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SLI 2010 Statement of Work

The Effect of Acceleration on the Crystallization

of Sodium Acetate

Madison West High School

December 4, 2009

Madison West High School PDR, SLI2010

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Table of ContentsSummary of PDR Report.................................................................................................6

Team Summary............................................................................................................6

Launch Vehicle Summary.............................................................................................7

Payload Summary.........................................................................................................7

Changes made since Proposal........................................................................................8

Changes made to Vehicle Criteria................................................................................8

Changes made to Payload Criteria...............................................................................8

Changes made to Activity Plan.....................................................................................8

Vehicle Criteria.................................................................................................................9

Design Review at System Level and Required Subsystems......................................12

Propulsion System..................................................................................................12

Entire Vehicle..........................................................................................................14

Sustainer.................................................................................................................15

Performance Characteristics for the System...........................................................18

Verification Plan and Status....................................................................................18

Matrix Legend.........................................................................................................19

Rocket/Payload Risks.............................................................................................20

Specific Two Stage Vehicle Risks...........................................................................21

Scheduling and Facilities Risks...............................................................................22

Integrity of Design...................................................................................................22

Recovery Subsystem..................................................................................................23

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Mission Performance Predictions...............................................................................24

Wind Speed vs. Altitude..........................................................................................25

Thrust Profile...........................................................................................................25

Acceleration Profile.................................................................................................26

Payload Integration.....................................................................................................27

Launch Operation Procedures....................................................................................27

Launch System.......................................................................................................27

Final Assembly and Launch Procedures.................................................................27

Safety and Environment (Vehicle)..............................................................................28

Safety Officer..........................................................................................................28

Risks and Mitigations..............................................................................................28

Physical Risks.........................................................................................................28

Rocket/Payload Risks.............................................................................................29

Specific Two Stage Vehicle Risks...........................................................................30

Toxicity Risks..........................................................................................................31

Environmental Concerns.........................................................................................31

Payload Criteria..............................................................................................................32

Selection, Design, and Verification of Payload Experiment........................................32

Design at System Level..........................................................................................32

Payload Systems....................................................................................................32

Performance Characteristics...................................................................................38

Verification Matrix...................................................................................................39

Payload Preliminary Integration..............................................................................40

Precision of Instrumentation, Repeatability of Measurement and Recovery System................................................................................................................................41

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Payload Concept Features and Definition...................................................................42

Creativity and Originality.........................................................................................42

Uniqueness or Significance....................................................................................42

Suitable Level of Challenge....................................................................................42

Science Value.............................................................................................................44

Science Payload Objectives....................................................................................44

Payload Success Criteria........................................................................................44

Experimental Logic, approach, and method of investigation...................................45

Test and Measurement, Variables, and Controls....................................................45

Relevance of expected data and accuracy/error analysis.......................................46

Preliminary Experiment Process Procedures..........................................................47

Safety and Environment..............................................................................................48

Activity Plan....................................................................................................................52

Budget........................................................................................................................ 52

Timeline......................................................................................................................53

Educational Engagement............................................................................................54

Conclusion.....................................................................................................................55

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Summary of PDR Report

Team Summary

School Name Madison West High School

Title of ProjectThe Effect of Acceleration on the Crystallization of Sodium Acetate

Educators and Mentors

Administrative Staff MemberWest High School Principal Ed HolmesMadison West High School, 30 Ash St., Madison, WI, 53726Phone: (608) 204-4104Email: [email protected]

Educators and Mentors:Ms. Christine Hager, Biology InstructorMadison West High School, 30 Ash St., Madison, WI 53726Phone: (608) 204-3181Email: [email protected]

Pavel Pinkas, Ph.D., Senior Software Engineer for DNASTAR, Inc.1763 Norman Way, Madison, WI, 53705Work Phone: (608) 237-3068Home Phone: (608) 238-5933Fax: (608) 258-3749Email: [email protected]

Brent Lillesand4809 Jade Lane, Madison, WI 53705Phone: (608) 241-9282E-Mail: [email protected]

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Launch Vehicle SummaryWe will use a two stage vehicle for our experiment. We will be observing the effects of different gravitational states on the crystallization of sodium acetate, and a two stage rocket will give us two distinct acceleration profiles during flight.

To have a successful mission we need to reach one mile AGL and have successful crystallization in all reactor tubes in the payload. The rocket will be 120 inches long, with a 4 inch diameter for both the booster and the sustainer. It has a liftoff weight of 20.6 pounds (sustainer itself is 13.7 pounds). The proposed vehicle and propulsion options are discussed in detail below. The propulsion is a K-class motor in the booster and a J-class motor in the sustainer and total impulse is 2421 Ns. The vehicle can launch from a standard launch rail.

Payload SummaryIn our experiment, we will investigate the effect of acceleration on the crystallization of supersaturated sodium acetate (CH3COONa) solutions. We will be testing pure supersaturated sodium acetate solutions, along with supersaturated sodium acetate solutions containing trace amounts of other impurities (dopes).

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Changes made since Proposal

Changes made to Vehicle CriteriaThere have been no significant changes made to the vehicle.

Changes made to Payload Criteria We have made a few minor changes to our payload since the SOW, including: shortening of the test tubes, changing of the test tube material, changing the attachment method of the thermistors, fan system, and changing the method of attachment of the reactor vessels.

After extensive research we have found that with our previous length of 20cm would give us a reaction time of 40 seconds, which is unnecessary because the rocket will reach apogee in 21 seconds. We decided to shorten the reactor vessel to a more reasonable length of 15 cm, which still gives us 10 seconds of after-apogee reaction time and reduces the payload weight significantly.

Originally we had the thermistor attached directly to the test tubes, but we ran into the problem of removing them from the test tube and re-attaching them to another. Instead we decided to attach the thermistors on a removable sleeve, and have the reactor vessels slide freely in the sleeve. The sleeve will be made of polycarbonate. The thermistors will be attached to the sleeve, more closely together where we predict the most changes will occur.

Changes made to Activity PlanThere have been no significant changes made to the Activity Plan.

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Vehicle Criteria

1. Payload: the rocket carries a scientific payload to measure crystallization under different gravitational forces.

2. Target Altitude: Rocket must reach altitude of 1 mile — (simulations show that our rocket will reach 7,400ft using Aerotech K1100T motor (booster) and Aerotech J1299N (sustainer)). At this stage of the project we are leaving ourselves a sufficient altitude margin to cover for possible rocket design changes and vehicle weight increase.

3. Launch: The rocket can launch from a standard launch rail and it needs less than 10ft of launch guidance to support the rocket and achieve the stable flight velocity. The rocket is designed to be launched using a standard 12V ignition system.

4. Propulsion: The total impulse of the vehicle is less than 2560Ns. Both motors contain solid ammonium perchlorate based propellant.

5. Safe Recovery: Booster and sustainer (including the payload) must land undamaged and suitable for re-flight — We will utilize ARRD (Advanced Rocket Recovery Device) deployment scheme with redundant charges and ejection triggers to ensure the ejection and will determine and verify the sizes of parachutes and ejection charges during static tests. Because of the booster’s high apogee (3,000ft) the booster will also use dual deployment via an ARRD. Ejection charges will be triggered by commercially available e-matches. Both the vehicle and the payload are reusable.

