AIAA 94-3065

ARIANE 5 MPS Igniter

Subsystem - Design
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Approach and Development

Phase Results
M. Santilli
EUROPROPULSION (F)
A. Fontana
BPD Difesa e Spazio (I)

30th AIANASMEISAWASEE Joint

Propulsion Conference
June 27-29, 1994 / Indianapolis, IN
~r permission to copy or republish, contact the American Institute of Aeronautics and Astronautics
370 L'Enfant Promenade, S.W., Washington, D.C. 20024
 diameter (656 m n is the flange maximum
diameter).
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main difference is that the contrast
is not realized by the metallic
projection of the two items to be
assembled, but by means of a suitable
circular metallic ring, which has the
function to block any possible
movement of the items in the axial
direction.

Pig. 1 - Assembled igniter

The final configuration was chosen

after a trade off among different
configurations, being strict Pig. 2 - Lock-wire junction
requirements imposed at design level
as far as geometric dimensions and This ring is made up of two bands to
igniter assembling sequence are be inserted, one by one, in a suitable
concerned. In particular, as to the window realized on the igniter flange,
integration, the most logical solution thus realizing the junction between
seemed to be a bolt junction the main basket and the flange. The
(configuration referred to as 'Bolts most important advantage obtained with
configuration'), in which the junction this type of junction is the increase
-./ of the main igniter metallic case and of the contrast area respect to the
the flange was accomplished by means traditional 'bayonet junction'. The
of 40 bolts. This solution was increased contact area, in fact,
rejected because of the thermal allows to distribute the interface
protection cold bonding, necessary to loads and to reduce the local stresses
cover the bolt junction after the of the material, thus resulting in
final assembling; the reliability of higher safety factors during the
this particular operation was not in functioning. Furthermore, the ring is
accordance with the final reliability not a critical item because it is
goal of the ARIANE 5 igniter. submitted to compression loads only.
Stress analyses (later on confirmed by The main charge case (see Fig. 3 ) has
hydraulic tests) and the above a cylindrical shell threaded to a
mentioned problems in the thermal hemispherical dome in which five
protection application led to the regularly spaced holes (450 respect to
design of the present configuration the longitudinal axis) are the seats
(referred to as 'Lock-wire', Fig. 2 ) . for the outlet carbon-phenolic
This junction was utilized for the nozzles.
first time by BPD on military The intermediate case is very similar
applications (torpedo) and it may be but smaller in size: it is threaded to
considered similar to the 'bayonet the igniter flange. Like in the main
junction': in fact, its functioning is igniter, five small holes are machined
based on the same logic, i.e. in the dome representing the seat for
"metallic contrast between two the carbon-phenolic nozzles.
different items capable of maintaining The pyrotechnic cylindrical basket,
themselves in proper position". The threaded to the body, has a flat
^i
2
 ARIANE 5 MPS P230
M. Santilli',
Abstract
This paper deals with the steps
performed to develop the ARIANE 5 MPS
P 2 3 0 igniter. In a solid propellant
rocket motor, a satisfactory
attainment of equilibrium chamber
pressure and gas flow is dependent on
several factors, among which its
design characteristics, motor
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propellant grain surface ignitability
within well defined instants of time
and heat transfer phenomena are of
primary importance. In order to reach
a frozen configuration fulfilling the
requirements (usually a combination of
igniter and vehicle requirements),
specific pre-development, development
and qualification tests are entailed.
These tests, currently performed at
BPD Difesa G Spazio facilities and
aiming to guarantee the high required
reliability goal are
I mainly
environmental (i. e. leak, thermal and
humidity cycles, vibrations and X-Ray)
and after firing (previous ones plus
ballistic and structural analysis)
tests. The methodology used to analyze
the experimental results is based upon
a comparison between these results and
performance predictions, carried out
in terms of chamber pressure and mass
flow rate data. As expected, the tests
performed up to now have shown a good
compliance between predicted
performances and experimental results.
General
The ignition system of the Ariane 5
MPS P 2 3 0 booster was defined taking
into account the experience acquired
during the development of the previous
Ariane 3 and Ariane 4 ignition
systems. The main duty of each igniter
is to provide a reproducible,
* EUROPROPULSION - F 921 SO SURESNES (F)
System engineer
'* BPD DIfesi & Spnzio - COLLEFERRO (I)
Propulsion group engineer
1
- IGNITION SYSTEM
A. Fontana**
reliable, and safe ignition of t h e w
relevant launcher (in a two-booster
launcher this ignition must be
simultaneous as far as possible):
therefore, the igniter is required for
a high mass flow-rate of gases to
reach the stated rise of temperature
and pressure, so as to respect the
allowable maximum delay between the
'Fire" command and the ignition of
each of the two MPS boosters.
In order to fulfil these stringent
functional requirements, the Ariane 5
Igniter is made up of the following
chain of components:
no 2 IFOCs (Through Bulkhead
Initiators)
no 1 Fyrotechnic Igniter
no 1 Igniter Initiator (also
referred to as Intermediate Igniter)
no 1 Main Igniter
in which an Igniter Initiatoi- of
reduced size was added to the Ariane 3-
and Ariane 4 configurations because it
can be easily ignited by a small
charge of pellets placed in the
Pyrotechnic Igniter; in this way a
great reliability and reproducibility
of performances are assured.
Experiences in large solid propellant
motors (Shuttle, Titan) confirm that
this configuration is the best.
Chosen c o n f i a u r a t m
The Ariane 5 igniter final
configuration is shown in Fig. 1
(assembled). It consists of four main
components: a main charge case, an
intermediate case, the pyrotechnic
body and basket and the igniter
flange. The overall dimensions are
1181 mm in length and 469.5 mm in
 motor and ignitei- level). That's why,
as far as tests, checks, technologies

