AD-AI30 047 SOLI0 PROPELLANT INFLATOR FOR PERSONAL FLOTATIONDEVICES(U) INFLATION SYSTEMS INTERNATIONAL CANYON

COUNTRY CA G B HOLCOMBE ET AL NOV 81 USCG-D-31-82

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Report No. C-D-31-82

SOLID PROPELLANT INFLATORFOR

( 3 PERSONAL FLOTATION DEVICES

Gordon B. Holcombe

Inflation Systems International25977 Sand Canyon RoadCanyon Country, CA 91351

November 1981

FINAL REPORT

>1 Document is available to the public through the0._ National Technical Information Service,oSpringfield, Virginia 22151

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Prepared for

U.S. DEPARTMENT OF TRANSPORTATIONUnited States Coast Guard

Office of Research and DevelopmentWashington, D.C. 20590

83 0t6 2 1983

8s 06 to got1

NOTICE

This document is disseminated under the sponsorship of the Department ofTransportation in the interest of information exchange. The United StatesGovernment assumes no liability for the contents or use thereof.

- I l " l l l I I I I 'e

Technicol Report Documentatlon Poge

1. Report me. 2. Gvrnment Accession No. 3. Recipiet's Catalog N.

WCo-D-3A-32o' /_ _""" ".4. Title nd Sutitlo S. RapW DoteDevelopment, Test, and Delivery of Solid Propellant October 22, 1981Generators for Inflation of PFD's 6. Perorming Organistio Code

8. Pedorming Orgenlietlee Relr No.7. Awthwl s)Gordon Iolcombe/Brian iamilton/Terry Borland

9. Periorming Orgaieme n Nome and Address 10. Work Unit No. (TRAIS)

Inflation Systems International

25977 Sand Canyon RoadCanyon Country, CA 91351 nT(2i- O-r-?nQAl

13. Type .9 Report Ad Period Covered

12. Sponsoring Agency Nome end Add#*s Final ReportUnited States Coast Guard October 1980 to October 19812100 Seconds St., S.W. 1Washington, D.C. 20593 r S

15. Supplementoery Notes

Abstrect

The objective of the program is to develop and test a solid propellant gasgeneration system as a practical replacement for CO2 cartridges for inflatable lifejackets and/or hybrid life jackets, with enhanced reliability and performance overa tfmperature range of -650F to 1850F. To document comparative performance of theCO2 and solid propellant systems, test beds of 20 lb. and 35 lb. buoyancyinflatables are employed. Repetitive tests are made of each system, over theindicated enviornmental span, with specimens subjected to shock, vibration, cycling,and many other tests necessary to prove futictional and life savings reliabilityand capability. The solid propellant inflat6r (SPI) test results reflect uniformperformance acros. the temperature range at time/pressure levels considered idealfor the usage. C02 cartridge performance was poor at soak temperatures below 20°Fand above 150°F. As the SPI is pressured only upon activation, leakage du~ingstorage is not possible -. Operating pressure is under 500 psi and a small over-pressure device negates/ lhe possibility of overpressore stress from a blocked orificAcondition. It is conclued that the SPI represents a significant improvement in theinflation of life jackets and similar buoyant devices having the need for prompt,reliable, fail/safe performance. ISf recor, iends further development in areas ofinsulatiou, visual evidence of fired unit, ard mating.hardware in the life jacket.

17. Key Weeds Is. Distribution Sto tment

Solid propellant inflator (SPI) Document is available through theReliability , Personal Flotation Devices National Technical Information Service,Lifesaving Devices, Inflation Research Springfield, VA 22151

19. Ioc.e,.ty Ciess. (of ths report) 20. Se rity Clessi . (of this po ) 21. No. of Pae 22. Price

Form DOT F 1700.7 (6-72) Reproduction of completed pego outhorizod

PREFACE

The reported work draws on earlier development work performed by InflationSystems International for the Naval Air Development Center (NADC), Warminster,PA, under contract N62269-79-C-0210.

The work for NADC was intended to produce a solid propellant gas gener.tor inflatorreplacement for the conventional carbon dioxide gas inflator for the USN MK7life raft. The NADC requirement was to design a replacement solid propellantgas generator having maximum dimensions of 4" X 29". The diameter constraintwas approached with a T-burner design burning from cylinder center outwardtoward both ends. The length/diameter (L/D) ratio exceeded the limits for properfunctioning and the raft (inflator) was not completely successful under thatcontract.

In working the problem, ISI developed a method of granulating te propellant toJ2 mesh size. These granules, in turn, were lightly pressed into the generatorchamber. The evolved approach produced low combustion pressere coupled with areadily tailored time-to-fill performance. This concept seemed ideally suitedto the task of inflating life rafts and life jackets where reliability andoperational safety are of primary importance, and where inflation time needs tovary by application.

Accordingly, IS1 made an unsolicited proposal to the U.S. Coast Guard forapplication of the technique to small volumes such as personal flotation devices.The advantages of solid propellant inflator's non-leakage and uniformity of gasgeneration over a broad temperature range extending down into arctic temperatures,suggested important life saving missions for these inflators in recreational,commercial marine, and military operations. In this duty, the solid propellantapproach could be demonstrated without constraint as to L/D ratio and in a smallsize representing the lower end of the spectrum of such devices. Ability tomake a successful application for life jacket life volumes would show the wide

application of the concept since very large volumes (to 400 ctibic feet) had beendemonstrated.