6. Separation: Only drogue parachute will be deployed at apogee allowing the rocket to descend to 700 ft where the main parachute will deploy. Booster is expected to coast to 3000 ft where it will deploy drogue parachute with the main chute deploying at 700 ft. This recovery scheme is designed to minimize drift while still allowing the rocket to recover safely.

7. Preparation: the vehicle will not take more than 4 hours to prepare for the flight. The payload is not time critical.

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8. Recovery: we are using an ARRD scheme and we expect that both stages will land relatively close to the launch pad and within the designated launch site.

9. Countdown: After the rocket is prepared for launch, only the standard 10 second countdown is required prior to ignition.

10.Data: data will be produced and recorded during flight and analyzed after the vehicle (including the flight computers) is recovered. We will use proper scientific methods during data analysis.

11.Tracking: The radio beacons and acoustic beacons will be used to aid us in the vehicle tracking and recovery, should the excessive drift occur.

12. Preparedness: The full scale vehicle will be launched at least once prior to the flight readiness review (FRR). A Level 2 NAR observer will observe the flight and fill out the required form.

13.Robustness: Both booster and sustainer must withstand acceleration up to 25g — (we will construct rocket from fiberglass tubing, G10 sheets (for fins) using industrial strength epoxy glue (West Epoxy) with fillers. We will mount the fins using through the wall construction in order to improve robustness).

14.Stability and thrust to weight ratio: Rocket must have a stability margin of at least 2.0 calibers — (our entire rocket has a stability margin of 5.7 calibers and our sustainer has a stability margin of 3.0 calibers). Both stages are propelled by motors providing at least 5:1 thrust to weight ratio.

15.Prohibited items: we are not using flashbulbs, rear ejection, forward firing motors or forward canards on our vehicle. The vehicle does not exceed Mach 1.

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Major MilestonesDecember 2009

4 Preliminary Design Review (PDR) report due7 Begin work on scale model

14 Acquire parts and supplies for scale model21-Jan 3 Winter break

January 20104 Scale Model Completed5 Purchase parts and supplies for full scale vehicle

13 Scale model test flight20 Critical Design Review (CDR) due24 CDR Presentation practice

28-Feb. 5 Critical Design Review presentations (tentative)February 2010

8 Payload design finalized, payload construction starts15 Full scale vehicle completed22 Sustainer (upper stage) test flight

March 201017 Flight Readiness Review presentation slides and CDR report due15 Two stage test flight, payload complete22 Payload test flight

25-Apr. 2 FRR presentations (tentative)April 2010

12 Rocket Ready for Launch in Huntsville14 Travel to Huntsville

15/16 Rocket Fair/hardware and safety check17-18 Launch weekend

19 Return HomeMay 2010

21 Post-Launch Assessment Review (PLAR) dueTable 1: Timeline of important events

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Design Review at System Level and Required Subsystems

Propulsion System

Booster Motor

Aerotech K1100-T is suggested as the first choice for the booster. It will provide sufficient thrust for the liftoff of the entire vehicle (thrust/weight ratio is 7.64) and will burn out at around 650 ft after accelerating the rocket to about 350 mph. The booster is expected to coast to 3,000ft and dual deployment will be used for booster recovery.

Motor Length [mm]

Diameter [mm]

Average Impulse [N]

Total Impulse [Ns]

Burn Time [s]

AT-K1100T 398 54 910 1586 1.74

Table 2: Primary booster motor

Sustainer Motor

After the separation from the booster, the J1299 motor will deliver the sustainer to the target altitude. The maximum estimated speed is 600 mph and the motor will burn for 0.7s.

Motor Length [mm]

Diameter [mm]

Average Impulse [N]

Total Impulse

[Ns]

Burn Time [s]

AT-J1299N 230 54 1253 850 0.68

Table 3: Primary sustainer motor

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Motor Alternatives

Two sets of suitable alternative motors are listed in the table below.

Motor Diameter [mm]

Total Impulse

[Ns]

Burn Time

[s]

Stability Margin

[calibers]

Thrust to weight ratio

Alternative 1

AMW-K700BB 54 1608 2.24 5.86 7.64

AT-J460T 54 813 1.90 2.93 6.98

Alternative 2

AT-K695R 54 1493 2.3 5.63 6.62

AMW-J357 54 999 2.95 2.64 5.2

Table 4: Motor alternatives

The motors will each be contained in a phenolic motor-mount tube, centered in the rocket body with three (booster) and two (sustainer) 0.50” plywood centering rings, and secured with a Lock’N’Load motor retention system.

Structural System

The structural system consists of 4” diameter fiberglass tubing. We are using 4” tubing because the rocket needs to be at least that big to accommodate our payload, also many members on our team have experience working with 4” tubing, both during construction and in flight (in past we have run many static ejection tests with 4" tubing). Two sets of four fins made of G10 fiberglass will be attached with through the wall construction to the motor mounts in either stage. Paper tubing and balsa fins are not acceptable, as they are too weak to withstand high-power rocket flight.

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Entire Vehicle

Figure 1: A two dimensional schematic of the entire rocket

Vehicle Parameters

Length

[in]

Weight

[lbs]Diameter

[in]Motor

Selection

Stability Margin

[calibers]


119.75 20.6 4 AT-K1100T 5.75 11.53

Table 5: The rocket’s dimensions, stability and propulsion

The figure below shows all compartments and section of our rocket. The entire payload is located in the sustainer. We will use ARRD dual deployment device in both stages.

Figure 2: A three dimensional schematic of the entire rocket

Letter Part Letter Part

A Nosecone H Payload Bay

B Main Sustainer Parachute

I Booster Drogue Parachute

C Sustainer J Drogue Sustainer

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D ECBAF G

H IKJ

M

N

L


E-Bay Parachute

Letter

Part Letter Part

DSustainer

Fins K

Sustainer

Motor Mount

EInterstage coupler L

Booster

Main Parachute

FBooster

E-BayM

Payload Electronics

GBooster

FinsN

Booster Motor Mount

Table 6: Rocket sections and parts

Sustainer

Figure 3: A two dimensional schematic of the sustainer

Sustainer Parameters

Length [in]

Weight [lbs]

Diameter [in]

Motor Selection

Stability Margin

[calibers]


81.75 13.9 4 AT-J1299N 3.00 20.43

Table 7: The dimensions of the sustainer, stability margin and propulsion

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Figure 4: A three dimensional schematic of the sustainer

Deployment System

The deployment system will be set up as follows:

1. Booster – The booster deployment system will consist of two dual event altimeters, with two ejection charges for the booster drogue parachute and two charges for the booster main parachute ARRD (two for redundancy). Both altimeters fire the charge when the booster’s apogee occurs. The drogue parachute will then deploy and the booster will descend to 700 ft. at which point the ARRD will be activated and the booster main will deploy.

2. Sustainer – The separation of the rocket occurs shortly before the sustainers motor starts its’ burn (a separation charge will be used). The sustainer then continues to apogee. When apogee is reached two altimeters fire two charges and deploy the sustainer’s drogue parachute (again two for redundancy). The sustainer descends to an altitude of 700 ft at which point the sustainer’s main chute is deployed by the ARRD.

