAYOUT 

95 
The following step involves the removal of the filled test 

cell and preparation for the next test. During each test run, 

the extra three test cells can be kept outside the experiment 

enclosure to allow vusual inspection, and working access. 

4.1.7 Thermal Control 

The Free Surface Phenomena Experiment requires no thermal 

control of the fluid in storage or during the experiment. Heat 

rejection from the camera power supply will be required. The 

specified unit is a muffin fan as listed in Table 3.3-1. 

4.2 SYSTEM ELECTRONICS 

The system electronics for the Free Sur~ace Phenomena 

Experiment are developed from the operating parameters above. The 

experiment operation requires short time intervals during 

operation and therefore is automated. The electronic block 

diagram for the experiment is given in Figure 4.2-1. The 

experiment design has three functions that require the control 

panel operation: 

o a power on - power off switch 

o an experiment start switch 

o an experiment select switch 

The power on/off switch activates the power supplies; the fan; 

and the light source. The experiment selector switch identifies 

the cell and determines the motor speed to the fluid drive - if 

this varies between experiments or if a different speed is 

indicated. 

96 
(' 

I 

The experiment start switch activates the experiment control 

which at pre-determined tim~s activates the camera then the motor 

to flow fluid into the cell. If an accelerometer is included in 

the experiment design the accelerometer outputs are displayed at 

LED's in the camera FOV. The circuit operation is shown in 

Figure 4.2-2. There is provision for fou~ displays and time or 

experiment temperature can be included. 

---

J.lPROC 

CONTROLLER 

8721 

SIGNAL 

SELECT 

SIGNAL 

MUX 

x 

..-____ Y-t ACCELEz ROMETER 

... -----.;.-1 

r----lI~-.. ---------___ - __ _ 

ACCELEROMETER 

DiSPlAY 

SELECT SWITCH 

Figure 4.2-2 FREE SURFACE PHENOMENA EXPERIMENT CONTROL 

97 
A rough estimate of the experiment power consumption can be 

made. 

Fan 34 watts 

Motor 30 watts 

Electronics 20 watts 

Camera 100-170 watts 

Total 184-254 watts. 

The camera power will be the determining factor in the power 

budget. Camera film speed must be maintained low enough that the 

265 watts is not exceeded. This budget assumes no regulated 

power supplies which implies that the camera power supply will be 

stable from 23-32 V. 

4.3 EXPERIMENT LAYOUT 

Figure 4.3-1 shows the detailed layout. An isometric view 

of the Free Surface Phenomena Experiment is shown in Figure 4.3-

2. The experiment enclosure is similar to that in Figure 4.3-3. 

The experiment is contained within the volume of a double middeck locker which provides space for all the equipment, 

electronics and controls. The equipment list is in Table 4.3-1. 

The layout shows the position of all four test cells in the 

stowed position during take-off and landing. For actual test, 

the three cells not in the test position are removed to allow 

working access. The arrangement shown in the layout was designed 

such that the camera-to-object distance can be optimized for the 

required FOV and the test cell be located near the front for 

access and visual inspection. The alternative layout shown has 

98 
H 

1 

J 

, IG 

.0 

.0 

F 

E 

D 

c 

B 

A 

) 

8 

6 

----~ 

Imv-<,~~ 

:L,_,,-~~_ 

'---1- - -- "C:I;;; J! 

I 

I 

li.JJ~ II I II 1 

L 

../ 

II 

i---.. I III 'J 

U~-L_ .l" • ..wa UYWY 

') 

5 

'ft1t_1.. .... 

'ftltau., ... 

4 

I J 

I ..... Ift' 

;'1 1', 

.: I 

'I 

I 

.!! j 

II . i " I i 

ii! ' /111 

ie .! 

: .. V I I ' ! 

Fig. 4.3-1 FREE SURFACE EXPERIMENT LAYOUT 

7 6 5 ~ " 

--

--

--

_.- .. ~'"' 

2 

.... I ... ~ 

'< ... '--1 -u .... CN. .•• 

I: 

.. 

'1 11--

, ..... 

h.I"'-.,..,.au) 

3 

) 

H 

.G 

F 

E 

D 

c 

B 

A 

·1l~"·:t."'U.O .. U ... 

L""OU" 

I --~ .. 2 
TEST 

CELL 

DIGITAL---+-

RE..ADOUT 

MIRROR~ 

\_-------

E.L[CTRON ICS 

/J tAMO}' 

LIQUIC 

FELt: 

ILL uMI N ATOR --1 -' QUICK l)1 SCONNECT i- "3 AXIS ACCELEROM EJ ER. 

Figure 4.3-2 FREE SURFACE PHENot1ENA 

100 
L -- - -- - - c.. / 

--- , 

c.. 

( 

(. t 

! 

\ 

" "-

:' 

,/ 

( 

( 

{ 

( 

\ 

I 4.-- ~ r---'-- -

-

"- , , 

/ / 

; 

\ 

\ 

_..1 

~ 

t, A 

I ~ 

~ 

::\ 

~ 

~ 

) 

-~ 

~ 0 

~ , 

e ~ 

tf fJ! .. 

I D 

El1 

Figure 4.3-3 EXPERIMENT ENCLOSURE 

101 

- - - -
Table 4.3-1 

EQUIPf·1ENT LIST 

COMPONENT DIMENSION VOLUr·1E 

Experiment 5 em x 15 em x 52 em 3.9 x 10",3 r~3 

Container (4) (each) 

Fluid Storage 10 em x 15 em 1.1 x 10-3 ~13 

Fluid Drive 26 em long 

Cine Cmaera 25 em x 32.5 em x 8 em 65 x 10-3 M3 

(max) 

III umination 50 em x 12 em 3 x 1 0-3 ~13 

(half cylinder) 

Air Pump 7.6 em (dia) x 3.8 em .2 x 10-3 M3 

102 
~ 

! 

basically the same features,· the difference being in the feed 

line connection arrangements and the left/right placement of the 

test cell. 

4.4 WEIGHT ESTIMATE 

The weight is estimated based upon the experiment design. 

The components identified are given in Table 4.4-1. Weight 

estimates for procured parts are considered fairly reliable. 

Items that require detailed design such as: 

o The optical components 

o The experiment container 

o Fluid drive assembly 

o Enclosure and door 

o Power supplies 

are estimates based upon current design philosophy. As with the 

Surface Tension Driven Convection Experiment 'we have utilized the 

current signel adpator - double adpator plate weights. If 

lighter weight plates are used a significant weight saving will 

be realized. The c. g. data in Table 4.4-1 is within the 

guidelines of Ref. 2.2. 

4.5 EXPERIMENT STATUS AND RECOMMENDATIONS 

The requirements for the Free Surface Phenomena Experiment 

reflect the requirements as given in Reference 1.3 and as 

modified at the conceptual design review. Some requirements are 

not defined due to a lack of knowledge of the experiment 

operation parameters. Some of the operational parameters will 

only be defined after one or more flights. 

103 
The experiment meets the STS mid-deck requirements as given 

in 2.7 for volume, weight and power. The design features for the 

experiment are given below. 

Experiment Volume. The experiment is contained in a double 

locker volume. There is adequate room for all components. The 

major considerations in the design were to accommodate the 

experiment container length and to obtain a maximum FOV, the 

entire tube length. 

FOV. The field-of-view of the entire cell is obtained by 

maximizing the camera to cell distance. The camera is maintained 

in the experiment structure to minimize alignment of extraneous 

vibrations. A 35 mm camera format will allow the entire cell 

length to be viewed. 

Diagnostics. The only requirements, except for the visual 

observation is that of ambient temperature and of acceleration. 

These can be measured at the camera using LED's. 

Power. The power within the mid-deck operating conditions 

depending on camera speed. 

Unresolved operational questions are as follows. 

Fluid Flow. The flow rate will be a critical factor in the 

experiment operation (Section 4.1.3). The flow rate should be 

maximized but is dependent upon the pore size that can be used. 

Film Speed. film speed should be maximized consistent with 

the power constraints and available footage. 

104 
~ .. ( 

COMPONENT 

Accelerometer 

16mm Camera 

35mm Camera 

Stepper Motor 

Cell 1 (in place) 

2 

3 

4 

Pump 

Light 

Fan 

Power Supply 

Mirror #1 

#2 

#3 

Single Adapter 

Double Adapter 

Q Disconn - Red 

Q #1 

#2 

#3 

#4 

Readouts (4) 

Hose and Fittings 

Enclosure 

Door 

E = 

m 

TABLE 4.4-1 FREE SURFACE PHENOMENA 

WEIGHT ESTIMATE 

WT (LBS) xa y¢ z- Mx My 

.50 16.88 -9.54 +6.80 8.44 -04.77 

14.00 10.00 

20.75 11.4 + .36 +5.74 236.55 7.470 

.65 6.66 -7.60 8.00 4.329 - 4.94 

5.06 13.50 + .28 -5,52 68.31 1.417 

5.06 17.24 + .28 -5.52 87'.234 1.417 

5.06 19.24 + .28 -5.52 96.747 1.417 

5.06 19.12 + .28 -5.58 96.747 1.417 

2.16 8.98 -8.36 +6.54 19.397 -18.058 

4.50 15.24 0 -5.58 68.58 0 

1.00 19.265 +8.50 0 19.265 8.50 

11.62 5.08 +8.46 +3.54 59.030 98.305 

.06 3.80 - .36 +3.72 - .228 - .022 

1.18 4.88 - .36 -4.00 5.758 - .425 

.31 13.30 - .36 -2.30 4.123 - .112 

13.00 .375 0 0 4.875 0 

12.50 1.187 0 0 14.838 0 

.084 13.50 -9.87 0 1.134 - .82 

.103 13.50 -9.76 -1.50 1.391 - 1.005 

.103 13.50 -9.76 -1.50 1.391 - 1.005 

.103 19.12 -9.76 -1.50 1.969 - 1.005 

.103 19.12 -9.76 -1.50 1.969 - 1.005 

.336 11. 70 -5.70 + .22 3.931 - 1. 915 

.15 13.00 -9.34 +4.00 1.950 - 1.401 

22.119 10.885 0 0 240.765 0 

4.834 20.265 0 0 97.961 0 

116.405 1147.298 83.503 

x=9.503 

y= .717 

z= .837 

105 

Mz 

3.40 

Alternate 

119.105 

5.20 

-27.931 

-27.931 

-27.931 

28.235 

14.126 

-25.11 

0 

41.135 

.223 

- 4.27 

- .713 

0 

0 

0 

- .155 

- .155 x = 9.856 

- .155 Y = .717. 

- .155 Z = 0.837 

.074 

.60 

0 

0 

97.453 
Cell Material/Constitution. Cell material must be 

compatible with the fluid and must give the appropriate contact 

angle. The smoothness and angle sharpness must be quantitatively 

defined. 

4.6 SAFETY 

The Hazard Reports and Safety Matrix are included in 

Appendix E. There are no obvious safety issues except the 

selection of the fluid. The fluid must be compatible with STS 

operations. The use of silicone oil .will probably be acceptable. 

Fluorocarbons may be allowed since there are minimal heating 

sources at the experiment. 

.'\ ) 

106 
~, 

( 

A P PEN D I X A 

Fluid Transfer In Zero Gravity 

This appendix describes an experiment concept derived 

during the performance of this study. The experiment 

investigates liquid handling techniques in low gravity. 

An appendix derives the modified Weber number discussed 

in the text. 

/~ ( , 

Al 
LIQUID TRANSFER INTO AN OPEN CONTAINER UNDER ZERO-GRAVITY 

The objective of this experiment is to investigate the feasibility 

of a liquid handling technique under zero-gravity conditions which may 

be useful in many scientific experiments and in other routine operations. 

More specifically, this experiment will provide experience which may 

enhance the success probability of the Fluid Physics Experiments which are 

presently undergoing preliminary design stages. The problem addressed 

is how to fill an open vessel (e.g. a cup) with a liquid in such a way 

that the liquid is collected on a predetermined surface (such as the 

conventional "bottom" of the cup). Under zero-gravity conditions a fluid 

cannot be simply poured; it has to be forced in a given direction. No 

guarantee exists, however, that the liquid will remain in contact with the 

surface upon which it is forced. In fact. the li.quid may splash, breakup 

to droplets, and detach from the surface. Simple minded fluids experiments 

performed on board Skylab, ·and more recently aboard the Shuttle, have 

demonstrated interesting and often unexpected behavior. 

The proposed experiment is extremely simple, it does not require any 

Shuttle interface, it is self contained, and can be perfonned by one crew 

member, while another crew member photographs the procedures with a hand 

held video camera. The technique involves forcing a liquid (water) into 

a cup through a porous element (see illustration 1). Under the correct 

conditions of fluid momentum, wetting angle, and surface tension, the 

fluid is expected to adhere to the porous bottom and th'~ walls of the 

vessel allowing the vessel to be filled to a desired level. 

Admittedly, the experiment is simple and will not resolve all 

questions which come to mind. The effect of surface material or liquid 

properties, are of secondary interest. The main objective is to perform 

an experiment which will require only a minimum level of funding, will 

have no safety or special planning requirements and will provide useful 

scientific and engineering information*. The proposed experimental set 

up, shown in illustration 2, made up of lucite, will be stored in one of 

the mid deck stowage lockers. It wil} be removed from the locker for 

testing and returned upon completion of the test. The data will consist 

* It is believed that a drop tower, KC-135, or Lear Jet experiments will 

be too costly due to the automation requirements. 

A-2 
· - I s:: 

0 

I .,... 

+.I 

.., /,,,61_" ~ 

s.. 

+.I 

- II! ! , :::I -- \ - \ 

\ 

A-3 
:;r:. 

I 

.j::> 

Cup 

,) 

-----. ---_ .. ---._----

~,., 

Syringe Piston 

Porous "fill plate" 

.,. .......... :1.-.. 

~~ ................ !. LA!t'J1 

/ 

/ 

Base plate 

o 1. " , I I~ fL ''I /6 Ii 10 

I I 

Sc.al .. J Cwt. 

translation stage feed screw 

Illustration 2: SCHEMATIC OF THE LIQUID FIll EXPERIMENTAL SET UP. 

J' ) 
of the recorded video tape of the experiment. The attached appendix 

describes in simple engineering terms the considerations leading to the 

proPOSE!d design. 

THE EXPERIMENT DESCRIPTION 

The experiment consists of a one liter syringe manually driven via 

a translation stage and a feed screw. and a 60 cm3 cup with a replaceable 

"feed plate". The cup, syringe and support plate are made of lucite 

allowing direct photography either through the side of the cup or through 

the support plate. 

The test procedure starts by the removal of the set up from the 

stowag~~ locker and positioning on a "test bench" and connection of the 

feed line between the syringe and cup. Feed rate is determined by how 

fast the screw is turned. At a ~ revolution per second, the feed rate 

is appr'oximately 1.2 cm3/sec (using a 64 threads/inch screw). The first 

trial should consist of slow filling of the cup, to about 1 cm depth 

over the "fill plate" (about 20 em3 ). The cup is then relOOved, the water 

in it wiped with a rag or a sponge and the cup reinstalled (using three 

wing nut screws). The experiment is then repeated at a different feed 

rate. The procedure will be repeated for several types of "fill plates" 

consisting of various solidity sintered metal elements. screen mesh, and 

honeycomb. All the "fill plates" are kept in a specially designed storage 

within the test setup. ~he rag or sponge used to wipe the cup dry between 

the experiments is also stored as part of the setup. 

The detailed test matrix and the specific "fill plates" information 

will be prepared during the detailed apparatus design. 

A-5 
APPENDIX 

Illustration j shows a liquid emerging through a pore of a porous 

element. The simple force balance states that the momentum of the emerging liquid jet should be sma11er than the restraining force of the liquid 

tension (adhering to the wall). 

(~) (0) 

(c~"G'", ItttJ~F~TiI"" T(,tJ /'fiJI. 'mIJ"'t it 114. 

III ustration 3. 

Once the liquid covers the "fill plate", the jets penetrate the bulk of 

the liquid and dissipate their momentum in a conventional maner ( due to 

viscosity), but the bulk of the fluid has to resist and absorb the total 

A-6 
momentum of the jets (illustration 4). 

- .. - -

... * - .. - ...... - - - - - - - -~­ .... -....,--_.------- ..... - .. --- --

- -- - - - ,..-----=--=:;.....;;.....;=-:::- r~l 

Illustration 4. 

where a is the fraction of open surface area of the "bottom" plate. 

In both cases, the analysis yields 

We = a. pV 2

d < 4 

cr 

or a modified Weber number sma 11 er than 4. 

A-7 
This Page Intentionally Left Blank 
A P PEN D I X B 

Surface Tension Driven Connection 

Flow Visualization 

This report is a result of work performed at Casel 

Western Reserve University for Dr. Y. Kamotani by a 

student, Tom Kerslake. The report includes studies on 

flow visualization. The report defines fluids and 

particles that are applicable for the experiment. It 

also contains information on heater power required, 

temperatures and flow patte.rns. 

B1 
This Page Intentionally Left Blank 
.. ~ 

Appendix B 

SU'lU"A::E TEKSION DRIVEN CONVECTION 

FLOW VISUALIZATION 

by 

Tom Kers1ake 

S~~~er Project Advisor: Dr. Y. Kamotani 

Department of l!.echanical and Aerospac~ Eneineering 

Case Western Reserve University 

June 14 - September 9, 1983 

B-la 
This Page Intentionally Left Blank 
( 

ABSTRACT 

The purpose of this project is to find opt.imurr. conditions 

for flow visualization of surface tension driven convection flow. 

These conditions include fluid type, particle type, heater geometry and corresponding temperature gradient output, and illurninetion system. Dimethyl silicone fluid was predetermined to 

be !~ good working fluid (ref. 3), and several different viscositiE~s are tested. Samples of 10 and 20 centistokes are found 

to be best suited. Particle size ranges from 0.3 urn to 5 urn, 

with three different types of particles tested. Alpha-AI Ur:1ina 

particles (1.0 urr.) are found to be the best suited and are used 

at !~ concentration of 3.0 - 6.0 mg per liter in 20cs fluid and 

5.0 - 7.0 I:lg per liter in 10cs fluid (ref. 2). Two different 

heaters are used at several power iI:lputs and heights above the 

fluid surface. Heater 2 (see Heatine System, PEe 4) is found to 

be the super1cr heater :lna 1t oreates an optilI.um oODvectio:Jn 

fl~w at a 5.0mm height ana a 17 watt ~ow~r in~ut. The pr:per 

laser for illumination was also predatermined. A cClI.promlse 

between ~ower li~it~tions :lna effe~tive particle illum1natlcn 

leads to the u~e of a 5 mil11watt Helium-Necn laser (ref. IJ. 

B-lb 
ACKNO~~'LEDGE~,!ENTS 

I would like to thank Dr. Yasuhiro Kamotani for his 

guidance and ideas regardine this project. I would also like 

to express my gratitude to Mr. l~ike Marhefka for his help and 

advice in building experimental apparatus. An lastly, my 

thanks go to Sudin If.anja for his input into this project. 

B-2 
( 

I 

I~ 

( 

ABSTRACT 

ACKNOWLEDGEMENTS 

1.0 INTRODUCTION 

JABLE OF CONTENTS 

2.0 DESCRIPTION OF EXPERn~NTAL EQUIPMENT A.~ SET-UP 

2.1 Test Section 

2.2 Fluids 

2.3 Particles 

2.4 Heating System 2.5 Optical System 2.6 Photography 

2.7 Thermocouple Probe 

2.8 Set-Up 

3.0 DESCRIPTION OF EXPE'qIMENTAL PROCEDURE 

4.0 'RESuLTS .AND CO!,:CLUSIOXS 

5.0 DISCUSSIC~!'; AND ~.e:::Ci'~VuiNLATlcr;s 

6.0 REF~RENCES 

7.0 DATA TABLES 

8.0 GRAPHS 

B-3 

Page 

1 

i1 

1 

;3 

8 

11 

16 
INTRODUCTION 

This experiment is designed to fUrther the existing knowledge of surface tension driven convection flow. Although this 

phenomenon often has negligible effects on fluids in normal 

earth-like conditions, it becomes a major contributing factor 

in how fluids behave under near zero-gravity conditions. This 

behavior is of great interest to us since the advent of Space 

Shuttle operations and hence, the ease at which we can obtain 

a near weightless environment (accelerations approximately 

lO-5g , ref~ 4) in low earth orbit. Many manufacturing processes can be greatly improved in space. Crystal grO'.';th, for 

example, can be done without the use of a container (e.g. floating zone technique) and therefore, eliminate the contamination 

and the imperfections associated v.'ith it. The weightless 

enviro~ent also minimizes imperfections due to the natural 

convection involved with fluids here on earth. Thus it is 

important that this surfact tension driven flow is studied 

and understood so that spa~e'manufacturing and production tp-chniques may be utilized to the fullest. 

