Results for “Arc jet testing” — Page 10

NASA NTRS2016

Heatshield for Extreme Entry Environment Technology (HEEET) Development Status

The Heat shield for Extreme Entry Environment Technology (HEEET) Project is a NASA STMD and SMD co-funded effort. The goal is to develop and mission infuse a new ablative Thermal Protection System that can withstand extreme entry. It is targeted to support NASAs high priority missions, as defined in the latest decadal survey, to destinations such as Venus and Saturn in-situ robotic science missions. Entry into these planetary atmospheres results in extreme heating. The entry peak heat-flux and associated pressure are estimated to be between one and two orders of magnitude higher than those experienced by Mars Science Laboratory or Lunar return missions. In the recent New Frontiers community announcement NASA has indicated that it is considering providing an increase to the PI managed mission cost (PIMMC) for investigations utilizing the Heat Shield for Extreme Entry Environment Technology (HEEET) and in addition, NASA is considering limiting the risk assessment to only their accommodation on the spacecraft and the mission environment. The HEEET ablative TPS utilizes 3D weaving technology to manufacture a dual layer material architecture. The 3-D weaving allows for flat panels to be woven. The dual layer consists of a top layer designed to withstand the extreme external environment while the inner or insulating layer by design, is designed to achieve low thermal conductivity, and it keeps the heat from conducting towards the structure underneath. Both arc jet testing combined with material properties have been used to develop thermal response models that allows for comparison of performance with heritage carbon phenolic. A 50 mass efficiency is achieved by the dual layer construct compared to carbon phenolic for a broad range of missions both to Saturn and Venus. The 3-D woven flat preforms are molded to achieve the shape as they are compliant and then resin infusion with curing forms a rigid panels. These panels are then bonded on to the aeroshell structure. Gaps exist between the panels and these gaps have to be filled with seams. The seam material then has to be bonded on to adjacent panels and also to the structure. The heat-shield assembly is shown in Figure 1. One of the significant challenges we have overcome recently is the design, development and testing of the seam. HEEET material development and the seam concept development have utilized some of the unique test capabilities available in the US. The various test facilities utilized in thermal testing along with the entry environment for Saturn and Venus missions are shown in Figure 2. The HEEET project is currently in its 3rd year of a four-year development. Figure 3 illustrates the key accomplishments to date and the challenges yet to be overcome before the technology is ready for mission infusion. This proposed presentation will cover both progress that has been made in the HEEET project and also the challenges to be overcome that is highlighted in Figure 3. Objective of the HEEET project is to mature the system in time to support the next New Frontiers opportunity and we believe we are well along the way to mission infuse HEEET.

Thermal Protection System↗

NASA NTRS2016

Heat-shield for Extreme Entry Environment Technology (HEEET) Development Status

The Heat shield for Extreme Entry Environment Technology (HEEET) Project is a NASA STMD and SMD co-funded effort. The goal is to develop and mission infuse a new ablative Thermal Protection System that can withstand extreme entry. It is targeted to support NASA's high priority missions, as defined in the latest decadal survey, to destinations such as Venus and Saturn in-situ robotic science missions. Entry into these planetary atmospheres results in extreme heating. The entry peak heat-flux and associated pressure are estimated to be between one and two orders of magnitude higher than those experienced by Mars Science Laboratory or Lunar return missions. In the recent New Frontiers community announcement NASA has indicated that it is considering providing an increase to the PI managed mission cost (PIMMC) for investigations utilizing the Heat Shield for Extreme Entry Environment Technology (HEEET) and in addition, NASA is considering limiting the risk assessment to only their accommodation on the spacecraft and the mission environment. The HEEET ablative TPS utilizes 3D weaving technology to manufacture a dual layer material architecture. The 3-D weaving allows for flat panels to be woven. The dual layer consists of a top layer designed to withstand the extreme external environment while the inner or insulating layer by design, is designed to achieve low thermal conductivity, and it keeps the heat from conducting towards the structure underneath. Both arc jet testing combined with material properties have been used to develop thermal response models that allows for comparison of performance with heritage carbon phenolic. A 50% mass efficiency is achieved by the dual layer construct compared to carbon phenolic for a broad range of missions both to Saturn and Venus. The 3-D woven flat preforms are molded to achieve the shape as they are compliant and then resin infusion with curing forms a rigid panels. These panels are then bonded on to the aeroshell structure. Gaps exist between the panels and these gaps have to be filled with seams. The seam material then has to be bonded on to adjacent panels and also to the structure. The heat-shield assembly is shown in Figure 1. One of the significant challenges we have overcome recently is the design, development and testing of the seam. HEEET material development and the seam concept development have utilized some of the unique test capabilities available in the US. The various test facilities utilized in thermal testing along with the entry environment for Saturn and Venus missions are shown in Figure 2. The HEEET project is currently in it's 3rd year of a four-year development. Figure 3 illustrates the key accomplishments to-date and the challenges yet to be overcome before the technology is ready for mission infusion. This proposed presentation will cover both progress that has been made in the HEEET project and also the challenges to be overcome that is highlighted in Figure 3. Objective of the HEEET project is to mature the system in time to support the next New Frontiers opportunity and we believe we are well along the way to mission infuse HEEET.