This report gives data on the successful demonstration of the solid propellantconcept for personal flotation devices.

i i i. ... . . . ... ....

TABLE OF CONTENTS

PAGE

1.0 INTRODUCTION 1

1.1 Contract Reference I1.2 Executive Summary I

2.0 PROGRAM DESCRIPTION 2

2.1 Objective of Project 22.1.1 Expended Cartridge Identification 22.2 Background 32.3 Apparatus 32.3.1 Solid Propellant Inflator Design 3

2.3.2 Heat Problem 4

2.3.3 Model Personal Flotation Device 8

2.3.4 Disposal of Cartridges 8

2.3.5 Compatibility of Pyrotechnic Elements 8

2.4 Tests Performed and Results 10

2.4.1 Phase I Design and Development Tests 10

2.4.2 Test Results 10

3.0 DESrGN VERIFICATION TESTS 11

4.0 CONCLUSIONS 11

5.0 RECOMMENDATIONS 11

APPENDIX A - Summary of Design Verification Test Data from

DVG-1019

APPENDIX 1 - Abstraci of the Phase I Test Report - ISI TR1OI3

APPENDIX C - Design Verification Test Plan - QTP-102

APPENDIX D - Reliant Testing Laboratory Letter Report -

81-7505

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1.0 INTRODUCTION.

1.1 Contract Reference. This final report summarizes the results of develop-ment work by Inflation Systems International under United States Coast GuardContract DTCC23-80-C-20031 dated 25 September 1980.

1.2 Executive Summary. The reported effort is to demonstrate the suitabilityof a solid propellant inflator (SPI) as an inflation means for,,personal flotationdevices. The SPI design has two sizes: 20 lb. and 35 lb. These sizes refer tothe cartridge output which provides 20 pounds of buoyancy in a smaller size and35 pounds of buoyancy in a larger configuration. The internal detail of designand construction are the same for each, except for the size and quantity ofpyrotechnic material.

The SPI provides an improved performance for personal flotation devices(life saving appliances such as life jackets, vests and belts, intended to aidindividual persons). The existing stored gas (carbon dioxide) gas cylindersfunction sluggishly at low temperature and do not provide the rapid inflationneeded to assure survival of users. They are also susceptible to undetectedleakage under the high pressures of liquid-state storage.

The reported work developed a small solid propellant inflator with a cooloutput not damaging to the personal flotation device (PFD) or the person using it.The SPI provides rapid, reliable inflation of PFD's at all temperatures ofprobable use including, particularly, arctic regions. The SPI design is approx-imately the same size as existing carbon dioxide units, is simple in construction,and reliable over long-term storage. It has the same simplicity in operation asthe existing CO2 system.

The SPI design consists of a separable gas generator cartridge of cylindricalshape and an actuating mechanism (AM) providing a lanyard-pull force tc cock andfire a spring-loaded firing pin which strikes a percussion primer in the cartridge,igniting the pyrotechnic train. The same AM is used for both size cartridges.Assembly is by screw thread. A port identical to existing PFD inlets mates withthe AM which serves as a conduit for the generated gas, delivering it to the PFDinlet port.

The technology of the pyrotechnic is a scaled down version of similar gasgenerators made by the contractor in earlier work for aircraft escape slides andother inflatables. The technology was developed by Allied Chemical for use inthe automoLive passive restraint ("air bags") systens. The delivered gas isnon-toxic and relatively cool due to the low burning temperature and a filter bedplus other heat control processes.

The reported testing has subjected 95 cartridges to environmental andperformance evaluations designed to indicate the ability of the concept to performsuitably in emergency service after the expected handling and storage of marineusage. Environmental testing was performed by an outside test laboratory. Firingsand functional evaluations were performed by ISI in its plant.

2.0 PROGRAM DESCRIPTION.

2.1 Objective of Project. The project had the objective of developing anddemonstrating a solid propellant inflator for personal flotation devices.

Testing included exposure of inflators to marine and probable handling environ-ments plus firings in model life jackets and in calibrated tanks. Life jacket

tests included dry and wet (underwater) firings.

The test program was designed to provide sufficient information to

indicate the validity and feasibility of U.S. Coast Guard approval of the concept

for use as a life saving application. The SPI would be a replacement for existingstored gas systems which are deficient in cold weather and are susceptible toundetected leakage in long term storage.

The solid propellant gas generator provides an improved performance forpersonal flotation devices (life saving appliances such as life jackets, vestsand belts) which are intended to aid individual persons.

The reported work was aimed to developing a small solid propellant gasgenerator with a cool output, not damaging to the personal flotation device (PFD)

or the person using it. The solid propellant inflators were designed to provide

rapid, reliable inflation of PFD's at all temperatures of probable uses, including

particularly, arctic regions. The design criteria were to have an inflator

approximately the size of existing carbon dioxide units, to be simple in construction

and reliable over long term storage. The cartridge should be better operating than

the existing system.