-
and approach to the design are
concerned, the qualification phase
will be carried out on the basis of
the same logical principles of the
development one.

Referenceg

Parker, K.H., Wenogard, J. and

Summerfield, M., "The ignition
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transient in solid propellant

rocket motors", A I P A Paper 64-126,
Solid Proellant Rocket Conference,
Palo Alto, C, Jan. 1964
Erinton, E.C. Kilminster,
J.C. , "Space Shuttle SRM
Development", A I A A Paper 79-1136
Sutton, G.P., "Rocket propulsion
elements", 1996, Wiley
Interscience.
"MPS P230 Technical
specif ication ,
" P.5-ST-1120000-
0609-EUP
 more reliable ignition of
intermediate igniter.
Once the preliminary firing tests
performed, a relevant change of the
configuration was made by introducing
.*/
a fiber glass external support for
the propellant grain (liner): in
order to inhibite the rear surface of
the propellant grains facing the
thermal protection (so as to prevent
the hot gases and flames from
reaching this surface, thus starting
its burning before the complete
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the attainment of the correct amount of
discharged mass flow rate towards the
MPS propellant grain (star and
cylinder shaped): only in this case a
correct and simultaneous ignition can
be reached, so as to avoid problems
of thrust imbalance at ignition.
This target could be reached first of
all by building two limit cases for
the igniter discharged mass flow. The
resulting gabarit shows two curves:
an 'upper curve , which
represents, for each instant of

COmbustiOn), to assure a reliable time, the highest value of the

joint between the propellant and the mass flow rate to be discharged;
thermal protection and to prevent higher values would result in
from a too high propellant radial dangerous motor overpressure;
shrinkage after the casting, this a 'lower curve', which represents,
special resin reinforced by for each instant of time, the
fiberglass was designed as the smallest value of the mass flow
interface between the thermal rate to be discharged; smaller
protection and the pi-opellant. values would result in no
Furthermore, this solution allows the ignition.
reduction of the efforts to be These two curves, report.ed in Fig. 4.
exerted in ordert to extract the were obtained by performing a
mandrel after the propellant casting statistical analysis of the
phase, thus reducing also possible parameters which are known to affect
damages on the propellant grain the performances: the propellant
surface (advantages in terms of costs geometry (represented by the
during the industrialization phase). combustion surface), the propellant
At present, the described burning rate and characteristic
~~ ~