An important part in understanding surfact tension driven 

flow comes frOffi observation and photogra~hic technique. Therefore, a system that can be visually studied is of great value. 

This project concerns itself solely with optimizing the conditions 

for flow visualization. This consists not only of finding ~he 

proper fluid, tracer particles and optics, but also of generating 

en acceptable flow. Since surface tension flow is heat induc~d, 

a suffici~nt temperature gradient must be maintainec scross the 

8-4 

/""\ / 
~. 

I 

surface of the fluid within the test sectio~. This necessitates 

investigation into different heat sources, heater configu~ations, 

power requirements and limitations. For this project, a 

niclhrome wire heating coil is used and the final power lim:' ts 

are dictated by the capacity of self-contained power units designed for use in space. This experiment attempts to optimize 

the heating system, as well as all th~ elements involved in a 

fl()w visualization, given the known restrictions and limitatiolts. 

B-5 
DESCRIPTION OF EXPERn.~Nrr..A~ EQ,UIPMEHT 

~ Section 

The test section is made in pa~t from tubular plexiglass 

stock, 100m outside diameter, 0.3cm wall thickness, and 5cm in 

height (ref. 3, fig.!). This cylinder is bonded to a plexiglass base plate, 15cm square and 0.6cm thick. An alumin~ 

base plate, 15cm square, 0.3cm thick, was also used. As the 

aluminum plate's thermodynamic properties inhibited the proper 

flow patterns, it was not used for further testing. 

The motivation for designing the test section in this 

manner comes from the fact that cross sections of ~luid in any 

plane may be studied, assuming the heat inducing the surface 

tension flow is symmetrical with respect to the test section. 

Fluids 

Silicone oil was predeter~ined tc be the workinC fluid for 

this type of experiment (ref. 3). It is clear, safe, easy to 

handle, and relatively insensitive to contamination. This last 

property is important since conta~inants from the air cr test 

section may cause concentration gradient type counterproductive 

flow (ref. 4). The specific type of siliconp. oil used in this 

case is dimethylpolysiloxane. Viscosities of 10, 20, 25, 50, 

100 centistoke are used. Both General Electric and Dow Corninp; 

fluids are tried, with final data taken using Dow Corcing-200 

10cs fluid and GeLe~~l ~:gctric SF96-20cs fluid. Fluoroinert 

Electronic Liquid FC-77 (31.: Company) was also tried but not used. 

This liquid was volatile enough that evaporation alone caused a 

surface tension flow vli thout any heat i:nput (ref. 1). The liquid 

also had little viscosity and would no~ suspend pa~tic1es. 

B-6 
Part:'cles 

An ideal particle would have the follo'Nine:; characteristics: 

small enough not to impede the natural convective flow of the 

fluid, reflective enough to be easily seen and photograDhed 

and finally, a density such that the particle would remain 

suspended in the fluid. Three such particle types are used: 

(Buehler) aluminum oxide - ).OU-Tn, (Buehler Micropolish) alpha 

Allli~ina - 1.0~~, and (Polysciences, Inc.) glass beads - 1 to 5~. 

Each type particle is within the desired size range of 1.0 - 5.0um 

(ref. 1) •. Several other particle types were tried and not 

used because the silicone oil would not suspend them. Examples 

are copper shots (0.51T'.,7,) ,copper beads (80-100 mesh), and Dylite 

F-40-C-Beads (0.5~~). 

Heetin,:;,- Syste!'!"~ 

ReQuirereents for ~he heating system are that the heater 

approxi~ate a point heat source (to produce a decreasing temperature grajient from the center of the test section outward), 

radiate heat sym:netrically, use a minimwn of power, and maxir.dze 

the te~perature gradie nt across the llquid surface, th;reby 

~axlmizlng the surf~~e tenslen flow. Two nlcnr~me wire 

(oi~meter-O.9mm) c~il h;~ter9 are used with both coils having 

ceramic cered (fiE.2). Heater 1 has ~ coil oiamet;r of 1.7cm 

and 13 coils s~a~ed approximately Imm apart. It h~s a resistence of 1.7 ohms at room temperature. Heater 2 has a col1 

diameter of O.6cm and four colls spaced ap~roxlmately 2mm 

apart. It has a resistence of 0.5 ohms at room tem~drature. 

Eaeh h'eater is connected to a 10werstat variable transformer, 

which is 1n tvrn plugged into line voltaEe_ In audition, a 

15 volt AC voltmeter (reading accuracy to 0.1 volts) ~nd 

B-7 
lPleure 11.. . 

• Test Sect10n 

I) 

l.Oom 

O.30m 

r - - - --- - 5cm _ .... -- .... --- ------ -" - -- 150m 

.~ -- - -L T O.6cm 

k 15cm ~ 

0 

F1eure 2 Heater aclls 

Heater 1. Heater 2 

B-8 
,/ " a l~ amp AC ammeter (readin~ accuracy to 0.1 amps) are connected into the heating coil circuit to monitor ~ower imfut 

(fig.3). For heater placement, the ceramic core is attached 

to a vertical posit1oner, which may raise or lower the heater 

above the ll~uid surface by means of preclsion screw threaa 

advancement. 

Ciptlcal System 

The illumin~tion source is provia;d by a Spectra-rhyslcs 

Stabllite 5m,'l Helium-Neon Laser (Kodel 12Js) using a SpectraFhysics LAser Exciter pO',oler source. The 5~d laser was chosen 

to comply with tne power requirements for a space experiment 

(ref. 1). The laser te~m is s~read into a ~lane (ap~roximate 

thickness of the plane is Imm) ty a cylindrical lens, 4.8 x 5.3mm 

in size and having a llmm fecal length. The plane of light 

passes throueh the test se~tion with an approxim~te thickness 

of 1.5mn:. 

Fhotoerakny 

~hotographs are taken using a Graphex rolarcia land 

camera and bellcws with a Graphex Cptar f/4.1 l35mm lens. 

The camera is positioneo perpendicular with respect t~ the 

laser plane with a distance of 23.5cm between the lens and 

the laser plane. The photographs are shet using only the 

laser light (room 11ehts are turned off) and thus require 

hiEh-speed film. Black ana wnite rol~roid film (type 41) 

ASA 300~ is used with an aperature size f-8 and a 3 se~nd 

shutter speed or f=11 and a 3.5 second shutter speed. ~he 

pri~ts are developed 25 seconds before peeling off the final 

• photograph. All shots are taken at room tem~erature, 78 F. 

6-9 
L1ne 

Voltae-e 

AC Souroe 

Heater C1rcuit 

+ 

.~--------~--------~ 

Variable 

Transformer 

Figure 4 

'Wires 

Junction / 

Therm::>couple 

Voltmeter 

t----1V,.....---. 

Nichrome 'Wire 

Heater COil 

/------------- Probe 

L1~uid 

Surface 

--------Test Section 

8-10 
(' ... I 

Thermocoukle frobs 

Temperature measuraments across the l1quid surface are taken 

with a Type T, Cop~er-Constantan thermocou~le. The bulb is 

small enou@h (J.3mm) and the wires are thin enou~h (O.15mm) not 

to slubtant1ally disturb the natural flow 0: the flu1d. The 

thermocouple wires are formed 1nto the shape of a hook to allow 

the small exposed portion of the w1res to be submersed under 

the liqu1d surface (fig. 4 ). This is done to min1mize the 

errc)r 1ntroduced by exposin@ the un1nsulated part of the thermocouple wires to direct heater radiation. Errors introduced by 

conduction alon@ the thermoccuple w1res are not cons1aered, assum1n@ the AT across the exposed re@10n of the wires is not able to 

drive a substant1al heat flow to or from the junction. The 

thermocou~le 1tself 1s contained within a probe attachea to a 

three de€rees of freedom ~csitioner. ~eaa1nEs are taken usin@ 

an Ome@a-CJ cold ~uncti~n ccmpen~ator connecteo to a Leecs and 

Northrup mil11volt potentiometer -cat. no. 8686 (rsacin@ accuracy 

to O.JOlmV). Tem~eratures may be determinea usin@ Cme@a, lnc. 

standara reference tables. 

Experimental Set-u~ 

The laser, lens and test section are lined Uf. and positioned 

on a track. The heater posit10ner stand is placea beside the 

test sect10n and is centered us1n@ the laser beam as a referencE~. The heater he1ght 1s ad justed from the l1qu1d surface by 

precis10n screw thread advancement. Knowin@ the lead of the 

thread, enables a spec1f1c he1@ht to be reached by a g1ven number 

of screw turns. The therm~couple pos1tioner stand is also 

placed bes1ae the test section ana the junction is centered 

by use of the laser beam. The thermocouple junction is then 

B-11 
adjusted downward (again by ~recisicn screw thread aavancement) 

until 1t is just submersed. Readings are taken at measured 

locations radially outw~rd from the center of the test section 

by means of a ca11brated s11der (one deeree of freedom of the 

~os1tioner). See f1gure5. The camera 1s placed 1n front of 

the test section (facing perpendicular to the track) on the 

same table as the track is resting. 

B-12 
Laser 

.ser Exclter 

Table Surface 

F1~ure 5 : Exper1mental Set-Up 

To Heater C1rcu1t 

Cy11ndr1cal 

Lense 

Prec1s1on Screw 

( 

Frec1s1on 

Screw 

ThermOCOUPlel Frobe 

) 

'lthermocouple W1res 

CBld Junction 

ompensator 

fotent1ometer 

/ 

c 

(V) 

...... I 

m 
LESCRlPTlON OF EXFERI~~TAL rRCC~URE 

fartlcle Determination 

The test section is filled with a given amount of silicone 

oil ~lOOml) of known viscosity using a burret. A given amount 

(~O.5mg) of the particles is weighed out to be tested. The 

particles are mixed into the silicone oil and the test section 

is illuminated with the lase~ plane. The heater is. then positioned 

and aajusted to the desired height above the liquid surface 

(~5mm) and a given ~ower setting ~15 watts) selected. Observations and comments with respect to the visibility of the particles, 

are recoraeu and a photograph taken. The ~rocedure is re~eated 

keeping everything constant exce~t the type of particle. After 

all particles have been tried, results ar~ com~ared. 

FLUl!.i VlS:::(.31TY 1ET..:.R1dNATJ.CN 

One-half (::>.5) mg of the best suitea i-:irticrles "from l-article. 

Letermination) are weighted out and then mixed into lOOml of the 

known viscosity s11icone oil in the test secti~n. the test section 

is illuminated with a l~ser plane ana tn~ h~at~r positicned 5mm 

above the 11qu1d surface, at a 15 watt power setting. Cbservati~ns 

and comments with respect to the speed of fluid met ion and how 

well the particles suspended in the fluid are recordeo. A 

photoeraph is taken. The procedure is repeated changing only the 

fluid, until all viscosities of Silicone 011 h~ve been tried. 

Results are compared. 

Al though the pO'tler couid conceivably be varied in this t-art 

of the proceci ure (t 0 in~rease the convect i ve flow f'Jr t-n'Jt agraphic 

purposes), it is best if the most fre~ flowing fluid is cnosan for 

power consiueraticns. Yet a ccmpromise must be reached between 

8-14 
/ 

r 

the flu1d1ty of th2 l1~u1d and 1ts ab1l1ty to suspend part1:1es, 

since the less viscou~~ free flcwin~ li3uids tena to suspend 

less particles. 

rart1cle Concentrat1on Determ1nat1on 

A c oncent ra ted mixt ure of 5m~ of the best part icle and 

lOml of the best flu1d is prepared. The teat sect10n 1s f111ed 

with lOOml of this same fluid. By p1pette, O.2ml (equival~nt 

to O.lmg of parti~les) of the concentrated mixture is transferred into lOOml of flu1d and stirred. The test section 1s 

illuminated ane the heater ~ost1oned 5mm above the 11qu1d surface at a 15 watt power sett1ng. Cbserv3.t1ons ana a photograph 

are made. The pipetting pro~edure 1s repeated until the opt1mum 

particle concentrat1on has been determined. Since ther,e is 

approx1mately one aadlt1~nal milliliter of fluid added ana 

there exists an error of ap~roximately t 1.Oml (fluid adher1n~ 

to the walls cf tt.e burret) when me3.sur1ng out the orig1nal IJJml 

of fluid, the final volu~e of fluid is subject to a toler~nce 

of" 2. Oml. This t cl erance 1s a~cepta ble within the aesired 

ex~erimental accuracy. 

Heater rower and Conf1gurat1on Determination 

~he test section is filled w1th the optimum flu1d-particle 

mixture and the heater posit1cned in the center of the test section 

abpve the liquid surface a determined distance. The heater is 

turned on to the des1red power sett1ng. The thermocou~le junction 

1s pos1t1oned in the center of the test section (a1rectly b~low the 

heater), just beneath the l1quid surface. The thermocouple reaa1ng 

1s monitored every five ~inutes unt11 equl11brium 1s reach;d 

(approx1m3.tely 1 hour). The read1ng is new recoraed and the 

thermocou~le repositioned radially outward O.5cm (1n scme cases, 

B-15 
distances of O.25cm are used). After five minutes, this rsaoin~ 

is recorded and the power level 1s checked. This ~rccedure continues until the therm~cou~le junction is 3.0cm or 4.0cm away 

from tne cienter startin~ polnt. After all tne reaain~s have been 

recorded, a ph~to~raph is taken and the heater height and ~cwer 

values noted. This procedure 18 repeated usin~ var10us power 

imputs, heater hei~hts, and two d1fferent size heaters. 

B-16 
~3LLT3 ANL ~ON~LU310NS 

The results are ~resented, sect10n by sect1on, as each 

ex~er1mental part was concucted. The nature of the results is 

both qua11tative and eomfarat1ve. Therefore, what ls dlscussed is 

sometimes in terms cf an optimum ranee as opposed to tne optlmum. 

fartlcles 

The best part lele type was found to be the Buehler alphaAlum1na mlcropollsh particles. They were easy to measure and to 

work wlth. The1r lMm size enabled them to flew freely wlth the 

fluid. Yet they were large enough and reflectlve enough to be 

seen very well, beth by the naked eye and on folaroid fllm. The 

alpha-Alumlca part1cles sus~ended well ln the 2Jcs s1l1cone 

fluid and sat1sfactorily ln the lJcs silicone fluid. In the 

less viscous fluld, approxl~~tely 50% settling woula occur over 

a 24 hour per1od. 

The aluminum-oxlce partlcles (3.0~m) suspended very well ln 

the s1l1~one fluid. The one drawback with these particles is 

that they 00 nct handle very well and are not easily measured. 

The particles would stick to all surf~ces (paper, glass, metal) 

when they were being we1ghed and transferrad leaving behina a 

light film of powder. This light film is a significant amount cf 

mass wnen measurements of magnltude lJ-4 grams are being taken. 

The alu~inum-oxide particles appear very much like the smaller 

alpha-Alu~ica when photcgraphed, yet the sm~ller particle woulj 

ultimately be des1red for its flow character1stics. 

The glass beads that were used in this eXfer1~ent ~are 

manufactured in a g1ven s1ze range; namely, from lAm to 5~. 

B-17 
Visually, they appeared similar to the other two ty~es ef particles, but phctoErap~i~~lly their appearance was nonuniform. 

Brieht, full particle traces, medium ~arti~le traces and very 

faint, hazy ~article traces are located·about trie 1l1uminated 

plane of fluid in the photograph. This leaves more er less a 

skeletal convection flow pattern that ls alfflcult to analyze. 

The elass beads dld suspend ana flow in the s111cone flula 

adequately. fhotographs of the elass beads, as well as the 

alumlnum-oxlde and alpha-Alumlna partlcles are snewn ln f1e.6 • 

Flulds 

S11icone fluld of 10cs and 20cs vlscoslty were found to 

exh1bit a~~eptable convect1ve flow. Cbv1ously, the 10cs fluld 

convectea better than the more v1scous 20~s flu1d. Yet a comprom1se must be met' between tne need for fluid ity and the need 

for a damp1nE' far:'tor sufficient to handle the mlner vlbratlons 

the fluld wll1 experlen~e ln a zero-gravity experiment. The 

h1eher vlscoslty flulds (25cs, 5Jcs, and IJOcs) dlsplayed very 

slueeish convect1ve flow. Increased power 1nput to the heater 

would 1ncrease the convectlve flOW, yet ~ower requirements should 

be m1n1m1zed to avold excess heat1ne of the test sectlon. 

As noted earlier, both General Electrlc and Low Corn1ne 

silicone flulds were used. There was no perceivable difference 

between the two w1th respect to what was done 1n this experiment. 

Availab1l1tv determlned which brand of fluid was used. 

farticle Concentratlon 

The opt1mum particle concentr~tion can be obta1ned at 

dlfferent concentration values. Depenaing upon wnat the researcher woulo ultimately like to gain from the convective flew 

photographs, a range of different concentrations would be oesired 

accordine to the spe~ific use in mind. For tne ~ur~cses of thls 

B-18 
Fieure 6 ~art iclea 

--"---o-:"",,,"~--- ----. 

al~ha-;\lum1na 

Part1cles 

lJ.lID. 

aluminum-oxide 

3)lm 

elass beads 

l.. ).UD-5 pm 

B-19 
report, particle concentration for flow visuallzatlon is said 

to be optlmum when the flow patterns are most clearly discernable 

and dlffe~entiated, vlsually and photographical~y (ref. 2). 

rarticles should also appear as individual bright pOints ot 

llght upon being llluminated. Categories, based on four particle 

concentration levels, will be spec1f1ed: sparse, li~ht, med1um, 

and hlgh (ret. 2), f1g.7. The way the ~articles are seen varies 

somewhat between d1rect visual observation and what the camera 

photographs. Therefore, the evaluation of the particle concentration also states whether 1t is a v1sual observation or a photographic one. 

The optimum ~article concentration was 5.0-7.0mg of particles 

in 1.00 liter of 10cs silicone fluld and 3.0-6.0mg of particles 

in 1.OJ liter of 2003 sillcone fluid. Detal1ed results a.re shewn -I"") 

in data ta hle 1 11. l-hot ographs are shown ln fig. 8 • 

Heater iower and ConflEuratlon 

Temperature grad lent graphs were made for each d 1fferent 

heating condition. Te~~er~tures were ~lotted agalnst the pOSition 

(relative to the center of the test section) at which the temperature measurement was taken to produce the characteristic tem~­

erature profile fer tnat g1ven set of condltions. Cn th~se graphs, 

the negative sloped portion of the profile represents the temperature gradient indu~in~ the surface tension convective flow. The 

pos1t1.'le sloped portion of the profile works to counteract the 

original convective flow. Yet the origlnal convective flow dominates slnce the counteractive temperature gradient acts u~on a 

relatively small reglon (~D2/4 cm2 , D=dlameter of heat;r col1s: 

0.6, 1.8cm) of the entire liquld surface area (~25~cm2). Tne 

ideal temper:3.ture pr:::Jflle would 1:e approximated by a negatlvely 

Sloped llne (flg.9 ). 8-20 
F1eure 7 ':Concentrat1::m Levels 

Sparse Concentrat1~n 

---,_.-

) 

, 

I j 

I 

. 

~ I 

. 

Lleht Concentrat1on 

~'\ 

8-21 

. -. 

\ 

\ , 

. 

~ ) 

, 

, 

) 
Med1um Concentrat1on 

.. __ ..... -... -..... _ ..

H1~h Concentration " _._-

! 