2.1.1 Expended Cartridge Identification. An important objective of this

project was to develop a means whereby a spent cartridge could be quickly identified

so that inadvertent reloading of the jacket's inflatable means would be extremely

unlikely. The means should be readily visible and not require the cartridge to

be removed to be weighied, eLc., as is the case with CO2

The problem initially appeared to be solvable with the application of

color changing paint on the base exterior of the cartridge. The storage temperatureof 160'F dictated the selection of a paint which turned color at 200°F or higher

and several paints were selected for testing.

It was quickly found that while the color change was effected on a

cartridge activated in the air, it was not when the cartridge was immersed in water.

In the latter case, readings were taken against the butt end of the cartridge

(an area at least as hot as any other) with the cartridge immersed in water when

activated. The recorded temperature peaked at 135 0F/140°F and decreased to

98°F at the end of 4 minutes. At no point did it rise above the starting

temperature.

Following this finding, a rod was implanted on the inside wall of the

butt end with its end imbedded into the propellant. Color-change paint was applied

to the exterior. It was believed the burning propellant would carry the generated

heat to the localized point on the generator and cause the paint to change

color at some elevated temperature. Again, when immersed in water, paint was

unaffected because of the heatsink effect of the water.

2

Coincident with consideration being given to a "window" in the cartridge

uall to enable interior color change to be observed, ISI evolved a concept of

implanting a hollow tube on the interior base of the cartridge, extending some

0.75" into tLe propellant. The tube diameter was 0.125" with an T.D. of about.080". Silicone "0" ring stock was inserted into the tube and held in placewith silicone vacuum grease. The silicone stock was then snipped off flush with

the cartridge exterior wall.

Upon initiation of the cartridge, the silicone cord ejects from the effect

of heat expansion, leaving a visible opening in the base wall of the cartridge.

As the end of the cartridge is not covered with insulation, although

protected from advertent contact by the polypropylene/foam cover, the hole is

readily seen and the expended cartridge identified.

While molded silicone plugs may be later employed, or other materials

and configuration, ISI believes the present system accomplishes the basic objectiveof the program in that it is both reliable and readily visible.

2.2 JL-IakLgound. The technology of the pyrotechnic is a scaled down version of

gas generators made by the contractor in earlier work for aircraft escape slidesand other inflatables. The technology was developed by Allied Chemical for use

in the automotive passive restraint ("air bags") systems. The delivered gas isnon-toxic and relatively cool due to the low burning temperature and a filter bedplus other heat control processes.

The combustion gases generated by the inflator consist of carbon dioxide

(80%) and oxygen (20%), with a trace of carbon monoxide (0.5 - 0.75%). (ascomposition Lest results on file at ISI verify the absence of other toxic constituents

such os chlorine, hydrogen chloride, carbonyls, formaldahyde, nitric oxides, etc.

2.3 App. arattus.

2.3.1 Solid Propellant Inflator Design. The solid propellant inflator design

evolved during the work consists of a separable gas generator cartridge ofcylindrica] shape and an actuating mechanism providing a lanyard-pull force to

cock and fire a spring loaded firing pin which strikes a percussion primer in the

cartridge, igniting its pyrotechnic train. Assembly is by screw thread. A port

identical to existing PFD inlets mates with the actuating mechanism which serves

as a conduit for the generated gas, delivering it to the PFD inlet port.

Thc solid propellant gas generator consists of the items shown in thefigures as indicated as follows:

M ..

FIGURE TITLE

2-I Solid Propellant Gas Generator Cartridge2-2 SPI Assembly2-3 Actuating Mechanism

The design burst pressure of the cartridge is 1500 psi minimum. This isverified by test results. The relief device is set for 1000 psi maximum.

In the event of a blocked orifice, internal gas pressure builds up inthe cartridge body until one of the two relief plugs releases. In the blockedorifice tests conducted by IST, release of only one of the relief devices issufficient to relieve the internal pressure to normal levels (200 psi). The tworelief devices are, thus, truly redundant.

2.3.2 Heat Problem. This topic will be discussed in two parts; i.e. theactivating mechanism, then the generator (inflator).

1) AM - The current production models are formed of aluminum. In the ,

test program which preceded shipment, it was found that heat from the generatorwas conducted to the AM to a degree that was uncomfortable. While the heated areawas confined to the section immediately adjoining the generator (with the shaft ofthe AM remaining cool), the condition dictated that a study be made. As thealuminum parts were about 6 weeks behind their scheduled delivery, there wasinsufficient time for in-depth testing of other material prior to delivery to USCG.Concurrent with the casting of aluminum parts; ISI had, however, ordered a singleplug made of nylon, suitable for machining. The nylon AM was then tested as astandard assembly. When the generator was fired and for the entire time oftemperature build-up following initiation, the AM remained cool to the touch orgrip. No degradation of the nylon AM was observed in repeated firings.

It appears feasible to replace the aluminum material with plastic (nylon,delrin, glass-filled polycarbonate, etc.). The cost of the required dies will besignificant, however, and such expense must be justified by a funded developmentor high-volwe production program.

2) Generator - The propellant burns at a temperature of about 900°F to10000 F. Through a coolant medium placed at the gas exit, the gas entering thelife jacket is reduced to an average of 2500 F.

Heat absorption and transfer is so rapid that the gas in a fully inflatedjacket is only a few degrees above ambient.