TPS↗

NASA NTRS2019

Development of Lyocell Based Phenolic Impregnated Carbon Ablators (PICA-D) for Future NASA Missions

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since 1999. Due to the obsolescence of the input fiber source, new PICA materials were developed using Lyocell, a domestic rayon fiber source. Results are presented from this effort. Manufacturing included fiber conversion, fabrication of tile component and near net shaped heatshield preforms, and conversion to PICA materials. Thermal, mechanical, and representative environment arc-jet testing have been conducted. Initial testing indicates comparable performance with respect to heritage PICA material, and likely "drop-in" replacement for future NASA mission needs.

Thermal Protection↗

NASA NTRS2019

Development of Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for Future NASA Missions

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since 1999. Due to the obsolescence of the input fiber source, new PICA materials were developed using Lyocell, a domestic rayon fiber source. Results are presented from this effort. Manufacturing included fiber conversion, fabrication of tile component and near net shaped heatshield preforms, and conversion to PICA materials. Thermal, mechanical, and representative environment arc-jet testing have been conducted. Initial testing indicates comparable performance with respect to heritage PICA material, and likely "drop-in" replacement for future NASA mission needs.

thermal protection↗

NASA NTRS2019

Development of Domestic Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for Future NASA Missions

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since the late 90's. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions. The rayon-based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues and required replacement and requalification at least twice in the past 25 years, and a third substitution is now needed. Due to the obsolescence of the input foreign rayon fiber source, a new variant of PICA has been developed using a domestic rayon-like fiber source, Lyocell. Results are presented from this effort including fiber conversion, fabrication of tile component and near net shaped heatshield preforms, and conversion to PICA materials. Thermal, mechanical, and representative environment arc-jet tests have been conducted. Initial testing of PICA-Domestic (PICA-D) indicates comparable performance with respect to "heritage" PICA materials and thus PICA-D is expected to be a sustainable solution for future NASA missions.

Drop-In Replacement↗

NASA NTRS2019

Development of Domestic Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for Future NASA Missions

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since the late 90's. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions. The rayon-based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues and required replacement and requalification at least twice in the past 25 years, and a third substitution is now needed. Due to the obsolescence of the input foreign rayon fiber source, a new variant of PICA has been developed using a domestic rayon-like fiber source, Lyocell. Results are presented from this effort including fiber conversion, fabrication of tile component and near net shaped heatshield preforms, and conversion to PICA materials. Thermal, mechanical, and representative environment arc-jet tests have been conducted. Initial testing of PICA-Domestic (PICA-D) indicates comparable performance with respect to "heritage" PICA materials and thus PICA-D is expected to be a sustainable solution for future NASA missions.