\ 

B-22 
(' 

\ 

· F1gure 8 Cpt1mum fart1cle Concentrat1cn 

alpha-Alum1na 0.60m!/lOOml 100s flu1d 

alpha-Alum1na 0.30m~/lOOm120cs fluid 

B-23 

(Note: lOOml volume 1s . 

subject to a ±lml 

tolerance ) 
F1e~re 9 Ldeal Temp. frof1le 

-r----------------------------------------------~? 

ros1t1on (relative to test sec~i~n center) 

8-24 
(\ 

Heater 2 was chosen over he~ter l_on the basis of tem~erature 

profiles. Heater 2 ~ad a smaller coil diameter and t~erefore 

~roduced profiles with smaller positively sloped pertions tnan 

did heater 1 (F.raph1d). Heater 2 also re:tuired less pO'lier to 

reach a eiven temperature (i.e., to ~ecome red hot, he~ter 1 

re~ulred 35 watts While heater 2 required 17 watts). 

The heieht at whi~h the heater was positiened above the 

li~uid surface w~s ~redete~mined to be approxim~tely 5.0mm (ref.l). 

This hel~ht was ~hosen to eive an acceptable marein between the 

heater and the unknown free su~face of the e~peri~ental fluid 

in ~ero-eravlty conditlcns •. ~istances nlener than 5.~mm were 

tested ana dld pr:duoe satisfa~tcry convective flows, th~ueh the 

opti~um ccnvective flow pattern usine heater 2 was prcducea at 

the lowest ex~erlmental he1eht (S.Omm, at 17 watts). See fle~O. 

A eccd pattern was alse ~~edu:~d with a he~ter helEot ef 7.0mm 

(at 14 watts). The de~th ~t whlch the ~onvectlve flow reaches 

is not as ere~t,but the flew ~attdrn is very clear and sy~metrlcal 

(f ie.lO ). 

(~sine heater 1) with the lowest neie~t (a.Omm, at 14 watts) aEaln 

.t:'rodu~ln~ the best ccn'le~tlve fl:w p::tttern (fle.10 ). Less power 

ls neeced at t:"'lis heient but a safe heient m:J.re1n must be maintained so that tne heate~ does not tOvch the li~uid surface. 

Should the heater tcuch the 11~uia surf:J.ce, the flui6 will wet 

to the 'tott:m heater coll 10op,chJ.neine the shape of tne free 

surface ~nd causin~ lo~alized, tu~bulent flow beneath tne neater. 

Power levels of 30, 60, and 1~0 watts to the he::tter \~ef. 3) 

were previously specified. Tnese ~ow~r levels f:J.r excede the 

re~uirements of both heate~s used in this ex~eriment. Assumine 

a he~ter heieht of 5.0mm, power ranees of 20-30 watts (heate~ 1) 

B-25 
F1~ure 10 ; Cpt1mum Flow Fatterns 

8-26 

Heater 2 

5.0mm 

1 7 watts 

( best) 

Heater 2 

7.0mm 

14 watts 

(~ood) 

Heater 1 

2.0mm 

14 watts 

(~ood ) 
and 14-18 watts (heater 2) were found to be the optimum 

for producin~ ~ood conve~tive flow. If the ~ower level is 

steadily increased beyond these ranees, the convective flo'li 

patterns become ~rc~ressively shallower and occur in a thin 

layer just telow the 11~u1d surface (fi~.ll). Another concern 

with 1ncreasin~ power levels 1s the radiant heatin~ of the 

exposed test secti:n side walls. If th~se walls are heated 

to a tem~erature ex~eoin~ that cf the peripheral fluid of the 

test secticn, additional conv~~t1ve effe~ts c:~ld be induced. 

Thcugh plexi~lass is an 1nsulatcr, d~ring ex~erl~entatl_n the 

side walls were hot. No ex~eri~ent was c:n~u~ted to det~rmine 

t~e effect, if any, cf s1~e wall he~ting ~n the ~onvect1ve flow 

pa ttern. 

Te~~erature ~rofiles we~e effecteo by three variables; namely, 

heater ~ower, heater height, ~nd Which of the two heaters was 

useo. This last variable listed was discussed earlier. rne 

effeet of in~re~sing t~e he~ter power input merely in~re~3eQ the 

temperature v~lues of the profile ana 6id not significantly Change 

the shape characteristics of t~e profile (graph 2ff). The effects 

of increasing th~ heater heie~t were cecre~sec overall tem~er~ture 

values and ~e~k tem~ar~ture values :cauring closer to the cent~r 

of the test se~ticn (gr:::l.~h31). This second etlect 1.:: aeslratle, 

since on:temperature profiles it represents a diminishing ~ositlve 

te~perature ~rad1e~t porticn ~nc henee, a shrink1ng ccunter= 

prcc uct 1 ve flow force. Detailed data may· be found 1n da tao table 2#. 

B-27 
F1e~re 11 : Increaa1ne ~ower to Heater 

6 watts 

8 watts 

32 watts 

B-28 
r 

,/' 

An 1mportant considerat1on when takine te~~er~ture data is 

the ac~uracy of the read1nes taken. 3curres of error 1n temperature readlnes ceme frem the followlng: de~tn pos1tl:nine of the 

therIDocouple junction, ca11bratlon of the milllvolt potentiometer, and randcm temperature o5c1ll~t1cns wlthin the fluid 

itself (ref. 1). Tne last of these sources could cause the 

~ ... potentiometer zerolne meter to vary as much as -O.02mV' <- -0.6 C:). 

But slnce these osc1llaticns are random ln nature, they seldomly 

appe~red effect1ne the overall data little. Tne de~th at which 

the thermocouple juncticn was maintained at, could be kept constant 

within one junctlcn cia~eter (O.3mm). rnia oe~th ranee corresponds 

to a potentlometer readlne tcl~rance of ±O.OlmV' (to.3°~). The 

error introduced by the p:tent~o~e:er is the la~st of tne tnree 

at ±O.l·C (ref. 1). Ine fin~l te~~eratu~e data fresented is 

rcuntec tc three significant dlelts, witn accur~oy claimed at 

'0.3°0. 1n thls ex~eriment, true temperature re~alnEs are not 

of extreme lmportance, but ratner tem~er~t~re gr~aients are of 

interest. Since temperature readines are c~m~arec tc one ~nctner, 

~xperlmental error tenes to be minimized. 

An interest ing effect W::iS not iced °llhen heat 1nE the silicone 

fluid. The illuminated cross sectien of fluid would develop a 

wedee shaped patch of darkness, crleinatlne at tne surf~ce un6ar 

the heater and extending tow~rc the test section wall (fig.12). 

The effect can te ex~lained ty the temperature eradient ~lthin the 

fluid c~using tne laser li~1t to bend (ref. 4). In~s, ~ll toe 

particles wit~in tnis dark zone can nct be detected, vis~~lly 

power is lncreased, creating anoth~r reason to minimize the 

B-29 
· ' 

F1eure 12 Wedee Effect 

To Laser 

Heater L 

at 36 ws.tts 

Heieht-6mm 

.~. ~t:}~"7';:\:"~~·'.23YYi'.' . -: - ~ ,... - .,. 

8-30 

Heater 2 

at 14 watts 

He1eht-6mIt 
(~ 

heater power input. 

The fcllowing 1s a list of areas wnere additicnal experlmentation is recommended: optical system, particle varlety, 

test environments, and tempersture measurement. Tne optical 

system should have a laser plane that is wide enough only to 

llluminate the li~uid cross section as opposed to a continuosly aiverging plane of light. A glare-free and darkness-free 

side view of tne illuminated cross section shculd be developed fer ~hotograpnlc study purposes. More'clfferent types of 

particles should be tried. This experiment would also benefit 

1f it were conducted in a clean-rocm facility to avoid possible 

contamination of the fluid or t~st section. l.astly~ .. a_!Xlore 

precise and faster method should be used to recc~d temperature 

data. An infrared radiometric microscope or a similar instrument could p~ssibly be used as a nonintrusive way of measuring surface temperature. These recommendaticns will hopefully help a1d future experimental research and ultimately, 

help to further the understanding of surface tension driven 

convection flow. 

B-31 
1) Kamotani, Dr. J., Department of Mechanical and Aerospace 

Engimeering, Case Western Reserve University, Cleveland, 

Ohio. 

2) Manja, Sudin, "Optimization of Particle Size and Concentration, 

and Fluid Type for Flow Visualization", Department of Mechanical and Aerospace Engineering, Case Western Reserve University, C1eveland,Ohio, August 1983. 

3) Concept Development (Two Space Shuttle Fluid Physics 

Experiments), contract NAS 3-23774, Briefing NASA/LEoNIS 

Research Center, Cleveland, Ohio, January 27, 1983. 

4) LOi\TY, Sa..TUue1, "An Ex:perime~ta1 Study of Heat Induced 

Surface Tension Driven Flo ... ;", Department of 1.!echanica1 

and Aerospace Engineering, Case Western Reserve University, 

C1evland, Ohio. 

8-32 

.-'\ 

: } 
- . 

lIATA TABU. 1i1 

-- Fluid :Earticle Comments - ,- -' ._- -- ----_ ..... _ ... _- - -_ ... --- - TYf-e Vol. Type rmss a-sparse 1-11eht m-medium h-h1S'h 

(m1 ) mS') v-v1sua1 p-pnot::lS'r3.ph10 c-coneent r:l ticn -,. -.. 

10es 611- 99.1 1a1pha- .05 v s e p, 8 0 

1eone 011 !"-1 um1na -- 99.2 ( 1 J;UI1 ) .10 v s c p 1 c 

--, 

99.3 .15 v 1 c p 1., c .. 99.4 .20 v 1 c p 1 c 

-, '.-

99.5 .25 v 1 c p 1 0 

- '-'--

99.6 .30 v 1 c p m c 

-""-

99.7 .35 v 1 c p -_._ m c ....... _--_ ... - ........ "-'---

,;-' 99.8 • 40 v 1 c ----.... ---.-.. ---.. - . _." ----.. _-_ .. 

100.0 • 50 v 1 c 

100.2 • 60 v m c p m c 

-B *-optlmum ... 

100 •4 .70 v m c 

-, -._-' ... ' , , ,'-- '---" _. _._, 

... _-----_._ .. __ .. _ ............ - ,._--_.-

,100.6 .80 v m c P m c 

20cs 611- t 99.2 1 alpha- ,10 v 1 c p 1 c 10cne el1 99:41 Al uml na ._--_ .. 

• 20 - - ~ .! ( l.L\m ) ... ,--- .-- --- ----...... _- - , .. , 

.. ,99 '~I .25 v 1 0 P 1 c 

99. .30 v m c 

- P m c ~ _ ... ----- _ .. - ... -.. - 99.7 .35 - ) 

99.8 .40 v !Ii 0 {:: m c 

- --<w::cpumum . i 

99.9 .45 - , 

, -, . t 100.0 .50 v m c p m 0 ) I- - I 

!100 .2 I ~ I 

.60 v m c ! 

I ~ ...-.. ----_._. __ .. -_ ... - j 

1100 •4 .70 v h,c I 

! 

--------_ ......... --.~ .... -.. ,. 

----_ .. _----_ .... __ .. _ ... - .OJ 

-- , 

i ---_.-.. ----_._ ..... _ ... 

B-33 - .. _- 0_' _ •• , .• , .. , ' . t'" -.-

I 
f I. ~ 

LATA TABl.E 211 

***Heater;:l*** Temper~ture·a, At ~os1t1on (gm) Relat1ve To Center 

Height Volts Amps Fower 

(n:m) (watts) 0.0 0.5 1.0 1.5 2.0 2.5. 3.0 3.5 4.0 (em) 

2.0 3.0 2.2 6.6 33.5 33.7 34.4 34.3 34.0 33 .. 7 33.6 33.7 33.4 

21:0 5.0 2.8 14.0 41.9 42.8 43.8 45.2 44.9 44.7 44 6 44.0 43.6 

2.0 6.0 3.0 18.0 49.9 50.2 52.0 52.9 52.0 52.0 51.8 51.5 50.2 

- 2.0 8.0 3·7 29.6 68.2 70.5 74.5 75.8 76.6 77.7 75.7 75.8 71.2 

3.0 5.0 2.8 14.0 . 43.4 43.4 44.6 44.6 44.0 43.5 43.2 42.8 42.4 

4.0 6.0 3.0 ·18.0 50.6 51.1 52.5 52.0 51.1 50 • .5 49.8 48.9 48.3 

4.0 8.0 3.7 29.6 68.6 69.4 72.5 13.4 73.3 72.1 72.2 10.6 10.6 

5.0 6.0 3.1 29.6 66.2 68.1 71.8 11.5 70.9 70.6 70.1 69.3 68.9 

6.0 9.0 4.0 36.0 18.8 79.5 ~0.8 81.S 81.11 8J.9 80.4 79.3 71:L9 

• . 

***Hea ter 2*** p.OO 0.25 0.50 0.15 1.00 1.50 2.00 2.50 3.00 (em) ; 

5.0 3.0 4.6 13.8 3~.6 39.9 41.4 40. € 40.3 39.7 39.4 38.8 35.4 

" 

5.0 5.4 5.0 17.0 45.9 46.3 47.1 46.S 46.c 46.:: 45.1 44.0 43.2 

6.0 3.0 4.6 13.8 41.5 42.; 42.€ 42. 41.' 41.' 40.-E 40.::;) 39.4 

6.0 3.5 5.2 18.2 41.; 41.9 48.1 48.' 49.: 48.' 48.3 47.: 47.0 

'3.0 4.6 13.8 41.3 41.E 42.3 41 :€ 41R 41.4 412 [40.4 4'J.O - 7.0 

7.0 3.5 5.2 18.2 47.6 41.1: 48. 48.C: 48.8 48.1 47.2 46.9 46.3 

- --

r 

. 

. B-34 I I -. . .... .. -
( 

o 

o 

• 

, 

I , 

, 

~' 

~' I 

.'-"-i- I 

, , 

, I 

o 

• ct . 

" .f 

+!- , I 

F I I I 

, 

, , I ;oL. , 

, I 

I, 

I 

, I 

,~. 

o 

Cl\ 

~ GarQ 680-.R~D;, i Gen. 5tn. #58540 

, , I 

I I I I , 

, , 

I , I , , I 

, , 

" , I 

i.o 

, 

I 

, 

GRAfH llJ 

, I , 

I I 

I , 

, , 

" 

It _. 

7' 

.-r.Ji': 

, I 

I 

I' 

I 

1.5 

I . __ .. 

, ; 

I 

I 

I +H , . I 

.. -1- ~ 

'-7+:-t-i-t-+-;-

, I 

, , 

'" 

2.0 

, 

; I 

...J....- I 

, I 

, , I 

I , , I , , I , 

...... I , , ., , I I 

L , 

'-+-l-ry....! I I 

I , I 

I , I ,-

i I -j , 

'7"1 

I , I 

I , I 

I 

~ 

I, 

, ' 

I , 

. I ' 

I 

1-i-4- i ;.-;-;-

, , 

, : ';-:-7 ~, - , , 

, , 

I I , , .--t...;+ , ,,.:.. :--L ' 

3.0 3.5 4.0 8.;.35 
( 

o 

o 

• o 

LC'I 

o 

'i' 

, 1 

II 

1 

, , 

, ' 

I, 

I I 

I I 

, , , 

, 1 

II 

, I 

, 1 

1'1 

I, 

1 I 

1 , 

, 1 

II 

, I 

III 

1 I 

i' 

I 

, 1 

, , 

I' 

o C .01.1 J ~ Form 680-R~v. 7/67 

Gen. Stn. #53540 

8-36 

Graph 2# . 

~ Increasing Heater rower and Temp. frofile 

, , 

1 , 

I I I I 

" , , , , 

1 

, , 

" , 

1 I 

, I 

1 ' 

, , 

, 1 

, 1 

, 1 

1 ' 

, 1 

II 

" I I. 

I, 

'I I " I 

II 

1 , 1 

II 

I I 

, 1 '" 

, 1 

I I 

,I 

I I 

1 i 

, 1 

II 

, 1 

, 1 

1 

II 

, I 

II 

, 1 

I I , 

, , 

, , 

1 I 

" I I 

1 I 

•• :> 

rcs1t1on, Cm 

II 

, I 

1 , 

, 1 

, ,I 

1 , 

1 

II 

I, 

, 1 

,~ .. - '~~-:i--1' -H-~-;;.: I 

, J ' ! 

I· -

LH-H+:~-H+ 

I, 

1 I 

I, 

II 

'I I 

I I 

I, 

,I 

I' 

:.= • ) 

(rel3.t1ve 

...L.;..' , I! I I 

~: 

to 

1 , 

the 

III 

.,-.-:l 

center 

, 1 

I I I 

1 I 

" , 

II 

,I 

, 1 

1 , 

II 

II 

" !:Tl 

I' I 

I, 

1 I 

, I 

I 

1 I 

I I 

or test 

II 

1 I 

I I 

, I 

, -t-, 

4.0 

section) 

-+-+-t 

\ I ~ ~+ ' ) 
1 

II 

o 

o 

Graph 311 lncreaslne Heater HelEht ana Temp. frofl1e 

10 

I I 

01 

10 

I 

01 

101 

I I 

I 

'10 

I' 

, I 

I I 

, I I I' 

I! 

• I I I 

O! 

10 

, I 

01 ,I I I 

o 

"t"'\-

t--. 

o 

I I 

101 

I ,0 

01 

00 

I 

f ,~~-! --;- - ~-- 'I ' 

0, 

I I 

1 0 

, I 

01 

01 

I' 

H-+++-

~~ 

-I~! I 

I 10 

I 

l±± 

I I 

I I 0 

I± l+-: 

Ii 

01 

1 0 

q~~., 

~ o'm0680-R •• 9;r~ Gen, SIn, #53540 

8-37 

" I : I 

, i 

I, 

I I 

, , 

I' I I 

I 

I, 

00 

0' 

o. I 

I, 

I I 

00 

10 

tiLL ~ 

01 

',I I 

I -1.. 

J. 

I I 

I, 

1.0 

rosH ion 

! 

, , 

1.5 

, em 

I I 

I 

01 

! 0 

, 

, I 

I 

I I 

I I ! 

i 

II~ 

10 

I: o~ 

I ' '_ i-.!-iI;... -t-t-+ ' I~!---.! __ ~ 

Ii 

I I 

I I 

01 

! ! 10 

2.0 2.5 

(with respect to 

-+;-, 

I I 

10 

'" 

, I 

I, , 

3.0 

00 

I, 

1'1 

I, 

I I I 

, I I· 

, I 

I I 

00 

-r 

I I 

LlI. 

-h-: 

'---:- , 

01 

, i 

.: ,.....--·I--'-+l + 

4.0 

test section center) 
This Page Intentionally Left Blank 
A P PEN D I X C 

Cameras and Films 

This appendix contains literature obtained on the 

camera chosen (Photosonics 35 mm-4ML) and films that 

will potentially be used in the experiment. The sensitivity curves are given where available. 

C1 
./ 

",' 

'I. 

'~ 

. INSTRUMENTATION , t '~, I I • I .,." "" I , , I I I , , I , , , I , , , I I I , 1 I I I I , I , • I I I •• I I I , , , , I • I I , It' 

. MARKETING CORP. 

820 S Mariposa St. Burbank. CA 91006/Phone 213 849·6:!51. Telex 67·3205 

Photo-Sonies 

magazine loading 

camera 

Series 2000 

35mm-4ML 

High-speed 

intermittent pin-registered 

Spec/Data Sheet 

May 1983 

.. -

, 

I f(;P\ '_. I / 

The most versatile high-speed 35mm motion picture camera available 

today ... capable of normal speed, and up to 200 fps ... featuring 

interchangeable magazines of 200', 400' and 1000', plus the new stateof-the-art synchronous phase lock and remote speed control options! 

\ 

This unique, rugged data recording camera is exceptionally clean 

in mechanical and electrical design for high reliability to meet exacting 

requirements for medium high-speed motion picture jobs today, 

\.W'irt\"_ 

Unique features -

• Variable shu Iter can be externally adjusted qUickly and 

easily with no tools; no re-timing of camera required. 

• Neon or LED timing liOhts may be easily replaced from 

outSide the camera, without disturbing the film load. 

• Boresight provides positive and direct straight-through 

viewinq. Because of quick-change magazine capability, 

boreslglltlng can be accomplished in minimum time. 

• If usage dictates different film capacities. different film 

magazines are available rather tllan purchasing an entire 

new camera. resulting in considerable cost savings; 200,' 

400' or 1000' magazines interchange With no adjustment to 

camera or magazine. 

