Engineering topics

Gasch, Matthew

Publications and source records attributed to Gasch, Matthew.

At least 19 records

NASA NTRS2019

Heatshield for Extreme Entry Environment Technology (HEEET) Thermal Protection System (TPS)

Starting in 2013 and completing in 2019, the Heatshield for Extreme Entry Environment Technology (HEEET) project has been working to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations with extreme entry environments such as Venus, Saturn, Uranus, Neptune and high-speed sample return missions to Earth. A key aspect of the project has been the building and testing of a 1-meter base diameter Engineering Test Unit (ETU) representative of what could be used for a Saturn probe. This paper provides a high-level overview of the HEEET project including manufacturing and testing of the ETU for structural model verification, establish system capability and verify manufacturing workmanship.

Extreme Entry Environment↗

NASA NTRS2019

Characterization of Thermal Protection Systems: An Analysis of Optical & Thermal Properties

Thermal Protection System Materials & thermal control coatings were characterized by a variety of methodologies including heat flow meter method (HFM), dynamic scanning calorimetry (DSC), fourier transform infrared spectroscopy (FTIR), and Ultra-Violet & Visible light spectroscopy (UV-VIS). Physical properties were measured to aid in the construction of thermal response models for a number a projects including MEDLI and MEDLI2. Comparing pre-flight predictions with actual flight data can allow for a reduction of margins and improve designs. The models enable design of TPS for flight missions and analysis of flight data to understand aerothermal environments experienced on the mission. This presentation reveals critical information: heat capacity (cp vs T), thermal conductivity ( vs T), and emissivity (E vs T) for Super Lightweight Ablative (SLA), Phenolic Impregnated Carbon Ablative (PICA-D), & Heatshield for Extreme Entry Environment Technology (HEEET). These properties were also measured for various thermal control coatings manufactured by AZ Technology. A portion of this work is incomplete and highlights questions to investigate in the future.

Cole, Brian↗

NASA NTRS2019

Overview of the Development and Testing of the Heatshield for Extreme Entry Environment Technology (HEEET) TPS

Over the last 5 years, the Heatshield for Extreme Entry Environment Technology (HEEET) project has been working to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations such as Venus and Saturn. A key aspect of the project has been the development of the manufacturing and integration processes/procedures necessary to build a heat shield utilizing the HEEET 3D-woven material. This has culminated in the building of a 1-meter diameter Engineering Test Unit (ETU) representative of what would be used for a Saturn probe. The present talk provides an overview of recent testing of NASA's Heatshield for Extreme Entry Environment Technology (HEEET) 3D Woven TPS. Under the current program, the ETU has been subjected to Thermal and Mechanical loads typical of deep space mission to Saturn. Thermal testing of HEEET coupons has performance up to 4,500 watts per centimeter squared at 5 atmospheres stagnation pressure and successful shear performance up to 3000 pascals at 1,650 watts per centimeter squared at 2.6 atmospheres pressure.

HEEET↗

NASA NTRS2019

Progress in Manufacturing & Characterizing Domestic Lyocell PICA (PICA-D) and Comparison to Heritage PICA

NASA ARC (Ames Research Center) is working with SMD-PSD (NASA Science Mission Directorate- Planetary Science Directorate) to address PICA ( Phenolic Impregnated Carbon Ablator) rayon sustainability concerns. In FY16/17, Lyocell Based PICA (PICA-D (Domestic)) was manufactured and limited testing performed showing it to be a good candidate as a potential replacement for heritage rayon. Establishing PICA-D as a "drop in replacement" will allow missions to depend on and design missions with PICA without any risk typical of a replacement. Establishing the extended capability of PICA-D will allow Sample Return Missions with higher entry speed that were not considered before.