Drop-In Replacement↗

NASA NTRSDate not supplied

Validation and Sensitivity Analyses of Arc-Jet Performance of Woven Thermal Protection Entry Systems

Woven thermal protection materials for the Adaptable, Deployable, Entry and Placement Technology (ADEPT) entry system are simulated using a dual layer formalism in a finite volume implicit framework. The model developed and demonstrated here includes multi-dimensional and time-varying thermal response of the material to arc-jet test conditions. This work further demonstrates the sensitivities of the macro-scale thermal response to the through-thickness and in-plane conductivities of the carbon fabric, and to other experimental measurements such as cloth emissivity and thickness. The modeling can be extended to the ADEPT system that would encompass a single-piece woven heat shield configuration

Pratibha Raghunandan↗

NASA NTRSDate not supplied

A survey of thermocouple anomalies: mechanisms, interpretation, and mitigation

Thermocouples (TCs) are a critical diagnostic sensor for high enthalpy environments including thermal protection systems (TPS) for atmospheric re-entry, hypersonic wind tunnels, and arc jet test facilities. They are used for both evaluating facility environmental conditions (enthalpy, heat flux) as well as for measuring in-situ material thermal response under test conditions (thermal conductivity, heat capacity, B’, etc.). Consequently, accurate TC measurements are fundamental for both material and facility verification and validation (V&V). However, a number of TC anomalies have been observed in both ground tests and flight instrumentation. These anomalies are caused via various coupling mechanisms: electrostatic gradients, temperature-dependent electrical shorts, radio pickup, magnetic induction, and pressure-dependent leaks. All of these mechanisms can, if unaddressed, result in obviously compromised results or worse, non-physical measurements which appear reasonable. This work will survey known anomaly mechanisms and discuss ongoing efforts to quantify and mitigate anomaly mechanisms including anomaly modeling, diagnostics, and new TC designs/development.

thermocouple anomalies↗

NASA NTRSDate not supplied

Electromagnetic Thermocouple (TC) Anomaly Mechanisms During Atmospheric Entry

Thermocouples (TCs) are a critical diagnostic sensor for high enthalpy environments including Thermal Protection Systems (TPS) for atmospheric entry, hypersonic wind tunnels, and arc jet test facilities. They are used for both evaluating facility environmental conditions (enthalpy, and heat flux) as well as for measuring in-situ material thermal response under test conditions (thermal conductivity, heat capacity, etc.). Consequently, accurate TC measurements are fundamental for both material and facility Verification and Validation (V&V). However, a number of electromagnetic TC anomalies have been observed in both ground tests and flight instrumentations. These anomalies are caused via various coupling mechanisms: surface voltage coupling, Hall effect currents, and RF rectification. All of these mechanisms can, if unaddressed, result in obviously compromised results or worse, non-physical measurements which appear reasonable. This talk will provide an overview of each of these anomaly mechanisms and discuss ongoing efforts to quantify and mitigate them.

Magnus Haw↗

NASA NTRSDate not supplied

A Survey of Thermocouple Anomalies: Mechanisms, Interpretation, and Mitigation

Thermocouples (TCs) are a critical diagnostic sensor for high enthalpy environments including thermal protection systems (TPS) for atmospheric re-entry, hypersonic wind tunnels, and arc jet test facilities. They are used for both evaluating facility environmental conditions (enthalpy, heat flux) as well as for measuring in-situ material thermal response under test conditions (thermal conductivity, heat capacity, B’, etc.). Consequently, accurate TC measurements are fundamental for both material and facility verification and validation (V&V). However, a number of TC anomalies have been observed in both ground tests and flight instrumentation. These anomalies are caused via various coupling mechanisms: electrostatic gradients, temperature-dependent electrical shorts, radio pickup, magnetic induction, and pressure-dependent leaks. All of these mechanisms can, if unaddressed, result in obviously compromised results or worse, non-physical measurements which appear reasonable. This work will survey known anomaly mechanisms and discuss ongoing efforts to quantify and mitigate anomaly mechanisms including anomaly modeling, diagnostics, and new TC designs/development.