The body of the inflator, which has no interior insulation, reaches atemperature of about 600°F and so must be insulated from contact with the humanbody. ISI investigated a number of approaches to the problem. The selected approachprovides protection AND reasonable cost. This system consists of the following:

;) Corrugated phunolic -impregnated paper is wrapped around thegenerator and inserted into,

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c) Epoxy is then applied to bond the corrugated paper to the tube,and to the generator.

d) As is commonly found on aircraft life Jackets to guard againstthe chill of an expended CO2 cylinder, a woven polethylene/foam laminate isused to loosely surround the insulated generator, adding heat protection to theinsulated assembly and isolating the AM from swimmer contact.

The combination inexpensively provides good protection, althoughsomewhat bulky.

2.3.3 Model Personal Flotation Device. An initial quantity of 230 units

(180 of the 20 lb. buoyancy size) were delivered to the USCG, Washington, D.C.Test inflations by USCG into a stock jacket in USCG inventory failed to fullyfill the jacket, although the same inflator employed in ISI tests had pressuredthe specimen "20 lb." jacket to 2 psi in 2 seconds.

Investigation disclosed that the 20 lb. buoyancy claimed by themanufacturer of the jacket used by ISI in the development program was actuallyonly 16.6 lbs., while the jacket employed in USCG tests was 22 lbs. Thereport of these findings is included as Figure 2-4.

The USMG reported that all tested units of the initially shipped 180 groupperformed as claimed by ISI when fired into the ISI specimen jacket. An additionallot, with an increase in propellant content, was subsequently forwarded to USCGand has successfully pressured the 22 lb. plus jacket.

2.3.4 Disposal of Cartridges. Fired cartridges may be disposed of bydiscarding in conventional trash receptacles. Each expended cartridge containsapproximately 10 grams of common salt, which will leak out of the fired inflatorif it Is improperly disposed of in water. This is the only significant environ-mental effect of such disposition as seen by IS, other than the physical presenceof the steel cartridge.

Unfired cartridges are best disposed of by firing the units and disposing

of the fired cartridge as above. In the event of a mis-fire, the cartridge shouldbe returned to the supplier.

Unfired cartridges present somewhat less hazard than unfired CO2 cylinders,since inadvertent piercing of the pressure vessel is not hazardous.

2.3.5 Compatibility of Pyrotechnic Elements. The pyrotechnic train ofthe inflator consists of the following elements:

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SOM-OR , IC.N2 47831908 FRIENDSHIP DRIVE

ELCAJON, CALIFORNIA 92020 INJOvetII e~ 98 I_

OCUR OAOU*S POO

Inflation Systems'International259771i Sand Canyoni Road & IQIARj lj.pCACanyon Country, CA 91351

QUANTITY _________ D9CSIPTION P_____ PICE AOUNT

Lot Measure buoyancy of three (3) customer-furnished I 1/cinflatable vests

Vest S.D. Measured Buoyancy (FW)

UJSCG SF-20 1' *22 lbs. 0 oz.Seatec 16 lbs. 6 oz.

lidter temp. 620F.Air temp. 730F.B~ar. Pres. 29.3 in. Hg.,

Measurement accuracy t 4 oz.

On 20 Nov 81, SoniForm, Inc. measured 3 inflatable vests,as described above, for rated buoyancy in fresh water.The equipment use~d is of the type specified by the USCG,for the purpose and the method followed is identical tothat commonly employed for determination of buoyancy of an inflatablodevice.

PW1~MONT? MSIA**O FOI 4 &AO SIMIFIGURE 2-49

a) Percussion primer (M-42G)b) Boron-potassium nitrage granulesc) Main charge propellant

As shown on ISI Drawing 100160, Cartridge Assembly, the percussion primerand the boron-potassium nitrate granules are in intimate contact in the 101305Igniter Housing A-sembly These two component have a long history of compatibleusage in thousands of military and aerospace applications. These two componentsare separated from the main charge propellant by a seal (Item 14 on AssemblyDrawing 100160) and a gap of approximately .25 inches.

To prove extended compatibility of the pyrotechnic components, twoworst case tests were conducted:

1. A unit was assembled in which the boron-potassium nitrage granuleswere contaminated with 25% by weight of powdered main charge propellant.

2. A second unit was assembled in which the main charge was contaminatedwith powdered boron-potassium nitrage, equivalent to 50% of the booster charge.

These two units were temperature cycled from -65 to +165 0 F, 5 cycles,then stored at +165OF for 2 days. The units were then fired at ambient temperature,with normal results.

2.4 Tests Performed and Results.

2.4.1 Phase I Design and Development Tests. The tests were conducted for thefollowing purposes:

1) iL.ablish propellant/coolant proportions appropriate to inflationof the specimen jackets, with gas temperatures barely above ambient.

2) Provide comparative data between C02 and SPI cartridge performance Vat -650 F, -400 F, ambient, and 1600F. Motion pictures (16mm) of life jacketdeployments were taken and are on file at ISI.

Tests were conducted in accordance with test procedures submitted to,and approved by, the U.S. Coast Guard. All tests were in heavywall ("workhorse")cylinders allowing ready refurbishment and reloading for multiple tests. Pressure-time recordings were made with a Visicorder oscillograph. Differences were notedin inflatable peak pressure due to the test condition described in Appendix A.