configuration fulfils the velocity (and the relevant efficiency

requirements imposed by the MPS on the characteristic velocity), the
Technical specification and Igniter propellant density, erosion
Techincal Specification, above all phenomena, firing temperature, delay
given in terms of: of time at ignition and s o on, were
thrust gabarit, i.e. the igniter taken into account at their nominal
must succeed in firing the MPS value (average values of BPD
booster within well def ined database) and a relevant dispersion
instants of time, at which the (30) was also calculated. If n is the
thrust must reach well defined number of the parameters, 2n+l runs
values; of the ballistic code employed at BPD
mass flow rate gabarit, which to analyze transient phenomena were
represents the mount of mass performed: a first run with all the
(minimum and maximum) to be parameters at their nominal value,
discharged in order to fulfil the the other 2n by varying all the
previous requirement. parameters one by one at their
maximum value (nominal + 3 0 ) and
minimum value (nominal - 30). In this
Ballistic behaviow way, a *Ami+' and a ,Ami-, were
obtained as the output of each
As previously stated, one of the most ballistic run, then they were grouped
important requirement to be fulfilled together on the basis of simple
at igniter level, concerns the statistical formulas in order to

4
 W
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Pig. 3 - Igniter exploded v i e w

bottom with five parallel holes for and then machined to the final
the outlet (through the same number thickness and shape.
of small graphyte nozzles) of the The intermediate and main igniter
combustion gases. On the pyrotechnic propellant grains are star shaped (30
body, 5 holes are machined, 2 for the and 25 tips respectively), designed
I F O C s and 3 for the instrumentation. in order to assure the suitable
The igniter flange has an ellipsoidal burning surface for the required mas:
d
shape in order to withstand in a flow rate, to reduce the sliver phase
suitable way the loads of both the of the combustion, to have a
igniter and MPS. In addition to the sufficient structural resistance
junction with the main igniter case, under the chosen internal pressure
it is also connected with the booster and the specific environmental
by means of 4 0 bolts; the tightness conditions. The chosen propellant is
is assured by 2 O-rings. a HTPB polymer (binder) with a high
All these components are made up of amount of aluminium, ammonium
commercial steels with high perchlorate as oxidizer.
characteristics from a stress The pyrotechnic charge is made up of
corrosion point of view (moreover, BKN03 pellets, randomly disposed
they are also zinc-plated for a inside a polyethilene bag placed
thickness of 13 microns), internally inside the basket; a plastic grid
and externally insulated by a keeps the pellets separated from the
variable thickness of thermal discharging nozzles. These nozzles,
protection (an EPDM based rubber once accomplished by machining the
filled with aramidic fibers), in thermal protection to the desired
order to withstand the thermal loads discharging area, are now made up of
during the igniter and the booster graphyte inserts. in order to
functioning. The application is made guarantee a more correct flow of the
with pre-molded layers glued conkustion gases and, thus, a higher
together by vulcanization 'in situ' reproducibilty of performances and a

3
 The post firing analysis is carried
out by making a comparison between
the predicted and the experimental
pressure curves.
u
m
After these operations, the new
obtained values of the ballistic
parameters are taken into account to
increase the available database: new
mean values and dispersions are made,
upon them the next predictions will
be based.

1' m e r m a l Drotection behaviour

Thermal protections were designed on

1: the basis of BPD know-how and taking
into account the results of the
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experimental tests. The thickness of

..
0

the external and internal layers was

.
I I
. " an
reduced at various times. Post firing
-I

analyses performed after B1 and M1

Fig. 6 -
Intermediate igniter firing tests showed that the maximum
pressure vs time curve ablated thickness is, on the main
igniter external surface, 358 of the
original one (before firing); this
means that large areas of the applied
thermal protection remains virgin.
At present, even though the thichness
is still oversize, further reductions
are not foreseen, because the gain in
weight is negligible with respect to
the high impacts to face in order to
improve the configuration.

A suitable test plan was made in

order to develop the final
Pig. 7 - Main igniter pressure vs configuration, pointing out the
time curve safety margins relevant to the
following main functions:
Of course, slight differences are to provide a mass flow rate vs
always present and thus the time in accordance with the
parameters from 1 to 3 are employed requirements set forth in the
to obtain the best matching of the Technical Specification;
curves: the scale factor is employed to assure the structural integrity
to tune the pressure during the of the whole motor.
steady phase, the flame spreading The ignition ballistic performances
during the rising phase, the time were analyzed by means of firing
delay is obtained to adjust the tests, while the metallic case
timing. These parameters are strictly structural integrity was checked by
joint one to the other, so that means of:
changing one of them causes the hydraulic burst test, performed on
change of them all: of course this one igniter only. The minimum
loop is generally converging to the pressure value requested to
final solution. validate the item was set to

