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NASA NTRS2019

Challenges in Qualification of Thermal Protection Systems in Extreme Entry Environments

Planetary entry vehicles employ ablative TPS materials to shield the aeroshell from entry aeroheating environments. To ensure mission success, it must be demonstrated that the heat shield system, including local features such as seams, does not fail at conditions that are suitably margined beyond those expected in flight. Furthermore, its thermal response must be predictable, with acceptable fidelity, by computational tools used in heat shield design. Mission assurance is accomplished through a combination of ground testing and material response modelling. A material's robustness to failure is verified through arcjet testing while its thermal response is predicted by analytical tools that are verified against experimental data. Due to limitations in flight-like ground testing capability and lack of validated high-fidelity computational models, qualification of heat shield materials is often achieved by piecing together evidence from multiple ground tests and analytical simulations, none of which fully bound the flight conditions and vehicle configuration. Extreme heating environments (>2000 W/sq. cm heat flux and >2 atm pressure), experienced during entries at Venus, Saturn and Ice Giants, further stretch the current testing and modelling capabilities for applicable TPS materials. Fully-dense Carbon Phenolic was the material of choice for these applications; however, since heritage raw materials are no longer available, future uses of re-created Carbon Phenolic will require re-qualification. To address this sustainability challenge, NASA is developing a new dual-layer material based on 3D weaving technology called Heat shield for Extreme Entry Environments (HEEET). Regardless of TPS material, extreme environments pose additional certification challenges beyond what has been typical in recent NASA missions. Scope of this presentation: This presentation will give an overview of challenges faced in verifying TPS performance at extreme heating conditions. Examples include: (1) Bounding aeroheating parameters (heat flux, pressure, shear and enthalpy) in ground facilities. How to certify TPS if environments can't be bounded or aeroheating parameters can't be simultaneously achieved. (2) Higher uncertainties in ground test environments (facility calibration and analytical predictions) at extreme conditions. (3) Testing in flows similar to planetary atmosphere composition (H2/He for Gas and Ice Giants). (4) Test sample size limitations for qualifying seam designs. (5) Lack of computational tools capable of simulating all significant aspects of TPS performance (including initiation and propagation of failures). This presentation will provide recommendations on how the EDL community can address these challenges and mitigate some of the risks involved in flying TPS materials at extreme conditions. Examples include: (1) Dedicated activity to understanding TPS failure modes. Develop computational tools capable of modelling fluid interaction with material's thermostructural response. Validate these tools through failure testing. A better understanding of failure mechanisms may eliminate the need to fully bound all aeroheating parameters in ground testing. (2) Enhancements to current testing facilities to simulate flight-like ablation mechanism (ex. testing in Nitrogen at Ames Interaction Heating Facility to limit oxidation in favor of more sublimation). (3) Improved characterization of test conditions with new diagnostic methods and determination of environment uncertainty through rigorous statistical analysis of available data. (4) Design margin policies that are directly tied to uncertainties in ground test environments and modelling fidelity

Mahzari, Milad↗
NASA NTRS2019

Challenges in Qualification of Thermal Protection Systems for Extreme Entry Environments

Planetary entry vehicles employ ablative TPS materials to shield the aeroshell from entry aeroheating environments. To ensure mission success, it must be demonstrated that the heatshield system, including local features such as seams, does not fail at conditions that are suitably margined beyond those expected in flight. Furthermore, its thermal response must be predictable, with acceptable fidelity, by computational tools used in heatshield design. Mission assurance is accomplished through a combination of ground testing and material response modelling. A material's robustness to failure is verified through arcjet testing while its thermal response is predicted by analytical tools that are verified against experimental data. Due to limitations in flight-like ground testing capability and lack of validated high-fidelity computational models, qualification of heatshield materials is often achieved by piecing together evidence from multiple ground tests and analytical simulations, none of which fully bound the flight conditions and vehicle configuration. Extreme heating environments (>2000 W/cm2 heat flux and >2 atm pressure), experienced during entries at Venus, Saturn and Ice Giants, further stretch the current testing and modelling capabilities for applicable TPS materials. Fully-dense Carbon Phenolic was the material of choice for these applications; however, since heritage raw materials are no longer available, future uses of re-created Carbon Phenolic will require re-qualification. To address this sustainability challenge, NASA is developing a new dual-layer material based on 3D weaving technology called Heatshield for Extreme Entry Environments (HEEET) [1]. Regardless of TPS material, extreme environments pose additional certification challenges beyond what has been typical in recent NASA missions.Scope of this presentation: This presentation will give an overview of challenges faced in verifying TPS performance at extreme heating conditions.

