Study of thermal protection requirements for a lifting body entry vehicle suitable for near-earth missions Final report
Reentry and abort trajectory analyses, and thermal protection requirements for lifting body entry vehicles
THERMAL PROTECTION↗
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Development of methodologies for the estimation of thermal properties associated with aerospace vehicles
Thermal stress analyses are an important aspect in the development of aerospace vehicles such as the National Aero-Space Plane (NASP) and the High-Speed Civil Transport (HSCT) at NASA-LaRC. These analyses require knowledge of the temperature within the structures which consequently necessitates the need for thermal property data. The initial goal of this research effort was to develop a methodology for the estimation of thermal properties of aerospace structural materials at room temperature and to develop a procedure to optimize the estimation process. The estimation procedure was implemented utilizing a general purpose finite element code. In addition, an optimization procedure was developed and implemented to determine critical experimental parameters to optimize the estimation procedure. Finally, preliminary experiments were conducted at the Aircraft Structures Branch (ASB) laboratory.
Scott, Elaine P.↗
X-Ray Diffraction and Reflectance Spectroscopy of Murchison Powders (CM2) After Thermal Analysis Under Reducing Conditions to Final Temperatures Between 300 and 1300°c
The asteroids Ryugu and Bennu have spectral characteristics in common with CI/CM type carbonaceous chondrites and are target bodies for JAXA’s Hayabusa2 and NASA’s OSIRIS-Rex missions, respectively. Analog studies, based primarily on the Murchison CM2 chondrite, provide a pathway to separate spectral properties resulting space weathering from those inherent to parent-body, mineralogy, chemistry, and processes. Ryugu shares spectral properties with thermally metamorphosed and partly dehydrated CI/CM chondrites. We have undertaken a multidisciplinary study of the thermal decomposition of Murchison powder samples as an analog to metamorphic process that may have occurred on Ryugu. Bulk analyses include thermal And evolved gas analysis, X-ray diffraction (XRD), and VIS-NIR and Mössbauer spectroscopy; micro- to nanoscale analyses included scanning and transmission electron microscopy and electron probe micro analysisWe report here XRD and VIS-NIR analyses of pre- and post-heated Murchison powders, and in a companion paper report results from multiple electron beam techniques.
Morris, R. V.↗
The continuing materials analysis of the thermal control surfaces experiment (S0069)
The long term effects of the natural and induced space environment on spacecraft surfaces are critically important to future spacecraft - including Space Station Freedom. The damaging constituents of this environment include thermal vacuum, solar ultraviolet radiation, atomic oxygen, particulate radiation, and the spacecraft induced environment. The behavior of materials and coatings in the space environment continues to be a limiting technology for spacecraft and experiments. The Thermal Control Surfaces Experiment (TCSE) was flown on the National Aeronautics and Space Administration (NASA) Long Duration Exposure Facility (LDEF) to study these environmental effects on surfaces-particularly on thermal control surfaces. The TCSE was a comprehensive experiment that combined in-space measurements with extensive pre- and post-flight analyses of thermal control surfaces to determine the effects of exposure to the low Earth orbit space environment. The TCSE is the first space experiment to directly measure the total hemispherical reflectance of thermal control surfaces in the same way they are routinely measured in the laboratory. The trend analyses of selected coatings performed as part of the continuing post-flight analysis of the TCSE are described. A brief description of the TCSE and its mission on LDEF are presented. There are several publications available that describe the TCSE, it's mission on LDEF, and initial results in greater detail. These are listed in the TCSE Bibliography.
Wilkes, Donald R.↗
Low-cycle thermal fatigue
A state-of-the-art review is presented of the field of thermal fatigue. Following a brief historical review, the concept is developed that thermal fatigue can be viewed as processes of unbalanced deformation and cracking. The unbalances refer to dissimilar mechanisms occurring in opposing halves of thermal fatigue loading and unloading cycles. Extensive data summaries are presented and results are interpreted in terms of the unbalanced processes involved. Both crack initiation and crack propagation results are summarized. Testing techniques are reviewed, and considerable discussion is given to a technique for thermal fatigue simulation, known as the bithermal fatigue test. Attention is given to the use of isothermal life prediction methods for the prediction of thermal fatigue lives. Shortcomings of isothermally-based life prediction methods are pointed out. Several examples of analyses and thermal fatigue life predictions of high technology structural components are presented. Finally, numerous dos and don'ts relative to design against thermal fatigue are presented.