2.4.2 Test Results. Test results were as summarized in Appendix A.

10

3.0 DESIGN VERIFICATION TESTS. A summary of the design verification testdata from IS1 Report DVT-1019 is included as Appendix A of this report.

4.0 CONCLUSIONS.

1) The SPI provides repeatable inflation of PFD's over the temperaturerange of -65 to +160 0 F, at pressures not less than the established minimum of 1.25psi, and within the time of not over 3 seconds. In the Design Verification TestProgram (detailed in Appendix A), one unit failed to function after salt fog exposure.This unit was dissected, and the failure mechanism was found to be leakage atone of the overpressure relief plugs due to damage during welding. As a resultof this failure, the relief plug installation and welding procedures were modifiedto preclude this failure mode. The new procedure has been tested, and found tobe an adequate fix.

The inflators operated at cold temperature (-65°F) sometimes produce apeak pressure at greater than 3 seconds. In each case, however, jacket pressurewould have been above 1.25 psig at 3 seconds.

As discussed in Appendix A, the peak pressures observed in the jacketduring the testing varied due to differences in residual air retained in thejacket prior to test, and to changes in inflated volume due to variations in theposition and tension of restraining belt. Tests no. 157 and 158 exceeded themaximum allowable of 3.5 psig for these reasons. Both of these tests were conductedat ambient temperatures. The elevated temperature tests (+165°F) all producednormal jacket pressures.

2) Actuating mechanism and gas generator are functionally compatible andadequate. The problem of slightly high actuator temperature, as discussed inSection 2.3.2, will be resolved by using a plastic housing in place of the currentaluminum actuator housing for production units.

3) Other sizes of gas generators can be provided by scaling upward tolarger output volumes. Some reduction in size is possible, but this conclusionrequires extrapolation rather than interpolation. Having produced a number ofmuch larger units for aircraft escape slides/rafts, the entire range of inflatorsizes from the PFD inflators to the raft/alide unit have shown to be availableand feasible.

5.0 RECOMMENDATIONS.

1 ) The aluminum housing for the activating mechanism absorbs heat fromits intimate contact with the inflator cartridge.

ISI produced a single housing of nylon which functioned in an entirelysatisfactory manner, but without heat. IS1, therefore, recommends that thealuminum housing be replaced with plastic.

2) The expended cartridge indicator probably needs refinements, andin any case, should be fully tested to document its ability to withstand temperaturecyrles, humidity, salt fog, shock, vibration, etc. ISI has no plans at presentfor such an undertaking.

1l

3) Attention should be given to automatic inflation and to manualoverride.

4) The matter of insulation should be investigated to find materials/methods to accomplish the containment of heat without the present bulk. ISIwould appreciate receiving any recommendations that USCG may offer in this regard.

1

12

REFERENCES

1) 151 Test Procedure QTP - Design Verification Test Plan

2) Reliant Testing Laboratory Teat Report 81-7505 covering environmental

testing of DVT specimens

3) MIL-STD-810C (Envornmental TEsting) covering salt fog testing of cartridges

13

APPENDIX A

Summary of Design Verification Test Data from DVT-1019

Environmental Testn. Environmental tests were performed as follows:

QTP- 102Ref. Para.

Random Vibration 6.2.2.3

Salt Fog 6.2.2.7Humidity 6.2.2.2Temperature Cycling 6.2.1.5

The environmental exposures were given to nine (9) solid propellant

inflators (5 ea. P/N 100160-I and 4 ea. P/N 100160-2). Details of the environmentalexposures are given in the outside laboratory's test report, included here as

Appendix D.

After exposures, all units were visually inspected. There was no evidence

of damage to any of the specimens as a result of random vibration, humidity, and

temperature cycling. Corrosion was noted on the two units exposed to salt fog(one 20 lb. and one 35 lb. unit) after 48 hours exposure to salt fog.

Function Tests. A total of 63 units were functioned in the DVT. The DV'F quantitiesand assignment of units to the various tests are shown in Figure A-i. Figure A-I

also gives the performance data on the firing tests - peak pressure and time to peak.

1'ROBLEMS.

Belt Adjustment. Belt adjustment was found to have a significant effect on peak

pressure. This was demonstrated during Test #7, Shot LF-067, when the belt

became hooked on a portion of the test stand while the inflatable was being

vacuumed. When inflation occurred, the belt was then not free to position itself

;anid became excessively tight. This was corrected 45 seconds into the test byunhooking the belt off the test stand and allowing it to seek its own position,

but this resulted in a .4 psi pressure drop in the inflatable.

Additional variations in ultimate pressure can occur from differences

in the extent of vacuuming of a jacket prior to packaging or to re-ose. None

of these variables are any different than what would occur from CO2 inflation,

and then only apply to jacket design and operating instructions rather than

to the inflator.

Air Retention in Inflatable during Vacuuminj. Prior to each test, each inflatable

was vacuumed down through the fitting used to measure inflatable interior pressuire.

Vacuum line was then removed and pressure transducer hose was attached. Due tostiffness of the fabric In specimen inflatables, it was difficult to achieve the'

same degree of vacuum from test to test.

Temperature recordings were taken during pre-Phase I testing, but were

found to be slight rause for pressure change, thus, the pressure drops from peak

to residual is held to hc due to material stretch. This was corroborated by filling

inflatables witLh shop air and monitoring pressure drop over a 5-minute period.