• Each magazine has a spring-loaded viewing port for viewing 

film loops. 

C-2 

• Magazines are near-automatic threading with no climbing 

loop. 

• Because the magazine can only be properly threaded one 

way, timing mark offset IS always 7'12Irames. 

• Film magazines can be interchanged in less than 5 seconds 

and cameralrnagazine drive interface is automatically 

aligned. 

• All film magazines thread identically and film is always 

positively locked by either the two register pins or the four 

pulldown pins. 

• Phase lock synchronization plug-in module option. 

• Remote speed control option. 

• Plug-in AC or DC power amplifier has unique reverse polarity 

protection including audible alarm to warn operator. 

!~ 
Camera body includes -

a 28V DC motor (115V AC 50/400 Hz motor available at 

no additional cost), shutter, top, bottom and side mounting 

provisions, continuously variable speeds from 10 to 200 fps, 

run out switch, 11 5V AC thermostatically controlled heaters 

for -65"F, special Photo-Sanies interrupted thread bayonet 

lens mount with dust cover, camera dust cover, dual neon 

timing lights (LEOs optional at no additional cost), manual 

advance knob, presS-la-operate switch, connector, oil and 

instruction manual. Out-aI-film indicator standard, 

Camera electronics -

The modular electronics are solid state and the motor speed 

control IS pulse width modulated, 

This type of system IS inherently less sensitive to voltage 

ancj temperature variations, providing greater accuracy and 

statJlllty than found In comparable analog systems, A unique 

protection Circuit prevents damage to the electronics in the 

tJvent 01 a mechanical lallure, 

An acceleration control circuit provides smooth starting, 

A remote start capability requires only 25 ma from a 28-volt 

source, ellrninating the need for switclling main camera 

power. A press-to-operate sWltell is located at the back 01 the 

camera; this allows check-out of the camera by the operator 

Without trigger circuits being actuated, 

The servo control is on one plug-in printed circuit 

board held in place by captive thumb screws, This board is 

completely interctlan(Jeable between cameras With no 

re cal ibration adjustments necessary, 

The complete electronics, Including harness, can be 

relllovf:Jcl from the camera without the use 01 a soldering iron, 

All carneras are wired to accept the synchronization 

phase lock module and remote speed selector module, 

Ut; ,Jffl{Jtiflt;/ 

I' Nul"~I:JI:.i ILU 

Boresight tool -

AC ampliller 

PiN 61-9511 

Two adapters are provided for 

maximum fleXibility: one right angle, 

and one straight, for side, top and 

" l .;. . , . 

back Viewing allOWing alignment and focusing from alrnost 

any position, The ground glass is spring loaded, assuring 

contact of the glass to the aperture plate or focal plane, 

Installation of the boresighl is the same as the magazines, " 

fasl an(J no problem 

C-3 

.,~ i. 

r 

I, 

( .... , . ., \ .' j 

A 

[J,e, 

Outstanding features include-

• ACIDC convertability, 

• Plug-in servo control board, 

• Plug-in option for phase lock and synchronization to 

external pulse, 

• Plug-in shutter correlation pulse electronics 

• Interchangeable PC board. power amplifier and phase lock 

electronics between the 35-4ML and Photo-Sol1lcs 16-1PL 

cameras, Minor adjustments required, 

• The old style 35-4M camera may be used as a master to 

drive the new 35-4ML cameras provided cameras are 

modified With a new shutter correlation pulse, 

• Out-of-film indicator, Contact closure to 28V DC return when 

magazine is out of film, 

• Plug-in AC or DC amplifier, DC power amplifier has unique 

reverse polarity protection including audible alarm to warn 

operator, 

Servo motor cootrul 

PiN 61-9640" 1U0 

Automatic 

exposure 

control-

• 

The 35-4ML accepts the field-proven Apex-S "bolt-on" 

automatic exposure control system manufactured by 

Photomatrix, Many accessories are available to meet most 

requirements, A separate data sheet covers the AEC, 

~---

'J 
r 

Magazines -

The real uniqueness of the 35-4ML lies in the 

magazine loading concept. The movement is built-in 

and provides positive film control through the use of 

dual registration pins and/or four pulldown pins at all 

times. The film may be threaded in less than one 

minute and the magazine installed on the camera in 

less than 5 seconds. There are no film guides or shoes, 

sprocket guards or levers to release or move in order 

to load the film. Even the climbing loop is gone. It is 

the closest thing to automatic threading - yet, still 

gives the operator complete control at all times. All 

magazines are gear driven and do not require any 

take-up motors. A sliding door is provided in the 

magazine door to allow viewing of the film transport 

and filni without disturbing the camera set-up. 

, 

'~ •. , 

35-4ML with 1000' 

coaxial magazine 

., 

400' vertical 

magazine 

400' horizontal 200' 

magazine magazine 

200' - darkroom loading, daylight 

threading; weight wlfilm, 7 Ibs. 

400' - darkroom loading, daylight 

threading; weight w/film, 11 Ibs. 

1000' - darkroom loading of one of two interchangeable film spools, daylight threading: 

weight wlfilm, 20 Ibs. 

Phase lock synchronization electronics ... 

• 

Phase lock electronics 

'1rlt~ ~~ .. .;<:' " , . " D.e, 

This module can be added to the side of the camera without any 

factory modification. It increases the overall camera width 

approximately %". The camera must be equipped with a shutter 

correlation pulse module which can also be easily installed 

in the field. 

The module provides several options in controlling one or more 

cameras. It can be used for phasing the shutter from an 

external pulse to an event which simultaneously makes the 

camera run synchronous to the input pulse . 

The shutter correlation pulse in a camera can be used as an 

input pulse to other 35-4ML cameras equipped witil thiS module 

which will make them run synchronous to the master cameri'! . .... _-......... ~....... A built-in dual sensor in the camera simultaneously 

........... permits synchronization and out-of-phase modes 

...... between cameras. For example. two cameras 

... , running at the same speed can also be 

" operated 180' out-of-phase With each "6., other, When three cameras with 

.. 140" shutters are phased 1 20' 

\ from each other ... an event can 

, be recorded continuously, 

• 100% of the time. 

I 

I 

, 

, 

I 

,./ 

" 

Remote speed control -

An optional remote speed control is available, using the 

same module as the phase lock electronics. This provides 

the additional capability of changing the frame rate, 

from a remote location, to any speed between 15 fps and 

200 fps, up to 500' away given proper interface. 

C-4 
Standard specifications, 35-4ML 

Frame rate: 10 to 200 fps by transistorized variable speed 

conlrol. Accuracy :t 1 % or :!: 1 frame, whichever is greater. 

Shutter: Variable rotary disc with openings of 9, 18, 36, 72, 

and 144 degrees. 

Aperture size: 0.745" x 0.995" 

Film specification: 

Standard·--

Timing lights: Two, one each side of film outside picture area; 

uses NE2J lamps. LEOs may be substituted at time of 

purchase at no additional cost. 

USA PH22.36 (KS .1870" pitch) 

Optlonal---· 

USA PH22.93 (BH .1866" pitch) 

USA PH22.34 (BH 1870" pitch) 

USA PH22 .139 (KS 1866" pitch) 

Camera accepts both .004 and .006 Illcll lilm. 

Film capacity: 200 II. lfIugcwne; 400 II. magaLlne 

(hofllontal and vertical); 1000 ft. magazine (coaxial). 

Film transport: Intern-littent, two registration pins and four pulldown pins with lilm held captive in aperture gate at all times. 

Outline drawing -

Motor: 115V AC, 50/400 Hz, 4 amps max. at 200 fps; 28V DC, 

12 amps max. motor available upon request at no additional 

cost at time of order. 

Weight: 9% Ibs. (camera body only) 

Mounting: Top, bottom, and right side of camera. 

Lens mount: Special bayonet Photo-Sonics interrupted thread. 

(Nikkor mount optional at extra cost) 

Heater: 115VAC or DC, 300 watts, thermostatically controlled. 

Specifications subject to change without notice. . .: 

( - - ll---, /" ~ __ 

I II I ,,-.. I II : / / // \(400 fl. VUllCAl MU ',/- 1000 rr. MU. COHIAl 

I I I I , \ 

~ II ~ I \ J'- 40D fl. MU \ 

I 1- - - -Ii II' I8H/,. MOUMflM' KOllS I /- - - - - I I II I '" UIPlACIS OfPOSIII SID! / /1/ II ''-", ... 

12.211 

o '(fJ--'-'---r r--- T -- -I' 

[ 

II (~ ----~-r -"-"'''''''' ,/) 

. ;: Q '~! "151 I

J

'" "[' "c~-'1' "::':!~~~,.": J ====L- J 1.0'. .-~ e 1,-· - I 

1lO~~~.~~ !~;: ----- 1.1i1.f= - ---- .1.. ......... +'---=-----,-•. -I-.-81-+1.-II-D~~'-'-'-----~--------J· / - --.- --.-. .. 

II) H/IWO SIll. or 1000 OIA ••. &. 

1---_ •. _210 __ -::::-_-_1 __ 1.000 --

r- - - t ---- ---- ----. ---------. 

J-rl'il"!!!!:; =======+====!====;===;= = = j =~---1- I III I I '.111 

~'!- -. I I I 1000 fl. 

I I I WH MK 

1/4 21111111 MOUNflN6 HOltS _.,--,-y I 1 I I 

(II PlAm OPPOSI!! S101 11.000 ' __ =c_=-=-_--=..::._~_ . .__l 

mOlm SIOI).tl=-..:: "", -~ -- --- ,,- ~J' --PINPTOIE·14·/9P(SR) 

1/. 11lVlI MOUN""' MOlU U, PlAen ______ / -~. -- -"~ Mating Plug 

1111611/8 MOU"""' "Oll '"IS SIOI ONLY - t L PIN PT06E-14·19S(SfI) I 4 20 I Viii IIIOUHtlHli KOll THI$ SlOI ONLY ... .,../ 

- I GOD I fiLM 'loUl 

-------1.101 -1.000--

. ,',I/L1(/I,d .1(-.1 iud/c,ltc's 

1'111.1:.1} luLl\ :,YlJt.//(()/II/c/{ftJfI 

Manufactured by Photo··Sonies, Inc., Burbank, California, U.S.A. Printed In U.S.A. 

4 C-5 
Our new demo vans are touring the 

country ... loaded with most of the 

equipment described herein, fully 

operative. 

To see the equipment in which you're 

interested, simply fill in enclosed 

postcard, mail, and we'll let you 

know when a demo van will be in 

your area. 

Photo-Optical Instrumentation .":. INSTRUMENTATION 

S d C .' MARKETING CORP. ystems an omponents 820~ M:'nDosaSt Burbank C:C~~~~:~~':~~:O;~3849620t Te'e, 6732"0 

16mm camerasRotary prism 

Photo-Sonies Model 16-1 B: High "G", 

extreme temperature and vibration; short run 

stop/start, full run of interchangeable 

magazines of 1 00' and 200' at speeds from 

1 0 to 1 000 fps. 

Model 16-1 BAC is 115V AC version of the 

16-1 S, also accepts 400' magazine, speeds 

of 200,400,600, 800 and 1000 fps, NOT 

for high "G" use. 

NAC Model E-10: 400' capacity, 100 to 

10,000 fps, stop/start up to 3000 fps, 

optional o$cillograph recording simultaneous 

with picture, mechanical event synchronizer, 

electronic speed, control, direct reflex 

viewing while running. 

SPECIAL PRODUCTION MODELS 

Photo-Sonies Model 16-1 C: High "G", 

extreme temperature and vibration, 400' 

magazine, speeds to 4000 fps. 

Photo-Sonies Model 16-1 E: 100 "G", 

very small, 25' daylight spools, 200 to 600 fps. 

Photo-Sonies Modej16-1 F: Watertight, 

operates under 150 "G"loads, 1 00' daylight 

load spools, 200 to 1000 fps. 

..... '-

-41t;.' ._ 

i;/. .. ...--- .... ' 

• ~..;.{f 

~"Ys";;.~ .-

'I)l 

C-G 

,\1 

,Y 

fff 

• 

16-18 

16-18AC 

E-10 
16mm camerasIntermittent pin-registered 

Photo-Sonies Model 16-1 PL: 10 to 500 fps, 

AC/DC convertible, interchangeable 200', 400' 

and 1 200' magazines. Sync phase lock, continuous 

reflex optics, pulse kit, built-in timing light generator, 

wired for automatic exposure control. 

Photo-Sonies Aetionmaster/500: Hand-held 

version of the 16-1 PL features continuous reflex 

viewing to 500 fps, dual speed controls, 24 fps 

crystal option. Ideal for instrumentation photography 

as well as documentary/super slow motion. 

Photo-Sonies Model 16-1 VN : Smaller than most 

Super-Bs and versatile! Up to 12 pps and cine to 

100 fps, or cine only from 24 to 200 fps, interchangeable 65', 100' and 200' magazines, and 

provisions for "add-on" automatic exposure control. 

SPECIAL PRODUCTION MODEL 

Photo-Sonies Model 16-1 W: Fastest intermittent 

16mm camera in the world! 24 to 1000 fps, 

interchangeable 200' and 400' daylight load 

magazines. 

35mm camerasIntermittent pin-registered 

Photo-Sonies 35-4ML: 10 to 200 fps, interchangeable 200', 400' and 

1000' magazines, plug-in electronics, AC/DC convertible, accepts 

"add-on" automatic exposure control. Synchronous phase lock and/or 

remote speed control options. 

35-4MLX: X-ray version of 35-4ML for cineradiological applications; 

16 to 200 fps in any 7 discreet speeds pushbutton-selectable, remote 

control indicators; camera triggers X-ray. Available in Single-plane or 

bi-plane systems. 

Automax Cine/Pulse Series G: Pulse to 10 pps, cine to 16 fps, variety 

of combinations of AC/DC, single/double frame advance and data box; 

100',200' and 400' Mitchell mount magazines, solid state electronics. 

Over 20 models to choose from. 

Automax 

C-7 

• Actionmaster/500 

16-1VN 

Automatic 

exposure controlsPhotomatrix Apex-B: For most 16mm and 

35mm cameras, "bolt-on", rugged. accurate. 

covers a light range from 5 to 20.4BO foot-iamberts. 

ASA 25 to 1600 in 1/3 f-stop increments, accommodates shutter speeds from 1/12 to 1/12.BOO 

sec. in 1/3 f-stop increments, response time less 

than 2 sec. through full 6 f-stop range, encapsulated 

integrated circuitry. 
(

_ .. -

.' 

f 

(" 

Projectors and 

film readersNAC analysis projector Model OF-16B: 

16mm, flicker-free at all speeds, 0 to 24 fps 

continuously variable forward/reverse, single 

frame forward/reverse, instantaneous stop for 

frame-hold at any speed, constant illumination 

at all speeds and stop-motion with no film 

damage, remote control box with illuminated 

electronic frame counter. 

NAC film reader systems Models 160B, 

350B, 700B: 16mm and 35mm are flickerfree at any speed forward/reverse; interchangeable 16mm, 35mm and 70mm 

projection heads rotate 360°, X-V motorized 

joystick, multiple frame advance and lamp 

intensity control. Available in metric or English 

readout. Angle measuring screen and 35mm 

camera attachment option. Optional RS-232 

output. 

, 

, 

, 

I 

I 

I NAC data analyzer Model 76: Combines 

the film motion analyzer with a digitizing tablet, 

mini-computer or micro-processor and teletype or HP-B5 terminal for use in cine 

angiography, biomechancis, ambulation 

and automobile safety film analysis. Programs 

include line length, angles, volume scale 

factors, stick figures and center of mass 

calculations. 

I ~ .@.~. ~~~ .... .--_~_oo-------.. --- .16ieo5a,-3i1isiiiioaliii,ii1i7iiioiilloaiiii 

Automatic film reading digital analysis systemsThese 16mm, 35mm and 70mm systems lend themselves to 

automatic film reading jobs where specific types of information 

are recorded on film such as dot matrices, alpha-numerics or 

vernier dials plus cooperative shapes which might include a 

dot, cross or quadradic target. 

These are often found in high-speed instrumentation films 

used in range tracking applications, car crash studies, biomechanics research, the medical field, plus a host of other 

categories. 

The standard NAC/POS Model 78: consists of NAC rear 

projection case and projection head, PDS electronic control 

console with scan converter and Data General Nova series 

78 C-8 

mini-computer, teletype, magnetic tape recorder and software. 

Variations might include video display terminal and disc. 

The standard Photo-Sonics/POS Model 80: The ModelBO 

consists of a front projection film reader console with digitizer 

table, control panel, cursor, floating keyboard and display. foot 

switch, x, y, frame LED display, film transport, light source and 

optics, plus PDS Digitizing camera and relay optics. The 

electronic control console with control unit, scan converter 

and Nova 4 digital processor, magnetic tape recorder. CRT 

remote display terminal, disc and software make up the 

remainder of the complete system. 
( 

Tim~ng systemsPhoto-Sonies timing light generator Model TLG: 

Small, solid state and accurate, drives more than 10 

neon lamps, provides pulses at 10,100 and 1000 per 

second. 28V DC or 115V AC. 

Model RTLG is the ruggedized high "G" version of 

the TLG, 28V DC only. 

Photo-Sonies timing pulse generator Model 

CTPG/LED: ProvidEIS coded output to facilitate reading 

at 100 and 1000 pulses per second, plus circuit for 

Event marks. Made Elspecially to drive LEOs. 115V AC, 

28V DC or 12V DC internal NiCad battery with built-in 

recharger. IRIG option available to drive LEOs. 

Photo-Sonies multiple camera driver Model 

MCD/LED: Accepts Time and Event data from the 

Model CTPG or other LED pulse generator and drives 

the data to as many as four cameras. These units may 

be ganged. 115V AC, 28V DC or 12V DC internal NiCad 

battery with built-in recharger. 

Miletus FDRS (film data recording system): 

Designed around CMOS technology for low power and 

noise immunity, adaptable to most 16mm, 35mm and 

70mm cameras, on-camera or remote-ground or 

airborne, contact-printing super miniature 7-segment 

format or BCD on every film frame up to 10,000 fps. 

Internal rechargeable battery provides 24 hours operation on a single charge, plus built-in translator to accept 

IRIG or operate on internal crystal clock. 

'\ 

TLG 

CTPG/LED 

Special equipment and accessoriesAirborne surveillance documentation system: A unique hand-held 

photographic data recording system for airborne, land and maritime 

surveillance that Simultaneously documents latitude, longitude, date, 

GMT, or additional data on every frame of film, 

The camera system is comprised of a selection of standard Hasselblad 

components, Customer's existing photographic equipment may also 

be utilized. 

The controller, designed around CMOS technology, is in a quarter-dwarf 

ATR chassis and accepts ARINC 571,575, etc., decodes it, and directprints data on the film by a 7 -segment recording head. 

NAC eye movement recorder Model 4: Continuously 

records a subject's discreet 

visual point of interest and 

simultaneously superimposes 

a field image on each frame of 

film taken through a main 

objective lens, and relayed via 

fibre optics to TV or 16mm 

camera. 

Camera mounts: With quick 

connect/disconnect dovetail 

mounting plates. 

O'Conner tripods and 

fluid heads: excellent 

quality and performance. 

Tracking finders: 

Superimposed reticle is 

illuminated by ambient 

light and allows direct 

viewing for easy tracking. 