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Figure 5: Flight sequence of the rocket from liftoff to touchdown 1. First stage burn, reaction starts 2. Stage separation 3. Booster coasts to its apogee and deploys drogue parachute 4. Booster deploys main parachute 5. Booster lands safely 6. Second stage motor burn 7. Sustainer reaches apogee, deploys drogue parachute. 8. Sustainer descends under drogue. 9. Sustainer deploys main parachute. 10. Sustainer lands safely.

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Performance Characteristics for the System

Verification Plan and StatusVerification Tests

V1 Integrity Test: applying force to verify durability.

V2 Parachute Drop Test: testing parachute functionality.

V3 Tension Test: applying force to the parachute shock cords to test durability

V4 Prototype Flight: testing the feasibility of the vehicle with a scale model.

V5 Functionality Test: test of basic functionality of a device on the ground

V6 Altimeter Ground Test: place the altimeter in a closed container and decrease air pressure to simulate altitude changes. Verify that both the apogee and preset altitude events fire. (Estes igniters or low resistance bulbs can be used for verification).

V7 Electronic Deployment Test: test to determine if the electronics can ignite the deployment charges.

V8 Ejection Test: test that the deployment charges have the right amount of force to cause parachute deployment and/or planned component separation.

V9 Computer Simulation: use RockSim to predict the behavior of the launch vehicle.

V10 Integration Test: ensure that the payload integrates precisely into the vehicle, and is robust enough to withstand flight stresses.

Tested Components

C1: Body (including construction techniques)

C2: Altimeter

C3: Data Acquisition System (custom computer board and sensors)

C4: Parachutes

C5: Fins

C6: Payload

C7: Ejection charges

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C8: Launch system

C9: Motor mount

C10: Beacons

C11: Shock cords and anchors

C12: Rocket stability

C13: Second stage separation and ignition electronics/charges

Matrix LegendXXX: Planned Tests

XXX: Finished Tests

V 1 V 2 V 3 V 4 V 5 V 6 V 7 V 8 V 9 V 10

C 1 P P

C 2 P P

C 3 P P

C 4

C 5

C 6

C 7

C 8 P

C 9

C 10

C 11 P P

C 12

C13

Table 8: Verification matrix for the vehicle

Our verification plan is 0% complete; however, all of the necessary tests will be completed before our departure to Huntsville.

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Rocket/Payload RisksRisks Consequences Mitigation

Unstable rocket Errant flight Rocket stability will be verified by computer and scale model flight.

Improper motor mounting

Damage or destruction of rocket.

Engine system will be integrated into the rocket under proper supervision and used in the accordance with the manufacturer's recommendations.

Weak rocket structure

Rocket structural failure

Rocket will be constructed with durable products to minimize risk.

Propellant malfunction

Engine explosion All members will follow NAR Safety Code for High Powered Rocketry, especially the safe distance requirement. Attention of all launch participants will be required. Mentors will assemble the motors in accordance with manufacturer's instructions.

Parachute Parachute failure Parachute packaging will be double checked by team members. Deployment of parachutes will be verified during static testing.

Payload Payload failure/malfunction

Team members will double-check all possible failure points on payload.

Launch rail failure

Errant flight NAR Safety code will be observed to protect all member and spectators. Launch rail will be inspected prior each launch.

Separation failure

Parachutes fail to deploy

Separation joints will be properly lubricated and inspected before launch. All other joints will be fastened securely.

Ejection falsely triggered

Unexpected or premature ignition/personal injury/property damage

Proper arming and disarming procedures will be followed. External switches will control all rocket electronics.

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Recovery failure

Rocket is lost The rocket will be equipped with radio and sonic tracking beacons.

Hypodermic Needle

Possibility of puncture wound

All members will follow safety procedures and use protective devices to minimize risk.

Sodium Acetate

Skin irritation Sodium Acetate will be handled using proper safety equipment. MSDS sheet is available.

Transportation damage

Possible aberrations in launch, flight and recovery.

Rocket will be properly packaged for transportation and inspected carefully prior to launch

Table 9: Risks associated with the rocket launch

Specific Two Stage Vehicle RisksRisks Consequences Mitigation

Stages fail to separate

Stage 2 motor burns while still attached to booster

Make sure coupler fit is exact, and use a previously tested method for use in two-stage rockets of this size. The size of separation charge will be verified in static testing.

Second stage motor fails to ignite

No second stage separation, rocket too heavy for safe descent rate

Recommended staging igniters will be used and the staging electronics will thoroughly tested before each flight. Recovery of all stages is triggered by altimeters and all recovery devices will deploy even if the second stage fails to ignite.

Second stage motor fires late

Horizontal second stage flight

Members will check that the timer is accurately set, a reliable igniter will be used, and we will use new batteries for each flight.

Motor failure (chaff or CATO)

Second stage mistakenly detects launch and ignites

We will use reliable motors and electronics. The timers require 2g+ acceleration for 0.5s before they trigger the timer countdown.

Table 10: Risks associated with a two stage rocket launch

Scheduling and Facilities RisksRisks Consequences Mitigation

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Workshop space unavailable

Unable to complete construction of rocket and/or payload

We will insure the availability of our workshop space for the times that we need it. We will also work at team members’ homes if necessary.

Design facilities unavailable

Unable to complete project

We will insure the availability of our design facilities and work at team members’ homes if needed.

Team members unavailable

Unable to complete project

We will plan meetings in advance and insure that enough team members will be present to allow sufficient progress.

Table 11: Risks associated with scheduling and facilities

Integrity of DesignWe have chosen standard high power rocketry materials – namely G-10 fiberglass balsa sandwich for the fins, half-inch plywood for the bulkheads, fiberglass tubing for the body, stainless steel hardware – to ensure structural integrity of the vehicle during flight and landing. The standard trapezoidal shape and proper size of our fins ensures the stable flight of our vehicle and reduces the risk of fin flutter during ascent. We will employ an Aeropack motor retention system to ensure motor does not dislodge during flight. Our use of West Systems Epoxy on the full scale vehicle will ensure the robustness of load bearing structural sections of the rocket; specifically, attachment points of the fins to the body tubes, connections of couplers to body tubes, and fixture points of permanent bulkheads and centering rings within body tubes.

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Recovery SubsystemOur rocket will deploy a total of four parachutes. We will utilize ARRD (Advanced Rocket Recovery Device) deployment scheme with redundant charges and ejection triggers to ensure the ejection and will determine and verify the sizes of parachutes and ejection charges during static tests.

Two parachutes are housed in the sustainer. The sustainer drogue chute will be deployed at sustainer’s apogee, slowing and stabilizing the rockets descent. The sustainer’s main chute will be deployed at 700ft, slowing the rocket to a safe descent rate.

The other two parachutes are housed in the booster. Because of the booster’s high apogee (3,000ft) the booster will also use dual deployment via an ARRD. The drogue chute will be deployed after the booster coasts to approximately 3000ft AGL and the booster main will be deployed at 700 feet.