6
 obtain the final * A m + ' and 'Am-' to intermediate igniter and the main
be added or subtracted to the igniter.
nominal mass flow rate (output of the The pyrotechnic igniter has an
impulsive trend: in fact it reaches
the maximum value of the pressure
(ranging from 160 to 200 b a r ) W
generally after 3 4 ms.
The intermediate and the main
igniter, both charged with a star
shaped grain, show the typical
pressure trend of such a grain
configuration: after a very steep
rising phase, in which the most
significant points are 10% of
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.. ** .n 8.
-lM
.m >. .s ..
111

Pig. 4 Mass flow rate gabarit !a

m
nominal run).
In the above shown Fig. 4 the mass
flow rate gabarit is reported
1:
together with an experimental curve,
in order to show the compliance
i: 0

between the requirement and the m

obtained result.
The attainment of such a compliance
was possible on the basis of a tuning
.DI om om
....
em 0- 0- ow

of the ballistic parameters employed Pig. 5 - Pyrotechnic igniter pressure

to carry out the predictions and the vs time curve
post firing analysis. In more ..&
details, analyses concerning each Pmax and 90% of P , T , ~ X , the maximum
firing test include: pressure is reached (generally after
ballistic predictions; a time ranging from 30 to 40 ms for
post-firing analysis: the intemediate igniter and from 90
database updating. to 110 ms for the main igniter); this
The main parameters (the ones which maximum ranges from 110 to 140 bar
may vary from one firing to the for the intei-mediate igniter and from
other), taken into account in order 85 to 105 bai- f o r the main igniter.
to carry out the ball istic Soon after a steady phase takes
predictions in terms of pressure, place, until the beginning of the
are: tail off phase (S5+120 ms and 330+430
1. burning rate scale fact.or,s.f.: ms respectively for the intermediate
2. flame spreading, f.s.: and the main igniter).
3. time delay, Td; Predictions, based on the Pn,ax, 10%
4 . characteristic velocity Pinax, 90% Pmax. tail off pressure and
efficiency, qc*; the relevant instants of time, are
5. throat diameter; carried out by employing the actual
6 . firing temperature. value of the above reported 6
Figures from 5 to 7 show the typical parameters and their dispersion (ID,
pressure vs . time curves respectively except for the temperature, on which
for the pyrotechnic igniter, the no dispersion is given), so as to
obtained the above mentioned ranges.
 PI “ l s r = s . f. X MEOP For the pyrotechnic igniter, the test
where s.f. is the requested ultimate sequence can be summarized as
safety factor. follows :
Success criteria for this test are: before firinq
no structural failure occurs up to 1. Natural Frequency research
4 burst pressure. 2. Transport vibrations
3 . Natural Frequency research
L€Ax 4 . Sinusoidal vibrations
Aim of this test is to verify that 5. Natural Frequency research
the fixed leak rates are sufficiently 6. Random vibration
small to guarantee the sealing I. Natural Frequency research
function during all the phases of the gfter f a
igniter life. The items or interfaces 1. Natural Frequency research
to be tested are protection plugs 2 . Sinusoidal vibrations
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(the pyrotechnic igniter is 3. Natural Frequency research

-
transported separately from the main 4 . Random vibrations
igniter and thus it is replaced by 5. Natural Frequency research
these plugs), the nozzle diaphragms, For the intermediate, and main
the IFOC/pyrotechnic body I igniters, the test sequence can be
pyrotechnic body/flange and summarized as follows:
flange/main basket interfaces.
Success criteria are: 1. Natural Frequency research
no leak rate higher than the 2 . Transport vibrations
required one is measured. 3 . Natural Frequency research
after fir-
Vibrations 1. Natural Frequency research
Vibration tests are performed in 2. Sinusoidal vibrations
order to prove the item capability to 3 . Natural Frequency research
withstand the dynamic: loads (induced 4. Random vibrations
on the igniter during the various 5 . Natural Frequency research
phases of its operative life) without These vibrations are performed within
performance or material degradation. well defined frequency bands and
The items under investigation are: giving, along the excitation axis,
the pyrotechnic ignitei- (assembled suitable peak accelerations and
with IFOCs and pressure sweeping rates (in the case of random
transducers). vibrations the acceleration spectral
the intermediate igniter is tested density is given); amplification
assembled on the actual flange, in factors are then calculated as the
two different configurations: ratio between the input g-peaks and
transport configuartion (without the output ones (along the three
pyrotechnic igniter, which is axes). Resonance frequencies were
transported separately) and before found around 90 and 500 Hz, while the
and aftex- firing test maximum amplification factor turned
configuration (assembled with out to be 20 (obtained when the input
completely instrumented and the output axis are the same, in
pyrotechnic charge); all the other cases amplification
the main igniter is tested in two factors are lower).
different configurations: Success criteria of these tests are:
transport configudrtion (without no rupture occurs in the metallic
pyrotechnic igniter, which is parts or in the propellant grain;
transported separately) and before output signals (in terms of g-
and after firing test peak) must not be. greater or
configuration (assembled with equal to the dimensioning static
completely instrumented flange). loads;