Lyocell↗

NASA NTRS2019

Charactarization of Thermal Protection Systems

In 2012, NASA's mission of landing the Mars Science Laboratory (MSL) on Mars was successful. MSL was protected by an ablative heatshield of tiled low density material known as PICA (phenolic impregnated carbon ablator). The heatshield was instrumented with MEDLI (MSL Entry Descent Landing Instrument) a suite of sensors & thermocouples at discrete locations in order to monitor the in-depth ablator temperature response and surface pressure. MEDLI was designed and developed by NASA Langley, in partnership with NASA Ames Research Center for the purposes of probing Mars and evaluating the performance of the spacecraft upon entry into the Martian atmosphere. The flight data reduces the uncertainty in engineer models for predicting the response of a spacecraft towards the extreme heating environment of an entry into the Martian atmosphere. MEDLI2 is a part of the Mars 2020 mission and is the next-generation sensor suite for entry, descent, and landing. This data will again help engineers validate their flight models. Additionally, the atmospheric data, can help us understand atmospheric density and winds. This is a critical study for reducing risks to both robotic and future human missions to Mars. Engineered models for Mars 2020 are dependent upon parameters related to the materials response to heating and radiation. In this work, the thermal properties and other measurements of various ablative materials are analyzed to achieve greater utility of the 2012 MEDLI flight data and more accurately determine the parameters being used in Mars 2020. The purpose of this study was to measure specific heat, thermal conductivity, char yield, reflectance as a function of wavelength, and other thermal parameters and optical properties of various ablative materials. CO2(g) at extreme temperatures emits radiation impacting MEDLI2 flight predictions. Emissivity & absorptivity as a function of temperature were calculated from FTIR and UV-Vis data as a means of investigating whether these materials might absorb CO2 radiation upon entry into the Mars atmosphere.

HEEET↗

NASA NTRS2018

Sustaining PICA TPS for Future NASA Robotic Science Missions

Phenolic Impregnated Carbon Ablator (PICA), invented in the mid 1990's, is a low-density ablative thermal protection material proven capable of meeting sample return mission needs from the moon, asteroids, comets and other "unrestricted class V destinations" as well as for Mars. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flagship class missions. It is important that NASA maintain this TPS material capability and ensure its availability for future NASA use. The rayon based carbon precursor raw material used in PICA preform manufacturing required replacement and requalification at least twice in the past 25 years and a third substitution is now needed. The carbon precursor replacement challenge is twofold â€“ the first involves finding a long-term replacement for the current rayon and the second is to assess its future availability periodically to ensure it is sustainable and be alerted if additional replacement efforts need to be initiated. Rayon is no longer a viable process in the US and Europe due to environmental concerns. In the early 80's rayon producers began investigating a new method of producing a cellulosic fiber through a more environmentally responsible process. This cellulosic fiber, lyocell, is a viable replacement precursor for PICA fiberform. This presentation reviews current SMD-PSD funded PICA sustainability activities in ensuring a rayon replacement for the long term is identified and in establishing that the capability of the new PICA derived from an alternative precursor is in family with previous versions of the so called "heritage" PICA.State of the Art Low Density Carbon Phenolic AblatorsStardust SRC post flight withPICA forebody heat shield(0.8m max. diameter)PICA Processing StepsRole of Rayon/Lyocellin PICA.

Stackpoole, Mairead↗

NASA NTRS2018

Progress in Manufacturing and Characterizing Domestic Lyocell PICA (PICA-D) and Comparison to Heritage PICA

NASA ARC is working with SMD-PSD to address PICA rayon sustainability concerns. In FY16/17, Lyocell Based PICA (PICA-D) was manufactured and limited testing performed showing it to be a good candidate as a potential replacement for heritage rayon. Establishing PICA-D as a "drop in replacement" will allow missions to depend on and design missions with PICA without any risk typical of a replacement. Establishing the extended capability of PICA-D will allow Sample Return Missions with higher entry speed that were not considered before.