Halford, G. R.↗
Associated with aerospace vehicles development of methodologies for the estimation of thermal properties
Thermal stress analyses are an important aspect in the development of aerospace vehicles at NASA-LaRC. These analyses require knowledge of the temperature distributions within the vehicle structures which consequently necessitates the need for accurate thermal property data. The overall goal of this ongoing research effort is to develop methodologies for the estimation of the thermal property data needed to describe the temperature responses of these complex structures. The research strategy undertaken utilizes a building block approach. The idea here is to first focus on the development of property estimation methodologies for relatively simple conditions, such as isotropic materials at constant temperatures, and then systematically modify the technique for the analysis of more and more complex systems, such as anisotropic multi-component systems. The estimation methodology utilized is a statistically based method which incorporates experimental data and a mathematical model of the system. Several aspects of this overall research effort were investigated during the time of the ASEE summer program. One important aspect involved the calibration of the estimation procedure for the estimation of the thermal properties through the thickness of a standard material. Transient experiments were conducted using a Pyrex standard at various temperatures, and then the thermal properties (thermal conductivity and volumetric heat capacity) were estimated at each temperature. Confidence regions for the estimated values were also determined. These results were then compared to documented values. Another set of experimental tests were conducted on carbon composite samples at different temperatures. Again, the thermal properties were estimated for each temperature, and the results were compared with values obtained using another technique. In both sets of experiments, a 10-15 percent off-set between the estimated values and the previously determined values was found. Another effort was related to the development of the experimental techniques. Initial experiments required a resistance heater placed between two samples. The design was modified such that the heater was placed on the surface of only one sample, as would be necessary in the analysis of built up structures. Experiments using the modified technique were conducted on the composite sample used previously at different temperatures. The results were within 5 percent of those found using two samples. Finally, an initial heat transfer analysis, including conduction, convection and radiation components, was completed on a titanium sandwich structural sample. Experiments utilizing this sample are currently being designed and will be used to first estimate the material's effective thermal conductivity and later to determine the properties associated with each individual heat transfer component.
Scott, Elaine P.↗
Thermal control surfaces experiment flight system performance
The Thermal Control Surfaces Experiment (TCSE) is the most complex system, other than the LDEF, retrieved after long term space exposure. The TCSE is a microcosm of complex electro-optical payloads being developed and flow by NASA and the DoD including SDI. The objective of TCSE was to determine the effects of the near-Earth orbital environment and the LDEF induced environment on spacecraft thermal control surfaces. The TCSE was a comprehensive experiment that combined in-space measurements with extensive post flight analyses of thermal control surfaces to determine the effects of exposure to the low earth orbit space environment. The TCSE was the first space experiment to measure the optical properties of thermal control surfaces the way they are routinely measured in a lab. The performance of the TCSE confirms that low cost, complex experiment packages can be developed that perform well in space.
Wilkes, Donald R.↗
Initial materials evaluation of the thermal control surfaces experiment (S0069)
The Thermal Control Surface Experiment (TCSE) was flown on the NASA Long Duration Exposure Facility (LDEF) with the basic objective of determining the effects of the near-earth orbital environment and the LDEF induced environment on spacecraft thermal control surfaces. The TCSE was a comprehensive experiment that combined in-space measurements with extensive post-flight analyses of thermal control surfaces to determine the effects of exposure to the low earth orbit space environment. The TCSE is the first space experiment to measure the optical properties of thermal control surfaces the way they are routinely measured in the laboratory. The specific mission objectives of the TCSE were to: (1) determine the effects of the natural and induced space environment on thermal control surfaces; (2) provide in-space performance data on thermal control surfaces; (3) provide in-space comparison to ground-based environmental testing of materials; and (4) develop and prove instrumentation to perform in-space optical testing of materials. Various aspects of the experiment are discussed.
Donald R. Wilkes↗
Thermal control surfaces experiment flight system performance
The Thermal Control Surfaces Experiment (TCSE) is the most complex system retrieved after long term space exposure. The TCSE is a microcosm of complex electro-optical payloads being developed and flown. The objective of the TCSE on the LDEF was to determine the effects of the near-Earth orbital environment and the LDEF induced environment on spacecraft thermal control surfaces. The TCSE was a comprehensive experiment that combined in-space measurements with extensive post-flight analyses of thermal control surfaces to determine the effects of exposure to the low Earth orbit space environment. The TCSE was the first space experiment to measure the optical properties of thermal control surfaces the way they are routinely measured in the lab. The performance of the TCSE flight system on the LDEF was excellent.