Component Weight

[oz]

Parachute Diameter

[in]

Descent rate

[fps]Booster drogue 62 12 53

Booster main 62 36 18

Sustainer drogue 199 24 48

Sustainer main 199 60 19

Table 12: Parachute sizes used for booster and sustainer

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Mission Performance PredictionsThe graph below shows the simulated flight profile for K1100/J1299 motor combination. A significant increase in slope is visible shortly after the first stage burnout (1.74s) and the sustainer reaches the apogee of 7,500ft twenty-one seconds after the ignition. At this stage of the project we consider 7,500ft “close enough” to one mile target altitude, especially considering that RockSim tends to overestimate apogees and the rocket tends to “gain weight” as the project progresses.

Figure 6: Altitude vs. time graph for K1100/J1299 motor combination. The rocket reaches 7500ft at 21s after ignition.

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Wind Speed vs. AltitudeThe effect of the wind speed on the apogee of the entire flight is investigated in the table below. Even under the worst possible conditions (wind speeds 20mph, the NAR safety limit) the flight apogee will differ by less than 4% from the apogee reached in windless conditions.

Wind Speed

[mph]

Altitude

[ft]Percent Change in

Altitude

0 7574 0.00%

5 7497 0.10%

10 7454 1.61%

15 7386 2.55%

20 7298 3.78%

Table 13: Flight apogee vs. wind speed

Thrust ProfileThe graph below shows the thrust profile for K1100/J1299 motor combination. The two distinct burns are clearly visible. The K1100 motor has a 1500N initial spike which will provide a sufficient speedup of the whole vehicle as it leaves the launch rail (the rocket needs approximately 6 ft to reach a safe flight velocity).

Figure 7: Thrust vs. time graph. The rocket has a maximum thrust of just over 1500 N.

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From the velocity profile below we can read that the first stage will accelerate to 350mph+ before the thrust tapers off, at which point a momentary negative acceleration can occur. The second stage will then take over, accelerating the sustainer to 600mph+ and delivering the sustainer to the flight apogee.

Figure 8: Velocity vs. time graph. The booster motor burns out at 1.74s and the sustainer motor burns out at about 2.3 seconds. After burnout the rocket slows down gradually until it reaches apogee.

Acceleration ProfileThe graph below depicts the estimated acceleration profile. Two separate peaks correspond to the two burns. Our rocket will be robust enough to endure the 25g+ acceleration shocks.

Figure 9: Acceleration vs. time graph. The rocket has a maximum acceleration of approximately 16 gee’s for the booster and a maximum of just over 22 gee’s for the sustainer’s burn.

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Payload Integration

The payload team has been provided two bays of adequate size for the payloads each of which is bounded by a thick plywood bulkhead. In addition, wherever the airframe of the rocket is punctured (e.g. vents) we will ensure that it does not compromise the structural integrity of the rocket and reinforce the airframe as necessary. Payload integration is in detail described in the Payload section.

Launch Operation Procedures

Launch SystemOur rocket will require the usage of a 12 ft. launch tower coupled with a blast deflector. To ignite the motor we will use a standard 12 volt ignition system with a commercially available igniter.

Final Assembly and Launch Procedures1. Install payload into the rocket2. Assemble rocket partway3. Fold parachutes properly with Nomex protection4. Attach shock cords to parachutes and to rocket5. Connect and place charges into rocket; check for continuity6. Insert parachutes into rocket7. Install and secure the motor in the sustainer, including the staging igniter.8. Fully assemble the rocket and check structural integrity9. Insert booster motor into the booster motor mount and secure with motor10. retention system11.Place rocket onto launch tower and make sure the rocket slides smoothly12.Place igniter into the rocket and place engine cap over the end to secure it13. in place14.Attach the igniter to the launch system and check for continuity15.Activate electronics, wait for boot and confirm continuity16.Move 300 feet away from the rocket (minimum safe launch distance of a complex

K class vehicle)17.Check sky for aircraft18.Arm ignition system19.Countdown20. Launch rocket

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Safety and Environment (Vehicle)

Safety OfficerOur Safety officer is Yifan Li.

Risks and Mitigations

Physical RisksRisks Consequences Mitigation

Saws, knives, Dremel tools, band saws

Laceration All members will follow safety procedures and use protective devices to minimize risk

Sandpaper, fiberglass

Abrasion All members will follow safety procedures and use protective devices to minimize risk

Drill press Puncture wound All members will follow safety procedures and use protective devices to minimize risk

Soldering iron Burns All members will follow safety procedures to minimize risk

Computer, printer

Electric shock All members will follow safety procedures to minimize risk

Workshop risks Personal injury, material damage

All work in the workshop will be supervised by one or more adults. The working area will be well lit and strict discipline will be required

Table 14: Risks that would cause physical harm to an individual

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Rocket/Payload RisksRisks Consequences Mitigation

Unstable rocket Errant flight Rocket stability will be verified by computer and scale model flight.

Improper motor mounting

Damage or destruction of rocket.

Engine system will be integrated into the rocket under proper supervision and used in the accordance with the manufactures’ recommendations.

Weak rocket structure

Rocket structural failure

Rocket will be constructed with durable products to minimize risk.

Propellant malfunction

Engine explosion All members will follow NAR Safety Code for High Powered Rocketry, especially the safe distance requirement. Attention of all launch participants will be required. Mentors will assemble the motors in accordance with manufacturer's instructions.

Parachute Parachute failure Parachute Packaging will be double checked by team members. Deployment of parachutes will be verified during static testing.

Payload Payload failure/malfunction

Team members will double-check all possible failure points on payload.

Launch rail failure

Errant flight NAR Safety code will be observed to protect all member and spectators. Launch rail will be inspected prior each launch.

Separation failure

Parachutes fail to deploy

Separation joints will be properly lubricated and inspected before launch. All other joints will be fastened securely.

Ejection falsely triggered

Unexpected or premature

ignition/personal injury/property

Proper arming and disarming procedures will be followed. External switches will control all rocket electronics.

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damage

Recovery failure

Rocket is lost The rocket will be equipped with radio and sonic tracking beacons.

Hypodermic Needle

Possibility of puncture wound

All members will follow safety procedures and use protective devices to minimize risk.

Sodium Acetate

Burns and skin irritation

Sodium Acetate will be handled using proper safety equipment. MSDS sheet is available.

Transportation damage

Possible aberrations in launch, flight and recovery.

Rocket will be properly packaged for transportation and inspected carefully prior to launch

Table 15: Risks associated with the rocket launch

Specific Two Stage Vehicle RisksRisks Consequences Mitigation

Stages fail to separate

Stage 2 motor burns while still attached to booster

Make sure coupler fit is exact, and use a previously tested method for use in two-stage rockets of this size. The size of separation charge will be verified in static testing.

Second stage motor fails to ignite

No second stage separation, rocket too heavy for safe descent rate

Recommended staging igniters will be used and the staging electronics will thoroughly tested before each flight. Recovery of all stages is triggered by altimeters and all recovery devices will deploy even if the second stage fails to ignite.

Second stage motor fires late

Horizontal second stage flight

Our members will check that the timer is accurately set, a reliable igniter will be used, and we will supply new batteries for each flight.