) 
l 

, 

( 

\ 

( 

KODAK TECHNICAL PAN FILM 2415 

DESCRIPTION 

• A black-and-white, panchromatic negative film having 

extended red sensitivity 

• Extremely fine grain and extremely high resolving power 

• Ability to vary contrast through changes in development 

to cover a broad range of applications 

• Superior pictorial film when using developers such as 

KODAK TECHNIDOL LC Developer or POTA Developer 

• Dimensionally stable, 0.004-inch (0.10 mm) KODAK 

ESTAR-AH Base with a built-in 0.1 density that suppresses light piping 

• Dyed-gel backing to suppress halation and curl 

• Good latent-image keeping 

TABLE OF CONTENTS 

Page 

DESCRIPTION ....................... 1 

APPLICATIONS . . . . . . . . . . . . 1 

SPECTRAL SENSITIVITY . . . . . . . . . . . . . . .. 2 

IMAGE STRUCTURE CHARACTERISTICS . . .. 2 

Diffuse RMS Granularity . . . . . . . . . . . . . .. 2 

Resolving Power .................... 2 

Modulation Transfer Function ........... 2 

EXPOSURE ......................... 2 

Pictorial Photography . . . . . . . . . . . . . . . .. 3 

Photomicrography . . . . . . . . . . . . . . . . . .. 4 

Copy Applications ................... 4 

FILTER FACTORS . . . . . . . . . . . . . . . . . . . .. 4 

RECIPROCITY FAILURE ................ 4 

PROC.ESSING ....................... 5 

Small-Tank Processing ................ 5 

Machine Processing . . . . . . . . . . . . . . . . .. 5 

CHARACTERISTIC CURVES ............. 6 

PRINTING .......................... 10 

HANDLING AND STORAGE .............. 10 

FILM SIZES AND ORDERING INFORMATION .. 10 

ADDITIONAL INFORMATION ............. 10 

c Eastman Kodak Company, 1982 

APPLICATIONS 

The ease with which Technical Pan Film can be processed 

to a wide range of contrast levels, together with its spectral 

sensitization and particular combination of speed and 

image structure properties, makes this an unusually versatile product. 

When processed to achieve wide latitude through the 

use of special low-contrast developers (e.g., KODAK 

TECHNIDOL LC and POTA Developers), this film is superior 

when used in pictorial photography. In this application, its 

fine grain permits enlargements at magnifications of 25X 

and more. In addition, its extended red panchromatic 

sensitivity has a haze-cutting effect when you are photographing distant landscapes or making aerial shots from 

helicopters or small airplanes. 

When processed to high or moderately high contrast, it 

provides contrast reinforcement in the photomicrography 

of specimens which are faintly stained or colorless and 

normally viewed by Nomarski or other contrast-enhancing 

methods. It is particularly effective in chromosomal or 

karyotyping studies. 

As with the precursors to this product, the extended red 

sensitivity and high contrast of 2415 Film are especially 

suited to solar photography at the H-alpha line (656 nm), 

but the film is also useful for lunar photography and for 

photographing the planets. Some investigators have used 

hypersensitization to extend the film range of applications 

to include stellar photography. 

The film is an excellent choice for photographing the 

images reconstructed from holograms with'a HeNe laser. It 

is equally appropriate for plotting and line-scan recording 

applications where the source is a HeNe laser (633 nm) or a 

light-emitting diode (LED) operating in the 640-660 nm 

range. 

Technical Pan Film 2415 is useful for a variety of 

applications in the fields of slide-making, copying, and 

personal microfilming, most of which require high or 

moderately high contrast coupled with fine grain and high 

resolving power. To cite a special example of copying, the 

film is particularly effective for photographing electrophoretograms. 

Resourceful photographers will surely find other applications where the performance characteristics and flexibility of Technical Pan Film are as valuable as in the uses 

mentioned here. 

C-10 

P-255 .. ~ 
2.0,-------------------------..,0.Q1 

« 

:; ~ 1.0 

j: 

en 

z 

w 

o 

" 00.0 

...I 

KODAK Technical Pan Film 2415 

Effective exposure: Visible 1,4 seconds 

Ultraviolet 0.2 second 

Developed In KODAK HC·110 D ••• loper (Dllullon D) 

8 minutes al 68°F (20°C), continuous agitation 

Densitometry: American Standard diffuse visual density 

I 

~ 0.10; 

a: 

j 

o 

o 

a. 

>< 

w 

1.0 ~ 

j 

...I 

o 

o 

ID 

c( 

1.0----'---......... ------'-----'---..&-------t-----..&--............. 10.0 ~ B ~ ~ ~ ~ ~ ~ ~ ~ 

WAVELENGTH (nm) 

'Sanllllvity = reciprocal 01 exposure (ergs/em') required to produce specified density 

SPECTRAL SENSITIVITY 

The spectral sensitivity of Technical Pan Film 2415 reflects 

an extensive effort to provide reasonably uniform sensitivity at all visiblE~ wavelengths out to 690 nanometres. To 

achieve a closer approximation to flat response, some 

users may wish to make exposures through a color 

compensating filter which selectively att~nuates red and 

blue-UV radiation, e.g., a KODAK Color Compensating 

Filter CC40C or CC50C (Cyan). The effect of using such a 

filter will be to yield reasonably flat response out to 655 nm. 

Note, in comparison, that films having conventional 

panchromatic sensitivity are designed to provide flat response only out to 625 nm. Thus even with a CC50C Filter, 

Technical Pan Film 2415 will record red portions of a scene 

relatively more efficiently than materials such as KODAK 

PANATOMIC-X Film or KODAK PLUS-X Pan Film. .... ' .. , .~~ ..... _._--.. _" 

IMAGE STRUCTURE 

CHARACTERISTICS 

All data given in this section are based on development at 

68°F (20°C) in KODAK HC-110 Developer (Dilution D) for 

8 minutes or in KODAK TECHNIDOL LC Developer for 

15 minutes (as indicated). 

DIFFUSE RMS 

GRANULARITY* 

RESOLVING POWERt 

. k- (lines per mm) 

...,q). .' ~~(U; IQ.<2.1000:1 

iI- : - - w.--\--,(,I\ r.o.C. 1.6:1 

KODAK Developers 

HC·110 TECHNIDOL 

(Dilution D) LC 

8 

320 

125 

7 

400 

125 

* Read at a net diffuse density of 1.0 using a 48-micrometre 

aperture and 12X magnification. 

t Determined according to a method similar to the one described in 

ANSI Standard No. PH-2.33-1976. Method for Determining the 

Resolving Power of Photographic Materia/s. 

2 

MODULATION TRANSFER FUNCTION 

These photographic modulation-transfer values were determined using a method similar to that of ANSI Standard 

PH-2.39-1977. The film was exposed with the specified 

illuminant to spatially varying sinusoidal test patterns 

having an aerial image modulation of a nominal 35 percent 

at the image plane, with processing as indicated. In most 

cases, these photographic modulation transfer values are 

influenced by development adjacency effects and are not 

equivalent to the true optical modulation-transfer curve of 

the emulsion layer in the particular photographic product. 

Modulation Transfer Function 

200~--------------------------------------_, 

150 

100 

70 

50 

l 30 

.. 

~ 20 

<II 

.. 

a: 10 

KODAK Technical Pan Film 2415 Modulation Tranlfer Function 

Exposure: Tungsten 

Temperature: 68°F (20°C) 

POT A Developer 15 minutes, intermittent agitation 

KODAK HC·110 Developer (Dilution 0) 8 minutes, COntinuous agItation 

21~---------7--~1~0--~2~0-----5~0~~1~OO~~20~O--~ 

SPATIAL FREQUENCY (cycIH/mm) 

EXPOSURE 

Since there is a wide range of specialized exposure 

conditions in which this film may be used, we give 

recommendations only for the most common applications. 

Note that the exposure index is closely related to the 

processing conditions and the resulting contrast. Consult 

the values presented with the characteristic curves in 

C-11 

) 

) 

.' )

' 
{ 

( 

( 

(, 

( 

choosing the appropriate contrast and exposure index. 

Exposure index values given here are for use with meters 

marked for ISO (ASA/DIN) speeds or exposure indexes 

and are suggested starting pOints for trial exposures. 

Note: 

So (logarithmic speed) = 1 + 10 IOg10 S (arithmetic speed) 

Le., "DIN" = 1 + 10 10glo "ASP;' 

Bracketing exposures by whole-stop intervals will 

usually be required for initial tests; use half-stop intervals 

for critical applications. 

PICTORIAL PHOTOGRAPHY 

This film yields superior image quality when processed in 

compensating developers such as KODAK TECHNIDOL LC 

Developer or POTA Developer. The grain and resolving 

power of this film are better than any other black-and-white 

pictorial film that Kodak has ever offered. 

Because the sensitivity of this film extends further into 

the red region than conventional panchromatic films, the 

recording of red objects will be slightly lighter than normal 

in the print. In some cases, this characteristiC may be 

desirable. For example, it helps reduce the effect of some 

types of skin blemishes and in many cases produces a 

luminous quality to skin tones which many observers 

consider quite pleasing. 

Filtration is usually not required in either portrait or 

scenic pictorial photography. However, in some cases 

filtration may be required. In particular, Caucasian flesh 

tones in full sun may look too light and possibly pasty. This 

effect is less evident in shade portraits outdoors because 

there is less red light present. In some cases, a KODAK 

WRATTEN Filter No. 38 or a KODAK Color Compensating 

Filter CC40C used without a filter factor, may be sufficient to 

lessen the excess red sensitivity. Because of variations in 

circumstances and tastes, experimentation is in order. 

KODAK TECHNIDOL LC Developer is available in a 

3-packet pouch. Each packet holds enough powder to 

make 1 U.S. pint (473 mL) of solution sufficient to process 

two 135-36 size rolls of KODAK Technical Pan Film 2415. 

For mixing instructions, refer to the packet. 

The suggested processing conditions for KODAK 

TECHNIDOL LC DEweloper with KODAK Technical Pan Film 

2415 are as follows: 

Exposure Index: 25 for trial exposures 

(Based upon the formula EI = .81 E is the 1/25 second 

exposure in lux seconds required for a density of .1 

above minimum density.) 

Development: Refer to small-tank processing section 

Temperature: 68°F (20°C) nOF (75°C) 86°F (30°C) 

Time: 15 min. 11 min. 8 min. 

Develop to the desired contrast index, based on the 

suggested starting points. The contrast index is dependent 

primarily upon the developer, temperature, dilution, and 

development time chosen. It is affected to a lesser extent by 

exposure time, specific processing techniques, and normal product variability. Therefore, the times given above 

should be considered as starting pOints only. 

NOTE: If one of the optional higher developer temperature 

recommendations are used, the rinse and fix temperatures 

should be maintained within 3°F (1. 7°C) of the developer 

temperature, and the wash temperature maintained within 

5°F (3°C) of the developer temperature. 

In addition to KODAK TECHNIDOL LC Developer, pictorial results may be obtained with this film when using POTA 

Developer. It will produce results somewhat similar to 

KODAK TECHNIDOL LC Developer and can be prepared as 

follows: 

Development in Small Tank 

Agitation at 30-Second Intervals 

Development Time 

Contrast KODAK (minutes) at 

Contrast Index Developer 68°F (20°C) 

High 2.50 DEKTOL 3 

2.25-2.50 D-19 2- 8 

1.20-2.10 HC-110 (Dil. B) 4-12 

1.00-2.10 0-76 6-12 

0.80-0.95 HC-110 (Dil. F) 6-12 

Low 0.40-0.80 TECHNIDOL LC or POTA 7-18 

Processing in KODAK VERSA MAT Film Processor, Model 11 

KODAK Developer 

Developer Temperature 

VERSAMAT 885 85°F (29.5°C) 

VERSAMAT 641 85°F (29.5°C) 

VERSAFLO 80°F (26.5°C) 

* Based on 1 /25-second exposure time. 

tBased on 1-second exposure time. 

Machine 

Speed 

(ft/min) 

10 

10 

8 

Developer Contrast Gamma Racks Index 

1 2.20 2.80 

1 1.40 1.55 

2 1.80 2.30 

C-12 

Exposure 

Index 

200 

100/200 

100/250 

50/125 

321 64 

251 32 

Exposure 

Index 

160/23° (Daylight*) 

125/22° (Daylight*) 

125/22° (Tungstent) 

3 
POTA Developer 

Use This Amount Of This Component 

1 litre distilled or deionized water 

1.5 grams 1-phenyl-3-pyrazolidinone* 

30 grams sodium sulfite 

• KODAK Balancing Developing Agent, BD-84, or ILFORD 

PHENIDONE Developing Agent. 

The suggested meter setting for trial exposures on 2415 

Film to be processed with this developer in a small tank for 

15 minutes at 68°F (20°C) with agitation at 30-second 

intervals is: 

EI 25 (Daylight) 

This exposure index is based on the formula EI = 0.8/E, 

where E is the exposure (at 1/25 second) in lux seconds 

required to produce a density of 0.1 above minimum 

density with the indicated development. Refer to the Small 

Tank processing for details. 

PHOTOMICROGRAPHY 

The following exposure index (EI) values are intended as 

starting pOints for trial exposures to give satisfactory 

results with photomicrography equipment having 

through-the-Iens meters. The indexes are based on the 

formulaEI = 10/E, where E isthe 1-second exposure in lux 

seconds required to produce a density of 0.6 above 

minimum density with the indicated development. 

COpy APPL.lCATIONS 

This film can be used in many applications where KODAK 

High Contrast Copy Film 5069 (a discontinued product) 

was previously used, such as copying printed material and 

making reverse-text title slides. 

It is recommended that two light sources be used: oneon 

either side of the copy material and arranged so that the 

light strikes the material to be copied at about a 45-degree 

angle. For originals larger than 16 x 20 inches, four lamps 

(two on each side) may be needed for added and more 

uniform illumination. 

For exposure meters marked for ISO (ASA/DIN) speeds 

or exposure indexes: 

Tungsten--320/26° 

(for incident-light readings and for reflected-light 

readings from gray card-18 percent reflectance-at 

the copyboard) 

Tungsten--64 I 19° 

(for reflected-light readings from matte-white card90 percent reflectance-at the copyboard) 

When using a through-the-Iens metering camera, replace the copy with a gray card while establishing exposure; otherwise, the camera may give incorrect readings, 

depending ()n the amount of text in the copy. 

The values above are intended as starting points for trial 

exposures and are based on development with KODAK 

Developer 0-19 for 4 minutes at 68°F (20°C) in a small tank 

with agitation at 30-second intervals. 

The exposure index is based on the formula EI = 36/E, 

where E is the 1-second exposure in lux seconds required 

~ 

for a density of 1.20 above minimum density with the 

indicated development. 

As an alternative to using an exposure meter to determine exposures, the following examples can be used as 

starting points to obtain correct exposure: With two No.2 

photolamps in matte-surfaced reflectors at about 4 feet 

from the copyboard, give 1 160 second at f18. With two No. 

1 photolamps, exposures will be approximately twice that 

needed with No.2 photolamps. 

FILTER FACTORS 

When through-the-Iens exposure meters are used, the 

following filter factors should be used to correct the meter 

reading obtained without the indicated filter in place; if the 

meter is read through the filter, the filter factor will be 

significantly less. 

KODAK WRATTEN Filter Filter 

Gelatin Filter Factor· Factort 

NO.8 1.2 1.5 

No.11 5 

No.12 1.2 

No.13 6 

No.15 1.2 2.0 

No. 25 2 3.0 

No. 38 3.0 

No. 47 25 

No. 58 12 

• Based on 1-second tungsten exposure with development for 

8 minutes at 68°F (20°C) in KODAK HC-110 Developer. 

Dilution D. 

tBased on 1 125-second daylight exposure with development for 

15 minutes at 68°F (20°C) in POTA Developer. 

RECIPROCITY FAILURE 

For exposures between 1/10,000 and 1 second, no correction in exposure conditions is required to compensate 

for reciprocity effects. However, for exposures shorter than 

1 1500 second, it may be desirable to increase development 

in order to compensate for the tendency towards reduced 

contrast with very short exposures. 

With This 

Exposure 

Time 

(seconds) 

1/10,000 

1/1,000 

1/100 

1/10 

1 

10 

100 

Changes in Speed and Contrast 

Due to Reciprocity Effects 

Increase 

Exposure Adjust 

OR Exposure by (lens Index to stops) 

None 125 

None 125 

None 125 

None 125 

None 125 

+ % 80 

+ 1 Y3 50 

Contrast 

Index 

Changes 

by This 

Amount 

-0.20 

-0.15 

-0.05 

0 

+0.07 

+0.07 

0 

Based on development in KODAK HC-11 0 Developer (Dilution D) 

for 8 minutes at 68°F (20°C) with agitation at·30-second intervals. 

C-13 

) 

) 

c 
( 

( 

KODAK TechnlCIII Pin Film 2415 

SPEED SHIFT' +0.10 ." 

A. 

e 

." 

CC 

II: 

W 

:IE 

CC 

u 

0 

-1/3 

-2/3 

~1 

-11/3 

-12/3 

l.potU ... : Tungsten Ot Daylight 

PIOCftI: KODAK Developer He- 1 10 Ollullon 0 

8 minutes 8168°F (20-C) 

o II! 

-0.10Cliil 

-0.20 go -0.30 !!c -0.40 W 

Iii CONTRAST INDEX SHIFT • ... +0.10 ~ .. .001l:W 

:t: 

... -ZX 

0'" 

U - 1.0 ~~ -0.200- (J 

....!... ..L ..L .l.. ..!. 1 2 4 810 32 100 100 ~ 2$ 10 5 

TIME In Second. 

'At. density 0.10 .bove grOlllOg 

IA! a denSity 01 0 10 above grOIl fog and .2.00 log eKposure range. 

PROCESSING 

SMALL-TANK PROCESSING 

In some cases, particularly when you are processing with 

spiral reels, this film may be susceptible to nonuniform 

processing effects especially when using compensating 

developers such as POTA. To avoid these effects, do not 

pour the developers in the top of the tank. First fill the tank, 

then drop the reel smoothly and without interruption into 

the solution. This action not only promotes more uniform 

development but also helps prevent the formation of 

bubbles or air bells. Rap the tank a few times initially to 

dislodge air bells that may have formed and agitate slightly 

all within the first 5 seconds. Cover the tank, and let it settle 

for 25 seconds. Avoid overagitation in the first 30 seconds. 

Thereafter, agitate the film gently by using 3 to 5 inversion 

cycles for 5 seconds every 30 seconds and finish processing in the normal manner. Experimentation will reveal the 

best method. 

Before using these developers, make sure that the 

solution is free of small air bubbles which, if they adhere to 

the emulsion surface, may cause small undeveloped clear 

spots on the film-dark spots on the print. Bubbles may 

form more easily if cold and hot water are mixed together; if 

bubbles do form, let the developer stand until they dissipate. Attaching an aerator to the water supply will help form 

very large bubbles which will rise immediately to the liquid 

surface without remaining in solution. 

For processing in small tanks with spiral reels and 

agitation' at 30-second intervals, use the following 

sequence: 

Develop to the desired contrast index based on information in the exposure section' and on the characteristic 

curves. The contrast index obtained depends primarily 

upon the developer, temperature, dilution, and development time chosen. It is affected to a lesser extent by 

exposure time (see Reciprocity Failure), specific processing techniques, and normal product variability. Therefore, 

. the times given should be considered as starting pOints 

only. 

Rinse at 65 to 70°F (18.5 to 21°C) in KODAK Indicator 

Stop Bath, KODAK Stop Bath SB-1a, or KODAK Stop Bath 

SB-5 for 15 to 30 seconds. Use running water for 30 

seconds if no stop bath is used. 

Fix at 65 to 70°F (18.5 to 21°C), with frequent agitation. 

KODAK Rapid Fixer 1 Y2 to 3 minutes 

KODAK Fixer 2 to 4 minutes 

KODAK Fixing Bath F-5 2 to 4 minutes 

Wash in clear, running water at 65 to 70°F (18.5 to 21°C) 

for 5 to 15 minutes, depending upon reduction of residual 

hypo needed. 

To save time and conserve water, KODAK Hypo Clearing 

Agent can be used. Rinse the fixed film in running water for 

15 seconds. Next bathe the film in KODAK Hypo Clearing 

Agent for 30 seconds with agitation. Then wash the film for 

1 minute in running water at 65 to 70°F (18.5 to 21°C), 

allowing at least one change of water during this time. 

Dryin a dust-free place. Heated forced air at 120to 140°F 

(49 to 60°C) may be used to reduce drying time. 

MACHINE PROCESSING 

Using the KODAK VERSAMAT Film Processor, Model 11, 

and the listed chemicals, follow one of the processing 

sequences described here. For the three processing 

sequences, fixing and drying are adequate at the recommended machine speeds. The user should run tests to 

determine that washing quality is adequate. 