PICA↗

NASA NTRS2016

Development of Advanced Conformal Ablative TPS Fabricated from Rayon- and PAN-Based Carbon Felts

The conformal ablative TPS first developed under NASA's Hypersonics Project in the early 2000's demonstrated very low through the thickness conductivity compared to state-ofthe- art PICA. However, in initial arcjet testing of Conformal-1, surface recession rates were 2x higher than PICA. Because commercial carbon felts are currently available as very thin substrates, this was a concern if conformal TPS were to be considered for a mission that required thicker material. Discussed in this paper are the results of the development of an Advanced Conformal TPS derived from thicker, higher density carbon felt. Two substrate systems were evaluated, the first material was a needled rayon-based carbon felt and the other a needled PAN-based carbon felt. Both substrates were impregnated with phenolic resin following the PICA/CPICA process to add a low density phenolic matrix to the system prior to aerothermal screening at the LaRC HyMETS facility and larger scale testing in the NASA ARC Interaction Heating Facility (IHF) at heating fluxes ranging from 250-1700 W/cm2.

Arcjet Testing↗

NASA NTRS2014

Arcjet Testing of Advanced Conformal Ablative TPS

A conformable TPS over a rigid aeroshell has the potential to solve a number of challenges faced by traditional rigid TPS materials (such as tiled Phenolic Impregnated Carbon Ablator (PICA) system on MSL. The compliant (high strain to failure) nature of the conformable ablative materials will allow integration of the TPS with the underlying aeroshell structure much easier and enable monolithic-like configuration and larger segments (or parts) to be used. In May of 2013 the CA250 project executed an arcjet test series in the Ames IHF facility to evaluate a phenolic-based conformal system (named Conformal-PICA) over a range of test conditions from 40-400Wcm2. The test series consisted of four runs in the 13-inch diameter nozzle. Test models were based on SPRITE configuration (a 55-deg sphere cone), as it was able to provide a combination of required heat flux, pressure and shear within a single entry. The preliminary in-depth TC data acquired during that test series allowed a mid-fidelity thermal response model for conformal-PICA to be created while testing of seam models began to address TPS attachment and joining of multiple segments for future fabrication of large-scale aeroshells. Discussed in this paper are the results.

Arcjet Testing↗

NASA NTRS2013

Testing of Advanced Conformal Ablative TPS

In support of the CA250 project, this paper details the results of a test campaign that was conducted at the Ames Arcjet Facility, wherein several novel low density thermal protection (TPS) materials were evaluated in an entry like environment. The motivation for these tests was to investigate whether novel conformal ablative TPS materials can perform under high heat flux and shear environment as a viable alternative to rigid ablators like PICA or Avcoat for missions like MSL and beyond. A conformable TPS over a rigid aeroshell has the potential to solve a number of challenges faced by traditional rigid TPS materials (such as tiled Phenolic Impregnated Carbon Ablator (PICA) system on MSL, and honeycomb-based Avcoat on the Orion Multi Purpose Crew Vehicle (MPCV)). The compliant (high strain to failure) nature of the conformable ablative materials will allow better integration of the TPS with the underlying aeroshell structure and enable monolithic-like configuration and larger segments to be used in fabrication.A novel SPRITE1 architecture, developed by the researchers at NASA Ames was used for arcjet testing. This small probe like configuration with 450 spherecone, enabled us to test the materials in a combination of high heat flux, pressure and shear environment. The heat flux near the nose were in the range of 500-1000 W/sq cm whereas in the flank section of the test article the magnitudes were about 50 of the nose, 250-500W/sq cm range. There were two candidate conformable materials under consideration for this test series. Both test materials are low density (0.28 g/cu cm) similar to Phenolic Impregnated Carbon Ablator (PICA) or Silicone Impregnated Refractory Ceramic Ablator (SIRCA) and are comprised of: A flexible carbon substrate (Carbon felt) infiltrated with an ablative resin system: phenolic (Conformal-PICA) or silicone (Conformal-SICA). The test demonstrated a successful performance of both the conformable ablators for heat flux conditions between 50-500 W/sq cm. The recession and temperature profile for these materials were comparable to PICA proving them to be viable alternatives for TPS technology development for future missions.