9
 no crack increase in the metallic
parts or in the propellant grain
is detected;
no unbonding increase between
thermal protection and case (or
nozzles) is detected.
mermal cvcles
Thermal cycles are performed in order
to verify the material behaviour (in
particular all the bondings) ,
physical damages and degradation of
S a l t foa test
This test is performed on all the
metallic parts in order to verify the
behaviour of the zinc superficia:
treatment, which must be able t o w
prevent the base metal from getting
attacked by extreme environments,
which are likely to be found in
French Guyana.
Success criteria are:
no corrosion attack at the base '

performances when the igniter is metal is detected;

submitted to a temperature variation. no failure of structural parts due
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In more details, thermal cycles are to stress corrosion occurs.

carried out by using two conditioned
chambers (each of them has a Visual/dimensional insDection8
continuous recording device for Each sub-assembly, before being
temperature vs time), the first assembled, is carefully examined to
regulated at 0 2 3 T and the other at determine the dimensions, the quality
+40+3 O C . Two complete cycles 0+40 OC of the activities carried out by the
over a period of 4 5 houi-s are operators, the use of proper material
performed. P. minor group of igniters and the visible defects or any other
undergoes thermal shocks, during imperfection.
which two complete cycles -20+40 O C
over a period of 4 8 hours are BadioaraDhic test (X-ravl
performed. Each sub-assembly, in order to verify
Success criteria are: the internal interfaces and sub-
no unbonding between metallic assembly status, undergoes
parts/thermal protect ion is radiographic inspections. A technique
detected ; capable of showing possible interna!
no unbonding between propellant grain defects or unbonding betweer.-
grain/thermal protection is metallic parts/thermal protection and
detected ; thermal protection/propellant grain
no rupture in the propellant gi-air, is employed.
is detected.

Humiditv cvcles Conclusiou

Humidity cycles are performed in
order to verify material behaviour, The ARIANE 5 MPS P230 ignition system
physical damages and degradation of has been completely developed. After
performances when the igniter is a Critical Design Review, the
submitted to extreme environments, development phase has come to an end,
which are likely to be found in while the qualification phase is
French Guyana. The test conditions about to start at igniter level only
are: temperature 30uCS0C, 1-elative (tests to be performed in EPD). The
humidity 9 5 % 5 % , time 2 4 h, 1 cycle logical principles underlining the
only. design, tests and checks performed
Success criteria are: during the pre-development and
no corrosion attack at the development phases, the employed
metallic parts is detected; technologies and production cycles
no unbonding between propellant proved to be successfull, on the
grain/thermal protection is basis of the obtained results
detected. (compliance with the requirements at

10 'ci
 to verify, from a reliability X-ray inspections;
point of view, the behaviour of visual inspections.
the ignition system;
to make the final tuning of those
parameters, whose influence on the Test descriDtiQQ
.-, performances is great;
to perform tests and checks proof t e s t .
already performed during the As above reported, tests are
previous phases, according to a performed by the metallic part
slightly modified logic: tests and supplier in order to detect possible
checks which showed a low impact cracks in the steel; these tests are
on the performances will be performed, after the forging
reduced. operation, with Ultra Sound system,
Of course, during this phase, only able to detect a well defined minimum
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slight modifications to the crack size; after the final machining