KODAK VERSA MAT 641 Developer Replenisher 

KODAK VERSAMAT 641 Developer Starter 

KODAK VERSAMAT 641 Fixer and Replenisher 

Processing Sequence 

Step No. of Path Length Temperature Racks 

Develop 1 4 ft (1.2 m) 85 ± 112°F 

(29.5 ± 0.3°C) 

Fix 3 12ft(3.7m) 85°F (29.5°C) 

nominal 

Wash 2 8 ft (2.4 m) 75 to 80°F 

(24 to 27°C) 

Dry - 8 ft (2.4 m) 135 to 140°F 

(57 to 60°C) 

To produce a contrast index of about 1.4, start with a machine 

speed of 10 feet per minute (3.05 m/min). 

5 

C-14 
,~ 

KODAK VERSAMAT 885 Developer Replenisher 

KODAK VERSAMAT 885 Developer Starter 

KODAK VERSA MAT 885 Fixer and Replenisher 

Processing Sequence 

Step No. of Path Length Temperature Backs 

Develop 1 4 ft (1.2 m) 85 ± 112°F 

(29.5 ± 0.3°C) 

Fix 3 12 ft (3.7 m) 85°F (29.5°C) 

nominal 

Wash 2 8 ft (2.4 m) 75 to 80°F 

(24 to 27°C) 

Dry - 8 ft (2.4 m) 135 to 140°F 

(57 to 60°C) 

To produce a contrast index of about 2.2, start with a machine 

speed of 10 feet per minute (3.05 m/min). Adequate washing is 

obtained at speeds up to 15 feet per minute (4.5 m/min). 

KODAK VERSA FLO Developer Replenisher 

KODAK VERSAFLO Developer Starter 

KODAK Rapid Fixer 

Processing Sequence 

Step No. of Path Length Temperature Flacks 

Develop 2 8 ft (2.4 m) 80 ± 112°F 

(26.5 ± O.3°C) 

Fix 3 12ft(3.7m) 80°F (27°C) 

nominal 

Wash 2 8 ft (2.4 m) 70 to 75°F 

(21 to 24°C) 

Dry - 8 ft (2.4 m) 135 to 140°F 

(57 to 60°C) 

To produce a contrast index of about 1.8, start with a machine 

speed of 8 feet per minute (2.4 m/min). Washing is not sufficient to 

provide archival quality but should be adequate for many scientific 

recording applications. Transport difficulties may be encountered 

when processing sheet or short strips of film in VERSAFLO 

Developer. 

6 

CHARACTERISTIC CURVES 

KODAK Technlc.1 Pin Film 2415 

Ch.r.cterl.tlc Curve 

Exposure: Tungsten. 1;25 second 

Proce .. : KODAK DEKTOL Developer 

3 minutes a168'F (20°C) In a small 

lank with agllallon al 30-second Intervals 

Densitometry: Amencan Standard 

diffuse visual density 

ElIpOlure Inde.: 200 

Cont,", Index: 2 SO 

JHA 

0.00 

LOG EXPOSURE (lux seconds) 

4.0 

3.0 

2.0 

1.0 

,..--------------:::;::0----,4.0 

KODAK Ttehnlc.1 Pin Film 2415 

CharacteflSllC curves lor 

development In 

KODAK O"eto,"' 0-19 al 68<F 120'C, small tank 

agllallon al 30-second intervalS 

Tunoil.n ,.polUr., 1 second 

Denillom.try: Amer.can Standard 

dllluse visual denSity 

Contrast 

Index 

Exposure 

~2!!... 

3001"""'---,200 

Development T .me 

Imlnutes' 

0.0 

LOG EXPOSURE (lux sec) 

C-1S 

LHX 

~ U; 

Z 

w 2.0 C 

w 

CJ) 

1.0 

1.0 

::> 

u.. 

u.. 

C 

> IU; 

Z 

w 

C 

w 

CJ) 

::> 

u.. 

u.. 

C 

) 

) 
( 

KODAK Technical Pan Film 2415 -Characterl,tlc: Curve 

Expo.urI: Tungsten, 1/25 second 

Proce .. : KODALITH Liquid Developer 

1:3 dilution. 3 minutes at 68°F (20°C) in a small tank with agltallon at 30-second 

intervals 

Dan,llomelry: American Standard 

diffuse visual density 

Expo.ure Index: 50 

Contr,.llnd.x: 2.50 

2.00 1.00 0.00 

LOG EXPOSURE (lux seconds) 

KODAK Technical Pan Film 2415- Ch,r.clerlllic Curv .. 

Expo.ure: Tungsten. 1125 second 

Proc ... : KODAK Hc-nO Developer. 

Dilution 8: 4. 6, 8, and 12 minutes at 

68°F (20°C). in a small tank with 

agitation at 30-second intervals 

Den,ltometry: American Standard, 

diffuse visuat density 

Contrast 

Inde)! Exposure Index 

~::0250 '.60 .,/'/' 200 

1.40 150 

1.20 100 

4 6 8 12 

Development Time (minutes) 

2.00 1.00 0.00 

LOG EXPOSURE (lux seconds) 

4.0 

3.0 

2.0 

1.0 

JHA 

4.0 

3.0 

2.0 

1.0 

JHA 

>- lii) 

z 

w 

Q 

w 

en 

::J 

II. 

II. 

Q 

>- lii) 

Z 

w 

Q 

w 

en 

::J 

II. 

II. 

Q 

KODAK TKhnlcli Pan FUm 2415 

CharacteristIc curves for development In 

KODAK YERSAMAT 115 D"~Ope, at 

85°F (29 5G C) In a KODAK VERSAMAT 

FIlm Processor. Model 11 (1 developer rack) 

D.~llghl eJipoaur •• 1/25 second 

Denlltometry: Ametlcan Standard dlltuse 

vIsual denSltv 

Exposure 

Index 

10 15 20 Processor Speed 

(I&at/mlnl 

2.0 1.0 0.0 

LOG EXPOSURE (lux sec) 

KODAK Technical Pan Film 2415 -Characterlsllc Curve, 

EJlpo,ure: Tungsten. 1/25 second 

ProceU: KOCAK Developer 0-76. 6.8. 10, and 12 mmutes at 68<>F (20°C). in a small tank with agitation at 

30-second Intervals 

Densnometry: American Standard 

diffuse visual density 

Contrast Exposure 

Index Index 

~~:0'25 1.50 ,/' '00 

1.25 l 75 

1.00 50 6 8 10 12 

Development Time 

(minutes) 

2.00 1.00 0.00 

LOG EXPOSURE (lux seconds) 

25 

LHX 

JHA 

C-16 

4.0 

i) 

>- li;; 

z 

W 

e 

2.0 w 

en 

::J 

II. 

II. 

is 

~-

1.0 

4.0 

3.0 

>- Iiii 

z 

w 

Q 

2.0 w 

en 

::;) 

II. 

II. 

Q 

1.0 

7 
.----------------::~-__,4.0 

KODAK Technical '.n FUm :24'5 

CharactenstlC curves lor development In 

KODAK VEASAMAT 641 D • .,.loper at 

85GF (29.5"C) In a KODAK YEFI$AMAT 

Film PrOcessor. Model 11 11 developer rack) 

D.,lIght It.polUf', 1 '25 second 

Den.llom.lry: American Standard dilluse 

Contrast 

Indell 

Visual denSIty 

Exposure 

Indel( 

220r------..,200 

1.00 

060'-....... _ ............ ~ 

5 10 

2.0 To 0.0 

LOG EXPOSURE (lux sec) 

LHX 

3.0 

~ 

en 

z 

w 2.0 Q 

w 

o 

::I 

LL. 

LL. 

E 

1.0 

1.0 

....------------------.....,4.0 

KODAK T,chnlc.1 Pan Film 24'5 

Characteristic curves lor development 10 

KODAK He-nO Dev.lopfi (Dilution D) al 

68'F 120'C) small lank. agltallon al 

30-second U'llervals 

Tung.t.n .. potu,., 1 second 

D.nlltoftMiry: American Standard 

dlHuse Visual denSity 

To 

Exposure 

Indell 

:::Ga"~/ ~~~ :: 140 

120 SO 

4 5 6 7 8 

Development Time 

(minutes) 

0.0 

LHX 

LOG EXPOSURE (lux sec) 

3.0 

~ e;; 

Z 

1&1 

2.0 0 

1&1 

I/) 

1.0 

1.0 

::I 

LL. 

LL. 

is 

....---------------==----,4.0 

KODAK Technlc.1 Pan Film 2415 

Characteristic curves fot development In 

KODAK VERSAFLO Oeveloper al 

aO'F (26.5'C) In a KODAK VERSAMAT 

Film Processor. Model 11 

12 developer raCks) 

Tung_'en e.po_ure, 1 second 

Oensltome1ry: American Standard 

dilluse Visual denSity 

2.0 1.0 

Exposure 

!'2!!. 

100 

a 12 16 Processor Speed 

Ileel per minute) 

0.0 

LOG EXPOSURE (lux sec) 

KODAK TechnlCl1 Pan Film 2415 -Chlrlcteri,tlc Curve. 

E.polure: Tungsten. 1/25 second 

P,oce .. : KODAK MICRODOL-X Developer, 

8.10 and 12 minutes al 68'F 120~C) In a 

small tank with agitation al 30-second 

Intervals 

Oenlltometry: Amencan Standard 

diffuse Visual denSity 

Developmg 

Time (min) 

8 

10 

12 

Contrast 

Index 

Exposure 

~ 

32 

50 

50 

::0 1.20 

1.00 

8 10 12 

Development Time 

(minutes) 

2.00 1.00 0.00 

LOG EXPOSURE (lux seconds) 

C-17 

3.0 

>- le;; 

Z 

1&1 

2.0 0 

1&1 

I/) 

::I 

LL. 

LL. 

is 

1.0 

'00 

50 

20 

LHX 

1.0 

4.0 

3.0 

2.0 

1.0 

JHA 

) 

}' 

). 

>- le;; 

Z 

1&1 

C 

1&1 

I/) 

::I 

LL. 

LL. 

is 

J' 
.~ 

2.0 

KODAK Technic.' Pan Film 2415 

Characteristic curves for development In 

KODAK HC·l10 Develop., (Dilution F) at 

68'F (20°C). small tank. 

agitatIOn at 3O-second Intervals 

Tung.ten •• polur •. 1 second 

Dln.ltornetry: Amellcan Standard dilluse 

Visual denSity 

Contrast Exposure 

Index Index 

, 0 

0.95 60 

090 

085 

080 30 

6 '0 

Devetopment Time 

(minutes) 

1.0 0.0 

LOG EXPOSURE (lux sec) 

SHEET FILM 

KODAK Technical Pin Film 2415 

Chlrlcl.rlalic Curve. 

Expo.ure: Daylight. 1/25 second 

Proc ... : PQrA Developer. 7 10. and 

12 minutes at 68" F (20" C) In a tray 

With continuous agitation 

Oen.llometry: American Standard 

dIffuse visual density 

Contrast 

Indell Exposure Indell 

o.e0(2) 32 070 

0 .. 60 25 

0.50 

040 20 

7 10 12 

Development Time (minutes) 

0.40 

LOG EXPOSURE (lux seconds) 

4.0 

3.0 

> Iiii 

Z 

W 

2.0 0 

W 

(Jj 

::> 

LI. 

LI. 

C 

1.0 

LHX 

1.0 

4.0 

3.0 

> lii) 

Z 

w 

c 2.0 w 

(Jj 

::> 

LI. 

LI. 

C 

1.0 

JHA 

The sensitometric curves and data in this publication 

represent product tested under the conditions of exposure 

and processing specified. They are representative of 

production coatings and, therefore, do not apply directly to 

a particular box or roll of photographic material. They do 

C-18 

KODAK Technical Pan Film 2415 

CharactenstlC curves lor development In 

porA Developer at 68· F (20' C). small lank. agllallon 

30-second mtervals 

Daylight expo.ure: 1 25 second 

Densitometry: AmeHcan Standard diffuse visual denSIty 

Contrast 

Inde ... 

070 

060 

050 

0.40 

030 

'0 

2.0 T.o 0.0 

LOG EXPOSURE (lUX sec) 

KODAK Technical Pan FUm 2415 

-Characteristic Curves 

Exposure: Daylight. 1.'25 second 

Process: KODAK TECHNIDOL LC Developer 

12. 15. and 18 minutes at 68°F (20~CJ In a 

small tank With agltallon at 30~second 

intervals 

Densllometry: American Standard 

diffuse visual density 

Contrast 

Index 

o.eU 0.7 

0.6 

05 

0.4 

0.3 

12 15 18 

Development Time 

In Minutes 

2.13 1.13 0.13 

LOG EXPOSURE (lux seconds) 

4.0 

3.0 

> Iiii 

Z 

w 

0 

W 

(Jj 

::> 

LI. 

LI. 

C 

1.0 

4.0 

3.0 

> le;; 

Z 

w 

c 

2.0 w 

C/) 

~ 

u. 

u. 

C 

1.0 

not represent standards or specifications which must be 

met by Eastman Kodak Company. The Company reserves 

the right to change and improve product characteristics at 

any time. 

I) 

/~ 
,~, 

PRiNTING 

The 0.1 neutral density built into ESTAR-AH Base is 

approximately half that found in conventional 35 mm 

picture-taking films. It follows that pictorial negatives 

which have been given optimum exposure and processing 

may appear to be "thinner" than normal. It is important to 

take this factor into account when judging the printability of 

negatives. 

The extremely fine grain of 2415 Film invites printing at 

higher magnifications than are usually considered acceptable with conventional picture-taking films. Enlargements 

made at magnifications greater than 25X with highly 

specular (point source) enlargers will be marred by a 

random distribution of poorly defined white specks in 

otherwise dense areas. The specks are caused by tiny 

matte particles which we find necessary to coat on the back 

surface ofthe film. Their presence can be masked with little 

loss in overall sharpness of the image by using an enlarger 

having a diffuse or semi-diffuse illumination system. 

HANDLING AND STORAGE 

Store unexposed film at 70°F (21°C) or lower in the original 

sealed container. Aging effects are lessened by storing the 

film at lower temperatures. If film has been refrigerated, 

allow the package to reach room temperature for 2 to 3 

hours before opening; if frozen, allow 5 hours. 

Load and unload the camera in subdued light, and 

rewind the film completely into the magazine before 

unloading the camera. For best results, process the film as 

soon as possible after exposure. 

When handling sheet sizes of KODAK Technical Pan Film 

2415 it is important to remember that it is coated on a 

support (ESTAR-AH Base) which has approximately half 

the thickness of the bases commonly used in sheet films in 

the days when most sheet film holders were being deSigned. To be sure of proper film location in the holder, it is a 

good idea to use a backing sheet made by exposing and 

processing a sheet of the 2415 Film to maximum density. 

The backing sheet should be clipped at a" four corners to 

provide easy identification when loading and unloading 

film holders with 2415 Film in total darkness. The support 

thickness of this product should be kept in mind also when 

processing sheets either manually or in machine 

processors. 

Total darkness is required when removing the film from 

the magazine or in loading and unloading film holders, and 

in processing. However, after development is half completed, a suitable safelight lamp with a 15-watt bulb and a 

KODAK Safelight Filter NO.3 (dark green) can be used for a 

few seconds if the safelight is kept at least 4 feet (1.2 

metres) from the film. 

Store processed film in a cool, dry place. 

FILM SIZES AND 

ORDERING INFORMATION 

Three sizes are listed and are available in single units 

through dealers who regularly supply Kodak products to 

professional photographers. In addition, the 135-36 size is 

available through dealers who carry Kodak products for 

general picture-taking. If your dealer does not have the film 

in stock, it can be ordered for you. 

Size & Specification 

135-36 magazine 

35 mm x 150 ft 

Sp 651 (Type AA core, KS perf) 

4 x 5-inch, 50 sheets per pkg 

CAT No. 

129 7563 

1299916 

1524594 

Because this film has a thinner base than conventional 

35 mm picture-taking films, 150-foot rolls finished to Sp 651 

will fit in bulk-film loaders designed to accept 1 OO-foot rolls. 

The 4 x 5-inch sheet film package contains two hermetically 

sealed envelopes, each holding 25 sheets. 

Other sizes are available on a special order, subject to 

manufacturing limitations and prevailing minimum order 

requirements. Minimum order quantities for special-order 

sizes correspond generally to 750 square feet of film. 

ADDITIONAL INFORMATION 

To obtain additional information regarding KODAK Technical Pan Film 2415, its availability in special-order sizes, and 

ways to optimize its performance in specific applications 

(e.g., photomicrography, astrophotography, copying. pictorial photography), please write in reasonable detail to: 

Scientific and Technical Photography 

Customer Technical Services 

Eastman Kodak Company 

343 State Street 

Rochester, New York 14650 

The Kodak materials described in this publication for 

use with KODAK Technical Pan Film 2415 are available from those dealers normally supplying Kodak 

photographic products. 

Consumer/Professional & Finishing Markets ~ 

EASTMAN KODAK COMPANY· ROCHESTER, NEW YORK 14650 ~ 

KODAK Technical Pan Film 2415 

KODAK Pamphlet No. P-255 

Reprint 11-82-AE 

Printed in the United States of America 

KODAK, KODALITH. D-76, MICRODOL-X, DEKTOL, TECHNIDOL. 

ESTAR-AH. PANATOMIC-X. PLUS-X, HC-110. D-19. 

VERSAMAT. VERSAFLO. and WRATTEN are trademarks. 

C-19· I 
This Page Intentionally Left Blank 
A P PEN D I X D 

SHUTTLE QUALIFIED LAMP 

This appendix describes lamps that are already qualified for operation. on the Shuttle Orbiter. These 

lamps represent available types. Discussions with 

ILC indicate that a similar lamp can be developed for 

the Free Surface Induced Phenomena experiment. 

D1 
I 

\ ........ _____________ , •.•.... . --________ . _. _iF.di'II_~,;jIIIi 

D-2 

.. ~ 
0 

I 

W I 

-) 

,,'_.-- --... 

''--

POSITION Af\!D TYPES OF I~~TER;OR CABIN LIGHTS 

Me 434-0068 

CONFIGURATION LOCATION SIS QTY 

-0009 MID DeCK PANEL 2 

-0011 AFT STATION 1 

-0014 GENERAL LIGHTING 9 

-0015 MISSION SPECIALIST 1 

-0016 PAYLOAD SPECIALIST 1 

-0019 AIR LOCK 2 

-0020 AIR LOCK 2 

-0021 CMDR OVERHEAD 2 

BUNK UGHT 4 

-0022 PILOT OVERHEAD 1 

-0023 GLARESHIELD 2 

-0024 GLARESH.!E-LD 1 

-0025 GLARESHIELD 1 

-0026 GLARESHIELD BALLAST 2 

----------.. --.... - --.-~ .. --.--.- ------------ .. 
o 

I 

..J::> 

INTERIOR LIGI'iT ASSEr~~BlIES 

* DEVELOPED AND QUALIFIED FOR SHUTTLE PROGRAM 

* SPECIAL PROCESS CONTROLLED FLOURESCENT LAMP SOURCES 

* QUALIFIED CIRCUITS FEATURING 

-DIMMING CONTROLS 

-NO VISUAL LAMP FLICKER 

-MEETS EMI REQS 

-ALL ENVIRONMENTAL REQS 

* NO HAZARDOUS MATERIAL CONTAMINATION 

* LONG LIFE, SUBSTANTIAL START/RE-START CAPABILITY 

* LOW POWER OPERATION 

-------'. 

-..... .--. -_._------------ .. - ------------ ----

J ) J 

( 

Q 

o 

I 

(l) 

(-----------------

VIBRATION 

DURATION 

DURATION 

'--

~) 

Hz 

20-150 

150-300 

300-400 

400-1000 

1000-2000 

48 MINI AXIS 

Hz 

20-150 

150-900 

900-2000 

48 MINIAXIS 

----------------------_._--_. - -- ---- -

.J 

LEVEL A 

+6dB/OCTAVE TO 0.2 9 2 1Hz 

COtlST AT 0.2 9 21Hz 

-6dB/OCTAVE TO 0.12 9 2 1Hz 

CONST AT 0.12 9 2 1Hz. 

- 9 dB I 0 C T A V E: F-R o. 1 2 9 2 1 Hz 

LE·VEl B 

+5dB/OCTAVE TO 0.09 9 2 1Hz 

CONST AT 0.09 9 2 1Hz 

-9dB/OCTAVE FR 0.09 9 2 1Hz 

'~"'~1 

( 

( 

J 
,.. 

