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Environmental and ablative materials performance affecting heat shielding requirements of slender and blunt vehicles during hyperbolic reentry
The Phenolic-Impregnated Carbon Ablator (PICA) heat shield, a lightweight material designed to withstand high temperatures, was used for the Stardust’s reentry into Earth’s atmosphere. Hawthorne, California-based SpaceX later worked with the inventors at Ames Research Center to outfit PICA on its Dragon capsule, which is now delivering cargo to and from the International Space Station through NASA’s Commercial Resupply Services contracts program.
Imagine entering Earth’s atmosphere after returning from the outer solar system. A heat shield less than 2 inches thick protects you from temperatures up to 2,900° Celsius (5,252° Fahrenheit). Such conditions were experienced by NASA’s Stardust capsule during reentry in 2006. The only materials capable of providing the necessary protection are composites with complex microstructures. Evaluating these materials is difficult, requiring precise knowledge of their properties. To this end, NASA scientists are developing research codes to compute material properties and simulate ablation at the microscale using agency supercomputers. Utilizing these tools, along with experiments, researchers are working to push the limits of spaceflight, allowing for greater flexibility in future space missions.
The fabrication, testing, and evaluation of materials and techniques employed in the fabrication of ablative heat shield panels are described. Results of this effort show projected reductions in labor man-hours for dielectric curing of panels when compared to panels molded in a steam-heated press. In addition, panels were fabricated with more than one density within the cross-section. These dual-density panels show significant weight and cost reduction potentials.
The research performed and the data obtained on candidate space shuttle antenna window and heat shield materials are presented. The measurement technique employs a free-space focused beam microwave bridge for obtaining RF transmission data, and a device which rotates a sample holder which is heated on one side by natural gas-air flames. The surface temperature of each sample is monitored by IR pyrometry; embedded and rear surface thermocouples are also used in obtaining temperature data. The surface of the sample undergoing test is subjected to approximately the same temperature/time profile that occurs at a proposed antenna position on the space shuttle as it re-enters. The samples are cycled through ten of these temperature profiles to determine the recycling effects. Very little change was noted in the materials due to the recycling.
Coupled computer code for transient thermal response and ablation of noncharring heat shields and nose tips
Heat-shield for Extreme Entry Environment Technology (HEEET) has been in development since 2014 with the goal of enabling missions to Venus, Saturn and other high-speed sample return missions. It is offered as a new technology and incentivized for mission use in the New Frontiers 4 AO by NASA. The current plans are to mature the technology to TRL 6 by FY18. The HEEET Team has been working closely with multiple NF-4 proposals to Venus, Saturn and has been supporting recent Ice-Giants mission studies. This presentation will provide progress made to date and the plans for development in FY18.
Heat-shield for Extreme Entry Environment Technology (HEEET) has been in development since 2014 with the goal of enabling missions to Venus, Saturn and other high-speed sample return missions. It is offered as a new technology and incentivized for mission use in the New Frontiers 4 AO by NASA. The current plans are to mature the technology to TRL 6 by FY’18. The HEEET Team has been working closely with multiple NF-4 proposals to Venus, Saturn and has been supporting recent Ice-Giants mission studies. This presentation will provide progress made to date and the plans for development in FY’18.
During the first two space shuttle flights the aft skirt heat shield curtain performed well during ascent but failed during reentry. This exposed the inside of the skirt and its subsystems to reentry heating. The resulting exposure damaged various expensive systems items and therefore a curtain reassessment is required. As a part of this reassessment, tests were conducted in the MSFC Hot Gas Facility (HGF). The purposes of these tests were to determine if the curtain would fail in a manner similar to that in flight and to demonstrate that meaningful tests of the curtain can be conducted in the HGF.
Calculated ablative quantities for nylon phenolic heat shielding materials of hyperbolic reentry vehicles
Environmental and ablator performance uncertainties effects on heat shielding requirements for blunt and slender hyperbolic entry vehicles
Make wire, light pipe and spring wire ablation sensors development for measuring parameters of heat shield materials for reentry vehicles
Structural sizing and performance are presented for two structural concepts for an aerobrake hexagonal heat shield panel. One concept features a sandwich construction with an aluminum honeycomb core and thin quasi-isotropic graphite-epoxy face sheets. The other concept features a skin-rib isogrid construction with thin quasi-isotropic graphite-epoxy skins and graphite-epoxy ribs oriented at 0, +60, and -60 degs along the panel. Linear static, linear bifurcation buckling, and nonlinear static analyses were performed to compare the structural performance of the two panel concepts and assess their feasibility for a lunar transfer vehicle aerobrake application.
A full scale segment of the actual Solid Rocket Booster aft skirt heat shield curtain was tested in the Large Radiant Lamp Facility (LRLF) at Marshall Space Flight Center. The curtain was mounted in the horizontal position in the same manner as it is to be mounted on the SRB. A shaker rig was designed and used to provide a motion of the curtain, simulating that to be caused in flight by vehicle acoustics. Thermocouples were used to monitor curtain materials temperatures. Both ascent and reentry heat loads were applied to the test specimen. All aspects of the test setup performed as expected, and the test was declared successful.
The development of slip-cast fused silica is discussed as a heat shield designed to meet the needs of outer-planet entry probes. The distinguishing feature of silica is its ability to reflect the radiation imposed by planetary-entry environments. This reflectivity is particularly sensitive to degradation by the presence of trace amounts of contaminants introduced by the starting materials or by processing. The microstructure of a silica configuration also significantly influences the reflectivity and other thermomechanical properties. The processing techniques attendant on controlling microstructure while maintaining purity are discussed. The selection of a starting material of essential purity precludes the use of purified natural quartz and requires the use of synthetic fused silica. The silica is characterized in a limited combined heating test environment. The surface mass loss is controlled by liquid runoff from a relatively low-temperature melt layer; the reflectance is basically maintained and the material achieves a surprisingly high heat of ablation.
Impact acceleration and landing system characteristics of Apollo spacecraft command module configurations with deployed heat shield
Procedures for low cost fabrication and direct bond installation of flat, single curved, and compound curvature ablative heat shields on a DC-3 aircraft are discussed. The panel sizes and attachment locations are identified. In addition to the bonding of the four contoured panels, two flat panels were bonded to the nearly flat, lower surface of the center wing section. The detailed requirements and objectives of the investigation are described.
Experimental and analytical natural frequencies, nodal patterns, and typical modal displacements for a corrugated, flexibly supported, heat-shield panel are discussed. Good correlation was found between the experimental data and NASTRAN analytical results for the corrugated panel over a relatively wide frequency spectrum covered in the investigation. Of the two experimental techniques used for mode shape and displacement measurements (a noncontacting displacement sensor system and a holographic technique using a helium-neon, continuous-wave laser), the holographic technique was found, in the present investigation, to be faster and better suited for determining a large number of complex nodal patterns of the corrugated panel.