Thermocouple Anomalies↗

NASA NTRSDate not supplied

Unified Material-Environment Interaction Model for Binary UHTC Composites

A new model for the surface chemistry of zirconium and hafnium diborides containing silicon-carbide when exposed to high temperature conditions in air is formulated. Oxidation dynamics are simplified by considering the diffusion-limited equilibrium regime within the material at elevated temperatures. This model is first assessed against experimental mass-gain data taken from UHTC samples heated to high temperature in an oxygen environment. Then, further evaluations of the new model are conducted using hypersonic CFD simulations to analyze conditions experienced by HfB2-SiC in arc jet experiments conducted at NASA Ames Research Center. Measurements of stagnation point heat transfer and pressure are then used to calibrate the simulations. Results of coupled CFD-material response simulations are then compared to the surface temperatures measured during the Ames arc jet test. Results support the use of the proposed model while highlighting the need for improved gas-phase data on the additional constituents considered.

ultra high temperature ceramic↗

NASA NTRSDate not supplied

Validation and Sensitivity Analyses of Arc-Jet Performance of Woven Thermal Protection Entry Systems

A material response model is developed for the determination of erosion rates and thermal response of woven materials to enable accurate thermal protection material sizing and future missions to Venus and giant planets. The stagnation-point thermal response is further evaluated using a Monte Carlo global sensitivity analysis to determine the interactions between key parameters in the material surface energy balance, such as, convective blowing correction parameter and weave material properties including isotropic and orthotropic thermal conductivites. The time-accurate material response for the dual layer weave erosion and surface temperatures show excellent agreement with stagnation flat face arc-jet tests involving time-varying aeroheating-cooling cycles. The high-fidelity Monte Carlo sensitivity analysis technique was used to address challenges in thermal protection sizing for the Adaptive Deployable Entry and Placement Technology (ADEPT) system, a low ballistic coefficient hypersonic decelerator. The results represent new correlations for such weaves involving Carbon-air oxidation equilibrium chemistry. Through the multi-variate regression analyses and uncertainty rankings performed, only three properties were found to contribute to the transient thermal response of the gore, with emissivity contributing to nearly 95% of the total output uncertainty.

Pratibha Raghunandan↗

NASA NTRS2021

Validation and Sensitivity Analyses of Arc-Jet Performance of Woven Thermal Protection Entry Systems

A material response model is developed for the determination of erosion rates and thermal response of woven materials to enable accurate thermal protection material sizing and future missions to Venus and giant planets. The stagnation-point thermal response is further evaluated using a Monte Carlo global sensitivity analysis to determine the interactions between key parameters in the material surface energy balance, such as, convective blowing correction parameter and weave material properties including isotropic and orthotropic thermal conductivites. The time-accurate material response for the dual layer weave erosion and surface temperatures show excellent agreement with stagnation flat face arc-jet tests involving time-varying aeroheating-cooling cycles. The high-fidelity Monte Carlo sensitivity analysis technique was used to address challenges in thermal protection sizing for the Adaptive Deployable Entry and Placement Technology (ADEPT) system, a low ballistic coefficient hypersonic decelerator. The results represent new correlations for such weaves involving Carbon-air oxidation equilibrium chemistry. Through the multi-variate regression analyses and uncertainty rankings performed, only three properties were found to contribute to the transient thermal response of the gore, with emissivity contributing to nearly 95% of the total output uncertainty.

Pratibha Raghunandan↗

NASA NTRSDate not supplied

Advanced TUFROC Thermal Protection System

TUFROC is a cost-effective, state of the art, high temperature reusable thermal protection system that is flight-proven as the wing leading edge of X-37B. The low-density dual layer system takes advantage of the high temperature capability of a carbon composite at the surface and transitions to a low-conductivity silica-based Shuttle tile material in depth. An updated surface treatment formulation has resulted in a better performing system, called Advanced TUFROC, which demonstrates lower surface temperature due to reduced catalytic atom recombination at the surface, compared to the original system. An overview of TUFROC and recent arc jet testing will be presented.

TUFROC thermal protection system↗

NASA NTRSDate not supplied

Backshell Thermal Protection Materials for Additive Manufacturing

NASA invests in additive manufacturing (AM) to enable new mission architectures and design methods, including autonomous fabrication. AM is suited for backshell thermal protection materials that require many complex closeouts that lead to integration challenges. Current work will review printable backshell thermal protection material formulation, development, and characterization, such as Arc-jet testing results.