,-

o 

o 

I 

I _________________________ ._~' 

D-7 

I 
. I 

I 

I 

I 

; 

I 

! 

I 

I 

I 

I 

\ 

:~ ~ 

: 

: 

, I&;· 

.. . ~ • \,,!'!. 

-~ 

I 

I 

I , 

I 

I 

I 

"""'-------~--,-----) D-8 
-0 

--.--------~------------~r_--------~ ,.. ~ 

° II) 

(~ ~ ,.. 

°0 

~ 

,.. 

I 

I W 

UJ 

I 

cc 

(!) ~ w I , ,.. e 0 °0 IJJ 0 (\ 0') -I ""-

,.. C) 

,.. z 

« 0 

o. ::e 

<C 

UJ 

CO 

°0 

(0 

0 

10· 

~ 

, L-______ ~ ______ ~~~~~ __ ~ __ ~ ______ ~oo 

l~ _________ _=:::.:3:.:3:.::.J=__.;:;e...;.! ~..;.:.1;..'f/;__.;S;...;;3;.;..'_O: V:>=J.:.::O:..::O::.;:I=-~-.:-_______ --" / 

D-9 
This Page Intentionally Left Blank 
A P PEN D I X E 

Accelerometer Data 

An accelerometer is optional for the Free Surface Induced Phenomena Experiment. This appendix describes 

the ACIP/HlRAP system that provides an accelermeter 

capable of measuring to the ~g level. 

E1 
kms 

inc. A Subsidiary of KMS Industries, Inc. 

3621 South State Road, P.O. Box 1567, Ann Arbor, Michigan 48106 313/769-8500 

Mr. Jack Kropp 

Sr. Project Engineer 

Advanced Technology Group 

Bldg. Rl, Rm 2216 

TRW-STG, One Space Park 

Redondo Beach, CA 90278 

Dear Jack, 

83-AERO-0150 

22 March 1983 

As a followup to our telecon of 21 March regarding Shuttlequalified micro-g accelerometer systems, I have enclosed a 

brochure describing our ACIP/HIRAP system and a possible block 

diagram for a modified HIRAP system conforming with your requirement. 

In the block diagram, the HIRAP package would provide triaxial accelerometer outputs over the range of one micro-g to 8 milli-g with corrected long term stability on the order of one micro-g. Changes in 

scaling and dynamic range are possible with minor modifications "J 

The existing Mini-Data Handling Electronics (DHE) assembly was designed to accept 6 channels of Orbiter control surface transducers 

but could be adapted to the HIRAP-only configuration for cost 

savings. I believe that only an additional formatter card would 

be required as new hardware to replace the PCM Master Formatter that 

we currently use for our 18 channel system. 

Since both the HIRAP and r1ini-DHE are Shuttle flight qualified and 

currently installed on Challenger for STS-6, I would expect only 

minimal qualification would be required for your mid-deck experiment 

implementation. 

For your budgetary planning purposes, the complete triaxial system 

with a Mini-DHE as shown in the block diagram has a rough order of 

magnitude (ROM) cost of l75K based upon minimal test and qualification. 

If I can assist you with further definition or information for your 

application, please contact me at 313 769 8500, ext 251. 

Very best regards, 

James 

~ C. Fox 

NASA Program Mgr. 

Aerospace Technology Group 

JCF:sh 

E-2 

1\ / 
IN 

AC 

a 

x 

a 

y 

a 

z 

I'Tl 

I 

W 

) 

PUT 

CEL 

) 

I I 

r-__________ ~~ __________ ~TEST 

I I 

I 

LOOP .TEST 

HIGH 

RESOLUTION TRIAXIAL 

ACCELEROMETER SIGNALS 

PACKAGE 

(HIRAP) 

HOUSEKEEPING 

TEMPS, VOLTS 

~ENERATOR CMD -----------

I PRESAMPLE 

FILTERS 

I 

I I 

HSK 

I SIGNAL CONDIT. 

I MINI-DHE ASSEMBLY 

MULTIPLEXER I 

AND ~ 

AID CONVERTER I 

I 

~ 

I 

! 

FORMATTER SERIAL DIGITAL 

OUTPUT 

(NRZ OR BI-!O) 

MID-DECK EXPERIMENT ACCELEROMETER SYSTEM 

.-1, 
Space Transportation and 

I<ms Aerospace Technology 

Aerodynamic 

Coefficient 

Identification 

Package 

Pulse 

Code 

Modulation 

System 

inc. 

High Resolution 

Accelerometer 

Package 

E-4 
! ,,\ 

~~ Flexible,~~~~~~~~~~~~ 

Growth Oriented System 

ACI P/PCM/HI RAP 

Data 

Handling 

Electronics. 

(DHE) 

ACIP/Orbiter 

Thermal Mounting 

Plate 

Humidity 

Cover 

.. . Designed for Future Expansion 

Harness 

E-5 

Triaxial Accelerometerl 

Gyro Instrument 

Package (TAGI~) 

High Resolution 

Accelerometer Package 

(HIRAP) 

Pulse Code 

Modulator 

(PCM) 

Master Unit 
----------Mission Objectives 

The primary objective of the Aerodynamic 

Coefficient Identification Package (ACIP) and the 

High Resolution Accelerometer Package (H I RAP) 

is to acquire accurate measurements of orbiter 

rates and accelerations during the critical reentry 

and atmospheric descent phases. By obtaining 

this information, uncertainties concerning orbiter 

behavior will be significantly reduced. Thus, in the 

future, it may be possible for spacecraft to perform 

new maneuvers, carry bigger payloads, and remain 

in orbit for longer periods of time. 

The Pulse Code Modulation (PCM) System 

provides the digital data formatting and encoding 

required to transfer the digitized ACIP/HIRAP 

sensor data to the Shuttle tape recorder. Post-flight 

data tapes are analyzed by NASA scientists and 

engineers to derive the Shuttle aerodynamic, stability 

and control performance parameters associated with 

each flight. 

The ACIP/PCM system was initially installed on 

Columbia and has provided critical flight data 

measurements for each Development Flight Instrumentation (D F I) Shuttle mission. 

The AClP/PCM/HIRAP system has been installed 

on Challenger and will be utilized to additionally 

measure the micro-g accelerations on-orbit and during 

initial reentry. Although ACIP/PCM/HIRAP was 

designed for, and utilized by, the Shuttle Orbiter 

Experiments Program, many basic features are 

applicable to other space-based systems, including 

Space Station experiments, Orbiter Transfer Vehicles, 

and Space Materials Processing. The ACIP system has 

been developed for the NASA Johnson Space Center. 

E-6 

• 

• 

• 

• 

• 

• 

• 

• 

• 

• 

• 

• 

ACIP/PCM/HIRAP 

CHARACTER ISTICS TABLE 

ACIP 

3 linear Accelerometer Sensors 

3 Angular Accelerometer Sensors 

3 Rate Gyro Sensors 

Handles data from 6 control surfaces 

HIRAP 

3 High Resolution Accelerometers 

Fine and Coarse Temperature Sensors 

Accurate to One Micro-g 

PCM 

Operates at 64 Kbps 

Up to 512 addressable channels 

Four selectable bit rates 

(16,32,64, 128 Kbps) 

Master/slave unit, up to 4 slaves 

Serial data/address transmission master 

master to slave 
- A Sensor System 

ACI P/PCMlHI RAP 

The ACIP is an orthogonal 3-axis sensor 

system which is made up of 3 hydrostatic 

suspension single degree of freedom rate 

gyros, 3 force balance linear accelerometers 

(T AG I Pl and 3 single axis, flu id rotor (T AAl 

angular accelerometers. The H I RAP provides ~~ orthogonal, pendulous proof-mass, 

force rebalanced precision linear accelerometers to the Shuttle data acquisition 

system. 

ACIP SENSOR PARAMETERS 

Unit Space Direction Range Sensor Resolution 

Linear X-Axis ± 1.5g 150J,Lg 

Accelerometer ( Longitudinal) 

Y-Axis ± 0.5g 50J.Lg 

(Lateral) 

Z-Axis ±3.0g 300J.Lg 

(Normal) 

Angular X-Axis (Roll) ± 2.0 rls2 240J.Lrls2 

Accelerometer Y-Axis (Pitch) ± 1.0 rls2 120 J.Lrls2 

Z-Axis (Yaw) ± 1.0 rls2 120 J.Lrls2 

Rate Gyro X-Axis (Roll) ± 30.0° Is .003°/5 The analog outputs of these sensors are 

presample filtered, multiplexed and converted to a serial digitial format_ Included 

in this format is the data from 6 control 

surface sensors which are correlated with 

data from the 3 axis sensor system. 

Y-Axis (Pitch) ± 10.0° Is .001° Is 

Z-Axis (Yaw) ± 10.0°/5 .001°/5 

Micro-g Linear X-Axis (Roll) ± 8.0 milli-g 1.0J.Lg 

Accelerometer Y -Axis (Pitch) ± 8.0 milli-g 1.0J.Lg 

r---OHE----·I 

3 Rates --r--"'- r-- 3 linear I I 

rlt--r I T -~~ .J-. 1 L..---. Ac~el. I r- ----------

-~~ 1 Accel. 

Z-Axis (Yaw) 

6 Control 

~Surfac8 

Signals 

Digital 

~Recorder 

Si~O/P 

_IRIG·S 

Input 

I ___ 4,_+-___ +-_ .. -To .. Command 

0-

1 I 

I· I 

1 1 I ___ -+I_+-_-+-~ ___ .. widOb.nd 

1 I Record .. 

_________ J 

-f---\---+----4t He.t 

Power 

~"T------'----.28 V 

E-7 

± 8.0 milli-g 1.0J.Lg 

The merged sensor digital data 

is transferred to the Orbiter 

Experiment system tape recorders 

via the PCM master unit serial 

Bi-phase output. 

Fourteen bit A/D conversion is 

performed at selectable rates up to 

8000 words/sec, By using a 

special design technique in conjunction with the I RIG-B time 

code, the time of any sample 

can be resolved to 0.1 msec. 
---------A Growth SystemACIP/PCM ... Accommodates Four Experiments 

The PCM is a master-slave system capable of 

supporting up to four slaves. Each slave constitutes a remote data collection terminal controlled 

by the resident master format program. Slave 

subsystems are responsible for their own power 

conditioning, analog and digital multiplexing, 

IRIG·B __ 48 

7 

Bit 1 __ 

8, 

I 8~ 

I • 

Bit 64 __ 

S.D. in 1 __ 

Enable 1 _ 

S.D. in 16 __ 

Enable 16_ 

.. 

... 

I 1 1 1 

tn tn tri tn I 

~ V I 

I • A To/From Slave Units 

E-8 

analog to digital and parallel to serial conversion, 

as well as for decoding of addresses, and format 

control and storage. Selectable bit rate clocks and 

all control signals necessary for proper operation 

of slaves are contained in the master unit. 

8 Bi ¢ 

/ 

- __PCM 

Output 

;U\ (:J External 

Programs 

'n/ 8 

Controls 

D System dJ + Timing Master 

Control Clock 

81, 

Regulated 

System Power 

<> j Test 

Outputs 

t 

+28V 

Unregulated 

Power 
,r 

! 

-Data Processing-----------

ACIP/PCMlHIRAP 

--+- --.-

t Tim., Temp 

Data t C.nb"tJo" 

Coefficient 

~ 

Preflight 

Cal Data 

Curves 

FLIGHT OPERATIONS 

Prior to the Shuttle orbiter reentry phase, two 

manual in-flight functional tests are performed. 

The first measures the ambient inertial variable 

date near the sensor's null state. The second verifies 

the sensor's servo loop operation at selected points 

over the full sCclle dynamic range. 

During the reentry phase minimum crew involvement is required to operate the ACIP/PCM/H I RAP. 

At approximately 400 to 450 Kft altitude, a 

command from the ACIP Orbiter Interface activates 

the ACIP/PCM/HIRAP system. 

.. . Operational Sequence 

-/~ 

t t .- 1.0 

Post-Flight 1\ ~ Power 

5Hz Spectral 

Analysis 

E-9 

DATA MEASUREMENT 

AND DATA REDUCTION 

Data measurements are obtained by sampling 

sensor outputs at a high rate after analog filtering. 

The data tapes are then transferred to the ground 

Orbiter Experiment Systems Analysis Laboratory 

for engineering unit conversion and sensor temperature logging. By using stored calibration, corrections 

are implemented before Finite Pulse Response 

digital filtering. This entire process results in a 

flexible, non-critical system with a dynamic range of 

10,000: 1 or greater. 
- Aerospace Advanced Instrument Systems -

KMS Fusion has developed and acquired significant capabilities in several technological areas that 

are directly applicable to NASA and DOD. These 

technologies include advanced instrumentation, 

lasers, optics, materials development and microfabrication techniques. In addition, KMSF has the 

capability to support its research and development 

with sophisticated engineering, computation and 

test facilities. 

KMS Fusion offers total systems capability to 

provide a broad spectrum of technical skills and 

experience encompassing all of the engineering and 

E-10 

ACJP\ 

Aerodynamic Coefficient Identification Package 

scientific disciplines required to develop and deliver 

end-to-end systems as well as an experienced program management team to guide the engineering 

effort through all program phases from concept 

development to production support. 

Future programs we are working on at KMSF for 

the Space Shuttle and proposed NASA Space 

Station include advanced inertial instrumentation, 

laser and optical instrumentation, space material 

manufacturing and processing, and potential microfabrication and biotechnology applications experiments. 

I<ms ) 

inc. 
I<ms 

inc. 

Ann Arbor, Michigan 

.~. 

E-11 
This Page Intentionally Left Blank 
A P PEN D I X F 

Surface Tension Induced Convection 

Safety Hazard Reports 

This appendix gives the Payload Safety Matrix and Payload Hazard Reports prepared for this experiment. 

F1 
~ .. ~O&O Surface Tension 

Convection EXD 

BiOllledical 

Ha,ard o.t~ction 

and Sarin.:-

CrYOlenicl 

Environ~ntal 

CCI"It rol 

fttdrluliCI 

x 

x 

x 

Driven 

x 

PAYLOAD SAFETY MATRIX 

x 

-

COl: 

c:t -z_ z ... - .. ........... - ... '" 0- co::..., CD 

&&I =z ...... a: _ .. """a.., 

.... 

- z .... 

-.,.jc.,) =-

x 

x 

"" ex:a = Q - .... - -..... -- co::::r _ a..co: ... ..., 

-

Q =--

....... co: -..., 

x 

II&TI 

2 Dec. 1982 

• 

~----------+-'-r--~~---r--T-~---r~+-~--~--+-~--~--~-+--4---~~ 

Wateriall x x x x 

Optical 

Prelsure Systems 

Propulsion 

Pyrohchnics 

Radiation 

Structures x x 

IS: F.,a 542 IF •• 7.) 

F-2 

.. ~ 
. r·· ~O • 

PAYLOAD HAZARD REPORT STDC-l 

~""1.0AO I'HAst 0 Surface Tension Driven Convection Experiment 

SUUYST~ Electrical ·~TII. 

2 December 1982 

M"URO TlTLl 

Temperature Extreme - Heater Runaway 

A~~"ICA'1.l IAHT., U~IU"'''TlI NHB 1700. 7A, Safety Policy and Requirements for Payloads Using the Space Transportation System (STS), paragraphs 201, Failure Tolerance, 201.2, Catastrophic Hazards and 213, Electrical Systems. 

OESCRI~TION 0' HAZ.RO. 

Inadvertent heater activation resulting in over-temperature of experimental 

fluid with possible over-~ressure and release to manned environment of 

fl ui d/vapor. 

HAURD CAUns. 

1. Loss of heater control. 

HUUD CONUOLS. 

,.VETY Y(RI'ICATION METHODS. 

STATUS. 

CONCURRENCE PHASE I 

l~ylOid Oraanilation 

STS Operator 

APPROVAL 

Payload 

O'amilation 

PHASE III 

I STS Operator 

19 

F-3 

PHASE II 

NASA-JSC 
1N0. 

PAYLOAD HAZARD REPORT STDC-2 

'''''UAO '''AU 

Surface Tension Driven Convection Experiment 0 

SUIS""~ : P4fJ, 

Electrical 2 December 1982 

I t1UIoIO T'TL.l 

Temperature Extreme - High Heater Current 

A"LICAII.I 'A'If,. "GUI"KINf" NHB 1700.7A, Safety Policy and Requirements for Payloads 

Using the Space Transportation System (STS), paragraphs 201, Failure 

Tolerance, 201.2, Catastrophic Hazards and 21.3, Electrical Systems. 

OlSC,.,T.ON 0' "AZA'O. 

Inadvertant failure of heater control allowing heater element to receive 

excessive current resulting in over-temperature of experimental fl ui d 

with possible over-pressure and release to manned environment of fluid/ 

vapor. 

"UloiD CAUSU. 

1. Heater Control (s) 

"AURO CO"TROLS • 

•• 'ITY YIR"'CAT.O" MITHOO •• 

STATUS. 

CONCURRENCE 

Payload Orleni •• tion 

m Operator 

'PPROYlL 

Payload 

Orleni •• tlon 

lie 'er. 5 4 2 ( • rllll 7 .) 

failure. 

PHASE I 

PHUE III 

1m Oper.tor 

19 

F-4 

PHASE II 

, 

i 

I 

/) 
(.?--. 

~O. 

PAYLOAD HAZARD REPORT STDC- 3 

""YI.O"O 1'14"" 

Surface Tension Driven Convection Experiment 0 

. DIITJ. lUlU""", Electrical 2 December 1982 

.. 61610 YITL.I 

Fire-Ignition of Flammable Atmospheres 

.... I'~IC ... L.' ."'ITy .'OUI.IM'.T •• NHB l700.7A, Safety Policy and Requirements for Payloads Using the Space Transportation System (STS), paragraph 219, Flammable 

Atmospheres. 

OlSC.,'TIOM 0' HA1 .. IO. 

Short circuit, electrical sparks, electrical or mechanical failures causing 

high temperature buildup within vicinity of flammable atmospheres resulting 

in ignition of flammable atmosphere and the production of smoke, contaminants, 

toxic fumes and fire. 

HA1UO CAUUS. 

l. Short ci rcui ts . 

2. Circuit overloads. 

3. Mechanical compbnent 

or fail ing. 

HAZUO COMTIOI.S • 

•• 'ITy Y'_"'CATIOM MlTHOOS. 

STATUS. 

CONCURRENCE 

Payloed Or • .ni •• tion 

ITS Operator 

APPROVAL 

Payload 

Orl.ni •• tion 

,ac '.f ••• 21 (f •• 71) 

4. Arcing or sparking. 

S. Poor grounding. 

freezing up 

PHASE I PHASE II 

PHASE III 

I 51'S Oper.tor 

19 

F-5 

MASA . JSC 
lNo. 

PAYLOAD HAZARD REPORT STDC-4 

'.YUAD '"AU 

Surface Tension Driven Convection Experiment 0 

SII .. yn~ Envi ronmenta 1 Control ·~T" 

2 December 1982 

I NAIA.D T,T .. ' 

Contamination - Inert Gas Escaping into Manned Environment 

A, .. ",CAI", UFITY n~IIl"'"TI. NHB 1700. 7A, Safety Pol i cy and Requi rements for Payloads 

Using the Space Transportation System (STS). paragraph 201, Failure 

Tolerance. 

DISCIII'TIDN D' "AIAIID. 

Failure of experiment container to isolate vapor of experimental fl ui d 

from manned environment. 

"AZARD CAUSes. 

1. Faulty non-redundant seals. 

2. Shattering of experiment container.' 

MAZARO CONTtlOL.I. 

'.'ITT VIRI'ICATION MITMOOS. 

STATui. 

CONCURRENCE 

"yloed Or,.nilation 

ITS Operator 

"PROYAL 

"yload 

O'a.niaation 

.lie fir • au • ( "1. 7 .) 

PHASE I 

PHASE III 

I 51'S Operator 

19 

F-6 

PHASE II 

IASA-JSC 
1"0. 

PAYLOAD HAZARD REPORT STDC-5 

'.YLDAD 'HAU 

Surface Tension Driven Convection Experiment 0 

pIIITJI. SUI 11''''''' Human Factors 2 December 1982 

• relulI.O'IT"1 

Injury - General 

A""ICAI"I IA'ETY .IOUIRIMIMTI. NHB 1700.7A, Safety Policy and Requirements for Payloads Usi ng the Space Transportation System (STS), paragraph 201, Failure 

Tolerance 

O(SCRI,TION 0' HalaRO. 