A-I

Repeated cycling of the two actuator mechanisms caused failures of the

mechanisms at 348 cycles and 390 cycles. While this is less than the required500 cycles, the portion of the actuating mechanism that failed (firing pinlatching arm) is a qualified fuze component for Army use (Army P/N 8822514).The part failed in a fatigue modi,(cracking of the latching arm). Fatiguingof this part is unlikely to occur at fewer than 200 cycles, which is well abovethe expected requirements for life jacket applications. No other suspectfailure modes were foreseen as a result of this testing.

Test Data Summaries. The firing data for DVT units are summarized in figuresas follows:

Figure A-2 Data for Post-Environment FiringsFigure A-3 Tank Firings - 20 lb. CartridgesFigure A-4 Tank Firings - 35 lb. CartridgesFigure A-5 Life Jacket Tests - 20 lb. CartridgesFigure A-6 Life Jacket Tests - 35 lb.-Cartridges

Figure A-7 20 lb. Cartridges - Combined Tank & JacketFigure A-8 35 lb. Cartridges - Combined Tank & JacketFigure A-9 All DFT Firings Combined

Original Data Recordings. Original oscillograms recording DVT are availablefor reference by USCG. Copies of any or all will be provided on request. Alloriginal data have beenreduced and are presented in the summaries of this report.The plots and summarles provide an easier mode of reference to analyze the testinformation than ref6rence to the original raw data.

Calibration records for instruments are also available for reference

as desired by the customer.

All original records will be retained for the life of the contract.

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APPENDIX B

Abstract of the Phase I Test Report - ISI TRIO13

The Phase 1 Test Program utilized heavyweight machined housings for the gas

generating cartridge. Otherwise, the internal workings of the gas generator

were Identical to the prototype design. The test program consisted of 40

developmental firings to establish the required propellant and coolant

proportions, nozzle sizes, etc. An additional 40 firings were made to provide

comparative data between CO2 bottles and solid propellant inflators (SPI's)

at conditioning temperatures of -650 F, -400 F, ambient temperature, and +160

0 F.

Results of these tests are detailed in the following figure, Figure B-i.

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'B-2

ISI Document: QTP-102 APPENDIX C

DI-ISIGN Vh dFICATIUN IEST PLAN - REVISED

6.2 DL SIGN VERIFICATION TEST PLAN.

6.2.1 Tonperature/Environmnental Range.

OODE: DRY firings will be into R-1 or R-2 speciren jackets

Ir firiigs will be into R-1 or R-2 specimen jacketssubmerged in wate2r to 2 foot depth. Surfacingwith inflation.

TANK firings will be made to establish fixed performancecriteria for follow-on Acceptance Testing

6.2.1.1 Anbient. 20# R-I+AM 35# R-2+AM

Dry 2 21et 2 2

Tank 3 3

6.2.1.2 Low TuperaLre, -650F.

Dry 2 2Wet 1 1Tank 3 3

Dty -40OF 1 1Tank I I

6.2.1.3 Lh__TseraLure +160°F.

Dry 2 21Wkt 1 1Tank 3 3

6.2.1.4 Surface TEnPerature.

Masurinents of surface toqperatures will be taken in the followingmanner,

a) Two each 20# and 35# spec&nens, fitted with thermocouples shall,as a minimim, be positioned to record the temperature of the aftside wall and the gas exit end of the cartridge over a periodof 5 minutes frcm actuation.

Additionally, any area of the activator which is significantlywarmed by its connection to the cartridge, or by gas expelledfrom the cartridge, shall also be fitted with thermcouplesand temperature recorded.

QTP-102 Sheet I of 9

c-I

'ile instrumentation shall be recorded continuously for ape.riod of five (5) minutes from actuation.

WiE: The iNoximun heat generated in aircraft slide inflatorsh-Lis been found to occur within 5 inutes of activation.It is believed the SPI for life jackets will reachzixinum teiperature within the sae period, but if itis found to be longer, the recording time will beextended.

6.2.1.5 Terperature Cyclg.

One (1) 201 and two (2) 35# cartridges shall be mounted withoutthermal protection in a facility capable of controlled tep-erature cycling between -65OF and +160OF and subjected withoutinterruption through the 25 cycles.

On ccupleticn of the cycling, the inflators shall be fired atanbient and performance shall be as specified in para. 6.2.1.1(Tank).

The cartridges will be conditioned at -65 F for 30 minutes andthen be conditioned at +160°F for 30 minutes, making a corpletecycle every hour for 25 hours.

6.2.2 Tests other than Teaperature.

6.2.2.1 Sorja& in Water.

At 2.0 ft. depth, stow exposed cartridges for 8 hours, then fireinto tank. Micasure time and pressure to confirm normal performance(to simulate condition where spare cartridges or jackets are stowedin wet bilge). Two (2) each 20# and 35/I cartridges, with AMs,shall be so tested.

QrP-102 Sheet 2 of 9

C-2

6.2.2.2 1hm th dLty!Jeak.qe.

Wne (1.) eacfh 20# and 3511 cartridge shall be tested by ReliantTe';t ]1.boratory in accordance with M1L-STD-810C, Metliod 507-1,Procedure 1.