Mahzari, Milad↗
NASA NTRS2009

NEXT Long-Duration Test Neutralizer Performance and Erosion Characteristics

The NASA's Evolutionary Xenon Thruster (NEXT) program is developing the next-generation ion propulsion system with significant enhancements beyond the state-of-the-art to provide future NASA science missions with enhanced capabilities at a low total development cost. A Long-Duration Test (LDT) was initiated in June 2005, to verify the NEXT propellant throughput capability to a qualification-level of 450 kg, 1.5 times the anticipated throughput requirement of 300 kg per thruster based on mission analyses. As of September 2, 2009, the thruster has accumulated 24,400 hr of operation with extensive durations at the following input powers: 6.9, 4.7, 1.1, and 0.5 kW. The thruster has processed 434 kg of xenon, surpassing the NASA Solar Technology Application Readiness (NSTAR) program thruster propellant throughput demonstrated during the extended life testing of the Deep Space 1 flight spare ion thruster and approaching the NEXT development qualification throughput goal of 450 kg. The NEXT LDT has demonstrated a total impulse of 16.1 10(exp 6zzz0 N s; the highest total impulse ever demonstrated by an ion thruster. A reduction in neutralizer flow margin has been the only appreciable source of thruster performance degradation. The behavior of the neutralizer is not easily predicted due to both erosion and deposition observed in previous wear tests. Spot-to-plume mode transition flow data and in-situ erosion results for the LDT neutralizer are discussed. This loss of flow margin has been addressed through a combination of a design change in the prototype-model neutralizer to increase flow margin at low emission current and to update the NEXT throttle table to ensure adequate flow margin as a function of propellant throughput processed. The new throttle table will be used for future LDT operations. The performance of the NEXT LDT neutralizer is consistent with that observed for long-life hollow cathodes. The neutralizer life-limiting failure modes are progressing as expected and the neutralizer data indicate none of the neutralizer failures are imminent.

Herman, Daniel A.↗
NASA NTRS2009

Radioisotope Electric Propulsion (REP): A Near-Term Approach to Nuclear Propulsion

Studies over the last decade have shown radioisotope-based nuclear electric propulsion to be enhancing and, in some cases, enabling for many potential robotic science missions. Also known as radioisotope electric propulsion (REP), the technology offers the performance advantages of traditional reactor-powered electric propulsion (i.e., high specific impulse propulsion at large distances from the Sun), but with much smaller, affordable spacecraft. Future use of REP requires development of radioisotope power sources with system specific powers well above that of current systems. The US Department of Energy and NASA have developed an advanced Stirling radioisotope generator (ASRG) engineering unit, which was subjected to rigorous flight qualification-level tests in 2008, and began extended lifetime testing later that year. This advancement, along with recent work on small ion thrusters and life extension technology for Hall thrusters, could enable missions using REP sometime during the next decade.