Wilkes, Donald R.↗
Analysis of thermal stresses and metal movement during welding
The research is reported concerning the development of a system of mathematical solutions and computer programs for one- and two-dimensional analyses for thermal stresses. Reports presented include: the investigation of thermal stress and buckling of tantalum and columbium sheet; and analysis of two dimensional thermal strains and metal movement during welding.
Muraki, T.↗
Finite element thermal-structural analysis of cable-stiffened space structues
Finite element thermal-structural analyses of large, cable-stiffened space structures are presented. A computational scheme for the calculation of prestresses in the cable-stiffened structures is also described. The determination of thermal loads on orbiting space structures due to environment heating is discussed briefly. Three finite element structural analysis techniques are presented for the analysis of prestressed structures. Linear, stress stiffening, and large displacement analysis techniques were investigated. These three techniques were employed for analysis of prestressed cable structures at different prestress levels. The analyses produced similar results at small prestress, but at higher prestress, differences between the results became significant. For the cable-stiffened structures studied, the linear analysis technique may not provide acceptable results. The stress stiffening analysis technique may yield results of acceptable accuracy depending upon the level of prestress. The large displacement analysis technique produced accurate results over a wide range of prestress and is recommended as a general analysis technique for thermal-structural analysis of cable-stiffened space structures.
Thornton, E. A.↗
Improved finite element methodology for integrated thermal structural analysis
An integrated thermal-structural finite element approach for efficient coupling of thermal and structural analysis is presented. New thermal finite elements which yield exact nodal and element temperatures 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.
Dechaumphai, P.↗
Trend analysis of in-situ spectral reflectance data from the Thermal Control Surfaces Experiment (TCSE)
The Thermal Control Surfaces Experiment (TCSE) on the LDEF was a comprehensive experiment that combined in-space measurements with extensive pre- and post-flight analyses of thermal control surfaces to determine the effects of exposure to the low earth orbit (LEO) space environment. The TCSE is the first space experiment to directly measure in-situ total hemispherical reflectance of thermal control surfaces in the same way they are routinely measured in the laboratory. In-space optical measurements performed by the TCSE provide the unique opportunity for trend analysis of the performance of materials in the space environment. Such trend analysis of flight data offers the potential to develop an empirical life time prediction model for several thermal control surfaces. For material research, trend analysis of the TCSE flight data, particularly the spectral data, can provide insight into the damage mechanisms of space exposure. Trend analysis for the TCSE samples has been limited to those materials that were not significantly eroded by the atomic oxygen (AO) environment. The performance of several materials on the LDEF mission was dominated by AO effects. Trend analysis was performed on both the detailed spectral reflectance measurements (in-space, pre-flight, and post-flight) and on the integrated solar absorptance. Results of this analysis for the five selected TCSE materials are presented along with the spectral flight data. Possible degradation and effects mechanisms will be discussed to better understand and predict the behavior of these materials in the LEO space environment.
Wilkes, Donald R.↗
Finite-Difference Solutions of the Alternate Turbopump Development High-Pressure Oxidizer Turbopump Pump-End Ball-Bearing Cavity Flows
These analyses were undertaken to aid in the understanding of flow phenomena in the Alternate Turbopump Development (ATD) High-pressure Oxidizer Turbopump (HPOTP) Pump-end ball bearing (PEBB) cavities and their roles in turbopump vibration initiation and bearing distress. This effort was being performed to provide timely support to the program in a decision as to whether or not the program should be continued. In the first case, it was determined that a change in bearing through flow had no significant effect on axial preload. This was a follow-on to a previous study which had resulted in a redesign of the bearing exit cavity which virtually eliminated bearing axial loading. In the second case, a three-dimensional analysis of the inner-race-guided cage configuration was performed so as to determine the pressure distribution on the outer race when the shaft is 0.0002 inches off-center. The results indicate that there is virtually no circumferential pressure difference caused by the offset to contribute to bearing tilt. In the third case, axisymmetric analyses were performed on an outer-race guided cage configuration to determine the magnitude of tangential flow entering the bearing. The removed-shoulder case was analyzed as was the static diverter case. A third analysis where the preload spring was shielded by a sheet of metal for the baseline case was also performed. It was determined that the swirl entering the bearing was acceptable and the project decided to use the outer-race-guided cage configuration. In the fourth case, more bearing configurations were analyzed. These analyses included thermal modeling so as to determine the added benefit of injecting colder fluid directly onto the bearing inner-race contact area. The results of these analyses contributed to a programmatic decision to include coolant injection in the design.
