NASA NTRS · 20250007793
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Bohdan O Wesely, Joshua N Hascall, Joseph G Mach, Eli R Hiss. Developmental Flight Heat Shield Instrumentation Technologies. https://ntrs.nasa.gov/citations/20250007793
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The Space Launch System (SLS) Core Stage base heat shield experienced the highest external heating environments on the entire launch vehicle during Artemis I ascent flight. This result was consistent with design predictions. The base heat shield experiences P50 cork combustion dynamics at low altitudes, plume-induced recirculation at moderate altitudes and then in-space base flow physics out to Main Engine Cut-Off (MECO). The base heat shield thermal protection system (TPS) is composed of a P50 cork ablator which is bonded to a substrate. The heat shield protects the gimbal actuation system, RS-25 turbomachinery systems and other aft section sensitive components during ascent. This paper estimates the base heat shield TPS performance from Artemis I using flight data from the NASA Langley Research Center’s Scientifically Calibrated In-Flight Imagery (SCIFLI) Airborne Multispectral Imager (SAMI), development flight instrumentation (DFI) and other TPS recession flight measurements. Predictions from computational and ground test-derived engineering ablation models and observations are also applied. Since no base heat shield substrate thermocouple data were obtained for Artemis I, an estimate of the TPS performance data is derived here. This data assesses thermal margin of the SLS Core Stage base heat shield and best informs the Artemis II Crewed mission to the moon.
Developmental thermal vacuum (TVAC) testing is a critical step in maturing hardware designs and validating performance prior to flight qualification. Unlike qualification or acceptance testing, developmental testing provides flexibility to explore design margins, uncover integration challenges, and refine test approaches before formal verification activities begin. This presentation highlights the value of developmental testing while sharing common pitfalls encountered during developmental TVAC campaigns. Lessons learned from hands-on testing experience, including extensive developmental testing at cryogenic temperatures, will be shared in this presentation. Topics include test planning and preparation, instrumentation strategies, contamination control considerations, troubleshooting unexpected anomalies, and approaches for staying on schedule while meeting test objectives. The audience will gain practical insights and best practices that can improve test efficiency, reduce risk, and enhance the overall success of future developmental TVAC efforts.
Since 2011 the Aerosciences Branch/EV33 at NASA Marshall Space Flight Center has been involved with the development of ascent external aerothermal environments for the NASA Space Launch System (SLS) Block 1 launch vehicle for the purposes of supporting thermal analysis and the design of thermal protection systems. The SLS Block 1 Artemis I and II launch vehicles successfully launched from Pad39B at NASA Kennedy Space Center on November 16th, 2022 and April 1st, 2026, respectively. Over 70 aerothermal islands, consisting of over 265 operational instruments captured aerodynamic heating and plume induced environments throughout the launch vehicles. Gauges consisted of calorimeters, radiometers, gas temperature probes, pressure transducers, bi-directional pressure probes and thermocouples. Prior to launch, aerothermal design environment models were generated to predict ascent aerodynamic heating and plume induced environments over a design space that covered a range of vehicle trajectories that varied atmospheric, vehicle performance, and off-nominal, engine-out conditions. Post flight reconstruction models were developed for each flight island using the Day-of-Launch (DOL) Best Equivalent Trajectory (BET) that provided freestream conditions and propulsion system boundary conditions. This paper discusses a summary of the ascent aerothermal environments observed during the flights and the respective modelling approaches and the performance of them through comparisons of flight data and predictions.