Motor failure (chaff or CATO)

Second stage mistakenly detects launch and ignites

We will use reliable motors and electronics. The timers require 2g+ acceleration for 0.5s before they trigger the timer countdown.

Table 16: Risks associated with a two stage rocket launch

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Toxicity RisksRisks Consequences Mitigation

Epoxy, enamel paints, primer, superglue

Toxic fumes Area will be well ventilated and there will be minimal use of possibly toxic-fume emitting substances

Superglue, epoxy, enamel paints, primer

Toxic substance consumption

All members will follow safety procedures to minimize risk. Emergency procedure will be followed in case of accidental digestion.

Table 17: Risks that would cause toxic harm to an individual

Environmental Concerns

With any activity such as rocketry, one can cause damage to the environment. Fumes emitted from the engine of the rocket during the launch can possibly cause air pollution; rockets that aren’t recovered could cause physical harm to animals, and any non-biodegradable material will remain for years. To try to minimize the potential environmental hazards associated with rocketry, we will strictly comply with all state and federal environmental regulations. We will keep track of everything we use to launch our rockets and the rockets themselves to ensure that all parts are recovered. We will use Nomex parachute protection to avoid littering the launch area with flame retardant wadding.

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Payload CriteriaSelection, Design, and Verification of Payload Experiment

Design at System LevelOur payload consists of five major systems, the reactor, the data acquisition, the air flow, the data processing and the deployment.

The reactor system houses the sodium acetate solution which starts to crystallize just after the rocket is launched. It consists of an initiation reaction system and temperature sensors (thermistors) along each crystallization vessel (reactor).

The data acquisition system acquires data from the reactor. The sensory attachment around the solution, or the sleeve, and various other sensory devices around the payload will send data to the main flight computer. The sensory equipment includes thermistors, accelerometers, and an ambient sensor.

The air flow system maintains an ambient temperature inside the payload. Two fans, that draw air from holes around the payload, are situated above and below the reactors.

The data processing system needs to convert the analog signal to a digital one. The main flight computer will take care of this.

Finally, the deployment system sends signals to the ejection sites above the payload. Wires from the vehicle main computer will pass through our payload.

Payload SystemsOur payload can be broken down into five main systems: Reaction Containment and Activation System (RCAS), Data Acquisition System (DAS), Ambient Temperature Regulation System (ATRS), Data Processing and Storage System (DPSS), and deployment.

Reaction Containment and Activation System (RCAS)

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Figure 10: Experimental Overview: 1-4 is the experiment in the rocket and 5-7 is post-flight research


Each payload module contains 4 crystallization vessels (reactors), each reactor made of 15cm by 1cm cylindrical test tube. It will contain solutions of sodium acetate. This solution of sodium acetate will be initiated at ignition using a solenoid placed at the bottom of each reactor vessel. A hypodermic needle is attached to the arm of the solenoid and will puncture the diaphragm of the reactor vessel. The hypodermic needle contains seed crystals which will initiate the crystallization reaction in the reactor vessel. Eight vessels will be launched, with four vessels per payload bay; each payload bay will have three vessels containing sodium acetate with specific dopes, and a fourth will contain pure sodium acetate. Each vessel will be held in a removable acrylic sleeve, which will have our temperature sensors (thermistors) attached on.

Figure 11: A sketch of all the subsystems of the RCAS (Reaction Containment and Activation System).

Subsystem Function Accuracy/Precision

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Requirements

Vessel The vessel is made of a 15 cm x 1 cm cylindrical polycarbonate tube. The tube has a membrane on the one end which will be punctured by the Initiation System

N/A

Reaction Activation Subsystem (RAS)

The initiation system consists of a solenoid, which contains a hypodermic needle. The needle will puncture the membrane of the reactor vessel.

It will successfully initiate the reaction when deployed

Supersaturated Sodium Acetate Solution (SSAS)

The supersaturated solution is inside the reactor tube. It will be activated by the Initiation system.

N/A

Sensor Attachment Unit (SAU)

The sensor attachment is an outer tube into which the test tube is inserted. The tube is made out of acrylic.

N/A

Table 18: RCAS subsystem with their function and accuracy/precision requirements

Data Acquisition System (DAS)

The thermistors attached to the sleeve will collect temperature data throughout the flight. The thermistors will be connected to the main flight computer using printed circuit boards. Also, there will be a single thermistor placed on a bulkhead in the center of the payload bay; this thermistor will relay temperature data from our payload bay during flight to the main flight computer. Also in the main flight computer is an accelerometer, the accelerometer will obtain acceleration vs. time data for the duration of the flight.

34 Figure 12: A sketch of all the subsystems of the DAS


Subsystem Function Accuracy/Precision Requirements

Reaction Temperature Monitoring Subsystem (RTMS)

The RTMS is a set of thermistors to measure the temperature and are mounted in the SAU. They are also soldered directly to the ADCS board.

The thermistors’ accuracy is within 0.1 of a degree and the thermistors take measurements 50 times a second

Reactor Chamber Ambient Temperature Sensor (RCATS)

The RCATS is a small thermistor located in the center of the payload bay. It allows us to find other possible correlations between our data and the ambient temperature.

The thermistor’s accuracy is within 0.1 of a degree and the thermistor take measurements 50 times a second

Acceleration Recording Subsystem (ARS)

The ARS is an accelerometer located in the electronics bay. The data is stored in the MFCSS. This allows us to track acceleration discrepancies and their relationship to the crystal structure and temperature.

Measures the acceleration hundred times a second

Cable and Data Transfer The cables allow us to relay data between the ADCB and the MFCSS

N/A

Table 19: DAS subsystems with its function and its accuracy/precision requirements

Ambient Temperature Regulation System (ATRS)

A fan is located at the end of each reactor chamber. The chamber will have a set of eight vents in each end to create airflow. Previously, our experiment involved a dynamic control of the fan speed based on the temperature of the reaction chamber. Instead, we will reduce complexity of the payload by constantly running the fans at the top speed provided by the power supply. We will monitor and log the temperature of the reaction chamber in order to determine other correlations for our data. The fan will be located on the end of each reactor chamber that is farthest away from the electronics bay, to reduce wiring that has to bypass the fan.

Subsystem Function Accuracy/Precision

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Requirements

Fans The fans push large quantities of air through the payload bays. This air prevents the reaction from overheating and slowing down.

The fans will continuously run throughout the experiment

Power and Fan Activation Subsystem (PFAS)

The power system contains several batteries. The activation system is a button that links the power system directly with the fans.

N/A

Table 20: ATRS subsystems with its functions and accuracy/precision requirements

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Figure 13: A representation of the fan within the payload and the fan is in red


Data Processing and Storage System (DPSS)

The main flight computer will have a temperature sensor, an altimeter, a pressure sensor and either a 1 dimensional or a 3 dimensional accelerometer. The CPU will drive the solenoids to initiate the reaction, collect the ambient and thermistor temperatures profiles and stores them in an EEPROM memory. The CPU also starts and powers the fans (using MOSFET switches). The Analog to Digital Conversion chips on data collection boards will convert the analog signal from thermistors to a digital signal.