Schmidt, George R.↗
NASA NTRSDate not supplied

NASA Progress on the Development and Qualification of a 12-kW Hall-Effect, Solar Electric Propulsion Thruster

The National Aeronautics and Space Administration (NASA) continues to evolve the human exploration approach for beyond low-Earth orbit and in a manner involving international, academic, and industry partners. The center of this approach is NASA’s Gateway program that will establish a permanent human presence in lunar orbit for human cislunar science, operations, and lunar surface access to eventually land the next American astronauts on the south pole of the Moon. In support of the effort, NASA’s Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The resulting Advanced Electric Propulsion System (AEPS) project has developed a 12 kW Hall-effect thruster in support of the Gateway program. The project is managed by the NASA Glenn Research Center (GRC), supported by the NASA Jet Propulsion Laboratory (JPL) with development, qualification & flight hardware all supplied by L3 Harris Aerojet Rocketdyne (AR). Development of the 12-kW Hall thruster electric propulsion system began with maturation of the Hall Effect Rocket with Magnetic Shielding (HERMeS) Technology Demonstration Units (TDUs). The technology development was then transitioned to AR via the AEPS contract, which built and tested two Engineering Test Unit (ETU) thrusters and multiple critical components. The project transitioned to the production of the three flight thrusters and entered qualification testing at the component and thruster levels.

Electric Propulsion↗
NASA NTRSDate not supplied

NASA Progress on the Development and Qualification of a 12-kW Hall-Effect, Solar Electric Propulsion Thruster

The National Aeronautics and Space Administration (NASA) continues to evolve the human exploration approach for beyond low-Earth orbit and in a manner involving international, academic, and industry partners. The center of this approach is NASA’s Gateway program that will establish a permanent human presence in lunar orbit for human cislunar science, operations, and lunar surface access to eventually land the next American astronauts on the south pole of the Moon. In support of the effort, NASA’s Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The resulting Advanced Electric Propulsion System (AEPS) project has developed a 12 kW Hall-effect thruster in support of the Gateway program. The project is managed by the NASA Glenn Research Center (GRC), supported by the NASA Jet Propulsion Laboratory (JPL) with development, qualification & flight hardware all supplied by L3 Harris Aerojet Rocketdyne (AR). Development of the 12-kW Hall thruster electric propulsion system began with maturation of the Hall Effect Rocket with Magnetic Shielding (HERMeS) Technology Demonstration Units (TDUs). The technology development was then transitioned to AR via the AEPS contract, which built and tested two Engineering Test Unit (ETU) thrusters and multiple critical components. The project transitioned to the production of the three flight thrusters and entered qualification testing at the component and thruster levels.

Electric Propulsion↗
NASA NTRS2008

Are Current SEE Test Procedures Adequate for Modern Devices and Electronics Technologies?

Believe it or not, this has been a simplistic look at starting a checklist for SEE testing. Given a memory that has 68 operating modes, when a SEU occurs that changes the mode, just how do you determine what's going on? Laser and microbeam tests can help, but not easily for modern packaged devices. Expanding this approach to other more complex devices such as ADCs or processors as well as analog devices should be considered. The recommendation is to use the existing text standards as the starting point. Just make your own checklist for the device/technology/issues being considered. At HEART 2007, we presented some of the burgeoning challenges associated with single event effect(SEE) testing of modern commercial memories: a) Package, device complexity, test fixture, and data analysis issues were discussed; b) "Complete" SEE Characterization would take 15 years; c) Qualification test costs have a greater than 4 times increase over the last decade. In this talk, we continue to explore the roles of technology with an emphasis on the existing SEE Test Procedures and some of the concerns related to modern devices. The primary objective of the briefing is to provide some overarching guidance concerning the many considerations involved in the formulation of a SEE test plan provided in a " Checklist" format.we note that there is no such thing as a complete check list and that the best approach is to develop a flexible test plan that takes into account the device type and functions, the device technology, circuit and package design, and, of course, test facility and beam characteristics.

