Comments by "SeanBZA" (@SeanBZA) on "Thunderf00t"
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Another thing is that avionics grade PTFE wire is typically a foamed structure to reduce mass, so there would have been a large surface area available, but in a small volume.
As Phil is in the EU there is no problems for him to look on Ebay for any cheap aircraft parts on auction, both from US origin, UK origin, French origin and ex Soviet era hardware, which almost always has PTFE wire involved in the construction. that will give a nice cross section of wire types and sizes, and of various ages and manufacture, to do a quick test. As a wire it is the correct form factor, and is not a pure PTFE, as typically the insulation used there has some filler or the other added to it to get it to extrude nicely onto the wire, which also has a nice silver plate on it to prevent any chemical reactions between the copper wire and the PTFE with time, contamination with chemicals and heat. The units are cheap in Euro prices, and shipping is very cheap as well. He will also get a good set of samples of the grades of aluminium alloys and stainless steels used in manufacture consistent with the era, for other tests.
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Thing is that they literally have the glue bond inside out, as the ring should have had an internal structure as well, to transfer the compression force from the carbon fibre to the inner titanium ring via the epoxy, not put a tensile pull on the epoxy join. That would lead to the carbon fibre delaminating with pressure cycles, and failing. They constructed that join surface as if the join was for a pipe with pressure inside, where the pressure will hold the epoxy onto the cap, not the other way round. Pipe shrank under pressure, and eventually some microscopic section of the join, likely with an embedded air bubble in it that had been compressed to have a sharp edge, caused a stress that started to propagate through the bulk resin, because there is no stress relief in the resin bond, and this then eventually grew to the outside, where water was able to fill the crack. Now the water is applying pressure to a section that can flex, and grows the crack into the joint further, aided by the tension in the epoxy join, and this then rapidly, basically the speed of sound in the epoxy as the growth speed, grew to open the joint to the inside.
That joint should have had an inner and outer lip, and have been filled with epoxy with a slow cure time, and then have the shell pressed down into it, also with a coat of the epoxy on the surfaces, and then pressed together, with a few vent holes for the excess resin to flow out in the titanium, that later on would have a cap bolted and bonded to it. Or a thicker section that you put a setscrew in to fill the hole, while the resin is still not cured, after it has bottomed out, then left and heated to cure fully before removing the pressure.
That join section should have been at least 3 times thicker, and longer, with a taper on the inside to allow a flexible sealer to be there, to allow the join to flex with pressure, not a solid non flex epoxy only. you want to not have stress risers, and a solid join with the different materials will have that stress riser. This hull was likely only going to last 3 cycles before you would have to replace it, they should have done testing, using a deep water area, and a cable and cage, to measure the number of cycles to failure first, not used the passengers as alpha testers.
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Yes, aircraft engines can run on gravity feed of fuel, just ignoring that if the pumps pack up they will not run for more than a few seconds, mostly because the fuel flow is now not even enough to run them at idle, and the whole pesky injectors need enough pressure to put it in against the pressure in the combustion chamber.
Now fuel tanks in the wings are there to have useful volume in the cargo space, plenty of aircraft can have tanks in the fuselage, often things like tankers, where that fuselage is used to carry fuel as the cargo. Airlines however have that pesky need to move things, like people, cargo and baggage, so need that room to fit them in, instead of them sitting cramped up in the wings. So instead they fit the tanks in the wings, using self sealing bladders so they do not leak all the fuel out in all the rivet holes, and then, to keep it sloshing about, they use open cell fibre foam to provide both support for the bladder material on top and bottom, and also prevent sloshing around, but still allow flow down to the fuel pick up points.
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@moeron9172 Yes do in the post combustion and post turbine exhaust, where the air is still hot enough, and has plenty of oxygen still to react with it. single injector there, cooled on the outside by the bypass air, and only energised with pressure when at altitude, so that it has enough time to cool off on the way down. Plus you can add in a purge valve, that will use compressed air to vent the line, and as the fuel likely will be solid at altitude, you would only need a little trace heater on the lines, that turns on after reaching 15000 feet altitude, and turns off and does the purge when descending again. Can be totally automatic as well, only a simple switch and light in the cockpit, or a message in the ECAM display, along with the others, and only flag a fault when it does have one. 20l of fuel will last quite a few flights as well, though the tank and pump will definitely need to be in a fire proof housing that will contain any leaks from damaging the airframe. Just going to be hard to fit, avionics bays tend not to have much spare volume these days, you can barely get in there to service them normally, and that space has to be there.