Benjamin, Theodore G.↗
Application of High-Temperature Extrinsic Fabry-Perot Interferometer Strain Sensor
In this presentation to the NASA Aeronautics Sensor Working Group the application of a strain sensor is outlined. The high-temperature extrinsic Fabry-Perot interferometer (EFPI) strain sensor was developed due to a need for robust strain sensors that operate accurately and reliably beyond 1800 F. Specifically, the new strain sensor would provide data for validating finite element models and thermal-structural analyses. Sensor attachment techniques were also developed to improve methods of handling and protecting the fragile sensors during the harsh installation process. It was determined that thermal sprayed attachments are preferable even though cements are simpler to apply as cements are more prone to bond failure and are often corrosive. Previous thermal/mechanical cantilever beam testing of EFPI yielded very little change to 1200 F, with excellent correlation with SG to 550 F. Current combined thermal/mechanical loading for sensitivity testing is accomplished by a furnace/cantilever beam loading system. Dilatometer testing has can also be used in sensor characterization to evaluate bond integrity, evaluate sensitivity and accuracy and to evaluate sensor-to-sensor scatter, repeatability, hysteresis and drift. Future fiber optic testing will examine single-mode silica EFPIs in a combined thermal/mechanical load fixture on C-C and C-SiC substrates, develop a multi-mode Sapphire strain-sensor, test and evaluate high-temperature fiber Bragg Gratings for use as strain and temperature sensors and attach and evaluate a high-temperature heat flux gauge.
Piazza, Anthony↗
Near-infrared mapping spectrometer optical subsystem development and testing
The Near-Infrared Mapping Spectrometer (NIMS) is one of the four remote-sensing science instruments of the Galileo Orbiter scientific payload. The NIMS scientific objectives require operating the detector and optical subsystem at cryogenic temperatures. The necessity of assembling, aligning, and testing the optics at room temperature and meeting design specifications at the cryogenic operating temperature (130 K) presented a set of challenging technical problems. A systematic approach to the development of athermalized mounts and supporting structures for optical components is described. A technique utilizing the visible spectral range and supplementary ray-trace information for alignment of an infrared instrument is presented. The optical subsystem point-spread function and spatial and spectral resolution were determined at room temperature using selected spectral and spatial targets. Based on thermal-distortion analyses of the structure and mounts, compensators were selected, implemented, and verified at cryogenic temperatures. The selection of the compensator and the overall system performance were verified in a thermal vacuum chamber. Various external and internal calibration targets were used.
Macenka, S. A.↗
The effect of coatings and liners on heat transfer in a dry shaft-bush tribosystem
The temperatures due to frictional heating within a solid lubricated or coated journal bearing were analyzed by using a finite element method. A solid model of the shaft-bush tribocontact was generated with an eight-node, three-dimensional, first-order isoparametric heat-transfer element and the Patran solid modeler software. The Patmar (Patran-Marc) translator was used to help develop the Marc-based finite element program for the system; this software was used on the Cray X-MP supercomputer to perform a finite element analysis of the contact. The analysis was performed for various liner materials, for thin, hard, wear-resistant coated bearings, and for different geometries and thermal cooling boundary conditions. The analyses indicated that thermal conductivity of the liner or coating material is the most vital thermal parameter that controls the interface temperature. In addition to design variations, the proximity of the cooling source to the heat-flux-generating interface is critically important to the temperature control in the system.
Ghosh, Mihir K.↗
Heated-Atmosphere Airship for the Titan Environment: Thermal Analysis
Future exploration of Saturn's moon Titan can be carried out by airships. Several lighter-than-atmosphere gas airships and passive drifting heated-atmosphere balloon designs have been studied, but a heated-atmosphere airship could combine the best characteristics of both. This work analyses the thermal design of such a heated-atmosphere vehicle, and compares the result with a lighter-than-atmosphere (hydrogen) airship design. A design tool was created to enable iteration through different design parameters of a heated-atmosphere airship (diameter, number of layers, and insulating gas pocket thicknesses) and evaluate the feasibility of the resulting airship. A baseline heated-atmosphere airship was designed to have a diameter of 6 m (outer diameter of 6.2 m), three-layers of material, and an insulating gas pocket thickness of 0.05 m between each layer. The heated-atmosphere airship has a mass of 161.9 kg. A similar mission making use of a hydrogen-filled airship would require a diameter of 4.3 m and a mass of about 200 kg. For a long-duration mission, the heated-atmosphere airship appears better suited. However, for a mission lifetime under 180 days, the less complex hydrogen airship would likely be a better option.
Heller, R. S.↗