LaBel, Kenneth A.↗
NASA NTRS2000

NASA Master Teacher Re-Certification Program

Edward Waters College is submitting a final report covering the grant period from January 1999 - April 30, 2000. The Teacher re-certification program at Edward Waters College created a high quality professional development opportunity for middle and high school science teachers which will contribute to the improvement of science education and the use of innovation technologies in the classroom for years to come. The following goals and objectives were met and exceeded during the grant period. 1) A focused and relevant educational technology curriculum based on National Science Education Standard and state-of-the art educational resources that are accepted as one of the qualifications for re-certification in the scientific discipline in Duval County, Florida. 2) The program goal was to recertify 40 middle and high school science teachers over a two- year period. This goal was met and exceeded the projected number by recertifying over 80 middle and high school science and math teachers over a two-year period. 3) Teachers that were recertified were given an opportunity to public information that they developed on EWC's Web page or develop a web page of their own. Area schools were made aware of this information through various forms of communication with the teachers in Duval County School District, i.e., flyers sent from EWC to participants, school newspapers, word of mouth, etc. 4) A multimedia technology resource lab is available at EWC for use as a "Learning Lab" for class field trips by Duval County teachers.

Okari-Brooks, Emma↗
NASA NTRS2003

Stirling Convertor Technologies Being Developed for a Stirling Radioisotope Generator

The Department of Energy, Lockheed Martin, Stirling Technology Company (STC), and the NASA Glenn Research Center are developing a high-efficiency Stirling Radioisotope Generator (SRG) for NASA space science missions. The SRG is being developed for multimission use, including providing electric power for unmanned Mars rovers and deep space missions. On Mars, rovers with SRGs would be used for missions that might not be able to use photovoltaic power systems, such as exploration at high Martian latitudes and missions of long duration. The projected SRG system efficiency of 23 percent will reduce the required amount of radioisotope by a factor of 4 or more in comparison to currently used Radioisotope Thermoelectric Generators. The Department of Energy recently named Lockheed Martin as the system integration contractor. Lockheed Martin has begun to develop the SRG engineering unit under contract to the Department of Energy, and has contract options to develop the qualification unit and the first flight units. The developers expect the SRG to produce about 114 Wdc at the beginning of mission, using two opposed Stirling convertors and two General Purpose Heat Source modules. STC previously developed the Stirling convertor under contract to the Department of Energy and is now providing further development as a subcontractor to Lockheed Martin. Glenn is conducting an in-house technology project to assist in developing the convertor for space qualification and mission implementation. A key milestone was recently reached with the accumulation of 12 000 hr of long-term aging on two types of neodymium-iron boron permanent magnets. These tests are characterizing any possible aging in the strength or demagnetization resistance of the magnets used in the linear alternator. Preparations are underway for a thermal/vacuum system demonstration and unattended operation during endurance testing of the 55-We Technology Demonstration Convertors. In addition, Glenn is developing a charging system for the convertors to ensure clean fills of the helium working fluid and to monitor levels of any possible contaminants at different test intervals. Possible oxidation effects depend on the level of any oxygen contamination-regenerator materials and displacer radiation shields are now being evaluated for possible oxidation effects.

Thieme, Lanny G.↗
NASA NTRS1999

Two Phase Technology Development Initiatives

Three promising thermal technology development initiatives, vapor compression thermal control system, electronics cooling, and electrohydrodynamics applications are outlined herein. These technologies will provide thermal engineers with additional tools to meet the thermal challenges presented by increased power densities and reduced architectural options that will be available in future spacecraft. Goddard Space Flight Center and the University of Maryland are fabricating and testing a 'proto- flight' vapor compression based thermal control system for the Ultra Long Duration Balloon (ULDB) Program. The vapor compression system will be capable of transporting approximately 400 W of heat while providing a temperature lift of 60C. The system is constructed of 'commercial off-the-shelf' hardware that is modified to meet the unique environmental requirements of the ULDB. A demonstration flight is planned for 1999 or early 2000. Goddard Space Flight Center has embarked upon a multi-discipline effort to address a number of design issues regarding spacecraft electronics. The program addressed the high priority design issues concerning the total mass of standard spacecraft electronics enclosures and the impact of design changes on thermal performance. This presentation reviews the pertinent results of the Lightweight Electronics Enclosure Program. Electronics cooling is a growing challenge to thermal engineers due to increasing power densities and spacecraft architecture. The space-flight qualification program and preliminary results of thermal performance tests of copper-water heat pipes are presented. Electrohydrodynamics (EHD) is an emerging technology that uses the secondary forces that result from the application of an electric field to a flowing fluid to enhance heat transfer and manage fluid flow. A brief review of current EHD capabilities regarding heat transfer enhancement of commercial heat exchangers and capillary pumped loops is presented. Goddard Space Flight Center research efforts applying this technique to fluid management and fluid pumping are discussed.