6.2.2.3 Vibration.

One each 20# and 35# cartridge, mated with AMs, to be tested byReliant in accordance with the following (or as modified to suitsize and type of article).

The test item shall be subjected to 30 minute random vibration ineach of three axis in accordance with the test envelope, shownin Figuire 1. The vibration shall have gaussion distribution.Instantaneous peaks may be limited to three times the rim value, andre-oant modes of the test itens within the test frequency rangeshall be equalized or coopensated. The overall acceleration shallbe recorded during each axis and shall be mnitored continuouslywith a true rms meter during the test to maintain the requiredt olerance. The pre-test runs may be repeated if necessary to iake!,pectrn correcticns. Filters may be used, if needed to attenuatesignals above 2000 cps.

14indom vibration spectra, when analyzed as above, shall be withinthe following tolerances on acceleration power spectral densityapplied to equipment under 50 pounds in weight.

Between 5 cps and 50 cps, +6 db, -3 db, -+3007., 507.Between 50 cps and 1000 cps, +3 db, -+1007., -507.Between 1000 cps and 2000 cps, -+ 1.5 db, -+417, -29%

Overall acceleration must be kept within +207. and -5%.

QTP-102 Sheet 3 of 9

C- 3

I I 7 - 7

10 .- .- ---- -. . I ---------- -

10 --

U*_ I I. , : iI .

10--- __________f IIe 1 ~ J

I- 1 0- WETS

41

Q''* -102 IG I She44o4

RADO VBRTIN ET EVLSC-4__ *

6.2.2.4 Vrp/h o ck.

Tn accordance with USCX; dixecLive, the test as prwiLe1 ~I I1be nodified as follow~s.

Onie (1) eacli 20#j iAd 35# Carr iiO shamll be dr-opped yuahiit nuto !.Leel plate om conicretea. u sprculi'i:; - 11

be progr1nii'ed to S-1ccefSsivly riuL;ct: on the butt end, sid!L'liorm-itl),nd orifice enid fixst.

The 3.51 inflator shiall th~en bc maited witi the AM m~d threesilmilar drops uode, except that "ori-fice" shall l~e "p)ull cord".

Upon ccxpletion of these droups, the spccecis shiall. be i i t i/4dand perfonRmnce shall f all within the paraw-xters of 6.2. 1.1 1', u k).

6.2.2.5 Blocke~d Orifice.

One (1) each 20#f and 35,# cartridge, miated wibui I,'.s, sliall beblocked in a non-leak n-ner. Thle cartrid ' e shall then,- 1-e iriti.1" --diwhile in vi tnW of a high speed c..knmra. Thefre. shiall- be no fra;-utqntation or action harmful to the w.earer.

6.2.2.6 Uiter Drop.

6.2.2.7 Salt Fog,.

Onie (1) ci. i 20,1j ,nd 35#/ cart.ridjge 111d (OllU /'1 'iit:, let in

v.11 bet !iujectced t~o salt fog test by bEeli ant toL!,UvA. 509-4, locedure 1. 'fic expo),tire to s~l:fo, s;hal11 't,

deteriously iflfect Cie finish, nor the nornonl opcration of tlicparts.

102 S1hc(' ofe

6.2.2.8 AcutqLi' Mechlisn Cycling.

A T.nmyard pull fixture will be asserrbled for the purpose ofrepetitive ouctivation of the iechamrism. A total ef 500 lanyard-pulled -ctivaticns shall be m.ide to prove physical capability ofrepetitive uage of the AM.

aSurerWInIn of pull force shall be recorded at the beginning of thetest . nd at each 100 pull interval.

An increase or decrease in pull force in excess of TBD is not

acceptable.

Buoyimcy Tests.

The i nimum acceptable inflated pressure shall be 1.2 psi and the'_mxi-mn 3.5 psi.

QTP -102 Sheet 6 of 9

-"C-6

'HASFE III

6.3 ACU-N'1ANGE- "ST PLAN.

6.3.1 RIvicw Shop Travelers.

1007 review shall be nade for assenbly comrpliance.

6.3.2 Visual knectni n

1007. inspection shall be miade of all deliverables, checkingrn ;urmnmmts, weight, finishes, absence of sharp surfaces, labeling,

packaging, serializing.

6.3.3 Leak Test.

Five (5) 20# and two (2) 35# cartridges shall be randomly selectedand, without AM, Veeco leak dhecked. Any leak thus disclosed will because for action as in para. 6.3.4.

6.3.4 PcrfoLnmnce Verification.

T.ink fire ten (10) 20# and five (5) 35# randomly selected cartridgesri, ited with A,-s. Perfornnce shall be normal. Any failure will bec'.)U'e for rj!ndom selection of a second lot for idcentical firing.If ny failure occurs in the second lot, or if investigation of thefailure in the first lot reflects other than a minor condition, theentire production lot of the failed item shall be rejected.

The qcLMtitics specified relate to a lot build of 250 combinedtotal units (6%). 11ll4er lots will require proportionately lessthan a ccnbinaticn of 6.

QTP-106 Sheet 7 of 9

-c-7

SiiRVIlI LLANCE PLAN - SPI FOR PFDs

To prnvide a base for monitoring life cxpectancy of SPIs, the folloiing isp1 anned:

Frorn the lot coi;iprising USCG deliverables and ISI testslecimens, ISI will preserve 20 each of 200 and 3S# SPIs.These will be activated on the schedule outlined below,with the unassigned units held in reserve for a T8D testprogram for the 2nd S year period and for reserves.