Material Function Accuracy/Precision Requirements

ADC (Analog to Digital Convertor)

Converts the analog to a digital signal

16bit, 3kSps

CPU (Central Processing Unit)

Initiates the reaction, collects the temperature profiles and controls the fans

A Parallax Propeller Chip, 8 cores, 80MHz clock, 32 kB RAM

Memory Stores Data Atmel AT26/25 flash memory, 2MB

Main Flight Computer (MFCSS)

Consists of an altimeter, accelerometer, and a temperature sensor and non-volatile memory, generates the timeline

N/A

Accelerometer (ARS) Measures the gravitational forces on the rocket

1600 times per second (100Hz samples with 16x oversampling), 12bit

Pressure/Altimeter Measures the pressure on the rocket and the altitude of the rocket

1600 times per second (100Hz samples, with 16x oversampling), 12bit

Table 21: Subsystems of the DPSS

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Figure 14: A sketch of each of the subsystems of the DPSS


Performance CharacteristicsSystem Subsystems Performance

Characteristics

Reaction Containment and Activation System (RCAS)

1. Vessel2. Reaction Activation

System (RAS)3. Supersaturated

Sodium Acetate Solution (SSAS)

4. Sensor Attachment Unit (SAU)

1. Adequately contains solution

2. Reliably initiates crystallization of solution

3. Reliably holds vessel in place, holds temperature sensors in place

Data Acquisition System (DAS)

1. Reaction Temperature Monitoring Subsystem (RTMS)

2. Reaction Chamber Ambient Temperature Sensor (RCATS)

3. Acceleration Recording Subsystem (ARS)

4. Cable and Data Transfer (CDT)

1. Reliably monitors temperature of reaction, measures accurate temperature

2. Reliably monitors ambient temperature of reaction chamber

3. Reliably measures acceleration of rocket

4. Transfers data correctly, high signal to noise ratio

Ambient Temperature Regulation System (ATRS)

1. Fans2. Power and Fan

Activation Subsystem (PFAS)

1. Adequately exchanges air within reaction chamber

2. Reliably activates and powers fan

Data Processing and Storage System (DPSS)

1. Analog to Digital Conversion Subsystem (ADCS)

2. Master Flight Computer Storage Subsystem (MFCSS)

1. Reliably converts analog signal to digital signal, high precision

2. Stores data reliably, low data corruption rate

Table 22: Performance Characteristics of each Systems and subsystems

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Verification MatrixThe components and tests for the verification matrix are listed below.

Verification Test

1. Drop Test: Drop components to ensure that they will not break in flight or during landing. Drop height will be chosen so that it simulates a rocket landing.

2. Connection and Basic Functionality Test: Ensure that all electronic components, devices and batteries are connected firmly and will not loosen in flight. When possible verify that powered up component functions correctly.

3. Pressure Chamber Test: We will place the altimeter in a chamber to make sure the altimeter registers the correct pressure

4. Scale Model Flight: When possible, include component in scale model flight to verify that the component can function during flight.

5. Temperature Sensor Test: Place temperature sensors in a known temperature setting to verify that the temperature sensors register the temperature changes correctly.

6. Durability Test: Verify that the various components will not detach during flight.7. Acceleration Test: Verify that the accelerometer is functioning properly.8. Battery Capacity Test: Verify that our batteries will supply enough power for our

electronics to function for a sufficient time duration (at least one hour).

P=PlanedF=Finished

1 2 3 4 5 6 7 8

Vessel P P PReaction Activation Subsystem P P P PSuper Saturated Sodium Acetate Solution P P PSensor Attachment Unit P P P P PReaction Temperature Monitoring Subsystem P P P P PReactor Chamber Ambient Temperature Sensor P P P P PAcceleration Recording Subsystem P P P P P PCable and Data Transfer P P P P PFans P P P PPower and Fan Activation Subsystem P P P P PAnalog to Digital Conversion Subsystem P P P P PMaster Flight Computer Storage Subsystem P P P P P P

Table 23: Verification Matrix of the Payload

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Payload Preliminary Integration

A B C D B

A: Sustainer ParachutesB: Payload BaysC: Vehicle Electronics (Ebay)D: Payload Electronics

The payload portion of our rocket integrates easily with the vehicle. There is no payload component in the booster; payload components in the sustainer will stay in place for the duration of rocket flight and are independent of vehicle subsystems. The payload meets size and weight constraints imposed by the vehicle, and will be able to withstand the stresses of rocket flight. We are looking for a design that will allow for easy installation and removal of the payload. There will be vents in the body tube above and below each payload bay to allow for airflow. Also, there will be a wire conduit through the upper payload bay for ejection charges, and a wire conduit through the ebay to the payload electronics chamber. Because of the large number of temperature sensors involved in the payload, wiring presents a potential size concern. We will use Printed Circuit Boards (PCBs) and analog to digital converters (ADCs) near the signal source to minimize necessary wiring.

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Figure 15: Sustainer of the rocket

Figure 17: The payload that will slide into the rocket

Figure 16: The payload will be encased in separate tube and slid into the rocket Figure 18: A top view of the payload which will be

slid into the rocket


Precision of Instrumentation, Repeatability of Measurement and Recovery System

Please refer back to the Payload Subsystem section for the precision of Instrumentation.

Our payload is designed for easy repetition of the experiment. Temperature sensors will be mounted on SAU sleeves rather than on reactor vessels themselves, so vessels of crystallized sodium acetate can quickly and simply be switched out for vessels of liquid solution. The payload will not eject from the rocket and therefore will not have its own recovery system.

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Payload Concept Features and Definition

Creativity and OriginalityThe study of crystallization is an entirely new field for Madison West Rocket Club. Previous experiments have involved biology and meteorology, but not chemistry. In this way our project is creative and original.

The idea for our experiment came from a sodium acetate hand warmer. The hand warmer is a pouch of supersaturated solution that crystallizes at a constant rate when exposed to a seed crystal. The reaction gives off heat for an extended period of time, and the resulting crystals can be returned to a supersaturated solution through heating, making the hand warmer reusable. We saw in this reaction potential applications in space flight, and decided to investigate the possible effect of extreme acceleration on sodium acetate: on the crystallization rate, heat of the reaction, and crystal formation. We also decided to investigate the effects of impurities on the crystallization process. These layers of experiment complexity make our project creative and original.

Uniqueness or SignificanceOur experiment is creative and original in that the crystallization of sodium acetate under the stresses of rocket flight has never before been investigated. There is very little research at all regarding the effects of acceleration on supersaturated solutions. Our project has the potential to provide new insights into this field of research.

Suitable Level of ChallengeOur project is complex enough, both from a rocketry standpoint and a scientific standpoint, to provide a suitable level of challenge. In terms of the vehicle, we have chosen to build a two-stage rocket to obtain two different acceleration profiles for our experiment, allowing for more variations in the rate, heat production, and the crystal formations of sodium acetate.

The challenges of high-power two-stage rocket flight are manifold. We must successfully separate the sustainer from the booster, ignite the sustainer motor, and then recover the booster and sustainer separately. We have three rocketry mentors who all have experience with multistage rocket flights and will be able to guide us through this process. With their advice and our hard work, we will be successful.

Our payload adds to the complexity of the project involving multiple flight and data analysis. The rocket will carry eight liquid filled tubes and will experience acceleration of 20g or more. Flight stresses can cause the leakage from the tube and the liquid could possibly cause short circuits if it reaches the electronics. We will have to carefully compartmentalize the rocket to prevent this.

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Complex electronics including accelerometer, barometric altimeter and array of thermistors will be needed to collect the payload and flight data. Furthermore, the ambient temperature of the payload chambers could have an effect on the reaction. A temperature sensor in each payload bay will record the temperature, and fans will create airflow to cool the chambers.

A mechanical moving arm will have to be constructed for the initiation of crystallization inside the reaction vessels. An alarm system monitoring the inadvertent initiation of the crystallization process prior to liftoff will be needed to ensure that the rocket does not take off with the payload already depleted.

Although the challenges are many, our experiences with TARC and SLI have given us the capacity to deal with such complicated projects as this. Our mentors are also a source of advice and their support will be crucial for the project success.

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Science Value

Science Payload ObjectivesCrystallization of sodium acetate under constant pressure only changes the structure of the sodium acetate. Therefore, the density and volume of the crystallized solution and the liquid solution stay constant. Research indicates that the ambient temperature and the concentration of sodium acetate change the rate of the reaction front. However, there is little research as to what happens to the reaction front, when the pressure variable is introduced. Also, there is well known research indicating that the number of structural deformities in a crystal decreases with the low-gravitational environment it has been crystallized in, but there is far less research on the crystal structure in a high-gravitational environment. Also, little to no research indicates what happens to the rate of crystallization and the structural deformities within the crystal when different impurities are added to the solution.

Therefore, our three main payload objectives are to correlate the changing gravitational forces, different impurities or known as doping, and the direction of initiation to the rate of the reaction front, the heat front created by the crystallization and to the structural deformities within the crystal.

We are currently experimenting with Sodium Acetate in a lab to learn more and create a hypothesis about the correlations aforementioned.

Payload Success Criteria Initiation of the Crystallization

The successful application of high and low gravitational forces on the crystallization process

No loss of Sodium Acetate solution and crystal during flight

Undamaged Payload

Reliable data from the thermistors and other electronic devices

Payload computer functions as designed and all mechanical devices function properly

Successful in maintaining the control variables

Successful post-flight research: Compare the control and the other impure crystals

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Experimental Logic, approach, and method of investigationThe data collected throughout the experiment will be taken for analysis. In a laboratory, we will investigate the occurrence of structural deformities throughout the crystallized solution. In the lab, the crystallized solution test tube will be removed from the sleeve and dipped into warm water to loosen the crystal. The crystallized solution will be quickly removed and cut into slices and the core will be examined under a microscope. Frequency of crystal deformities will be noted and compared with those of the control. Data from the data processing system will be downloaded, graphed and compared with the controls to find correlations.

Our primary research interests include the rate of the reaction front (R), the frequency of structural deformities(S) and the temperature of the reaction (T).

Correlations

R = f(I) Reaction rate in relation to ImpuritiesR = f(A) Reaction rate in relation to AccelerationR = f(D) Reaction rate in relation to direction of Initiation

S = f(I) Crystal Deformities in relation to ImpuritiesS = f(A) Crystal Deformities in relation to AccelerationS = f(D) Crystal Deformities in relation to direction of Initiation

T = f(I) Temperature of Reaction in relation to ImpuritiesT = f(A) Temperature of Reaction in relation to AccelerationT = f(D) Temperature of Reaction in relation to direction of Initiation

Test and Measurement, Variables, and ControlsTest Measurement

Reaction Rate (R)Data will be collected from the on-board electronic sensors (thermistors) and translated to provide relevant data

Temperature of Reaction (T)Data will similarly be collected from the on-board electronic sensors(ambient thermometer) and translated to provide relevant data

Crystal Structure Deformities (S)The crystallized substance will be removed from the rocket and cut into small sections to be analyzed through a microscope

Table 24: The test and measurement of the different dependent variables

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Independent Variables

C Pure sodium acetate solutionI1 Impurity number 1I2 Impurity number 2I3 Impurity number 3A AccelerationD Direction of Initiation

Dependent Variables

R Reaction RateS Crystal Structure DeformitiesT Temperature of Reaction

Constants

Temperature inside RocketAmount and concentration of Solution Thermistors (thermometers)Initiation of SolutionControls in Rocket and on-ground

Relevance of expected data and accuracy/error analysisThe correlations that can be made from our experiment can help us better understand the effect of high acceleration on Sodium Acetate. Silicon chips during manufacturing are placed in micro-gravity to reduce the number of structural deformities; however, there is not any relevant data of how high gravitational forces affect the number of structural deformities.

Also, the correlations between impurities in the solution and the heat storage capabilities can further research in situations when a heat release is required.

To ensure the accuracy of our experiment, we have a control along with the three experimental setups. There will be two controls, one in each compartment of the payload. The controls act to detect any inaccuracies and give us the ability to compare it with the other setups during post-research. To ensure that the reaction will not be disturbed, the entire payload will be encapsulated and will slide into the rocket. We will verify that both vessels follow all the steps aforementioned in the verification matrix. The accuracy of each instrument is noted in the Subsystems part of the document.

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Preliminary Experiment Process ProceduresIn the following weeks we plan start the lab work and learn the details and intricacies of the sodium acetate crystallization from the supersaturated solution. We will try different kinds of crystallization vessels, specifically focusing on the inability of the vessel itself to start the crystallization once the supersaturated solution is poured in.

The optimal and 100% reliable crystallization initiation process must be developed as well.

We will construct a functional prototype of the thermistor array and use breadboard prototyping to create a functional prototype of the crucial electronics. This setup will used to monitor the reaction front in lab settings and will become a starting point for the real payload.

We will seek and establish a contact with crystallography experts and labs for later analysis of the crystals produced during our lab runs and flights.

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Safety and Environment

Safety Officer: Yifan Li

NAR Safety Requirements

a. Certification and Operating Clearances: Mr. Lillesand holds a Level 3 HPR certification. Dr. Pinkas has a Level 1 HPR certification and plans on having a Level 2 HPR certification by the end of February 2010. Mr. Lillesand has Low Explosives User Permit (LEUP). If necessary, the team can store propellant with Mr. Goebel, who owns a BATFE approved magazine for storage of solid motor grains containing over 62.5 grams of propellant.

Mr. Lillesand is the designated individual rocket owner for liability purposes and he will accompany the team to Huntsville. Upon his successful L2 certification, Dr. Pinkas will become a backup person for this role.

All HPR flights will be conducted only at launches covered by an HPR waiver (mostly the WOOSH/NAR Section #558 10,000ft waiver for Richard Bong Recreation Area launch site). All LMR flights will be conducted only at the launches with the FAA notification phoned in at least 24 hours prior to the launch. NAR and NFPA Safety Codes for model rockets and high power rockets will be observed at all launches. Mentors will be present at all launches to supervise the proceedings.

b. Motors: We will purchase and use in our vehicle only NAR-certified rocket motors and will do so through our NAR mentors. Mentors will handle all motors and ejection charges.

c. Construction of Rocket: In the construction of our vehicle, we will use only proven, reliable materials made by well established manufacturers, under the supervision of our NAR mentors. We will comply with all NAR standards regarding the materials and construction methods. Reliable, verified methods of recovery will be exercised during the retrieval of our vehicle. Motors will be used that fall within the NAR HPR Level 2 power limits as well as the restrictions outlined by the SLI program. Lightweight materials such as fiberglass tubing and carbon fiber will be used in the construction of the rocket to ensure that the vehicle is under the engine’s maximum liftoff weight. The computer program RockSim will be utilized to help design and pre-test the stability of our rocket so that no unexpected and potentially dangerous problems with the vehicle occur. Scale model of the rocket will be built and flown to prove the rocket stability.

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d. Payload: As our payload does not contain hazardous materials, it does not present danger to the environment. However, our NAR mentors will check the payload prior to launch in order to verify that there will be no problems.

e. Launch Conditions: Test launches will be performed at Richard I. Bong Recreation Area with our mentors present to oversee all proceedings. All launches will be carried out in accordance with FAA, NFPA and NAR safety regulations regarding model and HPR rocket safety, launch angles, and weather conditions. Caution will be exercised by all team members when recovering the vehicle components after flight. No rocket will be launched under conditions of limited visibility, low cloud cover, winds over 20mph or increased fire hazards (drought).

II. Hazardous Materials

All hazardous materials will be purchased, handled, used, and stored by our NAR mentors. The use of hazardous chemicals in the construction of the rocket, such as epoxy resin, will be carefully supervised by our NAR mentors. When handling such materials, we will make sure to carefully scrutinize and use all MSDS sheets and necessary protection (gloves, goggles, proper ventilation etc.).

All MSDS sheets applicable to our project are available online at

http://westrocketry.com/sli2010/msds/msds2010n.html

III. Compliance with Laws and Environmental Regulations

All team members and mentors will conduct themselves responsibly and construct the vehicle and payload with regard to all applicable laws and environmental regulations. We will make sure to minimize the effects of the launch process on the environment. All recoverable waste will be disposed properly. We will spare no efforts when recovering the parts of the rocket that drifted away. Properly inspected, filled and primed fire extinguishers will be on hand at the launch site.

IV. Education, Safety Briefings and Supervision

Mentors and experienced rocketry team members will take time to teach new members the basics of rocket safety. All team members will be taught about the hazards of rocketry and how to respond to them; for example, fires, errant trajectories, and environmental hazards. Students will attend mandatory meetings and pay attention to pertinent emails prior participation in any of our launches to ensure their safety. A mandatory safety briefing will be held prior each launch. During the launch, adult

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supervisors will make sure the launch area is clear and that all students are observing the launch. Our NAR mentors will ensure that any electronics included in the vehicle are disarmed until all essential pre-launch preparations are finished. All hazardous and flammable materials, such as ejection charges and motors, will be assembled and installed by our NAR-certified mentor, complying with NAR regulations. Each launch will be announced and preceded by a countdown (in accordance with NAR safety codes).

V. Procedures and Documentation

In all working documents, all sections describing the use of dangerous chemicals will be highlighted. Proper working procedure for such substances will be consistently applied, such as using protective goggles and gloves while working with chemicals such as epoxy. MSDS sheets will be on hand at all times to refer to for safety and emergency procedures. All work done on the building of the vehicle will be closely supervised by adult mentors, who will make sure that students use proper protection and technique when handling dangerous materials and tools necessary for rocket construction.

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Activity Plan

BudgetProject Budget

VehicleTubing $ 600.00 Fin Material $ 100.00 PerfectFlite MAWD Altimeter (x4)* $ - PerfectFlite miniTimer3 (x2)* $ - Parachutes, recovery gear* $ - Waltson/Tracking System* $ - Miscellaneous supplies (tools, glues) $ 100.00 Scale ModelTubing $ 150.00 Fin Material $ 40.00 MotorsScale Model Motors $ 100.00 Preliminary Flight Motors $ 600.00 Final Flight Motors $ 150.00 Payload1cm diameter Acrylic Tubes * 2m $ 5.25 Fans $ 200.00 Sodium Acetate $ 191.00 Thermistors $ 257.00 Mini Push-type Solenoids $ 8.60 Total $ 2,501.85

Table 25 : Budget for 2009-10 SLI Program

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Travel Budget

Flight270/Person * 11 People $ 2,970.00Rooms119/Room * 5Rooms * 5 Nights $ 2,975.00Car Rental269 rental+ 228 gas $ 497.00Total $ 6,442.00NASA Supports $1200 $(1,200.00)Member cost $ 5,242.00Cost per Person $ 582.44

Table 26: Budget for the travel to Huntsville, AL

TimelineTimeline For SLI Project

December 20094 Preliminary Design Review (PDR) report due7 Begin work on scale model9 Preliminary Design Review Presentation

January 20104 Scale Model Completed20 Critical Design Review (CDR) due24 CDR Presentation practice28-Feb. 5 Critical Design Review presentations (tentative)

March 201017 Flight Readiness Review (FRR) presentation slides and CDR report

due25-Apr. 2 FRR presentations (tentative)

April 201012 Rocket Ready for Launch14 Travel to Huntsville15/16 Rocket Fair/hardware and safety check17-18 Launch weekend19 Return Home

May 201021 Post-Launch Assessment Review (PLAR) due

Table 27: Timeline of the SLI

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Educational Engagement

Educational Engagement Form

Team name: Madison West New Team

Date of event: 10/23/2009 and 11/04/2009

Location of event: Allied Drive Outreach Center, Madison, WI

Grade level or age range and number of participants: (If you are able to break down the

participants into grade levels: PreK-4, 5-8, 9-12, and 12+, this will be helpful.) 50 students, grades K-5

Are the participants with a special group/organization (i.e. Girl Scouts, 4-H, school)? Y N

If yes, what group/organization? MSCR (Madison School/Community Recreation)

Briefly describe your activities with this group: Team members helped young students build skill level-1 model rockets. Rocket launch held on second date.

Did you conduct an evaluation of your educational engagement? If so, what were the results?

All students were very engaged and enthusiastic, some even expressing their concern over launching their rockets, for fear of not being able to retrieve them. Team members enjoyed the appreciation from the younger students and truly enjoyed the experience. For the young students of this predominately minority, low-income neighborhood, this was the first time they have had any exposure to rocketry.

The rocket kits were generously donated by Mr. Lillesand and the motors were purchased out of our club funds. We have used the tools and supplies from our workshop during the building session with MSCR students. Dr. Pinkas made a launch controller with additional safety features to be used during the launch.

We have been invited to return again in the spring.

Rocket Building Worskhop Group Ready to Launch Launch Fever

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Conclusion

We have completed our preliminary design review and have identified the major components of each payload subsystem. The vehicle team will begin construction of the scale model. The payload team will continue finalizing the design, begin purchasing materials, and begin construction on schedule. We will also visit the university laboratory to learn microscopy techniques for crystal analysis.

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