Didion, Jeffrey R.↗
NASA NTRS1973

Apollo experience report: Launch escape propulsion subsystem

The Apollo launch escape propulsion subsystem contained three solid rocket motors. The general design, development, and qualification of the solid-propellant pitch-control, tower-jettison, and launch-escape motors of the Apollo launch escape propulsion subsystem were completed during years 1961 to 1966. The launch escape system components are described in general terms, and the sequence of events through the ground-based test programs and flight-test programs is discussed. The initial ground rules established for this system were that it should use existing technology and designs as much as possible. The practicality of this decision is proved by the minimum number of problems that were encountered during the development and qualification program.

Townsend, N. A.↗
NASA NTRS2010

Figure and Dimension Metrology of Extremely Lightweight X-Ray Mirrors for Space Astronomy Applications

The International X-ray Observatory (IXO) is the next major space X-ray observatory, performing both imaging and spectroscopic studies of all kinds of objects in the Universe. It is a collaborative mission of the National Aeronautics and Space Administration of the United States, the European Space Agency, and Japan Aerospace Exploration Agency. It is to be launched into a Sun-Earth L2 orbit in 2021. One of the most challenging aspects of the mission is the construction of a flight mirror assembly capable focusing X-rays in the band of 0.1 to 40 keY with an angular resolution of better than 5 arc-seconds and with an effective collection area of more than 3 sq m. The mirror assembly will consist of approximately 15,000 parabolic and hyperbolic mirror segments, each of which is approximately 200mm by 300mm with a thickness of 0.4mm. The manufacture and qualification of these mirror segments and their integration into the giant mirror assembly have been the objectives of a vigorous technology development program at NASA's Goddard Space Flight Center. Each of these mirror segments needs to be measured and qualified for both optical figure and mechanical dimensions. In this talk, I will describe the technology program with a particular emphasis on a measurement system we are developing to meet those requirements, including the use of coordinate measuring machines, Fizeau interferometers, and custom-designed, and -built null lens. This system is capable of measuring highly off-axis aspherical or cylindrical mirrors with repeatability, accuracy, and speed.

Zhang, William W.↗
NASA NTRSDate not supplied

X-57 Traction Power and Command Systems Development

This paper describes the final, as-built design of the X‑57 Maxwell aircraft power and command system architecture that implements the electrified propulsion capability. The development of the traction power, command, and avionics power subsystems proceeded as planned at the initial project critical design review, but improvements to the design were identified following the development of detailed operations concepts and integrated subsystem and system testing. The redundant architecture with A‑side and B‑side buses provided a robust framework for a developmental system that would turn out to have a lower technology readiness than had been assumed upon project formulation. As the project team identified reliability or performance gaps in the electrified propulsion powertrain components and their interactions with the other vehicle systems, the traction power, command, and avionics architectures were modified to accommodate the modified systems. Following the publication of the planned design approach at the critical design review milestone [1], the project team developed the flight hardware and software, integrated the systems, and adjusted the design and qualification activities to address gaps in the components, system architecture, and requirements as the gaps were realized. In addition to inherent challenges in development of these subsystems, the integration of this new technology with adjacent critical systems in an aircraft configuration posed additional challenges that drove design considerations across the subsystem development and the other vehicle systems. Integration complications included electromagnetic compatibility, thermal performance, and tolerance of single-point failures internal and external to the powerplant. Development of a qualification program was required for the new motors, inverters, and batteries, and hardware performance during component qualification fed back into the development process and led lessons learned and redesign of key elements.

distributed propulsion↗
NASA NTRS2021

NASA / NIST / FAA Technical Interchange Meeting on Computational Materials Approaches for Qualification by Analysis for Aerospace Applications