1st Year 1 each size, each quarter

2nd Year I each size, at 6 months and year's end

3rd, 4th, S .th Years 1 each size, each year

[:iii.,;s will be into a Tank and time and pressure compared with that obtained in

the De-sign Verification Test series.

Any sigtnificant varijn)tc from the norm will be reported to USCG'

QT[- 102 ,heet 8 of 9

C -8

'II.ST SLRIES RIILCAITULATION

SPI for PFDs

20N 35#

rcst Para. No. sj/AM wo/Aml w/AM wo/AM

6.2.1.1 7 7

6.2.1.2 8 8

6.2.1.3 6 6

6.2.1.4 2 2

6.2.1.5 2

6.2.2.1 2 2

6. 2.2.2 11

6.2.2.3 1

6.2.2.4 1 1

6.2.2.5 2 2

6.2.2.6 1 1

6.2.2.7 1 1

6.3.3 5 2

6.3.4 10 5

Total C;irtridi:es 37 10 33 9

47 42

Totnl AMs 70

QTI'-102 Sheet 9 of 9

C-9

APPENDIX D)

L E T T E R R E P 0 R T J .

t e , lu y U] "

Revisior N/IC

INFLATION SYSTEMS INTERNATIONAL25977-1/2 Sand Canyon RoadCanyon Country, CA 91351

Inflation Systems International Purchase Order Number 0702Reliant Testing Laboratory, Inc. Job Number 81-7505

Nine (9) Solid Propellant Inflators, Part Number 100160-1, Serial Numbers6 through 9, and Part tNu;.ber 100160-2, Serial Numbers 1 through 5, weresubjected to the following Qualification Tests, performed in accorddncewith Inflation Systems International Purchase Order Nu.nber 0702 and Infla-tion Systems International QTP-102.

TEST TITLE (REFERENCE PAPAGRAPH)OTP-102

RANDOM1 V I LRAT I ON 6.2.2.3

SALT FOG 6.2.2.7

H' JI DITY 6.2.2.2

TEMPEPATURE CYCLING 6.2.1.5

There %.as no visual evidence of damage noted to any of the specir.ens as a

result of the Random Vibration, Humidity, and Temperature Cycling Tests.

There was visual, evidence of corrosion noted to the specimens as a resultof the Salt Fog Test.

Upon completion of testing, all specimens were returned to Inflation SystemsInternational for evaluation and final disposition.

RELIANT TESTING LABORATO

Director, Quality Assurance

BGB/km

'1 SO. : ST. GAPOENA CALIF. 9e,2Z7

D-1A -

Customer- 1FAIO: SYSTLMS Job No. __ 2L 505 ___________

R1EPNATIOMAL -Report No. -81~-755___Part No. 100160-1. 100160-2 DaLe--6 July 1981spoc. - -QTP- 102 Amb. ep.1 0

Para. 6 ?.2 3 Photo- Set-UpS/N_____ 6, 1 Test Media ---Spcciinin Solid PrnDiellant Inflators Spucir.( n ____________pn

TE*ST TITLE: RLANDOM VIBRLAIN

INP2T ANIS N1I 4

BA.\ FREQUENCY (li) LE VE L SLOPL TO LE RANC E

From To -(n2/11z) j(i/at. (:dB)

U~~~~~~~ C.M I.TS UATO 0 A.'/''

2N Y RFLE 1.NWDH~n

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Serial No. I,(, t dTEST TITL ,-.......VIBRAT ION

TEST IITLE- PP~ 8T.P. No. OIP-102

CUSIO , ,' EkFIAT]O, SYSMInS INl PENAT'L Paragraph 'No. 6.2.2.3

EQUIPMENT LIST

e .. No. Cal. Due N;arre I.D. No. Cal. Due

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Notice of 'eviation Written__... Witnessed By. F=RT L

Sheet . of 7 Date__ _

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TEST TITLE SALT FOG T. P. No. OTP- i?

CUSTOMER N AME IFLATION SYSrIS INIERA IO(JAL Paragraph No. 6..?. 7

EQUIP:,IENT LIST

Na.0 I.D. No. Cal. Oue Na'me I.D. No. Cal. Du.e

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Sheet of <1HM Date_______________

S i NO.

Job No. .L5j, _Part N o. I ,.

TEST TIT E HUMID I r Serial Njo. 7 .7

T.P. No. rIP- 02

CUSTOMER NAME INFLATION SYSTENS INTLW AIIlAAL Paragraph No. 6.2.2 2

EIPMEN T LIST

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Sheet of Dat e

IUSI I ILE_ - IiU:IJl IY5

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Date 6 July 1rJ81

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SALT FOG

(sEI-UP)

:So 7'AV4 ST., GAR9DErJA. CALIF. 9 ;D- 13

FIT c;,rt '3

rag No. __14 of 14

Da te 6 July l'j?2A

Revision__ tq/C _____

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TEMPERATURE CYCLING

(SET-UP)

;6? So 1.AIN ST.. GARDENA. CALIF. 90247( CDPD- 14