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@eno2870 That would be extra, as you then have to use medical grade oxygen, which has a much lower concentration of contaminants, most notable being nitrogen, which is pretty close in boiling point, so you have to do fractional distillation of the liquid, or use molecular filters to reduce the volume of contaminants. Expensive and slow, as you do need to keep a very precise control on the pressures and temperatures.
For each passenger you would need around 3l of liquid oxygen, per flight, and probably around 15l of liquid nitrogen as well, so as to be able to make a one atmosphere environment, and simply dump all the exhaust out of the craft. Otherwise you need lithium hydroxide CO2 scrubbers to be able to recirculate the air, and then your gas needs are lower, but you do need a lot more mass in scrubbers. However the scrubbers need to be fed dry air, so you then need to extract almost all of the humidity out of the air first. So, probably a ton of scrubbers alone, another 2 tons of airconditioners, for the hundred passengers, to save the 1500kg of liquid nitrogen, but the LOX is not going to be much less.
That assumes you want to have the passengers feel like they are in an aircraft, though you could get away with dropping cabin pressure to a bit lower, and increasing oxygen concentration, but having them need to spend an hour before and after each flight doing a decompression would probably not be a desired thing. After all, the space shuttle and ISS takes the best part of a day to get ready for EVA, because the low pressure in the space suits requires all nitrogen to be removed, and the time for the Starship will not be much less.
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@YouCensored Seen plenty of PTFE wire with a pink tinge or a pink stripe in the insulation, there generally on sealed assemblies like motors, to allow you to indicate polarity on the motor during further assembly. Though yes the tiny amount of dye will be totally insignificant here to overall burning of the wire in the pure oxygen atmosphere when it got an ignition source.
With pure oxygen at atmospheric pressure and above, many things that are normally considered fine, like lubricant oils and greases, are forbidden, you have to use rather esoteric lubricants, like molybdenun sulphide, and powdered graphite, as lubricant, and even skin oil from handling is considered to be a contaminant.
Even such things like crush washers are a problem, they have to be copper, or ultra pure aluminium, or nickel, as the first application of oxygen to the newly crushed surface exposed to it will nearly instantly form an oxide layer, so the pressure has to rise slowly, so the reaction is not too violent during this time, and the heat can be dissipated. Not so bad as handling fluorine gas, where you have to do this even more carefully, as literally the only thing that is keeping your entire apparatus from dissolving, is the thin film of metal fluoride that is coating all surfaces, from the initial introduction of gas. Oxygen is only slightly less reactive.
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@JoeOvercoat Civilian aircraft cannot do inverted flight for long, only under around 10 seconds, before the fuel starvation stops the engines. Fighter aircraft have a fuel tank within the final feed tank, which allows inverted operation for a period of around 30 seconds at full afterburner, before it will start to run low. Yes it will gravity feed fuel to the LP pump, but after there it is pressurised, and fuel transfer from tank to tank in the airframe is done by pumps, generally self priming gear pumps, because the fuel in drop tanks, always below the fuselage, is always used first, so it has to be sucked up to the main fuel tanks, with overflow returning to the drop tanks till empty, then the shut off valves will stop that, along with the pumps.
Lose the pumps and the engine stops in short order.
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I think they forgot the second unit off there. Instead of 500Watts that they were bragging about, they forgot to use the second word in the actual unit, it is a 500 watt second battery, or, more prosaically in the more normal SI nomenaclature that people are more familiar with, it has 500 joules of stored energy in it. Not 500 watt hours, which would actually make it a really compact and high capacity power source, with 1.8 MJ of stored energy, far more than your similar size lithium pouch cell pack of the same volume, but instead it will store roughly the same energy in the "easy to replace charge collection plates" ( bet nobody saw that small print and thought why the charge collection plates wear out, but not the sea water) as a single standard duty ( hardest thing to find these days, even the cheapest Chinese one is marketed as heavy duty) IEC standard ( yes there is a standard for a zinc carbon cell, basically to get the ability to market it with a size in the IEC nomenclature, you have to meet the dimensions, and capacity has to be greater than the minimum in the spec) zinc carbon internally depolarised AAA cell. I think the AAA cell is a lot cheaper as well, and easier to recycle, as it only has zinc, carbon, a drop of tar, some wood pulp soaked in manganese dioxide and ammonia, and a bit of plastic as sleeve and top cap.
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