This report documents the goals, organization and outcomes of a Technical Interchange Meeting (TIM) on Computational Materials Approaches for Qualification by Analysis, co-organized by NASA, NIST and the FAA. The TIM was held at NASA Langley Research Center on January 15-16, 2020. Approximately 60 subject matter experts (SMEs) representing 8 aerospace manufacturers, 7 government organizations and 2 universities participated. Expertise of the SMEs spanned the Technology Readiness Level (TRL) scale from the low-to-mid TRL focus of government laboratories and universities to the high TRL perspective of the regulatory organizations and aerospace manufacturers. During this TIM, the future needs of the government regulators and manufacturers motivated the overall discussion and framed the input given by the participants. Hence, the key objectives of the TIM were to understand existing gaps in model-based, e.g., computational materials, processing and performance predictions for aerospace materials and components and forecast how they can be matured to support material, process and part-level qualification and certification (Q&C). The TIM focused on process-intensive metallic materials technologies, including, but not limited to, additive manufacturing. Participation was roughly evenly divided among the processing and performance tracks, suggesting that both topic areas are generally perceived as being both valuable and requiring additional investment. The output of this TIM may be used by both participating and other organizations, in part, as guidance for future national efforts on maturing computational materials capabilities for use in the Q&C of advanced metallic material systems in aerospace applications.

Edward H Glaessgen↗
NASA NTRS1982

Orbiter OMS and RCS technology

Orbiter Orbital Maneuver Subsystem (OMS) and Reaction Control Subsystem (RCS) tankage has proved to be highly successful in shuttle flights on-orbit propellant transfer tests were done. Tank qualification tests along with flight demonstrations were carried out future uses of storable propellants are cited.

Boudreaux, R. A.↗
NASA NTRS1991

The high temperature superconductivity space experiment

The history and the current status of the high temperature superconductivity space experiment (HTSSE) initiated in 1988 are briefly reviewed. The goal of the HTSSE program is to demonstrate the feasibility of incorporating high temperature superconductivity (HTS) technology into space systems. The anticipated payoffs include the development of high temperature superconductor devices for space systems; preparation and space qualification of a cryogenically cooled experimental package containing HTS devices and components; and acquisition of data for future space experiments using more complex HTS devices and subsystems. The principal HTSSE systems and devices are described.

Webb, Denis C.↗
NASA NTRS2002

Pure Water From a Pure Genius

Ammonium perchlorate is widely used throughout the aerospace, munitions, and pyrotechnics industries as a primary ingredient in solid rocket and missile propellants, fireworks, and explosive charges. This highly soluble salt has tainted soils and water sources all over the world, and is believed to be an endocrine disrupter, adversely affecting the growth patterns of a fetus or a young child. UMPQUA Research Company (URC), once a small drinking water testing laboratory and a research and development contractor for NASA's manned spaceflight applications, has evolved to become a leader in water purification and analysis. With a total of 11 patents issued for new technologies created by URC under NASA SBIR contracts and a 25-year commitment to water recycling, the company clearly possessed the qualifications necessary to tackle the presence of perchlorate in water. An SBIR contract with NASA's Marshall Space Flight Center that concentrated on the stringent water quality requirements of long-term, manned spaceflight was the source for URC's process and catalyst to facilitate the destruction of perchlorate and nitrate in water. URC licensed the rights of its unique reduction reaction process to Calgon Carbon Corporation for use with the company's perchlorate/nitrate remediation process, otherwise known as ISEP(R).

Source record↗
NASA NTRS2002

COBRA Main Engine Project

The COBRA (CO-Optimized Booster for Reusable Applications) project include the following: 1. COBRA main engine project team. 2. COBRA and RLX cycles selected. 3. COBRA proto-type engine approach enables mission success. 4. COBRA provides quick, low cost demo of cycle and technologies. 5. COBRA cycle I risk reduction supports. 6. Achieving engine safety. 6. RLX cycle I risk reduction supports. 7. Flight qualification. 9. Life extension engine testing.

Snoddy, Jim↗