configutation are likely to be made, piercing 1iquids and X-ray
without altering the general design. inspections are performed in order to
The qualification phase of the detect possible superficial cracks.
igniter, to be performed at BPD The proof acceptance test is
plants. will give the go-ahead for performed only on the metallic parts.
the full scale qualification tests, Aim of this test is to check the
to be performed the next year on at. mechanical properties of the item
least two motors. These full scale under investigation, in order to meet
tests complete the whole the relevant functional requirement,
qualification phase of both the motor which states that the igniter must
and the igniter. withstand the mechanical loads
induced by its and MPS functioning.
This test is performed by
Tests and checks pressurizing each metallic sub-
assembly with emulsified water up to
During the pre-development and the the proof pressure, which is:
development phases, the following P ~ > r v >=f S . f . X MEOP
tests and inspections were carried where s.f. i s the requested safety
out before and after each firing factor and the MEOP is defined
test : according to the propellant grain
tests performed by the metallic configuration. This pressure is kept
part supplier to detect possible for a holding time of 120,180 sec.
defects of the steel; Success criteria for this test are:
hydraulic test; no leak is detected up to proof
dimensional inspect ions, in order pressure;
to verify the geometric compliance no permanent deformation greater
with the design requirements than 0.2% is detected up to proof

-
(before and after hydraulic and/or pressure.
burst test);
environmental tests (thermal and Burst test
humidity cycles, salt fog test, Aim of this test, is to verify that
vibrations), some Of them the mechanical properties of the item
performed before and after the under investigation fulfil the
firing test; requirement on the ultimate safety
8 leak tests, in oredr to verify the factor.
tightness requirement after the This test is performed by
assembling phase and the case pressurizing each metallic sub-
behaviour before and after firing assembly up to the burst pressure,
vibration tests. which is:

8
 2xMEOP. wher MEOP stands for ballistic code, already employed for
Maximum Expected Operating P.RI?.NE 3 and f.RIANE 4 igniters, was
Pressure; definitively tuned.
hydraulic acceptance test for each
igniter sub-component, by means of
proof test at a pressure of pevelopment Dhase
1.3xMEOP; u
pre-firing vibration test (random The aim of this phase was:
and sinusoidal fi-equencies, plus to submit all the sub-components ,
natural frequency research), to all the structural, ballistic
simulating the acoustic loads and environmental tests above
induced by the motor functioning described. Firing tests at
(booster MPS P230 plus WLCAIN different temperatures were
motor) ; performed once again in order to
Ultra sound, piercing liquids and evaluate the effects of a
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Rx inspections. temperature variation (coupled

Besides, in order to simulate all the
stresses induced during the transpoi-t
and the storage phases,. each igniter
of the development phase iindei-went
the following tests:
thermal cycles;
humidity cycles;
salt fog tests;
transport vibrations.
The capability of t.he igniter to seal
the whole struct,ure was proved by
means of:
leak tests (to be performed before
and after firing).
The main goals of the test plan were
attained in three different st.eps,
i.e. the pre-development, the
development and the qualification
phases (still in progress).
Pre-develoDment phase
The aim of this phase was the
analysis of the requirements imposed
by the applicable Technical
Specification, the pi-eliminary design
of all the components with the
relevant ballistic and structural
calculations and a preliminary
testing of the chosen configuration.
In particular, firing tests performed
at different temperatures plus post
firing test analyses aimed to verify
the ballistic characteristics and the
behaviour of the components submitted
to the loads induced during the
burning phase of the igniter. The
with a variation of the nozzle
throat diameter plus the variation
of the propellant bur,ning rate) on
the ballist ic performances,
expecially on the mass flow rate,
whose values must fall inside the
well defined range set forth in
the Technical Specification;
to analyze the results of each
test in comparison with both the
ballistic performance predictions
and the outcomes of the structural
analysis;
to make all the possible
modifications to the design. In
fact, during this phase, th6
configuration was not yet f r o z e n , U
thus, once the ballistic.
structural and thermo-ablative
critical points individuated, they
were one by one re-designed;
to fix all the aspects relevant to
the industrialization phase of the
igniter and in particular to make
the maximum effort to finalize the
objective costs to be reached;
to investigate the igniter
behaviour on full scale tests, in
which the igniter itself is fired
with the MPS P230 booster, thus
checking the behaviour of the
interface.
Qualification Dh ase
The aim of this phase is: