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We are conducting DSC/EGA experiments at Mars ambient temperature and pressure using the TEGA engineering model. These tests illustrate the outstanding capabilities of a TEGA-like instrument on the surface of Mars.
A series of engineering analysis studies were conducted to investigate the potential application of nanoclay-enhanced graphite/epoxy composites and polymer cross-linked silica aerogels in cryogenic hydrogen storage tank designs. This assessment focused on the application of these materials in spherical tank designs for unmanned aeronautic vehicles with mission durations of 14 days. Two cryogenic hydrogen tank design concepts were considered: a vacuum-jacketed design and a sandwiched construction with an aerogel insulating core. Analyses included thermal and structural analyses of the tank designs as well as an analysis of hydrogen diffusion to specify the material permeability requirements. The analyses also provided material property targets for the continued development of cross-linked aerogels and nanoclay-enhanced graphite/epoxy composites for cryogenic storage tank applications. The results reveal that a sandwiched construction with an aerogel core is not a viable design solution for a 14-day mission. A vacuum-jacketed design approach was shown to be far superior to an aerogel. Aerogel insulation may be feasible for shorter duration missions. The results also reveal that the application of nanoclay-enhanced graphite/epoxy should be limited to the construction of outer tanks in a vacuum-jacketed design, since a graphite/epoxy inner tank does not provide a significant weight savings over aluminum and since the ability of nanoclay-enhanced graphite/epoxy to limit hydrogen permeation is still in question.
Analyses of Graphite/Polyimide laminates shown that the thermomechanical strains cannot be separated into mechanical strain and free thermal expansion strain. Elastic properties and thermal expansion coefficients of unidirectional Graphite/Polyimide specimens were measured as a function of temperature to provide inputs for the analysis. The + or - 45 degrees symmetric Graphite/Polyimide laminates were tested to obtain free thermal expansion coefficients and thermal expansion coefficients under various uniaxial loads. The experimental results demonstrated the effects predicted by the analysis, namely dependence of thermal expansion coefficients on load, and anisotropy of thermal expansion under load. The significance of time dependence on thermal expansion was demonstrated by comparison of measured laminate free expansion coefficients with and without 15 day delay at intermediate temperature.
The proposed Hydrostar mission used a large orbiting antenna array to demonstrate synthetic aperture technology in space while obtaining global soil moisture data. In order to produce accurate data, the array was required to remain as close as possible to its perfectly aligned placement while undergoing the mechanical and thermal stresses induced by orbital changes. Thermal and structural analyses for a design concept of this antenna array were performed. The thermal analysis included orbital radiation calculations, as well as parametric studies of orbit altitude, material properties and coating types. The thermal results included predicted thermal distributions over the array for several cases. The structural analysis provided thermally-driven deflections based on these cases, as well as based on a 1-g inertial load. In order to minimize the deflections of the array in orbit, the use of XN70, a carbon-reinforced polycyanate composite, was recommended.
The thermal convective velocities during the 4-21/2R and 74-21/3R flight tests were calculated. The 74-21/2R and 74-21/3R ground tests were analyzed using a convection formula. Thermal convection velocities of 0.1 to 0.5 cm/sec were calculated for the 74-21/2R and 74-21/3R ground tests which were two to four orders of magnitude greater than for the flight tests. For the 74-21/2R flight test, solutal effects do not produce any convective motion. For the 74-21/3R flight test closed form convection equations estimated the solutal convective velocities on the order of 1/0.003 cm/sec.
An integrated thermal-structural finite element approach for efficient coupling of thermal and structural analyses is presented. New thermal finite elements which yield exact nodal and element temperature for one dimensional linear steady state heat transfer problems are developed. A nodeless variable formulation is used to establish improved thermal finite elements for one dimensional nonlinear transient and two dimensional linear transient heat transfer problems. The thermal finite elements provide detailed temperature distributions without using additional element nodes and permit a common discretization with lower order congruent structural finite elements. The accuracy of the integrated approach is evaluated by comparisons with analytical solutions and conventional finite element thermal-structural analyses for a number of academic and more realistic problems. Results indicate that the approach provides a significant improvement in the accuracy and efficiency of thermal stress analysis for structures with complex temperature distributions.
This paper presents detailed results from linear and nonlinear finite-element thermal stress analyses of a new tile, Thermal Protection Systems (TPS) concept. A very thin coating of Reaction Cured Glass (RCG) is used to "temper" the surface of Toughened Uni-Piece Fibrous Insulation (TUFI) tiles to improve resistance to thermal shock and thermal cycling effects. The coating also serves to reduce catalytic heating and may improve waterproofing. Calculations include trajectory-based aerothermal heating environments for X-34 wing leading edge TPS designs and arc jet environments for TPS test articles. The nonlinear analyses include the high temperature plasticity of RCG to demonstrate the reuseability of the material.
The NASTRAN thermal analyzer (NTA) which performs large-scale unified thermo-structural analyses with the NASTRAN (NASA structural analysis) computer program is described. The mathematical similitude between these two distinct disciplines of thermal and structure is examined. It serves as the theoretical basis upon which the implementation of the thermal capability in NASTRAN was accomplished. The program structure, the functional flow, the solution algorithms, the organization of an input data deck and the solution capabilities of NTA are summarized. Emphasis is placed on the interface of the unified approach in thermo-structural analyses where stresses, deflections, vibrations and bucklings induced by the effect of temperature change are of concern. Attentions are also directed to the preprocessor and post processors. As a specially designed preprocessor, the VIEW program is capable of generating exchange factors which can be output, at user's option, in formats compatible with that required by NTA. Two post processors that serve specific objectives are included. They are the thermal variance analysis and the graphical displaying capability of temperatures in color or black and white.
Thermal analyzer computer program for venting cryogenic tanks
Mars landed and orbiter missions have instrumentation capable of detecting oxychlorine phases (e.g. perchlorate, chlorate) on the surface. Perchlorate (~0.6 wt%) was first detected by the Wet Chemistry Laboratory in the surface material at the Phoenix Mars Landing site. Subsequent analyses by the Thermal Evolved Gas Analyser aboard the same lander detected an oxygen release (~465°C) consistent with the thermal decomposition of perchlorate. Recent thermal analysis by the Mars Science Laboratory’s Sample Analysis at Mars instrument has also indicated the presence of oxychlorine phases (up to 1.2 wt%) in Gale Crater materials. Despite being at detectable concentrations, the Chemistry and Mineralogy (CheMin) X-ray diffractometer has not detected oxychlorine phases. This suggests that Gale Crater oxychlorine may exist as poorly crystalline phases or that perchlorate/chlorate mixtures exist, so that individual oxychlorine concentrations are below CheMin detection limits (~1 wt%). Although not initially designed to detect oxychlorine phases, reinterpretation of Viking Gas Chromatography/Mass Spectrometer data also suggest that oxychlorine phases are present in the Viking surface materials. Remote near-infrared spectral analyses by the Compact Reconnaissance Imaging Spectrometer for Mars (CRISM) instrument indicate that at least some martian recurring slope lineae (RSL) have spectral signatures consistent with the presence of hydrated perchlorates or chlorates during the seasons when RSL are most extensive. Despite the thermal emission spectrometer, Thermal Emission Imaging System, Observatoire pour la Minéralogie, l’Eau, les Glaces et l’Activité and CRISM detection of hundreds of anhydrous chloride (~10–25 vol%) deposits, expected associated oxychlorine phases (>5–10 vol%) have not been detected. Total Cl and oxychlorine data sets from the Phoenix Lander and the Mars Science Laboratory missions could be used to develop oxychlorine versus total Cl correlations, which may constrain oxychlorine concentrations at other locations on Mars by using total Cl determined by other missions (e.g. Viking, Pathfinder, MER and Odyssey). Development of microfluidic or ‘lab-on-a-chip’ instrumentation has the potential to be the next generation analytical capability used to identify and quantify individual oxychlorine species on future landed robotic missions to Mars.
The plasma sprayed graded layered yittria stabilized zirconia (ZrO2)/metal(CoCrAlY) seal system for gas turbine blade tip applications up to 1589 K (2400 F) seal temperatures was studied. Abradability, erosion, and thermal fatigue characteristics of the graded layered system were evaluated by rig tests. Satisfactory abradability and erosion resistance was demonstrated. Encouraging thermal fatigue tolerance was shown. Initial properties for the plasma sprayed materials in the graded, layered seal system was obtained, and thermal stress analyses were performed. Sprayed residual stresses were determined. Thermal stability of the sprayed layer materials was evaluated at estimated maximum operating temperatures in each layer. Anisotropic behavior in the layer thickness direction was demonstrated by all layers. Residual stresses and thermal stability effects were not included in the analyses. Analytical results correlated reasonably well with results of the thermal fatigue tests. Analytical application of the seal system to a typical gas turbine engine application predicted performance similar to rig specimen thermal fatigue performance. A model for predicting crack propagation in the sprayed ZrO2/CoCrAlY seal system was proposed, and recommendations for improving thermal fatigue resistance were made. Seal system layer thicknesses were analytically optimized to minimize thermal stresses in the abradability specimen during thermal fatigue testing. Rig tests on the optimized seal configuration demonstrated some improvement in thermal fatigue characteristics.
Materials that pyrolyze at elevated temperature have been commonly used as thermal protection materials in hypersonic flight, and advanced pyrolyzing materials for this purpose continue to be developed. Because of the large temperature gradients that can arise in thermal protection materials, significant thermal stresses can develop. Advanced applications of pyrolytic materials are calling for more complex heatshield configurations, making accurate thermal stress analysis more important, and more challenging. For non-pyrolyzing materials, many finite element codes are available and capable of performing coupled thermal-mechanical analyses. These codes do not, however, have a built-in capability to perform analyses that include pyrolysis effects. When a pyrolyzing material is heated, one or more components of the original virgin material pyrolyze and create a gas. This gas flows away from the pyrolysis zone to the surface, resulting in a reduction in surface heating. A porous residue, referred to as char, remains in place of the virgin material. While the processes involved can be complex, it has been found that a simple physical model in which virgin material reacts to form char and pyrolysis gas, will yield satisfactory analytical results. Specifically, the effects that must be modeled include: (1) Variation of thermal properties (density, specific heat, thermal conductivity) as the material composition changes; (2) Energy released or absorbed by the pyrolysis reactions; (3) Energy convected by the flow of pyrolysis gas from the interior to the surface; (4) The reduction in surface heating due to surface blowing; and (5) Chemical and mass diffusion effects at the surface between the pyrolysis gas and edge gas Computational tools for the one-dimensional thermal analysis these materials exist and have proven to be reliable design tools. The objective of the present work is to extend the analysis capabilities of pyrolyzing materials to axisymmetric configurations, and to couple thermal and mechanical analyses so that thermal stresses may be efficiently and accurately calculated.
STS-132 was launched in May 2010 and delivered the Russian Mini Research Module 1 (MRM1) cargo element to the International Space Station as part of the ULF-4 assembly flight. The cargo element consisted of the module outfitted with externally mounted Multi-purpose Laboratory Module (MLM) Airlock, MLM radiator, Portable Work Platform (PWP), and a European Robotic Arm (ERA) spare elbow. Prior to every Shuttle flight, hardware developers are required to determine compatibility of their hardware to thermal environments experienced during the Shuttle mission and once the element is integrated with the ISS. Thermal models are provided to the Shuttle program to determine the impact of the payload on the Orbiter hardware, as well as the ISS program to determine impacts on other ISS payloads in the Orbiter. Historically the Russian International Partner (IP) develops models in formats not compatible with software used by Space Shuttle or ISS programs. This prompted NASA and Lockheed Martin to develop a unique set of thermal models for the MRM1 cargo element. Subsequent ULF-4 mission analyses performed with the models assessed the launch to activation response, identified operational criteria documented in flight rules, and ensured compliance with the mission timeline and no hazards to the crew, orbiter, or ISS. This presentation provides an overview of the work performed, depicts unique approaches in model development, discusses lessons learned, and issue resolution approaches. Though development and analysis efforts spanned over four years and presented various integration challenges it provided an example of successful collaboration with our International Partners.
Thermal neutron activation analyses were carried out for various space systems components to determine gamma radiation dose rates and food radiation contamination levels. The space systems components selected were those for which previous radiation studies existed. These include manned space vehicle radiation shielding, liquid hydrogen propellant tanks for a Mars mission, and a food supply used as space vehicle radiation shielding. The computational method used is based on the fast neutron distribution generated by the BRYNTRN and HZETRN transport codes for Galactic Cosmic Rays (GCR) at solar minimum conditions and intense solar flares in space systems components. The gamma dose rates for soft tissue are calculated for water and aluminum space vehicle slab shields considering volumetric source self-attenuation and exponential buildup factors. In the case of the lunar habitat with regolith shielding, a completely exposed spherical habitat was assumed for mathematical convenience and conservative calculations. Activation analysis of the food supply used as radiation shielding is presented for four selected nutrients: potassium, calcium, sodium, and phosphorus. Radioactive isotopes that could represent a health hazard if ingested are identified and their concentrations are identified. For nutrients soluble in water, it was found that all induced radioactivity was below the accepted maximum permissible concentrations.
The global change technology initiative calls for a geostationary platform for Earth science monitoring. One of the major science instruments is the high frequency microwave sounder (HFMS) which uses a large diameter, high resolution, high frequency microwave antenna. This antenna's size and required accuracy dictates the need for a segmented reflector. On-orbit disturbances may be a significant factor in its design. A study was performed to examine the effects of the geosynchronous thermal environment on the performance of the strongback structure for a proposed antenna concept for this application. The study included definition of the strongback and a corresponding numerical model to be used in the thermal and structural analyses definition of the thermal environment, determination of structural element temperature throughout potential orbits, estimation of resulting thermal distortions, and assessment of the structure's capability to meet surface accuracy requirements. Analyses show that shadows produced by the antenna reflector surface play a major role in increasing thermal distortions. Through customization of surface coating and element expansion characteristics, the segmented reflector concept can meet the tight surface accuracy requirements.
Engineering model gives useful predictions. Pair of reports presents theoretical and experimental analyses of thermal responses of multiple-component, lightweight, porous, ceramic insulators. Particular materials examined destined for use in Space Shuttle thermal protection system, test methods and heat-transfer theory useful to chemical, metallurgical, and ceramic engineers needing to calculate transient thermal responses of refractory composites.
Thermal, surface, and deformation analyses for predicting thermal contact resistance for metal surface characteristics in vacuum and fluid environment
This paper analyzes, defines, and sizes cryogenic storage thermal control systems that meet the requirements of future NASA Mars human exploration missions. The design issues of this system include the projection of the existing Multilayer Insulation data base for cryogenic storage to much thicker (10 cm or more) insulation systems, the unknown heat leak from mechanical interfaces, and the thermal and structural performance effects of the large tank sizes required for a Mars mission. Acknowledging these unknown effects, heat loss projections are made based on extrapolation of the existing data base. The results indicate that hydrogen, methane, and oxygen are feasible propellants, and that the best suited thermal control sytems are 'thick' MLI, thermodynamic vent sytems, cryocoolers, and vacuum jackets.