Injuy'y to personnel due to sharp corners, protruding equipment, accessible 

high temperature surfaces, dangerous procedures, and improperly restrained 

drawers. 

MaURO Cauns, 

l. Fa 11 ure to meet the requirements of MIL-STD-1472C, Human Engineering Desi gn Criteria for Military Systems, Equipment and Facilities. 

HUUO CONTROl,S • 

•• '[TY V[.I'ICATION METHODS. 

STATUS. 

CONCURRENCE PHASE I PHASE II 

"ylo.d Or&~ilation 

ITS Operator 

APPROUl PHASE III 

PIIyload 

Clrl~i lation J 51'S Operator 

JSC 'Ifa 5.21 (Fl. 71) 19 

F-7 

NASA . JSC 
~O. 

PAYLOAD HAZARD REPORT STDC-6 

'."LOAD 

'HAU 

Surface Tension Driven Convection Experiment 0 

SUU""JM P'lTJI. 

Human Factors 2 December 1982 

I MunD '''L.' Contamination~Release of Glass Particles to Manned Environment 

A"'.ICAIL' IA"T" IC~"ICM'''TI. NHB 1700.7A, Safety Policy and Requirements for Payloads 

Using the Space Transportation System (STS), paragraphs 201, Failure 

Tolerance and 206, Failure Propagation. 

DeSCII,TION 0' "AZAID. 

Shattering of glass lenses, fluid containers, and light bulbs by temperature 

transients, vibration and collision, causing injury to personnel . 

.. AUlD CAUUS. 

1. Changes in temperature which coul d cause fracture. 

2. Defective parts. 

3. Shock during g~ound loading. 

4. Unshielded shatterable materials. 

HUARD CONT.OLS. 

'.'IT., VII"ICATION MeTHODS. 

STATUS. 

CONCURRENCE 

Payload Orl.nia.tion 

STS Operator 

APPROVAL 

PIIylo.d 

O'l.niaation 

,ac 'I" 5.21 (fib 'I) 

'HASE I 

'HUE III I S1S Operator 

19 

F-8 

PHASE II 

·JSC 
IND. 

PAYLOAD HAZARD REPORT STDC-7 

'.VLOAO 'HA" 

Surface Tension Driven Convection Experiment 0 

SUIIY"..-

CPi'Tr. 

Human F~ctors 2 December 1982 r .... UJJO TITLE 

Electrical Shock - General 

."Lle.ILI "'ITv .IOUI.IMIWT •• NHB 1700.7A, Safety ~olicy and Requirements for Payloads 

Using the Space Transportation System (STS), paragraphs 201, Failure Tolerance 

and 213, Electrical Systems. 

OESC.I,TION 0' HAZ'.O. 

Injury to fl i ght personnel due to electric shock during contact with control 

panel. 

NAJAflO CAuIlS. 

l. Improperly secured or 

2. Defective conne~tors. 

3. Improper grounding. 

4. Improper fusing. Nuno CO"T-OI.S. 

iA'ETY V'_"ICATIO" WETHOOS, 

STATuS. 

CONCURRENCE 

hyloed Orillftilatian 

m Operator 

"PROUL 

hyload 

O'linilation 

Jlt FI,a 5.21 (FI~ 71 

vibrated loose connectors. 

PHASE I 

PHASE III 

I STS Operator 

19 

F-9 

PHASE II 

NASA . JSC 
~o. 

PAYLOAD HAZARD REPORT STDC-8 

Surface Tension Driven Convection Experiment o Pl'\T~ 

Materials 2 December 1982 

Contamination - Toxic Fumes A"~ICA'~I IA'ITY lIOUII'MIMTI. . . NHB 1700.7A, Safety Policy and Requirements for Payloads Using the Space Transportation System (STS), paragraph 209.1, Hazardous 

Materials. 

Non-compatibility of photographic film with a failure induced environment, 

causing a release of toxic fumes and/or fire. 

Muno CAUsn. 

1. Photographic film capable of discharging toxic fumes in a failure 

induced environment • 

.. unD C:OIiTItOLS. 

STATUI. 

CONCURRENCE 

Payload Orl.niaation 

ITS Operator 

'''ROUl 

Payload 

O'I.niaation 

PHASE I 

PHASE III I ITS Operator 

19 

F-10 

PHASE II 

~, 

) 
~O. 

PAYLOAD HAZARD REPORT STDC-9 

""'LOAO Surface Tension Driven Convection Experiment , .. AU 

0 

suuyn~ . PoIIT~ 

Materials . 2 December 1982 

MAu.o '''L.l Contamination-Electric Motors 

A""IUI .. ' .UITY ac~"acll'''TI. NHB 1700. 7A, Safety Policy and Requirements for Pay10ads 

Using the Space Transportation (STS), paragraphs 201, Failure Tolerance, 

202, Control of Hazardous Functions and 209.3,. Flammable Materials. 

orSCIII"IOH 0' .. AIA.o. 

Jammed electric motors can cause overheating resulting in mel ting and/or 

burning of material (insulation, bearing lubricant) 

production of smoke, contaminants, and toxic fumes. 

MAUIIO CAUns. 

Use of flammable 

.. AZAIIO Co"UOI.', 

S.'lTY YIIII'ICATIO" .l'MOOS • 

• UTU •• 

CONCURRENCE 

Payloecl OrUMilat1on 

STS Operator 

APPROYAL 

Payload 

OrlMhatlon 

• lie h,a 5 • 2 ( IF.II 71 

materials . 

'HUE I 

. 

'HASE I ITS Operator 

19 

F-ll 

III 

which leads to the 

PHASE I' 
IND. 

PAYLOAD HAZARD REPORT STOC-10 

"''ILOAO '"ASE 

Surface Tension Driven Convection Experiment 0 

: PIIT" SUIS,.n~ Materials 2 December 1982 lTuuo TITL.E 

Stress Corrosion I nduced Fa i1 ures 

A"LICAlL'UHT'IUOUIIEIIIIIITI'NHB 1700.7A. Safety Po~icy and Requirements for Payloads 

Using the' Space Transportation System (STS), paragraph 208.3, Stress 

Corrosion. 

Olscal,TIOII 0' "A%Aao. 

Failure of metal structures and parts due to stress (intergranular) corrosion 

allowing weakened structures to become flying projectiles. 

NunD CAUSES. 

1. Use of materials not meeting the requirements of MSFC-SPEC-522A. 

2. Manufacturing .stresses. 

HAZARD COMTROLS. 

~A'ETY Y[RI'ICATIOM METHODS. 

STATUS. 

CONCURRENCE PHASE I 

P.yload Oraenil.tion 

STS Oper.tor 

APPROVAL 

P.yloed 

Oralftiution 

ne 'er. 5 .21 rFtll 7.) 

PHASE III 

r STS Oper.tor 

19 

F-12 

PHASE II 

IlASA-JSC 
IND. 

PAYLOAD HAZARD REPORT STDC-ll 

",..,..OAO "HASI 

Surface Tension Driven Convection Experiment 0 

IUlSyn,... Materials . ~TJ, 

2 December 19132 

IMAUIO TI fL.' Contamination-Film 

A",,,IUIL' UHT'!' U~"I1"'"TI. NHB 1700.7A, Safety Policy and Requirements for Payloads 

Using the Space Transportation System (STS), paragraphs 201, Failure Tolerance, 

202, Control of Hazardous Functions and 209.3, Flammable Materials. 

orSCI,"T,OH 0' HAZA.O. 

Jammed rotating members can cause overheating resulting in melting and/or 

burning of,material (film) which leads to the production of smoke, contami nants, 

and t()X; c fumes. 

HAZUD CAUseS. 

l. Use of flammable materials. 

HAZUD CO"UOLS. 

,."TY V,.,"CATIO" .. £THODS. 

STATuS. 

CONCURRENCE PHASE I 

Payloed Ormlni •• tion 

ITS Operator 

APPROVAL 

Paylold 

Orllni •• don 

uc Flfl 542 I ( rhll 1 I) 

PHASE III 

I S1S (]perltor 

19 

F-13 

PHASE II 

MASA-JSC 
lNo. 

PAYLOAD HAZARD REPORT STDC-.12 

'."LOAO 'H'''I 

Surface Tension Driven Convection Experiment 0 

SUlSynJlt . ""'~ Structures 

liu ... o TlYU Projectiles 

."LIC •• LI '.'1'" .IOUI.'.IMTI. NHB 1700.7A, Safety PGlicy and Requirements fo r Payl oa ds 

Using the Space Transportation System (STS), paragraphs 208.1, Structural 

Design and 208.2, Emergency Landing Loads. 

OISCRI"IOM 0' MAZARO. 

Injury to personnel caused by failed structures or securing hardware allowing 

objects to become projectiles. 

HAURO CAUUS. 

l. Appropriate safety factors not applied. 

2. Propagation of·a pre-existing flaw·;n the materials used. 

Muno CONTIOLS. 

'.'IT,. VIII'ICATION METHODS. 

STATUS. 

CONCURRENCE 

PWyloed Orl~ilation 

m Operator 

APPROUl 

PWyload 

Orl~i .. tion 

.Ie Fir. 5.21 ("~ 71) 

PHASE I 

PHASE 

I 51'S Operator 

19 

F-14 

PHASE II 

III ~, 

) 
APPENDIX G 

Free Surface Phenomena 

Safety Reports 

This appendix contains the Payload Safety Matrix and 

the Payload Hazard reports for this experiment. 

Gl 
... "OAO 

Free Surface 

~ 

GROUP 

SUBSYSTEM 

BiOllledical 

Cr),ocenici 

Electrical 

Env i ronmen t a1 

Cantrol 

H\lUn F.ctors 

~drau1icl 

... terialt 

,"chanical 

Optiul 

P'.llur. SYlt.mS 

Propulsion 

Pyrotechnics 

Radiation 

Structures 

Phenomena 

ZW - Qz --"" . _ 0 .. - 0 

- z_ ... - ~~ .. ~ 

- 0 

? -... a: ZO a: .:= =- .:= c.:a .... - .... 

x 

x 

x 

x x X 

X 

PAYLOAD SAFETY MATRIX 

"AY~O·O O_G.""."O" ".'e 

Exp. 2 Dec .1982 

-

a: 

- .., ... 1:1 .. 

w -

0 .. 

:z .... 

--- --=- - 0 -... - - ............ - .. ... Of' .... -~ 0-

-.. :r --= 0 ..... -.. ....... w .... ... &oW =z .... -- a.. .. _c:o A. 

--.... .... 0.. CI ~= ... - :II: .... =- =- - -.... WJ ..... WJ .... ----" .. -..... 

x 

x x 

X 

x 

G-2 
PAYLOAD HAZARD REPORT FSPE-l 

Free Surface Phenomena Experiment o 

PIT .. 

Electrical 2 December 1982 

Fire-Ignition of Flammable Atmospheres 

ap,,,ICAI'" .""y I'~III"IIITI. NHB 1700.7A, Safety Policy and Requirements for Payloads 

Using the Space Transportation System (STS), paragraph 219, Flammable 

Atmospheres. 

DI.cal'TION 0' IIAIAID, 

Short circuit, electrical sparks, electrical or mechanical failures causing high temperature buildup within vicinity of flammable atmospheres resulting in ignition of flammable atmosphere and the production of smoke, contaminants, 

toxic fumes and fire. 

IIUAlD CAu.lS, 

1. Short circtiits. 

2. Circuit overloads. 

3. Mechanical compbnent freezing up 

or failing. 

STUUI, 

CONCURRENCE 'HASE I 

m Open'or 

"PROUl 

4. Arcing or sparking. 

5. Poor grounding. 

PHASE II 

'HUE III 

Payload 

Orllni.a,lon J 51'S Operator 

19 

G-3 
100. 

PAYLOAD HAZARD REPORT FSPE-2 

'.\'LO"O ...... " 

Free Surface Phenomena Experiment 0 

su .... n~ Envi ronmental Control . ~T" 

2 December 1982 

flil.1 ... 0 YIYU 

Contamination - Inert Gas Escaping into Manned Environment 

""".IC"I'" ... ",., 1I~'III1'.'" NHB l700.7A, Safety Policy and Requirements for Payloads 

Using the Space Transportation System (STS), paragraph 201, Failure 

Tolerance. 

O"CI.".o. 0' M"I"IO, 

Failure of experiment container to isolate vapor of experimental fl uid 

from manned environment. 

MUAIO CAU"', 

1. Faulty non-redundant seals. 

2. Shattering of experiment container,' 

MnUD COllno"" 

"'IT, ".".C .. T.OII WI'MODS, 

STATUS, 

CONCURRENCE 

Payloed Orl.ni.ation 

ITS Operator 

aPPRoval 

Paylold 

O'I.ni.atlon 

IIC ' •• a ,.21 ("~ 71) 

'HASE I 

. 

'HUE III 

T ITS Operator 

19 

G-4 

'HASE II 
/,,0. 

PAYLOAD HAZARD REPORT FSPE-3 

'."UAO '''A'' 

Free Surface Phenomena Experiment 0 

"' .... n .... PIIIT" 

Human Factors 2 December 1982 1 ... 610 ,,,'" • 

Injury - General A"~IC.'~' I."V" I'OUII,.,.TI. NHB 1700.7A, Safety Policy and Requirements for Payloads .using the Space Transportation System (STS), paragraph 201, Failure 

Tolerance. 

OUCII,TION 0' .. AUIO. 

Injury to personnel due to sharp corners, protruding equipment, accessible 

high temperature surfaces, dangerous procedures, and improperl y restrained 

drawers. 

MUUO CAuln. 

1. Failure to meet 

Design Criteria 

.. Auno COII,IOLI. 

,.,,'y VIII'ICATIOII .'T"OOI. 

STATUI. 

CUCURRENCE 

"yla.d Or,uni.ation 

m Operatol/' 

aPPROUl 

"yload 

Orl_la.tion 

JlC h,. U21 :". ,. 

the requirements of MIL-STD-1472C, Human Engineering for Military Syste"!s, Equipment and Facilities . 

'HASE I 

'HASE I srs Operator 

19 

G-5 

'HASE II 

III 

. C 
~O. 

PAYLOAD HAZARD REPORT FSPE-4 

"I\'UAO \ ~"A5E 

Free Surface Phenomena Experiment 0 

SllIIY"JM . P"'TJ. 

Human Factors 2 December 1982 

If AUlD '''L.' Contamination-Release of Glass Particles to Manned Envi ronment A~~L.I'AIL' .A'ITY I'OUII'.INTI. NHB 1700.7A. Safety Policy and Requirements for Payloads 

Using the Space Transportation System (STS), paragraphs 201. Failure 

Tolerance and 206, Failure Propagation. 

D(SCII'TION 0' "AIAIO' 

Shattering of glass lenses, fluid containers, and light bulbs by 

vibration and collision, causing injury to personnel. 

NUUO 'AUSlS. 

1. Changes in temperature which could cause fracture. 

2. Defective parts. 

3. Shock during ground loading. 

4 . Unshielded shatterable material s. 

.. A,A.O CDNT.OL.S. 

i.'(TY VI.I'ICATION .ITHOOi. 

STATuS. 

CONCURRENCE 

P.yloed Orl~ilation 

m Opentor 

APPROYAl 

P.ylOld 

O'I~iaatlon 

IIC ',ra '.21 (fl. 'I) 

PHASE I 

PHASE In 

I STS Operator 

19 

G-6 

PHASE II 

... SA . JSC 

/~ 
1-0. 

PAYLOAD HAZARD REPORT FSPE-5 

'.""ClAO , .... ,' 

Free Surface Phenomena Experiment 0 

"'lIvnJM PO\T~ 

Human Factors 2 December 1982 

I ilaaAlto "'L.I 

Electrical Shock - General 

""LIC"'LI ,,,'ITT a'OUlalMI.T •• NHB 1700.7A, Safety Policy and Requirements for Payloads 

Using the Space Transportation System (STS), paragraphs 201, Failure Tolerance 

.and 213, Electrical Systems. 

Duell "" ON 0' .AlUO. 

Injury to flight personnel due to electric shock during contact with control 

panel. 

MUAnD CAUSCI. 

1. Improperly secured or 

2. Defective conne~tors. 

3. Improper grounding. 

4. Improper fusing. .. uuo COIIT-DLI. 

,,'aT' ¥(."ICATIOII MET .. OO •• 

STATUS. 

COIICURRElltE 

Pwyloed Or&.ni.ation 

ITS Opent .. , 

'''ROYAL 

hylo.d 

Orc.ni •• Uon 

vibrated loose connectors. 

'HASE I 

'HUE III I STS Operato, 

19 

G-7 

'HASE II . 

MA5AoJSC 
~o. 

PAYLOAD HAZARD REPORT FSPE-6 

,",,, ",.,LOU Free Surface Phenomena Experiment o 

PIT,. 

Materia 1 s 2 December 1982 

Contamination - Toxic Fumes 

A""ICAI"'''''TYII~''''''.TI. NHB 1700.7A, Safety Poiicy and Requirements for Payloads 

Using the Space Transportation System (STS), paragraph 209.1, Hazardous 

Materi a1 s. 

O(sc •• ".o. 0' MAIAIO. 

Non-compatibility of photographic film with a failure induced environment, 

causing a release of toxic fumes and/or fire. 

lI"AlO CAUSlS. 

1. Photographic film capable of discharging toxic fumes in a failure 

induced environment. 

STATUS. 

CONCURRENCE 

Pay I oed Orl8ni.atian 

ITS Operator 

APPROUl 

Payload 

O'I8ni.adan 

'IC 'Ir. '~2' (Fl. 1.) 

PHASE I 

~HUE III 

I m Operator 

19 

G-8 

PHASE 'I 

/~ 
lNo. 

PAYLOAD HAZARD REPORT FSPE-7 

'flnOAD ~"A" 

Free Surface Phenomena Experiment 0 

su.syn~ : Pl\T~ 

Materials 2 December 1982 

IlAlAID TlTli 

Stress Corrosion Induced Fail ures 

Am, I Call.I UHT'I uou .. , .. rIlT"NHB l700.7A. Safety Po~icy and Requirements for Payloads 

Using the' Space Transportation System (STS), paragraph 208.3. Stress 

Corrosion. 

orSCA.,TIOII 0' "A1A.0. 

Failure of metal structures and parts due to stress (intergranular) corrosion 

allowing weakened structures to become flying projectiles. 

NUAlO CAUSU. 

l. Use of materials not meeting the requirements of MSFC-SPEC-522A. 

2. Manufacturing .stresses. 

HAIAIO CONTAOLS. 

,A"T'I VIII'ICATION WlTMOOS. 

STATuS. 

CONCURRENCE PHASE I 

Payload Orleniaation 

STS Operator 

APPROV lL 

Payload 

O'leniaaUon 

JSC f.ra 5.al <f •• 71) 

PHASE III 

I srs Opentor 

19 

G-9 

PHASE II 

NASA-JSC 
1-0. 

PAYLOAD HAZARD REPORT FSPE-8 

~,..,"o ... ~MAU 

Free Surface Phenomena Experiment 0 

SUllY""" Materials ~Pi'T" 

2 December 1982 

[MAulO "T", Contamination-Film 

A""IeAl'" 1A"T'lII~III1"'''TI' NHB l700.7A, Safety Policy and Requirements for Payloads 

Using the Space Transportation System (STS), paragraphs 201, Failure Tolerance, . 202, Control of Hazardous Functions and 209.3, Flammable Materials. 

D'SC'I~TION 0' MAZA.O. 

Jammed rotating members can cause overheating resulting in melting and/or 

burning of material (film) which leads to the production of smoke, contaminants, 

and toxi c fumes. 

MAU.D CAuns. 

1. Use of flammable materials. 

MAZUD CO"T'OL.S. 

$AFIT., VI_"ICATIO" MITHODI. 

STATUS. 

COIICURRENCE PHASE I PHASE II 

Payloed Orl.nl.atlan 

as Operator 

"'ROUL PHASE III 

Payload 

O'I.niaatlon T 51'S Operator 

UC ,.,. SUi I fl' 71 19 IlASA·JSe 

G-10 
End of Document