Gasch, Matthew↗

NASA NTRS2012

Testing of Candidate Rigid Heatshield Materials at LHMEL for the Entry, Descent, and Landing Technology Development Project

The material testing results described in this paper were part of a material development program of vendor-supplied, proposed heat shield materials. The goal of this program was to develop low density, rigid material systems with an appreciable weight savings over phenolic-impregnated carbon ablator (PICA) while improving material response performance. New technologies, such as PICA-like materials in honeycomb or materials with variable density through-the-thickness were tested. The material testing took place at the Wright-Patterson Air Force Base Laser Hardened Materials Laboratory (LHMEL) using a 10.6 micron CO2 laser operating with the test articles immersed in a nitrogen-gas environment at 1 atmosphere pressure. Test measurements included thermocouple readings of in-depth temperatures, pyrometer readings of surface temperatures, weight scale readings of mass loss, and sectioned-sample readings of char depth. Two laser exposures were applied. The first exposure was at an irradiance of 450 W/cm2 for 50 or 60 seconds to simulate an aerocapture maneuver. The second laser exposure was at an irradiance of 115 W/cm2 for 100 seconds to simulate a planetary entry. Results from Rounds 1 and 2 of these screening tests are summarized.

Sepka, Steven↗

NASA NTRS2011

Characterizing TPS Microstructure: A Review of Some techniques

I. When seeking to understand ablator microstructure and morphology there are several useful techniques A. SEM 1) Visual characteriza3on at various length scales. 2) Chemical mapping by backscatter or x-ray highlights areas of interest. 3) Combined with other techniques (density, weight change, chemical analysis) SEM is a powerful tool to aid in explaining thermo/structural data. B. ASAP. 1) Chemical characteriza3on at various length scales. 2) Chemical mapping of pore structure by gas adsorption. 3) Provides a map of pore size vs. pore volume. 4) Provided surface area of exposed TPS. II. Both methods help characterize and understand how ablators react with other chemical species and provides insight into how they oxidize.

Gasch, Matthew↗

NASA NTRS2011

An Overview of NASA's Current Materials Development Efforts for Mars EDL

Current roadmaps point to landing heavy masses (cargo, followed by manned vehicles) on Mars in the 2030's and the existing entry, descent and landing (EDL) technology will not be sufficient to facilitate such missions. In 2009 the Exploration Technology Development Program (ETDP) established the Entry, Descent and Landing Technology Development Project (EDL TDP), to be managed programmatically at Langley Research Center (LaRC) and technically a Ames Research Center (ARC). The purpose of the project is to further the technologies required to land heavy (approximately 40 metric ton) masses on Mars to facilitate exploration. The EDL TDP contains three technical elements. They are: 1) Thermal Protection Systems (TPS) development 2) Modeling and Tools (MAT) development 3) Supersonic Retropropulsion (SRP) development The primary goals of the EDL TDP TPS element is to design and develop TPS materials capable of withstanding the severe aerothermal loads associated with aerocapture and entry into the Martian atmosphere while significantly decreasing the TPS mass fraction contribution to the entry system. Significant advancements in TPS materials technology are needed in order to enable heavy mass payloads to be successfully landed on the Martian surface for robotic precursors and subsequent human exploration missions. The EDL TDP TPS element is further divided into two different TPS concepts for Mars EDL those being: 1) Rigid TPS for a mid L/D aeroshell with the capability to withstand dual pulsed heating environments as high as 500 W/square cm for aerocapture and 130 W/square cm for entry 2) Flexible TPS for a deployable aerodynamic decelerator with the capability to withstand dual pulsed heating environments as high as 120 W/square cm for aerocapture and 30 W/square cm for entry NASA, along with its vendors, has begun developing and testing materials for each of the deceleration approaches. These include multi-layer rigid ablators and flexible ablative materials. In order to model the response of these types of materials, new and improved modeling techniques will be required. This presentation will outline the types of materials that are under development and illustrate the need for advancement in modeling of ablative materials.

