Abstract
Through bulkhead initiators (TBI) used in launch vehicle stage separation are shock-based systems employing high explosive and pyrotechnic charges inside vessels that have a need to maintain bulkhead integrity. The TBI is initiated by an explosive stimulus generated by a mild detonating cord. This causes detonation of the donor charge [pentaerythritol tetranitrate (PETN)] and transfers the resulting shock across the bulkhead and gets attenuated. The attenuated shock results in the deflagration of acceptor charge (PETN) and finally initiates the pyro charge (Ti/CuO), which gives the output in terms of heat and pressure. The TBI housing is fabricated from cold-worked AISI 302 stainless steel. During routine testing on one of the assemblies, the required pressure output was obtained in a closed vessel. However, the housing of the TBI developed cracks on the surface. The cracked hardware was submitted for detailed metallurgical analysis to identify the cause of failure. This paper details the analysis and information obtained therefrom and presents conclusions.
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