Tane Boghozian↗

NASA NTRSDate not supplied

Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields

Introduction: Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and re-quire extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk. Material Development: A critical challenge for the project is development of a material system that can (1) be printed in a near-net shape process and (2) perform well as an ablator. Achieving printability requires the material to flow under applied pressure, but maintain its shape once extruded from the printer nozzle. Ablative performance is measured by a multitude of markers, including char yield, char strength, thermal conductivity, and recession rate. Furthermore, there are several mechanical and thermal property considerations for vehicle integration including coefficient of thermal expansion (CTE) and residual stress. AM technology will be leveraged to grade the material formulation and properties through the thickness of the heat shield, an architecture not possible with current manufacturing processes. To this end, “robust” material formulations have been pre-pared with higher density for use on the surface where most ablation will occur. “Insulative” material formulations, with lower density and lower thermal conductivity, are prepared for use in the depth of the heat shield. This graded architecture will re-duce the overall mass of the heat shield and reduce costs and/or increase scientific payload capacities. To achieve a material system with the required properties, multiple resins have been investigated in collaboration with NASA Ames Research Center. To tune printability and performance, resin additives were studied to improve flexibility of the cured material while maintaining acceptable ablative performance. Material coupons were printed and studied via a suite of mechanical and thermal characterization methods. Arc jet testing was conducted at NASA Ames Research Center to evaluate ablative performance and thermal protection under conditions expected in atmospheric entry. Manufacturing Scale-Up: A partnership with Oak Ridge National Laboratory (ORNL) aims to enable full-scale fabrication of a 3D printed heat shield. Leveraging expertise in manufacturing and 3D printing at ORNL, a mid-scale manufacturing demonstration unit will be built and tested, using a dual-layer ablative system printed directly onto the titanium structure. Work on robotic system integration is ongoing and efforts to scale up material mixing with a material compound will ensure accurate and homogenous composition. Flight Test: A hypersonic sub-orbital flight test will provide a rigorous test of material performance ranging from ablation, thermal management, and mechanical integrity. Design of the capsule has taken place in collaboration with the University of Kentucky. Data collected from the flight will inform future design efforts in material formulation, printing methodology, and heat shield-capsule integration.

additive manufacturing↗

NASA NTRSDate not supplied

Advanced TUFROC Thermal Protection System Evolution Under Re-entry like Conditions

Toughened Unipiece Fibrous Reinforced Oxidation-resistant Composite (TUFROC) and its successor, Advanced TUFROC, are state-of-the-art thermal protection systems (TPS) for high temperature reusable applications. Originally designed for use on the wing-leading edge of X-37B, TUFROC is an insulative tiled system consisting of a low-conductivity ceramic base, a carbonaceous cap, and multiple coatings for thermal performance. The improved Advanced TUFROC has demonstrated reusability up to 2900 °F and single use capabilities exceeding 3200 °F. This effort explores the evolution of Advanced TUFROC when exposed to re-entry like conditions via arc jet testing. Chemical reactions and constituent migration resulting from the aerothermal heating are known to occur and are studied in detail. Further, the interaction between the multiple constituents and layers will be discussed as this is believed to have a significant impact on the overall performance. Characterization includes structural analysis via optical microscopy, scanning electron microscopy and energy-dispersive x-ray spectroscopy.

Thermal protection system↗

NASA NTRSDate not supplied

Development of Advanced Conformal and Soft Pica for Future Nasa Missions and Commercial Space

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since the late 90’s. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions, from Sample Return missions such as Stardust, OSIRIS-REx to large Mars Lander missions such as MSL and Mars 2020. Continued development of a more mass efficient and compliant versions of PICA that use a carbon felt as the substrate will be presented. The felt based versions of PICA known as Conformal PICA (C-PICA) and Soft PICA (S-PICA), are very comparable in terms of peak heat-flux capabilities compared to standard PICA. The lower density and of C-PICA and S-PICA further show a much higher thermal protection efficiency and hence more mass savings. The compliant nature of these materials allows for use on a wide variety of substrates and therefore makes it very attractive for commercial low earth orbit missions as well as NASA’s aerocapture missions to Ice Giants. NASA is currently working with several commercial partners (Varda and Inversion Space) to Technology Transfer C/S-PICA variants for commercial LEO missions. Thermal, mechanical, and representative environment arc-jet tests have been conducted comparing the performance of Conformal and Soft-PICA materials.

Matthew J Gasch↗