Bursting of shielded pressure vessels subject to hypervelocity impact

Abstract

During the 30-year lifetime of the Space Station, NASA is concerned that a large piece of orbital debris could strike one of the inhabited or laboratory modules. The modules are basically cylindrical pressure vessels, 4.3 meters in diameter and 9.1 meters long, made of Al 2219-T87. There is a potential for unstable crack growth (“unzipping”) in these pressure vessels if a sufficiently-long crack were formed in the pressure vessel wall. The ragged hole generated when debris strikes an exterior shield and impulsively loads the pressure vessel wall could lead to such a crack. The central concern of this research is quantifying the minimum crack length (critical crack length) to initiate unstable crack growth. This paper reports on a two-part investigation into this problem: 1) fracture experiments and analyses aimed at determining the fracture resistance and critical crack length of the module walls, and 2) examination of impact data to determine the impact conditions that could cause the critical crack length to be exceeded. Al 2219-T87 was found to be a modestly rated sensitive material, exhibiting an increase in both ultimate strength and fracture toughness at high strain rates. The results of the conservative linear elastic fracture mechanics analyses indicate critical cracks at least 22.9 cm in length are required for unzipping (3.17-mm thick wall), and 45.7-cm length (for 4.83-mm thick wall). The dynamic analysis results indicate that the critical crack lengths are even longer, about 48.3 to 61.0 cm in length. Examination of the rather limited experimental database indicates that the dynamic analysis values are more realistic, and that under certain conditions of projectile size, wall stress, and shield design the critical crack length can be exceeded.