Beck, Robin A.↗

NASA NTRS2003

Arc Jet Testing of Hafnium Diboride Based Ultra High Temperature Ceramics

Hafnium Diboride (HFB,) based materials have shown promise for use in a number of high temperature aerospace applications, including rocket nozzles and as leading edges on hypersonic reentry vehicles. The stability of the materials in relevant environments is key to determining their suitability for a particular application. In this program we have been developing HfB2/SiC materials for use as sharp leading edges. The program as a whole included processing and characterization of the HfBJSiC materials. The specific work discussed here will focus on studies of the materials oxidation behavior in simulated reentry environments through arc jet testing. Four flat face models were tested to examine the influence of heat flux and stagnation pressure on the materials oxidation behavior. The results from arc jet testing of two HfB2/SiC cone models will also be discussed. Each cone model was run multiple times with gradually increasing heat fluxes. Total run times on a single cone model exceeded 80 minutes. For both the flat face and cone models surface temperatures well in excess of 2200 C were measured. Post test microstructural examination of the models and correlations with measured temperatures will be discussed.

Ellerby, Don↗

NASA NTRS2003

Alternative Processing of High Temperature Hafnium and Zirconium Based Materials

The behavior of refractory hafnium and zirconium based materials are being investigated at NASA Ames as part of ongoing research aimed at developing superior heat resistant materials for aerospace applications. Hafnium and zirconium diboride based materials have shown high temperature capabilities in simulated reentry environments indicating that these materials may successfully operate as reusable oxidation resistant components for leading edge applications. Due to the refractory nature of these materials, processing of fine-grained uniform microstructures poses a number of challenges. To better understand the process-property-microstructure relationship, processing of these materials has been carried out with conventional hot pressing in addition to the novel approach of Spark Plasma Sintering (SPS). The two processing methods are compared and contrasted in an evaluation of the sintering behavior of high temperature diboride based materials and preliminary physical and mechanical properties are presented.

Gasch, Matthew↗

NASA NTRS2003

Processing and Properties of HfB2 Based Materials

Contents include the following: Modified hot pressing schedule has significantly improved UHTC billet processing: density and microstructure uniformity have improved. 2 in. dia. x 2 in. tall UHTC billets have been successfully hot pressed: scaled up billets have slightly higher density gradients axially than 1 in. billets. Hot press schedule has not been optimized for scaled up billets. Strengths and strength distributions are improving with experience: need to evaluate strength uniformity in the center of the billets. CTE or ARC materials compares favorably with heritage materials. Thermal conductivity of ARC materials considerably different than that of heritage materials.

Johnson, Sylvia M.↗

NASA NTRS2003

Behavior of HfB2-SiC Materials in Simulated Re-Entry Environments

The objectives of this research are to: 1) Investigate the oxidation/ablation behavior of HfB2/SiC materials in simulated re-entry environments; 2) Use the arc jet test results to define appropriate use environments for these materials for use in vehicle design. The parameters to be investigated include: surface temperature, stagnation pressure, duration, number of cycles, and thermal stresses.

Ellerby, Don↗

NASA NTRS2002

Oxidation Behavior of HfB2-SiC Materials in Dissociated Environments

Hafnium diboride based materials have shown promise for use in extremely high temperature applications, such as sharp leading edges on future reentry vehicles. During reentry, the oxygen and nitrogen in the atmosphere are dissociated by the shock layer ahead of the sharp leading edge such that surface reactions are determined by reactions of monatomic oxygen and nitrogen rather than O2, and N2. Simulation of the reentry environment on the ground requires the use of arc jet (plasma jet) facilities that provide monatomic species and are the closest approximation to actual flight conditions. Simple static or flowing oxidation studies under ambient pressures and atmospheres are not adequate to develop an understanding of a materials behavior in flight. Arc jet testing is required to provide the appropriate stagnation pressures, heat fluxes, enthalpies, heat loads and atmospheres encountered during flight. This work looks at the response of HfB2/SiC materials exposed to various simulated reentry environments.

Ellerby, Don↗