Failure Mode Avoidance of Solid Rocket Motor Pressure Monitoring Joint Seals

The sealing joints used for pressure monitoring of solid propellant rocket motors (SRMs) of launch vehicles are very critical, as they are large in number, and leak through any of them is a single point failure mode. Identification of failure modes and its prevention is the key for reliable performance of an SRM. Failure modes are identified and the failure mechanisms of different seals in the pressure monitoring system studied through investigative tests with deliberately induced variations in the design parameters and nonconformance. Systematic analysis is carried out for the proposed designs through a failure mode effects analysis (FMEA), failure modes ranked in accordance with Risk Priority Number (RPN) and reliability of the joints worked out from the data. Design concerns are analyzed, alternate designs explored and innovative design solutions evolved. The effectiveness of the final design is brought out quantitatively by reduced RPN ratings and quantum jump in the reliability. Critical design, process and quality control parameters were identified, and procedures to ensure them evolved for failure mode avoidance.